Organization –

A Leading Manufacturer of Aluminum Collapsible Tubes

Location –

Maharashtra

Domain –

Ship Management

Solution Offered –

Electrical Audit

Overview – 

One of our esteemed customers, a leading manufacturer of aluminum collapsible tubes based in Maharashtra, partnered with Network Techlab (I) Ltd. to conduct an Electrical and Safety Audit at their facility. The objective was to evaluate their power quality, electrical safety, and energy efficiency, ensuring compliance with industry standards and mitigating operational risks.

Challenges –

During the audit, several critical electrical and safety challenges were identified:

1. High heating in cables and busbars, leading to potential fire hazards and equipment damage.
2. Improper wiring and loose terminations, increasing the risk of short circuits and power failures.
3. Absence of a Surge Protection Device (TVSS), making sensitive equipment vulnerable to power fluctuations.
4. Low Power Factor (PF) below 0.90, causing energy inefficiencies and higher electricity bills.
5. Dust accumulation in electrical panels, leading to overheating and reduced equipment performance.
6. Improper cable management, including hanging cables and exposure to sharp edges, increasing physical damage risks.
7. Lack of safety signage and first aid kits, compromising workplace safety standards.

No provision for emergency tripping mechanisms, delaying responses in critical electrical fault situations.

Solutions –

To address these challenges, Network Techlab executed a series of corrective actions:

1. Conducted thermographic analysis to identify overheating points and recommended proper tightening and crimping of connections.
2. Ensured proper dressing of cables, using lugs and adhering to standard electrical practices to enhance wiring safety.
3. Installed 25kA TVSS as per IEEE C62.41 guidelines to protect equipment from voltage spikes and electrical surges.
4. Recommended and maintained capacitor banks to improve power factor correction (PFC) and reduce energy losses.
5. Implemented a regular cleaning schedule for breaker chambers and cable compartments to prevent dust accumulation.
6. Secured cables with cable trays and protective glands, eliminating the risk of physical damage and exposure.
7. Installed safety measures, including danger boards, shock treatment charts, and first aid kits, ensuring compliance with electrical safety norms.

Integrated remote emergency tripping systems, enabling quick shutdowns in case of hazards, reducing response time to electrical failures.

Benefits –

By implementing these solutions, the manufacturer gained significant operational advantages:

1. Prevention of overheating issues, reducing fire risks and enhancing overall plant safety.
2. Improved reliability and system stability, leading to fewer breakdowns and increased operational uptime.
3. Lower risk of equipment failure, minimizing maintenance costs and unexpected downtimes.
4. Enhanced energy efficiency, resulting in reduced electricity expenses and optimized power utilization.
5. Extended lifespan of electrical equipment, reducing long-term capital expenditures on replacements.

Enhanced workplace safety compliance, reducing hazards and improving overall worker protection.

Conclusion –

The Electrical and Safety Audit conducted by Network Techlab (I) Pvt. Ltd. identified crucial areas for power optimization and safety enhancement at the manufacturing facility. Through a proactive approach to energy efficiency and electrical safety, the company now benefits from a safer, more reliable, and cost-efficient electrical infrastructure.

By implementing these recommended solutions, the manufacturer has positioned itself for sustainable growth, reduced operational risks, and regulatory compliance—ensuring a robust and efficient working environment for the long term.

For expert electrical safety and energy efficiency solutions, contact Network Techlab (I) Ltd. today!

If you have any query or would like to request a demo for any of our services, please feel free to connect with us at info@netlabindia.com or 8879004536

Network Techlab (I) Pvt. Ltd.
41, Sarvodaya Industrial Estate, Opp. Paper Box, Off. Mahakali Caves Road, Andheri East, Mumbai – 400093. India
P: 022-6681 4141 | info@netlabindia.com | www.netlabindia.com
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