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rmonroe

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I recently started working at a company in the Cincinnati area. My background is primarily in machine controls. The position title at this time is Plant Engineer with the possibility of turning into Maintenance manager.

At first it seem like a great opportunity, but after a couple of months I?m starting to see the nightmare. The electrical system though out the plant has been piece together over 30 years of learn as you go electricians. The maintenance personal I do not believe have ever seen the N.E.C. I had to bring my own codebook in, nothing? absolutely no electrical referance books in the plant. With that said?I have a few issues to resolve in regards to our electrical system.

1- 800 Amp feeders each phase ran in the same conduit (Three conduit runs 2-1/2?)
2- Two Sullair compressors with 250 HP Motors. Both having a S.F. of 1.15. Each compressor is rated at 274 Amps at 460 Volts. At times these compressor are running at 335 Amp for a substantial time (10 mins or more).
3- Power factor is at 87 to 89 percent.
4- Control panel with two different supplies not marked. 480 Volts and a separate 120 Volts coming into the panel
These are a few of the issue that relate to their electrical system not to mention compressed air and mechanical issues. The main reason I?m looking for advice is? a man was just killed on a piece of equipment this week. It happen on third shift March 8, 2004.

Looking for some answers.

Thanks

rmonroe
 
Re: advice

You can take the issues on one at a time, or go after the whole package. I would start by creating as comprehensive a list as you can (you seem to have gotten off to a good start). Then I would look for the issues that have an immediate safety impact, and work on those first.

The first item on your list looks like a safety issue to me. If I understand what you are saying, you have all three phase A wires in one conduit, all three phase B wires in a second conduit, and all three phase C wires in a third conduit. If that is true, you have a fire waiting to happen. It?s also a violation of NEC 300.3(B).

Whatever you do, do not allow the management to dismiss safety issues with a careless ?it hasn?t been a problem in the past, so what?s your problem?? It hasn?t been a problem in the past because you have been lucky in the past.
 
Re: advice

1- 800 Amp feeders each phase ran in the same conduit (Three conduit runs 2-1/2?)

Not clear what you are saying here. You should have a A,B,C,N, and EGC in each conduit.

3. Power factor is at 87 to 89 percent.

Normal power factor for industrial applications.

4- Control panel with two different supplies not marked. 480 Volts and a separate 120 Volts coming into the panel.

Only problem is identification. Suggest you use colored tape to distinguish between systems.
 
Re: advice

It seems you have a problem waiting to happen. As suggested put together a list of items to replace/fix. Also try to estimate a cost factor to get this work done. Concentrate on life and safety FIRST. If all else fails notify AHJ, and OSHA. You may put your job in jeopardy, but you will sleep better.
 
Re: advice

Sorry on the confusion..Charlie your right, all A Phase in one conduit, all B Phase in one conduit and all C Phase in one conduit. I understand about the current flow through the conductor, which produces an Eddy current. This cutting action from the Eddy current into the metal can produce enough heat in a high current application to cause a fire.

I just needed some reinforcement. Thanks for helping. I will not stop until I achieve an on going safety environment in this company. The only way to stop me is to fire me.

rmonroe
 
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