Severfield: Optimising Electrical Safety with Efficient, Minimal Downtime Testing

The Challenge

The nature of Severfield’s operations demands that its factory runs efficiently with minimal downtime. Given the complexity of its machinery, it is crucial that the electrical systems, spanning nearly 3,000 circuits, are continually checked to safeguard both staff and equipment.

With a need to balance safety with production output, Severfield’s challenge was to conduct regular electrical safety inspections without disrupting daily operations. Closing the factory for safety checks would lead to significant downtime and reduce productivity, something the business could not afford.

Our Solution

Hawkesworth has partnered with Severfield for several years to provide comprehensive electrical safety testing, offering the following services:

• EICR Inspections: Carried out every three years to ensure compliance with safety standards. Given the scale of the factory, we stagger the inspections, completing a third of the 3,000 circuits each year over a three-year cycle. This approach ensures continuous operation while maintaining compliance.
• Thermographic Surveys: Given the critical role of Severfield’s distribution boards, which power the factory’s machinery, we conduct annual thermographic surveys. These infrared camera inspections detect any heat anomalies within the distribution boards, without needing to cut the power supply. By monitoring the temperature variations in key components, we can pinpoint faults before they lead to equipment failure or fire hazards.
• Familiarity with the Site: We assign the same team of engineers to conduct inspections each year, ensuring consistency, familiarity with the factory layout, and swift identification of key risk areas.

The Results

By implementing this structured, staggered approach to testing, Hawkesworth helps Severfield maintain its operational efficiency while ensuring full electrical compliance and safety. Key outcomes include:

• Minimal Disruption: By staggering EICR inspections and using thermographic surveys to avoid shutting down the power, we ensure that the factory’s production line experiences minimal downtime.
• Enhanced Safety and Compliance: Through regular and thorough testing, Severfield’s electrical circuits and distribution boards remain in peak condition, significantly reducing the risk of electrical faults and ensuring staff safety.
• Cost-Effective Solution: With a clear, long-term testing schedule, Severfield benefits from predictable costs and avoids unnecessary shutdowns or disruptions.