Redundant Cable Register & Electrical Safety Assessment

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SectorManufacturing - Beverage Production

ServiceElectrical Safety Assessment & Redundant Cable Management

Duration12 Days

UK Beverage Manufacturing Sector

The UK’s food and drink industry is the country’s biggest manufacturing sector by turnover, valued at £104.4 billion. It is larger than the automotive and aerospace industries combined.

2

engineers deployed
Over

18

locations across the facility (warehouses, valve houses, switchrooms) assessed
250

redundant cables identified

CLIENT CHALLENGE

A major spirits manufacturing facility identified an opportunity to enhance their electrical safety standards through comprehensive identification and cataloguing of redundant electrical cables across their production site to ensure compliance with the Electricity at Work Regulations 1989. The client recognised the importance of maintaining exemplary electrical safety standards whilst continuing operations at their busy production facility.

The facility's electrical infrastructure had evolved over many years, this evolution had resulted in a comprehensive network of electrical installations where numerous cables had become redundant following equipment upgrades, process improvements, and facility enhancements. These redundant cables, ranging from small 1.5mm² installations to substantial 70mm² power cables, including both Steel Wire Armoured (SWA) and Mineral Insulated types, required systematic identification, assessment, and safe removal planning to optimise electrical safety performance.

This presented an opportunity to systematically manage 250 redundant cables across multiple warehouses, valve houses, and electrical switchrooms.

Operational continuity was however paramount, as the facility operates continuous production processes meaning the assessment needed to be conducted whilst maintaining full production capability which required careful coordination and planning.

The client sought to ensure full regulatory compliance across the facility's complex layout, including hazardous areas with explosive atmosphere classifications where specialised safety protocols were essential, whilst maintaining production continuity. The hazardous areas demanded particular attention to ensure compliance with DSEAR (Dangerous Substances and Explosive Atmospheres Regulations) alongside electrical safety requirements. Some cables were also located in areas with limited access, requiring careful planning for safe identification and future removal to maximise the operational efficiency of the facility.

OUR SOLUTION

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BENEFITS

The comprehensive redundant cable assessment delivered significant operational and safety improvements for the client, establishing a foundation for enhanced electrical infrastructure management and regulatory compliance across the facility. Key benefits included:

Enhanced Regulatory Excellence:

Complete documentation ensuring optimal compliance with the Electricity at Work Regulations 1989 and HSE guidance HSR25. The comprehensive register provides clear evidence of systematic electrical safety management, supporting regulatory inspections and demonstrating exemplary due diligence in electrical risk management across the facility, establishing industry-leading safety standards.

Systematic Risk Optimisation:

Structured identification and prioritisation of 250 redundant cables with clear removal protocols established for each installation. This systematic approach enables planned maintenance activities whilst ensuring safety standards are enhanced throughout the cable removal process, significantly reducing potential electrical hazards and improving overall infrastructure reliability.

Operational Excellence Assurance:

Assessment conducted with minimal disruption to production processes, ensuring continuous facility operation whilst advancing electrical safety requirements. The phased approach to cable identification and removal planning allows maintenance activities to be optimised around operational requirements, enhancing both safety standards and production efficiency through improved infrastructure management.

Comprehensive Safety Documentation:

Detailed register providing unique identification codes, cable specifications, locations, and removal priorities for all redundant installations. This documentation supports enhanced maintenance planning, regulatory excellence, and provides clear guidance for safe removal procedures across all facility areas including hazardous zones, establishing a benchmark for electrical infrastructure management.

Expert Technical Excellence:

Professional assessment by qualified electrical engineers ensuring compliance with current regulations and industry best practices. The technical expertise provided includes hazardous area protocols, regulatory interpretation, and practical guidance for optimising complex electrical infrastructure whilst maintaining exemplary operational safety standards and establishing long-term maintenance excellence.

George

White

Senior Electrical Consultant

Bureau Veritas

What made this project particularly valuable is how it transformed what could be a reactive safety issue into a planned, manageable process. The comprehensive register we've delivered gives the client complete visibility of their electrical infrastructure risks and empowers them to make informed decisions about removal priorities, creating a safer working environment for everyone on site.

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