An exposed electrical heat trace conductor on a sludge tank sample line valve was discovered by an employee after a heat trace end seal kit fell off resulting in an uncontrolled electrical hazard. The installed end seal kit model was incompatible with the heat trace model. The heat trace is a thermostatically controlled circuit utilized to provide heat to the sample line valve when ambient temperatures are less than 40 degrees Fahrenheit. An end seal kit is installed on the end of the heat trace to prevent exposure of the conductor.
Lesson Learned: Specify compatible materials and installation instructions in work documents. Material compatibility must be confirmed when installing electrical components to ensure safe configurations and avoid unexpected outcomes.
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