1. ELECTRICAL SAFETY AUDIT for XYZ Gujarat
October 4 to 6, 2004
Cholamandalam MS Risk Services Ltd.
Chennai

2. Cholamandalam Risk Services Ltd.
A JV between Murugappa Group & MS Insurance, Japan
Executed RM services for various clients- India & rest of Asia

3. ELECTRICAL SAFETY SERVICES -CLIENTS
MRPL Refinery, Mangalore
Shasun Chemicals, Cuddalore
Ahmedabad Electricity Company, Ahmedabad
Orchid Pharmaceutical Company, Chennai
EID Parry Biochemicals, Tamil Nadu
BPCL, Manmad
Vikram Cements, Madhya Pradesh
Chambal Fertilizers, Rajasthan
TI Diamond Chain, TN
HLL, Haldia
Visaka Cements, Andhra Pradesh
Bombay Dyeing, Patalganga
GMR Power plant, Mangalore
CP Aqua Culture, TN
Surat Electricity Company, Surat
Aditya Cements, Rajasthan

4. Close Out Presentation
ESA –approach, methodology & coverage
XYZ- High Priority Areas
XYZ-ESA- observations & recommendations

5. ESA – Scope, Methodology & Coverage

6. ESA- Scope of work Compliance to IER Electrical hazard identification:
Shock, fire
Lightning Protection
HAC
Earthing
Static electricity issues
EPM
Accidents
Review of All records & documents
Training
Electrical Protection
Sample tests
Temperature
Current
Earth Resistance

7. ELECTRICAL SAFETY AUDIT
ESA IS A SYSTEMATIC INDEPENDENT REVIEW TO VERIFY CONFORMANCE WITH ESTABLISHED GUIDE LINES OR STANDARDS TO IDENTIFY, ASSESS & CONTROL ELECTRICAL RISKS
ESA IS CARRIED OUT BY WAY OF PHYSICAL EXAMINATION, SAMPLE TESTS, REVIEW OF RECORDS AND DISCUSSION WITH VARIOUS DEPARTMENTS & PLANT PERSONNEL

8. ESA Methodology Opening Meeting -Familiarization
Discussion with Head-Electrical, review of key SLD
ESA
Physical inspections
Sample Testing
Document & records review
Meeting –various departments
Close-Out meeting
Interim Report
Final report submission

9. AUDIT SCHEDULE (4 – 6 October 2004)
4 October - opening meeting, electrical system briefing, Main SLD review, switchyard visit, SS A,B, C, DG House, manufacturing blocks
5 Oct - Auditing of balance manufacturing areas completed
6 Oct – ER tests, Review of records & close out meeting+ discussion with relevant departments (safety, R&D, health centre, instrumentation, documentation, contractors, contract department, purchase, etc.)

10. Audit Coverage 66 KV S/Y DG House All Sub Stations (A, B, C, E)
Transformers-various areas
CNC Shop
HT Motor Building
VPI Area
IMB Area
DT Area
Transformer Manufacturing Area, SS E
Admin Building
Relay Building
Auxiliary I & II building
Electroplating/ Anodizing
Turbocharger Area
HV Disconnector Area
Fuel Tanks (HSD, Solvent, Transformer oil)
LTB Area
Health Centre
Workers’ Canteen

11. ESA -Standards & Codes BIS Publications NFPA Codes OISD Standards
Indian Electricity Rules, 1956
British Standards
Best Engineering Practices

12. ESA – Observations & Recommendations

13. Very receptive to improvement suggestions
Availability of skilled technocrats, global expertise
OHSAS certified plant
Availability of testing resources
Existence of systems and procedures

14. LIMITATIONS VERY OLD PLANT UNPLANNED EXPANSIONS RAPID GROWTH
REQUIRES FUTURE PLANNING
LIMITED MAINTENANCE FORCE IN CERTAIN AREAS

15. XYZ -High Priority Areas
PTPT Area- 1.5 MVA transformer, overloaded electrical panel
CNC Shop floor- bay lightning panel
Earthing issues
SS- E, PTPT areas – responsibility to be defined
Electrical hotspots at terminations – potential fire hazard
Electrical Panels – requires due attention
Fire Hydrant system to be installed
DGs in another plant area

16. Transformers Silica gel in several transformers- to be re-activated
Neutral & body earth pits are not identified
Oil soak pit for transformers with oil capacity above 2, 275 L (IER- 64- iv), eg. 4 MVA
Oil draining arrangement for transformers above 9 KL capacity (Transformer EHV testing yard, 30 MVA transformer)- IER 64 v
Annunciation for 7 MVA transformer not operational

17. Electrical Injuries Use HRC fuse pullers to remove fuses
30 mA ELCBs used in DBs, extension boards
Insist on using PPEs while working on live lines
Battery rooms-cover battery terminals
Identification of feeders / panels / circuits - missing
Use of live U/G cable locator before excavation
Maintain U/G cable lay out for reference
No resuscitation chart displayed

18. Automated External Defibrillators (AED)
250,000 deaths every year due to sudden cardiac arrest
AEDs - to be part of Emergency Medical Kit
For every minute that passes w/o defibrillation, the chances of survival decreases by 10%
Has a voice prompt, cost USD 3000/-
UK - not a legal requirement, but a Statutory requirement in US
No legal liability for deaths involving the use of AEDs

19. Fire Detection & Protection
Install smoke detection in:
Un manned sub stations
Review the Fire Alarm panel maintenance (discharged batteries)
Heavy grass growth noted in outdoor switch yard and SS E transformer yard
Review smoke detector adequacy and installations in buildings as per TAC FA rules
Review Portable Fire Extinguisher installation based on IS 2190 (Turbocharger area) DG MCC room- install smoke detection
Install Passive Fire Protection (PFP) measures in DG house, SS, various cable passes
Include electrical fire scenarios in EMP

20. Fire Protection XYZ to consider installation of fire protection system
Review PFE installation in various manufacturing blocks
Consider HVWS system for 30 MVA transformer

21. Electrical Systems & Procedures
Electrical WPs / Electrical isolation Procedure:
To be defined
At present, only for contractors, include for XYZ employees also
LOTO / Tag Out with fuse removal recommended
Electrical Change Control Procedure (ECCP) to be incorporated in all equipment modifications /additions (overloading issues in PTPT –MDP 1)
Display updated & approved SLDs in all SSs (no SLDs available for MDPs, SDPs) for ready reference
Include electrical fire scenarios (SS, transformers) in Emergency Management Plan (EMP)

22. Earthing Earth resistance tests to be done for individual pits too.
Earthing lay out to be updated
Earth pits may be provided with identification marks
Single earthing for 415 V equipment –several areas
Structures to be earthed (PTPT Area- solvent tanks, etc.)
4.5 Ohms noted in PTPT area
Ensure supervision while ER measurement
66 KV SY fence to be earthed

23. Earth Leakage Tester
The earth resistance from the equipment to the earth pit can be measured
Non-Contact measurement
Continuity loop test
No electrodes required
Cannot be used on flat conductors

24. Electrical Preventive Maintenance
Sky wire maintenance may be taken up annually to check up its physical condition /replace with vertical rods
Bucholtz relay to be simulated for operation for transformers
Install surge counters and leakage meters in S/Y
Gravel to be put in yards (66 KV, SS E transformers)
66 KV SW /Y -SF6 cubicle – not maintained, relay not calibrated, PS setting

25. Electrical Maintenance….
SS A- battery charger power comes from another plant through a COS
SS log – to be reviewed by electrical maintenance in charge on a daily basis
DGs- diesel oil level also needs to be monitored
Electrical Protection co-ordination study to be done (various load additions, HT motor test, etc.)
DGs- include trip and alarm settings in the log book

26. EPM…. Non-standard electrical rubber mat used in several places
DGs installed in another plant premises:
BC II (between XYZ DGs & another plant DG)to be locked in off condition
Approval from CEIG?

27. EPM…. Series earthing for equipment
Non-qualified electrical contractor electricians also are available
Large lug for termination
Loose terminations
No cable glands
Cable trenches behind electrical panels- require periodic cleaning- fire hazard

28. EPM…
Consider SRVs for 5 MVA indoor transformer (4050 L oil) at HT Motor test bay
Consider oil soak pit
Extension boards not fitted with RCCBs
CNC SHOP Main Electrical Panel:
Oil soaked rubber mat
Saw dust
Oil barrels kept close to the panel
Aluminum lugs used on copper bus bars
CNC lighting bay distribution panel- requires immediate attention

29. EPM…
Electricians & test personnel to be given electrically tested safety shoes
Use DI portable tools, instead of metallic tools
No reference drawings for SDP / MDPs
Re-wirable fuses used in SDP A2 Fuse DB – IMB Area
Electrical isolation – to be defined as part of the electrical work procedure

30. EPM….
Store room in DT building – install master control switch outside the room
List of C- license holders may be displayed in main SS
SS- E electrical maintenance- requires immediate attention:
1.5 MVA transformers- low oil level, yard full of grass, all alarms on
Overloading in one of the DPs
Compressors- identification and load distribution requires review

31. EPM…. SS E – Compressors- series earthing followed
HSD, solvent pipelines – flanges may be bonded to avert static discharges leading to fires, install FLP on-off push buttons
Now almost all mobile equipment has cable ends w/o plugs, install power receptacles wherever needed
Keep all transformer yards locked ( SS E)
All feeders may be identified (Electroplating section)

32. EPM….
Turbocharger electrical panels – no access, broken switch handles
ER tests:
No updated L/O drawing
High ER value PTPT area: 4 ohms plus
Electrical maintenance to supervise ER tests
SS C- identify both rear and front panels with the same identification marks
EPM- not complete, panels not included, not based on standards- re-align EPM based on NFPA 70 B

33. EPM…
SS B- 25 KVA UPS panel & batteries installed on wooden boards, temporary manner
MCC / MDP / SDP maintenance:
Cob webs
Dust
Open cable openings
Keep panel keys at every sub station
Keep HRC fuse pullers in sub stations- now pliers / bare hands are used.
Use fully insulated fuse pullers / tools as required

34. EPM… Heavy oil leak at radiator flange- SS B transformer 1.5 MVA
Critical loads- consider redundant cable from another feeder, follow another route
Single isolator used for multiple loads (HT Motor MDB 1, VPI DP 3)
Almost all spare feeders got used- consider revamp of electrical system, considering load additions for 10 years
U/G cable installation – to be done as per IS 1255
Use live U/G cable locator before digging
Use U/G cable lay out for reference / install route markers

35. OISD 137-Electrical Equipment Inspection
Polarization Index Test
PI = R10m /R1 m
2.5 –Excellent /Good
1-2-Questionable
Relative value, shows IR deterioration trend
Moisture Absorption Test
K = R1m / R15s
1-damp insulation
1.3 or greater-dry

36. Electrical Maintenance
Transformer OLTC counter reading- OEM recommended maintenance to be carried out
Consider using NFPA 70 B or OISD 137 for electrical preventive maintenance
XYZ to consider hotspot detection and Thermography surveys as part of predictive maintenance
XYZ to define AMC jobs as per standard practices (battery maintenance, etc.)

37. EPM……
OLTC counter based EPM – not done, including oil test for diverter compartment
Load currents of various loads taken:
PTPT building- MDP 1- overloaded
Final report will have more details, based on details sought
Hotspot Detection:
MDP 1, PTPT- 150 Degree C
LTB Area– A4, Bay IV DP – 110 Degree C
DT Area, Main Panel, 2 F2 DB Panel 2 – 77 Degree C

38. Infra-Red Hotspot Detector
Used as part of effective EPM
Hotspot surveys on critical, high capacity motor terminations, measurement of continuously running critical motors
Uses infra-red technology, with laser sighting
Very effective as a predictive maintenance tool
Interpretation of readings - very critical

39. Thermography Surveys
Part of E-RBM Programme
Identification of potential survey points / equipment and interpretation - very crucial
NFPA 70 E recommends Thermographic surveys

40. Ultrasonic Detectors
Detects fault conditions from sounds due to tracking, corona, arcing
Portable instrument, can be used on outdoor switchgear, panels, etc.
Non-Contact type

41. ‘All electrical accidents are preceded by rise in temperature & sound’

42. Lightning Protection Number of thunderstorm days, Baroda: 8
LP not as per IS 2309 / NFPA 780- identify critical plants / areas and install LP for critical plants / buildings
Buildings
EHV test stations

43. Surge Protection
Most modern electronic systems are at risk:
   
computers
data communication networks
building management systems
PABX telephone exchanges
CCTV equipment
fire and burglar alarms
telecom base stations
uninterruptible power supplies (UPSs)
programmable logic controllers (PLCs)
plant sensors
telemetry and data acquisition equipment.
Ensure surge protection for your EPBAX, DoT lines, UPS & Communication equipment

44. Innovative Electrical Safety Products

45. More ES Products Non-Contact type voltage detector (magnetic field)
Plug-In Wiring Checker (detects 14 wiring defects, ideal for testing sockets, BS 1363, faulty N, missing E, reverse P& N)
Videoscanner, Metalliscanner (detects metallic pipes, conduits, rebar, within 15” concrete)

46. Automatic Fire D&E System
Fire Trace - local flooding application inside electrical switch gears / power panels- detects heat and the heat -sensitive tube punctures, letting out Ozone-friendly fire extinguishing gas

47. Linear Heat Sensing Cables
* Advantageous than detectors, more effective
Consists of two cores separated by heat sensitive insulation
LHSC applications:
Cable trays in cable galleries
Transformers
Switch gears

48. AFCIs
Arcs - temperatures up to 20,000 degree C, Sun’s outer temperature degree C
No material on earth can withstand arc temperature
RCCBs cannot detect arcing faults
AFCIs - the innovative ES device after RCCBs
AFCIs detects arcing waveforms and trips
AFCIs - mandatory in all US homes from 2002 January onwards

49. Arcing Waveforms A loose wire at one terminal of a light bulb.
Arcing generated by a loose wire at a screw terminal.

50. THANK YOU!!!
Cholamandalam Risk Services Ltd.