October 4 to 6, 2004

Cholamandalam
Risk Services
ELECTRICAL
SAFETYMS
AUDIT

Ltd.for

XYZ
Gujarat

Chennai
www.cholarisk.com

Cholamandalam Risk Services

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

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

Close Out Presentation

ESA approach, methodology & coverage
XYZ- High Priority Areas
XYZ-ESA- observations &
recommendations

ESA Scope, Methodology &

Coverage

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

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

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.)

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

ESA -Standards & Codes

BIS Publications
NFPA Codes
OISD Standards
Indian Electricity Rules, 1956
British Standards
Best Engineering Practices

ESA Observations &

Recommendations

 Very receptive to improvement suggestions

Availability of skilled technocrats, global expertise
OHSAS 18001 certified plant
Availability of testing resources
Existence of systems and procedures

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

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

Transformers
Silica gel in several transformers- to be reactivated
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

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

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

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

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

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)

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

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

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

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

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?

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

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

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

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

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)

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

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

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

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

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.)

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

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

Thermography Surveys
Part of E-RBM Programme

Identification of potential survey points /

equipment and interpretation - very crucial
NFPA 70 E recommends Thermographic surveys

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

All electrical accidents are

preceded by rise in temperature
& sound

Lightning Protection
Number of thunderstorm days,
Baroda: 8
LP not as per IS 2309 / NFPA 780identify critical plants / areas and
install LP for critical plants / buildings

Buildings
EHV test stations

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

Innovative Electrical Safety

Products

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)

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

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

AFCIs
Arcs - temperatures up to 20,000 degree C, Suns outer
temperature- 5000 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

Arcing Waveforms

A loose wire at one terminal of

a light bulb.

Arcing generated by a loose

wire at a screw terminal.

THANK YOU!!!
Cholamandalam Risk Services Ltd.