ELECTRICAL SAFETY AUDITforXYZGujarat
Cholamandalam MS Risk Services Ltd. Chennai
www.cholarisk.com
October 4 to 6, 2004
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 -CLIENTSMRPL Refinery, MangaloreShasun Chemicals, CuddaloreAhmedabad Electricity Company, AhmedabadOrchid Pharmaceutical Company, ChennaiEID Parry Biochemicals, Tamil NaduBPCL, ManmadVikram Cements, Madhya PradeshChambal Fertilizers, RajasthanTI Diamond Chain, TNHLL, HaldiaVisaka Cements, Andhra PradeshBombay Dyeing, PatalgangaGMR Power plant, MangaloreCP Aqua Culture, TN Surat Electricity Company, SuratAditya Cements, Rajasthan
Close Out Presentation
ESA –approach, methodology & coverage
XYZ- High Priority Areas
XYZ-ESA- observations & recommendations
ESA – Scope, Methodology & Coverage
ESA- Scope of workCompliance to IERElectrical 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 -FamiliarizationDiscussion with Head-Electrical, review of key SLDESA Physical inspections Sample Testing Document & records review Meeting –various departments Close-Out meeting
Interim ReportFinal 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 Coverage66 KV S/YDG House All Sub Stations (A, B, C, E)Transformers-various areasCNC ShopHT Motor BuildingVPI AreaIMB AreaDT AreaTransformer Manufacturing Area, SS EAdmin BuildingRelay BuildingAuxiliary I & II buildingElectroplating/ Anodizing
• Turbocharger Area
•HV Disconnector Area
•Fuel Tanks (HSD, Solvent, Transformer oil)
•LTB Area
•Health Centre
• Workers’ Canteen
ESA -Standards & Codes
BIS PublicationsNFPA CodesOISD StandardsIndian Electricity Rules, 1956British StandardsBest 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 PLANTUNPLANNED EXPANSIONSRAPID GROWTHREQUIRES FUTURE PLANNINGLIMITED MAINTENANCE FORCE IN CERTAIN AREAS
XYZ -High Priority Areas
PTPT Area- 1.5 MVA transformer, overloaded electrical panelCNC Shop floor- bay lightning panel Earthing issuesSS- E, PTPT areas – responsibility to be defined Electrical hotspots at terminations – potential fire hazardElectrical Panels – requires due attentionFire Hydrant system to be installedDGs in another plant area
Transformers
Silica gel in several transformers- to be re-activatedNeutral & 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 linesBattery rooms-cover battery terminalsIdentification of feeders / panels / circuits - missingUse of live U/G cable locator before excavationMaintain 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 rulesReview Portable Fire Extinguisher installation based on IS 2190 (Turbocharger area) DG MCC room- install smoke detectionInstall Passive Fire Protection (PFP) measures in DG house, SS, various cable passesInclude electrical fire scenarios in EMP
Fire Protection
XYZ to consider installation of fire protection system Review PFE installation in various manufacturing blocksConsider 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 updatedEarth pits may be provided with identification marksSingle earthing for 415 V equipment –several areasStructures to be earthed (PTPT Area- solvent tanks, etc.)4.5 Ohms noted in PTPT areaEnsure supervision while ER measurement66 KV SY fence to be earthed
Earth Leakage Tester
The earth resistance from the equipment to the earth pit can be measuredNon-Contact measurementContinuity loop testNo electrodes requiredCannot 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 rodsBucholtz relay to be simulated for operation for transformersInstall surge counters and leakage meters in S/YGravel 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 COSSS log – to be reviewed by electrical maintenance in charge on a daily basisDGs- 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 placesDGs 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 barsCNC lighting bay distribution panel- requires immediate attention
EPM…
Electricians & test personnel to be given electrically tested safety shoesUse DI portable tools, instead of metallic toolsNo reference drawings for SDP / MDPsRe-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 followedHSD, solvent pipelines – flanges may be bonded to avert static discharges leading to fires, install FLP on-off push buttonsNow 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 mannerMCC / MDP / SDP maintenance: Cob webs Dust Open cable openings
Keep panel keys at every sub stationKeep 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 MVACritical loads- consider redundant cable from another feeder, follow another routeSingle 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 yearsU/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 outConsider 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 compartmentLoad 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, arcingPortable 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: 8LP not as per IS 2309 / NFPA 780- identify 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, Sun’s 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.