ELECTRICAL SAFETY AUDIT for XYZ Gujarat

1. ELECTRICAL SAFETY AUDITforXYZGujarat Cholamandalam MS Risk Services Ltd. Chennai www.cholarisk.com October 4 to 6, 2004

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. 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

8. 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.)

9. 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 Audit Coverage • Turbocharger Area • HV Disconnector Area • Fuel Tanks (HSD, Solvent, Transformer oil) • LTB Area • Health Centre • Workers’ Canteen

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

11. ESA – Observations & Recommendations

12. Very receptive to improvement suggestions • Availability of skilled technocrats, global expertise • OHSAS 18001 certified plant • Availability of testing resources • Existence of systems and procedures

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

14. 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

15. 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

16. 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 cablelay out for reference • No resuscitation chart displayed

17. 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

18. 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 perTAC 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

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

20. 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)

21. 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

22. 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

23. 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

24. 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

25. 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?

26. 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

27. 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

28. 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

29. 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

30. 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)

31. 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

32. 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

33. 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

34. 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

35. 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.)

36. 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

37. 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

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

39. 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

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

41. 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

42. 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. Surge Protection Ensure surge protection for your EPBAX, DoT lines, UPS & Communication equipment

43. Innovative Electrical Safety Products

44. 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)

45. 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

46. 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

47. 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

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

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