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ELECTRICAL SAFETY AUDIT for XYZ Gujarat. 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

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electrical safety audit for xyz gujarat


Cholamandalam MS Risk Services Ltd.



October 4 to 6, 2004

cholamandalam risk services ltd
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
Close Out Presentation
  • ESA –approach, methodology & coverage
  • XYZ- High Priority Areas
  • XYZ-ESA- observations & recommendations
esa scope of work
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
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
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

Audit Coverage
  • Turbocharger Area
  • HV Disconnector Area
  • Fuel Tanks (HSD, Solvent, Transformer oil)
  • LTB Area
  • Health Centre
  • Workers’ Canteen
esa standards codes
ESA -Standards & Codes
  • BIS Publications
  • NFPA Codes
  • OISD Standards
  • Indian Electricity Rules, 1956
  • British Standards
  • Best Engineering Practices

Very receptive to improvement suggestions

  • Availability of skilled technocrats, global expertise
  • OHSAS 18001 certified plant
  • Availability of testing resources
  • Existence of systems and procedures
xyz high priority 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
  • 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
electrical injuries
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

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
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
fire protection
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 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)
  • 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
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
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
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
  • 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?
  • 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
  • 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
  • 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
  • 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
  • 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)
  • 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
  • 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
  • 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
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 maintenance1
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.)
  • 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
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
lightning protection
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
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.

Surge Protection

Ensure surge protection for your EPBAX, DoT lines, UPS & Communication equipment


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


  • 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.


Cholamandalam Risk Services Ltd.