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 meetingInterim 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 glandsCable 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

soughtHotspot 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.