1 / 49

ELECTRICAL SAFETY AUDIT for XYZ Gujarat

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

lesley-dyer
Download Presentation

ELECTRICAL SAFETY AUDIT for XYZ Gujarat

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  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.

More Related