Professional Documents
Culture Documents
for XYZ
Gujarat
October 4 to 6, 2004
www.cholarisk.com
Shock, fire
Lightning Protection HAC Earthing Static electricity issues EPM Accidents Review of All records & documents Training Electrical Protection
Sample tests
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
AUDIT SCHEDULE
(4 6 October 2004)
briefing, Main SLD review, switchyard visit, SS A,B, C, DG House, manufacturing blocks
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
Turbocharger Area HV Disconnector Area Fuel Tanks (HSD, Solvent, Transformer oil)
LTB Area
Health Centre Workers Canteen
LIMITATIONS
VERY OLD PLANT UNPLANNED EXPANSIONS RAPID GROWTH REQUIRES FUTURE PLANNING LIMITED MAINTENANCE FORCE IN CERTAIN AREAS
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
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 cable lay out for reference No resuscitation chart displayed
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/-
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 rules Review Portable Fire Extinguisher installation based on IS 2190 (Turbocharger area) DG MCC roominstall smoke detection Install Passive Fire Protection (PFP) measures in DG house, SS, various cable passes Include electrical fire scenarios in EMP
Fire Protection
XYZ to consider installation of fire protection system Review PFE installation in various manufacturing blocks Consider HVWS system for 30 MVA transformer
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 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
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
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?
EPM.
Series earthing for equipment Non-qualified electrical contractor electricians also are available
EPM
Consider SRVs for 5 MVA indoor transformer (4050 L oil) at HT Motor test bay
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
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
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 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)
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 manner MCC / MDP / SDP maintenance:
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
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
PI = R10m /R1 m
2.5 Excellent /Good 1-2-Questionable Relative value, shows IR deterioration trend
K = R1m / R15s
1-damp insulation 1.3 or greater-dry
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.)
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
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, arcing Portable instrument, can be used on outdoor switchgear, panels, etc. Non-Contact type
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
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
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)
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
AFCIs
Arcs - temperatures up to 20,000 degree C, Suns outer temperature- 5000 degree C
Arcing Waveforms
THANK YOU!!!
Cholamandalam Risk Services Ltd.