ENGINEERING BULLETIN

DOCUMENT No: EB-0008

CATEGORY: Electrical Fires

ISSUED BY: ROB SALBEGO

DATE: 03/05/2021

TOPIC: Reducing the risk of electrical fires on our sites

PROBLEM / CONCERN:
There is a growing concern of the risk of electrical fires on our sites, which can be avoided by following some simple
instructions and implementing simple but effective solutions.

An electrical fire is a fire, ignition or burning caused anywhere along the electrical circuit and can be caused by various
factors. In this case, we are specifically referring to the AC circuit from where the grid enters the site, through the AC
Mains Box, APS or LCU, generator ATS and beyond to the AC DB and all loads (rectifier, shelter, air conditioning, etc.).

Due to fluctuations in the grid voltage, whenever the voltage decreases, the current increases. An increase in current
results in wires and connection terminals experiencing higher temperatures and if terminals are not tightened correctly,
then arcing can occur, which could result in ignition of a fire. When equipment is designed for 220VAC, it is expected that
the voltage would be within 10 or 15% of this designed range. Unfortunately, voltages in some areas can go beyond this.

In addition, the most important reason for a Main Circuit Breaker (MCB) or a Moulded Case Circuit Breaker (MCCB) to be
installed where the grid enters a site, is to protect all the site equipment that follows from high currents. If these
breakers are bypassed or if fuses are installed on a site and bypassed, then the next pieces of equipment in the circuit
are left exposed and at risk.

Note also that because we have introduced Auto Phase Selectors on many sites and because these are designed to
operate down to 150VAC, we are potentially introducing higher currents into our AC circuit.

Electricity is dangerous and the rules need to be respected both from a Health and Safety perspective but also from the
point of respecting all the equipment on our sites.

For all the reasons above, it is imperative that everyone on site follows the instructions indicated below.

EB-0008 - Electrical Fires - EN

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 Typical Wiring Block Diagram of a Helios Site

IMPROVEMENT / NOTIFICATION:

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The following applies to ALL sites that have grid connected:

Correct Wiring & Connections

 All terminals and screws need to be checked at every PM visit to ensure that all screws where wires are
connected, are tight and wires are secure. This includes main breakers and surge protection units in AC Mains
Box; APS terminals, Grid meter terminals, LCU terminals, Gave switch and contactor terminals and any other
breakers and terminals carrying the grid power.

 All rigid pin lugs fitted to any of the above-mentioned components need to be replaced with bootlace ferrules.
This is even more important for high load sites and sites with an Auto Phase Selector.

 In some cases, such as the MCCB’s in the AC Mains Box, ring lugs are required to terminate the wires. Ensure
that the correct size ring lugs have been used, that the lugs have been crimped correctly and securely and that
the screws/bolts are tight.

 There must never be any joints in a cable anywhere in the AC circuit. If a cable has been damaged in any way,
the entire length of the cable from device to device must be replaced.

 The correct size cable must be used along the entire circuit. If any cable is found to be too small, it must be
replaced.

Effective Site Protection

 Fuses at the main incoming need to be replaced with circuit breakers. In countries (such as Congo B), where
fuses are still required by the local grid company, Helios must install a circuit breaker after these fuses. So in the
case that fuses are bypassed, the breaker will still trip in the event of an over current. There must always be a
circuit breaker between the grid company and all our equipment on site.

 Circuit breakers must never be bypassed – without a breaker between the grid and our equipment on site, there
is no protection from over current.

Gave Switches, Grid Meters & Phase Selectors

 For any site with a Gen Logic generator, the Gave switch needs to be checked to ensure that a “zero” wire has
been installed. If any gave switch is found without a “zero” wire, this must be rectified as a matter of urgency.
Please refer to EN-0001 and SOP HT-PE-01-11-WIN – this details what needs to be done and how.

 For any site fitted with an Auto Phase Selector, please ensure that you read EB-0007 and follow the SOP HT-PE-
01-66-WIN very carefully. These work instructions must be implemented on all sites with an APS.

 If there is a Smart Meter installed within a generator housing or canopy, this must be removed and the smart
meter must be installed outside in the AC Mains Box or in a separate housing. The generator vibrations could
result in terminations loosening on the meter which increases the risk of fire.

EB-0008 - Electrical Fires - EN

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 Pin Lugs to be replaced with Bootlace Ferrules

Fuses to be replaced with Circuit Breaker

Gave Switch with “zero” wire missing to have wire installed

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 ACTION:

MUST DO: PROOF OF COMPLETION: DUE:

All items mentioned in this document are to be

SWO opened after every PM site visit
checked at each PM site visit and a SWO Next PM
where a problem has been found.
opened where applicable.

ALL Zonal heads, Field Supervisors

This Engineering Bulletin must be shared with
and Field Technicians must
all field personnel. Also available in the E- Immediately
acknowledge receipt of this document
Learning Portal.
and confirm that they have understood.

Anyone who does not understand the content of Managers of all field teams confirm
this document must seek clarity from their that all team members understand and Immediately
respective manager. will comply to this document.

FINAL NOTE:

It is the duty of each field technician to ensure that electrical installations on site are safe, neat and tidy and to
open SWO’s and to ensure that SWO’s are closed if any of the above or any unsafe installations are found.

EB-0008 - Electrical Fires - EN

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