Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

ELECTRICAL SAFETY AUDITING CHECKPOINTS

P.G. Sreejith
Cholamandalam MS Risk Services Ltd. Chennai, INDIA [email protected]

Compliance to Statutory Rules

Applicability of rules (Indian electricity Rules, Petroleum Rules, etc.) Compliance to inspectors reports Submission of accident intimation reports, forms, etc. in time Intimation of inspector before energizing new / changed electrical installation

Electrical Shock/ Flash / Injury Hazards

RCCBs selection, installation and maintenance Aspect of Nuisance Tripping and bypassing of RCCBs Bypasses fuses, MCB (Miniature Circuit Breaker), etc. Use of re-wirable fuses Earthing defects Use of double insulated (class II) tools, centre tapped power supply, extra-low voltage equipment for confined spaces Accessible live parts Electrical rubber mat Wrong identification of equipment / feeders Defective electrical portable tools Are the necessary PPEs (Personal Protective Equipments) used? Interlocks provided for multiple power sources? Is the interlocking system in place? Are MCC (Motor Control Centers) /PCCs (Power Control Centers) / DBs (Distribution Boards) maintained to avert flash incidents? Operational clearance as per IER 51 Tripping hazards due to loose cabling/cords, etc. Adequacy of illumination in electrical rooms/around panels, DBs, etc. Stand-by power supply (Diesel Generator set)

Electrical Fire Hazards

Storage of combustible materials near electrical equipment / fuse units RCCBs Master switch in warehouses Proper cable joint procedures as per manufacturer

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Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

Earthing defects Use of non-standard fuse wires Bypassing of protection devices Deteriorated insulation Selection, deployment of PFEs ( (Portable Fire Extinguishers) Sealing of cable passes, openings, baffle walls (Passive Fire Protection) Tracking possibility Unused openings in live panels, etc. Possibility of ground fault / short circuit Mechanical protection to cables Loose terminations due to improper supports, crimping Improper gland installation, wrong lug size Over-rated fuses, wrongly set protection relays, etc.

Electrical Safety Training

Need for electrical safety training Training content identification Periodicity Competency of faculty members Objective of training

Earthing System

Installation as per approved design? Installation and Maintenance as per IS 3043? Earth resistance measured periodically? Test procedure Acceptable earth resistance values Is the earthing system modified when electrical installation is modified? Are neutral earth pits independent and separate? Are earth pits identified? Are two and distinct earth connections provided? Is the earth continuity tested? Is bonding and earthing carried out to avoid ESD hazards?

Competency and Adequacy of Electrical Personnel

Competency of electrical O&M personnel Understanding of electrical hazards Are the operating and maintenance procedures amended after accidents? Awareness of latest electrical protection devices, hazards, etc. Workmanship Adequacy of electrical personnel

P.G. Sreejith/Cholamandalam MS Risk Services

Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

Frequency and severity of electrical accidents Nature of electrical accidents Safety attitude

P.G. Sreejith
[email protected]

Electrical Preventive Maintenance

Is there an EPM programme in place? Is the programme implemented? What is the slippage? Are the relevant standards (statutes and non-statutory) referred and incorporated in the EPM programme? Electrical Tests, Records, Test Procedure and periodicity (earth resistance, insulation resistance tests) Is the EPM programme only documented? Transformer tests (dielectric strength, acidity, sludge deposits, dissolved gases, etc.) and periodicity Periodic calibration of meters (ammeter, voltmeter, relays, temperature gauges) and test instruments (insulation resistance megger, earth resistance megger, multi-meters, etc.)

Electrical Accident Investigation Procedure

Is every accident / near-miss electrical accidents investigated in detail? Is the root cause identified and included in the APP (Accident Prevention Programme)? Are the recommendations incorporated in the O&M procedures/ work permit Are these accident causes given importance in safety training sessions? Are the hazard identification techniques such as job safety analysis, Fault Tree Analysis, etc. utilized?

Importance of Electrical Safety in the Overall Safety System

Periodicity of comprehensive ESAs Understanding of electrical hazards Electrical checkpoints in the safety checklist Electrical safety items the in safety committee agenda Implementation priority for electrical hazards Electrical Work Permit System Electrical Operating Procedures Electrical hazard identification techniques used (Electrical HAZOP, Electrical Job safety analysis, etc.)

P.G. Sreejith/Cholamandalam MS Risk Services

Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

Lightning Protection
Is the Lightning protection system as per IS 2309? Are the numbers of down conductors direct and adequate? Are all the structures and building under the zone of protection? While reviewing lightning protection, are both the plan and elevation of structures, etc. considered? ESP (Electronic system Protection) for electronic system / equipment Is the earthing for the electrical and lightning systems interconnected? Are the storage tanks / chimneys and other special structures protected? Earth electrodes- maintenance / periodic tests / acceptable value Awareness of basic concepts of lightning such as types of lightning, predictability factor, protection concepts, etc.

Hazardous Area Classification and Installation of Special Electrical Equipment

Are hazardous areas classified as per IS 5572? Are the special electrical equipments selected and installed as per IS

5571?

Are the electrical equipments maintained as per IS 2148 and IS 13346? Review of area classification in case of process change / plant modification, etc. Approval of area classification drawings as per statutory rules Maintenance of flame-proof equipments Use of ordinary electrical equipment in hazardous areas Awareness of O&M personnel about hazardous area and flame-proof equipments

Electro-Static (ES) Hazards and Control

Are the ES hazards identified in the plant? Are the non-conductive parts where ES hazards are identified, bonded & earthed? Is the concept of equi-potential bonding and ESD hazards clear to O&M personnel? Does the tanker (carrying flammable chemicals) de-canting procedure, switch-loading, etc. defined and made clear to all concerned?

Electrical Protection System

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P.G. Sreejith
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mind?

Are the protection relays in place and set in the main PCC / MCC? Are the relays set in accordance with calculated, design parameters in

Are they calibrated and tested periodically? Availability of HRC fuses, standard fuse wires, MCBs, MCCBs, RCCBs, etc. Are the transformer protection devices in place? (Bucholtz Relay, Oil Temperature Relay, Winding Temperature relay, Silica Gel Breather, Explosion Vent, etc.)

Electrical Single Line Diagram / Lay Out Diagram / Equipment Layout / Electrical Control diagram

Unauthorized Temporary Installations? Updated? SLD reflects the actual installation? Duly approved by statutory authorities?

Permission to photograph electrical hazards to highlight the situation Assistance of an electrician to carry out various measurements / tests (load current, insulation resistance, earth resistance) including the test instruments as necessary Access to relevant test reports /records/inspection records/maintenance documentation/accident investigation reports/work permits/training records, etc. Permission to isolate section of the electrical system or equipment as necessary without affecting production

II. ELECTRICAL SAFETY AUDITING

Field Visit

The field /plant visit is the most important part of the ESA programme. This involves visiting the plant to identify electrical hazards as per the scope of the audit. In electrical safety audits, the incoming electrical supply receiving section (outdoor substation and main transformer) is inspected first. Then the main sub-station housing the PCCs or MCCs and the cable gallery (if present) is inspected. Next are the electrical equipments installed in various process sections, the cabling and the distribution transformers located in the plant are visited. The aspects such as earthing, lightning protection, maintenance condition, loose cabling, temporary wiring, electrical fire hazards, shock potential, etc. are critically looked-into. The checklist provided in the Pre-audit

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Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

Preparation section is rather a comprehensive attempt, covering almost allelectrical safety aspects. The verification of the actual installation against available drawing (such as electrical single line diagram, earthing lay out, etc.) is also carried out during the field visit. Discussion with Safety and Electrical personnel

Clarification / discussion is carried out with the plant officials (electrical /safety) during the field visit. A senior electrical engineer and preferably, safety officer should also be part of the external electrical safety audit team. This is a continuous activity right from the beginning of the audit. Clarifications help to ascertain facts and to understand the system in a better manner. The on-site interactions will help to clear many doubts and to suggest many practical solutions to the client.

Review of Documentation / Records

Normally, this part is taken-up after the field visits. All the relevant maintenance documentation, test records, electrical records, electrical inspector reports, OEM (Original Equipment Manufacturer) service manuals, History cards are subjected to detailed examination. All the relevant drawings (electrical single line diagram, earthing layout, hazardous area classification drawings, protection system schematic, equipment layout, lightning protection drawings) are also checked against actual installation and commended upon, with reference to applicable standards.

III. POST-ESA ELEMENTS

Report Format There is no standard ESA report format available. Considering aspects such as clarity of report, usefulness to the client, and to streamline the report, the following format is recommended. Sl. No. Observed Electrical Implicati Hazard / Unsafe on Condition /NonCompliance Recommendati on Implementat ion Priority

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Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

The implication column helps the user to appreciate the hazard, to understand the potential and to prioritize the implementation based on its severity. The report format where the observations and recommendations are written together (non-tabular format) is popular and is the one that is commonly in use nowadays. The tabular report format helps to streamline the report, by shedding the unnecessary written matter, making the report crisp and focussed. The implementation priority helps the management to take appropriate action in an organized manner. Several clients specifically requested LPA to recommend implementation priority of the recommendation.

Implementation Priority Ranking

Sl. No. 1 Electrical Risks -Statutory noncompliance -Fatal shock hazards - Sustained fault condition due to defective earthing - -Fire / explosion due to improper electrical equipment selection / maintenance in flammable atmospheres - -Fires / Explosion due to electrostatic dissipation in flammable atmospheres Severity -High Risk - Hazards that pose immediate threat to life & property Consequence -Fatal /catastrophic -Penalty from statutory authorities Implementation Priority

Priority A Immediate correction

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Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
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2 -Defects in protection system -Maintenance flaws that could lead to equipment failure /fire / flash -Operational problems due to poor illumination wrong identification, inadequate clearance, etc. -Deterioration of equipment insulation / earthing condition due to lack of monitoring /testing

-Medium Risk

-Critical

-Priority B -Corrective action in the next available opportunity

-Hazards that pose no immediate threat to life and property -Lack of implementation of maintenance programme due to inadequate personnel

Low Risk

Marginal

- Priority C Corrective action in a phased manner recommended -Long-term corrective measure

P.G. Sreejith/Cholamandalam MS Risk Services

Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

Sample ESA (Electrical Safety Audit) Report Contents

Management Abstract

The management abstract as the name implies contains the salient observations noted during the audit and the recommendations in a nutshell. The top management is a busy lot and generally appreciates when matters are presented in a crisp and focussed manner, highlighting the most critical aspects. They will be eager to understand those hazards that are harmful to their employees and to the property. Any prudent management will consider seriously potential hazards that can affect their business (directly as well as indirectly) and will take immediate action. Considering the importance of this
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Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

section, every care has to be taken in choosing appropriate words and to effectively convey the message, depending upon the criticality of the hazard.
Introduction

This section generally contains the ESA scope of work, exclusions in the audit scope, assistance provided during the audit, details of the audit team, clients officials contacted during the audit, audit methodology, and the audit duration. This section can also contain summary of the clients safety system, safety auditing policy, training strategy, Accident Prevention Programme, and the management commitment towards safety. The details of clients business interests and other specific details of the plant process also could form part of this section.
Overview of Electrical System

The overview section contains the details of the electrical power supply and the power distribution. This section can also discuss the details of critical electrical installations, name plate details of critical electrical equipment, recent alterations/additions carried in the electrical installation, captive generation details, etc. This section can also discuss about the future expansion plans with respect to electrical capacity.
Specific Observations and Recommendations

This is the most important section containing the specific observations and recommendations in the plant observed during the audit. Normally, the observations are noted area/plant wise. Checklist method is found effective and various standards (both statutes and non-statutes) are available for reference. The format for this section is given in this paper.
Lightning Protection System Evaluation

The review of the existing lightning protection system of the plant as per the applicable national (IS: 2309) and international standards (NFPA 780) is carried out in this section on a sample basis. The various maintenance aspects are also evaluated in this section. If required, the fundamental step of ascertaining the need for protecting buildings /structures by calculating the risk factor is also carried out. The experience the audit team gained while auditing other similar plants /installations are also discussed in the report for the benefit of the client.

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Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

Electro-Static Hazards- Control Measures

ESD (Electro-Static Discharges) is a critical area where the potential ESD hazards are to be identified and necessary solutions are to be provided. Making the client aware of the potential accidents that can occur due to Electro-static discharges, minimum ignition energy required for fire /explosion, concept of equi-potential bonding and earthing, etc. are also crucial to make them understand the ESD hazards in the right light. Many plants handling flammable chemicals do not understand the concepts of ESD and hence do not follow de-canting procedure that is very unsafe. The reference standards used for identifying and controlling electro-static hazards are IS:7389 and NFPA 77.
Hazardous Areas Observations and Recommendations

This is another crucial area that needs to be evaluated critically. Although hazardous areas are critical, they are mostly neglected in most of the hazardous plants. The design principle of flameproof equipment makes it a special equipment that needs special care. Area classification into zones and installing various types of electrical equipment are the critical factors in controlling accidents in hazardous areas. Once the hazardous areas are classified and the right electrical equipments are installed, the onus of maintaining these special electrical equipments becomes the duty of the electrical maintenance personnel. In almost 90 % of the cases, the maintenance of these electrical equipments is not up to the required level. The hazardous area classification is carried out by process experts depending upon the possibility of existence of flammable vapour/gases as per IS:5572 /OISD 113 /API RP 500. The selection of electrical equipments is carried out as per IS:5571 and is to be maintained as per IS:13346 and IS:2148 provides the details of special features of flameproof equipments.
Review of Electrical Accidents and Control Measures

The electrical accident record in the plant is analyzed in this section. Discussions are also carried out with electrical and safety officers to fully understand the accident and to pinpoint the root cause. The accidents report format as well as the root cause identification methods are analyzed and recommendations are provided.
Review of Fire Hazards and Fire Protection Measures for Electrical Installations

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Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
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This section covers the identified potential electrical fire hazards, fire prevention methods and the fire protection strategies to be adopted by the client. The suitable fire detection (LHS Linear Heat Sensing cable, smoke/fire detectors) and extinguishing medium (fixe as well as portable) are also recommended depending upon the application. The focus areas will be the electrical installation / equipment where potential of fire hazards are relatively high such as MCC/PCC rooms, transformers, power plants, DG rooms, cable galleries, warehouses, store rooms, office buildings, etc.
Electrical Maintenance Review

The electrical maintenance aspects in toto will be reviewed in this section. The standards followed competency of O&M personnel, tests carried out as part of maintenance, etc. will be reviewed in detail. Implementation slippage, test value interpretation, appropriateness of action taken, etc. will also be evaluated. Various national standards (partial list provided in this paper) are used for this purpose.
Review of Electrical Test Records and Test Procedures

Tests that are carried on sample basis are evaluated in this section. Tests are carried out when it is felt that the values recorded are not credible. Normally, the following tests are carried out. 1. Insulation resistance values of select cables / motors 2. Load current measurements of feeders/motors 3. Earth resistance tests The test procedures that are adopted in the plant are also verified against national standards. OSD standards as well as national standards provide valuable guidance regarding acceptable values. The load currents measured are checked against the current carrying capacity of cable/motor after applying applicable rating/de-rating factors to identify overload condition.
Annexures (for reference, guidelines, etc.)

This section consists of various published reference materials that could be beneficial to the client in the area of electrical safety. The plant electrical single line diagram and the key electrical equipment lay out diagram may also be attached in this section for future ready reference.
Photographs (to highlight electrical hazards)

This is an important section, which is used to highlight electrical hazards identified in the plant. The permission to photograph plant sections is taken in

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Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
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the pre-audit meeting. Generally, auditing agencies maintain confidentiality of the safety audit report as well as the photographs. Once the photograph is attached in the report with the relevant caption, management appreciates the hazard in a better manner than when it is expressed in text form.

P.G. Sreejith
Manager, Cholamandalam MS Risk Services Ltd. Chennai, INDIA [email protected]

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Cholamandalam MS Risk Services Ltd.

P.G. Sreejith
[email protected]

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