Electrical Safety Auditing

8/8/2019 Electrical Safety Auditing

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ELECTRICAL SAFETY AUDITING

INTRODUCTION

In India, efforts for control of major chemical plantaccidents began in the aftermath of the Bhopal Gastragedy in 1984. In 1989, the Ministry of Environment &Forest, Government of India formed the important MIHC(Manufacture & Import of Hazardous Chemicals) rules.Ministry of Labour, Government of India implemented anILO (International Labour Organization) project to establishMAHC (Major Hazard Control) system to identify & assess

hazards in MAH plants, to frame new legislation for MHC,etc. Over 1000 industrial plants have been identified as MHplants in India. Unlike natural hazards, chemical hazardscan be prevented by proper planning & in case ofaccidents; the consequences can be minimized to theextent possible.

World wide, the total loss figure has doubled every 10years despite increased efforts by the chemical processindustry to improve safety. The increases are mostly due toan expansion in the number of chemical plants, an

increase in chemical plant size, an increase in the use ofmore complicated & dangerous chemicals. Within the past10 or 15 years, the chemical & petroleum industries haveundergone considerable changes. Process conditions suchas pressure & temperature have become more severe.Plants have grown in size & inventory. The scale of possiblefire, explosion has grown & so has the area that might beaffected by such events, especially outside the workboundary.

Why Safety Audits?

Safety audit is a systematic approach to evaluate potentialhazards and to recommend suggestions for improvement.SA is an important tool for identifying deterioration ofstandards, areas of risks or vulnerability, hazards andpotential accidents in plants for determining necessaryaction to / minimize hazards and for ensuring that thewhole safety effort is effective & meaningful.


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Safety audits are carried out due to various reasons suchas:

1. Statutory requirement (environmentalconcerns, Risk Analysis for hazardous industries,

etc.)2. Requirement of financial institution (for loans,etc.)3. Suggestion of an regulatory authorities4. Process change / plant capacity addition5. Change of management (Merger / Acquisition)6. Genuine management concern as a measure ofimprovement7. Part of OH& S (Occupational Health & Safety)policy of the organization8. Major accident in the plant / major accident in

the neighboring industry / major accident in a similarindustry9. Requirement of foreign partner

Many organizations in India are in the process ofestablishing the system of periodic safety audits althoughsafety is still not a statutory requirement In India. This is avery positive and welcome change in a developing countrylike ours. The collaboration with developed nations alsohelped to re-orient the safety perception of several Indiancompanies. Safety audits also provides an opportunity to

get updated with latest information on safetydevelopments and statutory amendments. It is a normalpart of good business practice to initiate and carry outsystems of inspection and checking to ensure thatoperations are carried out in an efficient and profitableway.

The loss potential in industry is not restricted to large-scaleincidents related to accidents, fires, explosions and similarincidents. For example, failure or damage to cables andinstrumentation equipment as a result of a minor incident

has led to lengthy downtime of plant, resulting in heavyfinancial loss.

The major objective of a safety audit is to determine theeffectiveness of the companys safety and loss preventionmeasures. It is an essential requirement of an audit systemthat it should originate with the policy-making executive


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and a consensus should be arrived at regarding the safetyaudit and its objectives.

Factories Act, 1948 (Section 7A) makes the occupierresponsible for providing a safe working environment for

the employees. Safety audit is one method of evaluatingthe safe environment provided in the plant, althoughsafety audit is not a direct requirement by Factories Act.Considering the changing international legislature trends,safety audits could become mandatory in India too in thenear future.

The statutory Manufacture, storage and Import ofHazardous Chemical Rules 1989 framed under theEnvironment Protection Act, 1986, stipulates companieshandling hazardous chemicals above the threshold

quantities specified to submit details of their safetysystems. Hazard identification and risk analysis arerequired to be carried out if the quantities of chemicalsstored are very higher than the threshold limits.

Moreover, safety auditing should be an integral part of anyorganizations safety management system. Auditing helpsthe organization to check the appropriateness of its safetypolicies, organization and arrangements, and to check thatthese are being applied in practice.

Why Electrical Safety Audits (ESA)?Identifying potential electrical hazards to prevent orminimize loss of life and property is perceived seriously bymany chemical industries the world over. General safetyauditing is popular where the objectives & concepts areclear whereas ESA is a specialized area that is still in theprocess of being understood by many.

Chemical industries are exposed to fires and explosionhazards due to the combustible properties of the chemicals

handled. As per the statistics available from Indian OilCompanies, for a five-year period, 263 major accidentstook place out of which 42% were due to fire. Whileanalyzing the probable causes for fires & explosions,electrical reasons are undoubtedly the top among themost probable causes. Hence, electrical safety deservesmaximum attention especially in hydrocarbon industry,where classified hazardous atmosphere is normally


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encountered and electricity constitutes one of the majorsources of ignition that could cause a fire or an explosion.

In factories, around 8% of all fatalities are due to accidentscaused by electricity. Data compiled by international

organizations like Fire Protection Association (FPA), UK andthe National Fire Protection Association (NFPA), USAindicate that nearly one fourth of all fires are caused byelectrical appliances or installations. In India, the conditionis still worse. Investigations of major fire incidents invarious types of occupancies over a number of years showthat nearly 40% of the fires are initiated by electricalcauses such as short circuits, overloading, loose electricalconnections, etc.

Our experience shows that either the top management or

the electrical department initiates ESAs and not the safetydepartment. The reason could be the lack of in depthknowledge of safety officers in electrical aspects coupledwith their limited involvement in electrical departmentsday-to-day functions.

Although electrical hazards will be identified and assessedin general safety audits, comprehensive electrical safetyaudits can provide a thorough review of the electricalsystem. This could identify potential electrical hazards,flaws in design system, maintenance system, etc.

Myths and Facts about Safety audits

Sl.No.

Myth Fact

1 Fault finding exercise Safety audit istechnique to evaluto understand whan organizatstands in terms safety.

2 More the safety audit teammembers, the better

The team compositshould be strateand should consist


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competent peowith right attitude.

3 Lowest quotation is the mainselection criterion for choosing the

safety auditing agency

Factors such competency, qual

credibility of reporhistory,organizationalinfrastructure,positive cliereference are to given due weightain the selectprocess. Agenshould be able provide unbiaspractical and coeffective safsolutions.

4 Hazard identification is a one-timeexercise. Need not be doneperiodically since the hazards doesnot change or grow in a plant unlessmodified or process changed.

Hazards grow wtime and with chanin process. As tigoes by, statutes well as technolochange. To comwith updatstatutory regulatioperiodic complianassessments aneeded.

5 The plants have competent technicalpersonnel. An external team cannotenvisage hazards that the internalsafety audit team failed to identify.

An unbiascompetent exterauditing agency wbe able to identhazards that internal safety auteam might nidentify due reasons such familiarity, etc.

Types of Safety Audits


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Internal Safety Audit External Safety Audit

o Electrical Safety Audit byInternal Audit Team

The disadvantages of internal safety audit could be theblinkers-on approach, avoiding noting electrical hazardsdue to the reluctance to change. Another disadvantage isthat the team members may refrain from criticallyevaluating a colleagues unit. When one is familiar with ahazardous situation, he tends to forget the nature of the

situation over a period of time, especially when nothingadverse happens.

The ESA team should ideally consist of:

Senior Electrical Manager / Engineer Safety Manager / Officer Process Engineer Engineering Officer Top Management Representative An external specialist, if needed

Since auditing is a specialized activity, the identifiedinternal team members may be exposed to training onSafety Management System Auditing principles.Experience has shown that training yields particularly richreturns in this field in the form of more meaningful auditingand reporting.

o Electrical Safety Audit by ExternalAuditing Agency

Experts or competent safety audit agencies are normallyentrusted with this task. The advantages include unbiasedreporting, and an expert view of the electrical system fromthe safety point of view. The most obvious advantage ofengaging external auditing agency is that they might beable to identify hazards that the internal team might fail todetect. Since the auditing agency is exposed to the latestsafety information, and will be inspecting various plants,


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the client can expect the best cost-effective safetysolutions through safety audit.

Periodicity of Safety Audits

Generally, the audit frequency will depend on the natureand type of activities within each area of operation. Areasonable general guide is that inspections should becarried out once each year, with more frequent inspectionsfor specific areas or activities. Records of injury anddamage accidents should be examined and use to identifyhigh-risk areas and activities and consequently thoseneeding more frequent inspection.

As a general thumb rule, audits by external agencies arecarried out every three years and the internal team does

the audit every year. Other than the routine safety audits,electrical safety audits should be initiated whenever thereare capacity additions & major alterations in the electricalsystem, frequent electrical accidents, and process changein the plant that may require a re look at the electricalinstallations in the changed process section. It isrecommended that the electrical design review and theimplementation should be carried out prior to initiating theexercise of ESA when the above mentioned changes areplanned / observed. Many organizations still confusethemselves with the terms ESA and electrical engineering

studies.

As per Indian electricity Rule 46, all electrical installationsare to be inspected with respect to Indian ElectricityRegulations with a periodicity not exceeding once in 5years by authorized electrical inspecting authorities.Electrical inspectors inspection and approval is requiredwhen the electrical installations are changed (added ormodified) as per rule 63.

As per OISD standard 145, internal safety audits are to be

carried out every year in refinery/installation and LPGbottling plants. OISD- GDN 145 09 provided theguidelines for carrying out internal safety audit checklistfor electrical system.

ELEMENTS OF ELECTRICAL SAFETY AUDITINGPROGRAMME


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ESA Programme can be broadly classified into 3 majorareas namely:

1. Pre-Audit2. Audit

3. Post-Audit

The efficacy of the audit (identification & control ofelectrical risks) largely depends on the pre-audit and thepost-audit sections. Pre and post audit elements are user /client dependent and obviously the audit depends on theaudit team. Unless the ESA objectives are clearly definedand audit recommendations considered, the ESAprogramme will not be successful.

An effective ESA programme should include elements such

as competent audit team formation, pre-audit briefing,collection & review of relevant information (preventivemaintenance documentation, accident reports, electricalinspectors reports, history cards), discussion with safety &electrical officers, plant visit and then the consolidation tothe top management. Finalizing the audit methodologyshould be in consultation with the requirements of theauditee. The ESA programme elements are discussedbelow.

Pre-Electrical Safety Audit Elements

ESA Scope of Work

Many are still unclear about the scope of Electrical Safetyaudits. The terms, Electrical energy audits, Electricalengineering studies and Electrical Safety audits areinterchangeably used even by many top technical officialsof industries. Unless the scope of study is well understood,the objectives of the audit cannot be attained. Definingscope of Electrical Safety audit based on the specificrequirement is the first step in the process of Electrical

Safety auditing.

Typical ESA scope of work could include:

Physical inspection of the plant with referenceto applicable Indian standards, Indian ElectricityRules and other relevant codes of Practice &identifying electrical hazards (shocks, fires, etc.).


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Reviewing the role of electrical safety in thetotal safety system. Review of protection devices / system of theelectrical installation. Review of adequacy of cables, motors, etc.

based on actual load current measurements andcable current carrying capacities. Examination of adequacy of plant lightningprotection system as per national and internationalstandards to suggest recommendations as perapplicable standards. Review of the hazardous area classificationcarried out in the plant as per IS: 5572 and to reviewthe selection, installation of special electricalequipment as per IS: 5571 to suggestrecommendations as per applicable standards.

Review of electrical accidents to identify rootcause of the accidents. Review the EPM (Electrical PreventiveMaintenance) programme in the plant and toexamine the documentation, checklists, work permit,test records, etc. and to suggest recommendationsas per applicable standards. To identify training needs of the plantemployees from the point of view of electrical safety. To evaluate the earthing system (installationand maintenance) in the plant based on IS 3043 and

to suggest recommendations. Review of the following test records, evaluatingthe test results and to suggest recommendations asper applicable standards. Transformer oil test. Insulation Resistance Tests. Earth Resistance tests.

(The checking of test procedures and checking of testresult interpretations are also part of this exercise).

To evaluate the potential electrical fire hazardsin the plant electrical installation and to suggest fireprotection measures as per applicable standards andIndian Electricity Rules. To identify the ESD (Electro-Static Hazards inthe plant and to suggest recommendations as perapplicable standards.


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Note: Generally, all the above inspections, reviews, etc. arecarried out on a sampling basis.

ESA Team Composition

The ESA audit could be internal or external. Safety bodieslike OISD recommends audits by internal team as well asexternal teams. The external ESA team should consist ofcompetent electrical engineers that are experienced inconducting similar types of audits. The client can ask forthe resume of the ESA team members of the externalagencies to make sure that they get the desired result inthe areas of electrical safety by having the right people inthe audit team. To ascertain the credibility of the agency,many prospective clients ask for references (where thisagency has conducted ESAs for them) that can provide a

better assessment of the auditing agency.

The team member should of course be familiar with allsafety-related issues such as safety auditing elements,accident investigation, safety training, etc. The abilities tointerpret rules, standards, etc. and to suggest practical andcost-effective safety solutions, etc. are also expected fromthe audit team. Effective communication skills,competency, right attitude, will to constantly update, willto share information, openness, belief in teamwork andperseverance are the other necessary qualities needed for

a safety auditor. The safety audit team leader should leadthe team and communicate to the clients representative inan effective manner.

Pre-Electrical Safety Audit Questionnaire

The details that would help the audit team (especially incase of external audit) will be included in the pre-auditquestionnaire. Although the generic details will be madeavailable to the audit agency in the initial stages, thespecific details would help the team to prepare themselves

to carry out the safety audit in an efficient manner. Thepre-audit questionnaire for ESA could include the followingaspects:

Process details Electrical Single Line Diagram Name plate details of major electricalequipment


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Details of classified zones in the plant Details of flammable chemicals handled in theplant Details of electrical accidents in the plant Details of addition / expansion of the plant

including electrical installation Overview of electrical maintenance system

Audit Preparation / Reference

The questionnaire is a vital tool for successful inspectionand time spent on its preparation is as valuable as thattaken by the audit itself. Auditing experience will revealthe need for supplementing or modifying it, provided thatthe auditors adopt a flexible approach to their task, andthe danger of confining attention only to those matters

listed in the original questionnaire must be avoided.

Checklists can be made with reference to:

Statutory Regulations Non-Statutory Standards (national andinternational)

ESA checklists could be prepared based on variousapplicable statutory and non-statutory standards andcodes of practice. Good engineering practice found during

other ES audits in similar installations can also be includedin the checklists. International standards such as API andNFPA can also referred wherever found necessary. Anotherimportant aspect in referring to various standards is thepossible confusion in reconciling a safety recommendation. The factors listed below are to be considered whilesuggesting a recommendation, if contradicting statementsare mentioned in rules / standards.

Compliance to statutory requirement Safety of the people and the plant

The experience gained by the ESA team members is a verycrucial factor in the compilation of audit checklists.Experienced and competent team members can offermany practical, cost-effective safety suggestions andsolutions.


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The checklists could contain the following sections withspecific checkpoints. Grouping the observations in thefollowing manner helps to identify and evaluate the areasof concern. Another way of categorization is having thecheckpoints grouped under various plant sections / areas,

which is the popular method. An advantage of this popularmethod is that a process section / unit in-charge can beasked to comply with the recommendations by giving acopy of the report section to him. But for the managementto understand the efficacy of the various electrical safetyelements, the grouping as indicated below will be of use.This way of grouping enables the consolidation exercisemore effective.

Compliance to Statutory Rules

o

Applicability of rules (Indian electricity Rules,Petroleum Rules, etc.)o Compliance to inspectors reports

o Submission of accident intimation reports, forms,

etc. in timeo Intimation of inspector before energizing new /

changed electrical installation

Electrical Shock/ Flash / Injury Hazards

o RCCBs selection, installation and maintenance

o Aspect of Nuisance Tripping and bypassing of

RCCBso Bypasses fuses, MCB (Miniature Circuit Breaker),

etc.o Use of re-wirable fuses

o Earthing defects

o Use of double insulated (class II) tools, centre

tapped power supply, extra-low voltage equipment forconfined spaceso Accessible live parts

o Electrical rubber mat

o Wrong identification of equipment / feeders

o Defective electrical portable tools

o Are the necessary PPEs (Personal Protective

Equipments) used?o Interlocks provided for multiple power sources?

o Is the interlocking system in place?

o Are MCC (Motor Control Centers) /PCCs (Power

Control Centers) / DBs (Distribution Boards) maintainedto avert flash incidents?o Operational clearance as per IER 51

o Tripping hazards due to loose cabling/cords, etc.


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o Adequacy of illumination in electrical

rooms/around panels, DBs, etc.o Stand-by power supply (Diesel Generator set)

Electrical Fire Hazards

o Storage of combustible materials near electricalequipment / fuse unitso RCCBs

o Master switch in warehouses

o Proper cable joint procedures as per

manufacturero Earthing defects

o Use of non-standard fuse wires

o Bypassing of protection devices

o Deteriorated insulation

o Selection, deployment of PFEs ( (Portable Fire

Extinguishers)o

Sealing of cable passes, openings, baffle walls(Passive Fire Protection)o Tracking possibility

o Unused openings in live panels, etc.

o Possibility of ground fault / short circuit

o Mechanical protection to cables

o Loose terminations due to improper supports,

crimpingo Improper gland installation, wrong lug size

o Over-rated fuses, wrongly set protection relays,

etc.

Electrical Safety Training

o Need for electrical safety training

o Training content identification

o Periodicity

o Competency of faculty members

o Objective of training

Earthing System

o Installation as per approved design?

o Installation and Maintenance as per IS 3043?

o Earth resistance measured periodically?

o Test procedure

o Acceptable earth resistance values

o Is the earthing system modified when electrical

installation is modified?o Are neutral earth pits independent and separate?

o Are earth pits identified?

o Are two and distinct earth connections provided?

o Is the earth continuity tested?


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o Is bonding and earthing carried out to avoid ESD

hazards?

Competency and Adequacy of Electrical Personnel

o Competency of electrical O&M personnel

o Understanding of electrical hazardso Are the operating and maintenance procedures

amended after accidents?o Awareness of latest electrical protection devices,

hazards, etc.o Workmanship

o Adequacy of electrical personnel

o Frequency and severity of electrical accidents

o Nature of electrical accidents

o Safety attitude

Electrical Preventive Maintenance

o Is there an EPM programme in place?

o Is the programme implemented? What is the

slippage?o Are the relevant standards (statutes and non-

statutory) referred and incorporated in the EPMprogramme?o Electrical Tests, Records, Test Procedure and

periodicity (earth resistance, insulation resistance tests)o Is the EPM programme only documented?

o Transformer tests (dielectric strength, acidity,

sludge deposits, dissolved gases, etc.) and periodicityo Periodic calibration of meters (ammeter,

voltmeter, relays, temperature gauges) and testinstruments (insulation resistance megger, earthresistance megger, multi-meters, etc.)

Electrical Accident Investigation Procedure

o Is every accident / near-miss electrical accidents

investigated in detail?o Is the root cause identified and included in the

APP (Accident Prevention Programme)?o Are the recommendations incorporated in the

O&M procedures/ work permito Are these accident causes given importance insafety training sessions?o Are the hazard identification techniques such as

job safety analysis, Fault Tree Analysis, etc. utilized?

Importance of Electrical Safety in the Overall SafetySystem


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o Periodicity of comprehensive ESAs

o Understanding of electrical hazards

o Electrical checkpoints in the safety checklist

o Electrical safety items the in safety committee

agendao Implementation priority for electrical hazards

o Electrical Work Permit Systemo Electrical Operating Procedures

o Electrical hazard identification techniques used

(Electrical HAZOP, Electrical Job safety analysis, etc.)

Lightning Protection

o Is the Lightning protection system as per IS

2309?o Are the numbers of down conductors direct and

adequate?o Are all the structures and building under the zone

of protection?o While reviewing lightning protection, are both the

plan and elevation of structures, etc. considered?o ESP (Electronic system Protection) for electronic

system / equipmento Is the earthing for the electrical and lightning

systems interconnected?o Are the storage tanks / chimneys and other

special structures protected?o Earth electrodes- maintenance / periodic tests /

acceptable valueo Awareness of basic concepts of lightning such as

types of lightning, predictability factor, protection

concepts, etc.

Hazardous Area Classification and Installation ofSpecial Electrical Equipment

o Are hazardous areas classified as per IS 5572?

o Are the special electrical equipments selected

and installed as per IS 5571?o Are the electrical equipments maintained as per

IS 2148 and IS 13346?o Review of area classification in case of process

change / plant modification, etc.

o Approval of area classification drawings as perstatutory ruleso Maintenance of flame-proof equipments

o Use of ordinary electrical equipment in hazardous

areaso Awareness of O&M personnel about hazardous

area and flame-proof equipments

Electro-Static (ES) Hazards and Control


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o Are the ES hazards identified in the plant?

o Are the non-conductive parts where ES hazards

are identified, bonded & earthed?o Is the concept of equi-potential bonding and ESD

hazards clear to O&M personnel?o Does the tanker (carrying flammable chemicals)

de-canting procedure, switch-loading, etc. defined andmade clear to all concerned?

Electrical Protection System

o Are the protection relays in place and set in the

main PCC / MCC?o Are the relays set in accordance with calculated,

design parameters in mind?o Are they calibrated and tested periodically?

o Availability of HRC fuses, standard fuse wires,

MCBs, MCCBs, RCCBs, etc.o Are the transformer protection devices in place?

(Bucholtz Relay, Oil Temperature Relay, WindingTemperature relay, Silica Gel Breather, Explosion Vent,etc.)

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

o Unauthorized Temporary Installations?

o Updated?

o SLD reflects the actual installation?

o Duly approved by statutory authorities?

As part of safety auditing, for that matter, in any auditing,cross-checking helps to ascertain facts although auditing isnot a policing activity. For instance, checking of the statusof actual equipment maintenance against documentedmaintenance checklist, say, earthing of a motor. Indocumented checklist, it may be marked as in order buton actual verification, earthing may be missing. Ourexperience in carrying out ESAs prove that generally,maintenance checklists are compiled and filed for the sakeof satisfying either ISO certification or statutory / audit

requirements and that actual implementation is seldomreligiously carried out.

Audits are carried out on a sampling basis. Although largesampling helps to get a more realistic view of the safetyaspects in the plant, this may not be practically possibledue to various factors such as time, etc. However, if theclient so desires, the sampling percentage can be clearly


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defined and communicated to the auditing agency.Generally in ESAs, the main areas are sub-station, mainpower transformer, distribution transformers, PCC room,One or two MCCs, Lighting panel, a few DBs, criticalmotors, etc. are inspected. Obviously, the sampling

depends on the size of the plant electrical system,criticality / hazardous nature of plant process, etc. Theareas that need focussed study will have to be looked intoin depth. The aspects that need focussed study could befrequent electrical accidents in an area/plant, electricalpanel flash incidents, major statutory non-compliance, etc.

Pre-Audit Meeting

Single point coordination is recommended from both thesides of the audit agency & the client. The person should

be well aware of the entire electrical installation andpreferably a senior electrical engineer. He should havegood rapport with all departments and should becommunicated with all departments to get the requiredinformation. The areas to be visited and activities to beinspected should be agreed with the members of themanagement concerned before the auditing begins. It is anormal practice to brief the clients officers in the openingmeeting the audit scope, methodology, etc. The clientshould also be informed about the possible assistance theESA team might require such as:

Permission to photograph electrical hazards tohighlight the situation Assistance of an electrician to carry out variousmeasurements / tests (load current, insulationresistance, earth resistance) including the testinstruments as necessary Access to relevant test reports/records/inspection records/maintenancedocumentation/accident investigation reports/workpermits/training records, etc.

Permission to isolate section of the electricalsystem or equipment as necessary without affectingproduction

II. ELECTRICAL SAFETY AUDITING

Field Visit


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The field /plant visit is the most important part of the ESAprogramme. This involves visiting the plant to identifyelectrical hazards as per the scope of the audit. Inelectrical safety audits, the incoming electrical supplyreceiving section (outdoor substation and main

transformer) is inspected first. Then the main sub-stationhousing the PCCs or MCCs and the cable gallery (if present)is inspected. Next are the electrical equipments installed invarious process sections, the cabling and the distributiontransformers located in the plant are visited. The aspectssuch as earthing, lightning protection, maintenancecondition, loose cabling, temporary wiring, electrical firehazards, shock potential, etc. are critically looked-into. Thechecklist provided in the Pre-audit Preparation section israther a comprehensive attempt, covering almost all-electrical safety aspects.

The verification of the actual installation against availabledrawing (such as electrical single line diagram, earthing layout, etc.) is also carried out during the field visit.

Discussion with Safety and Electricalpersonnel

Clarification / discussion is carried out with the plantofficials (electrical /safety) during the field visit. A seniorelectrical 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 theaudit. Clarifications help to ascertain facts and tounderstand the system in a better manner. The on-siteinteractions will help to clear many doubts and to suggestmany practical solutions to the client.

Review of Documentation / Records

Normally, this part is taken-up after the field visits. All therelevant maintenance documentation, test records,

electrical records, electrical inspector reports, OEM(Original Equipment Manufacturer) service manuals,History cards are subjected to detailed examination. All therelevant drawings (electrical single line diagram, earthinglayout, hazardous area classification drawings, protectionsystem schematic, equipment layout, lightning protectiondrawings) are also checked against actual installation andcommended upon, with reference to applicable standards.


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III. POST-ESA ELEMENTS

Report Format

There is no standard ESA report format available.

Considering aspects such as clarity of report, usefulness tothe client, and to streamline the report, the followingformat is recommended.

Sl.No.

Observed ElectricalHazard / UnsafeCondition /Non-Compliance

Implication

Recommendation

Implemenion Priorit

The implication column helps the user to appreciate thehazard, to understand the potential and to prioritize theimplementation based on its severity. The report formatwhere the observations and recommendations are writtentogether (non-tabular format) is popular and is the one thatis commonly in use nowadays. The tabular report formathelps to streamline the report, by shedding theunnecessary written matter, making the report crisp andfocussed.

The implementation priority helps the management to takeappropriate action in an organized manner. Several clientsspecifically requested LPA to recommend implementationpriority of the recommendation.

Implementation Priority Ranking

Sl.No.

Electrical Risks Severity ConsequenceImplementationPriority

1 -Statutory non-compliance

-Fatal shock hazards

Sustained faultcondition due to

-High Risk

- Hazardsthat poseimmediate threatto life &

-Fatal/catastrophic

-Penalty fromstatutoryauthorities

Priority A Immediate

correction


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defectiveearthing

-Fire / explosiondue to improper

electricalequipmentselection /maintenance inflammableatmospheres

-Fires / Explosiondue toelectrostaticdissipation inflammableatmospheres

property

2 -Defects in protectionsystem

-Maintenance flawsthat could lead toequipment failure/fire / flash

-Operational problemsdue to poorillumination wrongidentification,inadequate clearance,etc.

-Deterioration ofequipment insulation /earthing condition dueto lack of monitoring/testing

-MediumRisk

-Critical -Priority B

-Corrective action inthe next availableopportunity


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3

-Hazards that pose noimmediate threat to

life and property

-Lack of implementation ofmaintenanceprogramme due toinadequate personnel

LowRisk

Marginal

- Priority C

Corrective action ina phased mannerrecommended

-Long-termcorrective measure

ESA Report Contents

o Management Abstract

The management abstract as the name implies containsthe salient observations noted during the audit and therecommendations in a nutshell. The top management is abusy lot and generally appreciates when matters arepresented in a crisp and focussed manner, highlighting themost critical aspects. They will be eager to understandthose hazards that are harmful to their employees and to

the property. Any prudent management will considerseriously potential hazards that can affect their business(directly as well as indirectly) and will take immediateaction. Considering the importance of this section, everycare has to be taken in choosing appropriate words and toeffectively convey the message, depending upon thecriticality of the hazard.


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o Introduction

This section generally contains the ESA scope of work,exclusions in the audit scope, assistance provided duringthe audit, details of the audit team, clients officials

contacted during the audit, audit methodology, and theaudit duration. This section can also contain summary ofthe clients safety system, safety auditing policy, trainingstrategy, Accident Prevention Programme, and themanagement commitment towards safety. The details ofclients business interests and other specific details of theplant process also could form part of this section.

o Overview of Electrical System

The overview section contains the details of the electrical

power supply and the power distribution. This section canalso discuss the details of critical electrical installations,name plate details of critical electrical equipment, recentalterations/additions carried in the electrical installation,captive generation details, etc. This section can alsodiscuss about the future expansion plans with respect toelectrical capacity.

o Specific Observations andRecommendations

This is the most important section containing the specificobservations and recommendations in the plant observedduring the audit. Normally, the observations are notedarea/plant wise. Checklist method is found effective andvarious standards (both statutes and non-statutes) areavailable for reference. The format for this section is givenin this paper.

o Lightning Protection SystemEvaluation

The review of the existing lightning protection system ofthe plant as per the applicable national (IS: 2309) andinternational standards (NFPA 780) is carried out in thissection on a sample basis. The various maintenanceaspects are also evaluated in this section. If required, thefundamental step of ascertaining the need for protectingbuildings /structures by calculating the risk factor is alsocarried out. The experience the audit team gained while


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auditing other similar plants /installations are alsodiscussed in the report for the benefit of the client.

o Electro-Static Hazards- ControlMeasures

ESD (Electro-Static Discharges) is a critical area where thepotential ESD hazards are to be identified and necessarysolutions are to be provided. Making the client aware of thepotential accidents that can occur due to Electro-staticdischarges, minimum ignition energy required for fire/explosion, concept of equi-potential bonding and earthing,etc. are also crucial to make them understand the ESDhazards in the right light. Many plants handling flammablechemicals do not understand the concepts of ESD andhence do not follow de-canting procedure that is very

unsafe. The reference standards used for identifying andcontrolling electro-static hazards are IS:7389 and NFPA 77.

o Hazardous Areas Observations andRecommendations

This is another crucial area that needs to be evaluatedcritically. Although hazardous areas are critical, they aremostly neglected in most of the hazardous plants. Thedesign principle of flameproof equipment makes it aspecial equipment that needs special care. Area

classification into zones and installing various types ofelectrical equipment are the critical factors in controllingaccidents in hazardous areas. Once the hazardous areasare classified and the right electrical equipments areinstalled, the onus of maintaining these special electricalequipments becomes the duty of the electricalmaintenance personnel. In almost 90 % of the cases, themaintenance of these electrical equipments is not up tothe required level.

The hazardous area classification is carried out by process

experts depending upon the possibility of existence offlammable vapour/gases as per IS:5572 /OISD 113 /API RP500. The selection of electrical equipments is carried outas per IS:5571 and is to be maintained as per IS:13346 andIS:2148 provides the details of special features offlameproof equipments.


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o Review of Electrical Accidents andControl Measures

The electrical accident record in the plant is analyzed inthis section. Discussions are also carried out with electrical

and safety officers to fully understand the accident and topinpoint the root cause. The accidents report format aswell as the root cause identification methods are analyzedand recommendations are provided.

o Review of Fire Hazards and FireProtection Measures for ElectricalInstallations

This section covers the identified potential electrical firehazards, fire prevention methods and the fire protection

strategies to be adopted by the client. The suitable firedetection (LHS Linear Heat Sensing cable, smoke/firedetectors) and extinguishing medium (fixe as well asportable) are also recommended depending upon theapplication. The focus areas will be the electricalinstallation / equipment where potential of fire hazards arerelatively high such as MCC/PCC rooms, transformers,power plants, DG rooms, cable galleries, warehouses, storerooms, office buildings, etc.

o Electrical Maintenance Review

The electrical maintenance aspects in toto will be reviewedin this section. The standards followed competency of O&Mpersonnel, tests carried out as part of maintenance, etc.will be reviewed in detail. Implementation slippage, testvalue interpretation, appropriateness of action taken, etc.will also be evaluated. Various national standards (partiallist provided in this paper) are used for this purpose.

o Review of Electrical Test Recordsand Test Procedures

Tests that are carried on sample basis are evaluated in thissection. Tests are carried out when it is felt that the valuesrecorded are not credible. Normally, the following tests arecarried out.

1. Insulation resistance values of select cables /motors


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2. Load current measurements of feeders/motors3. Earth resistance tests

The test procedures that are adopted in the plant are alsoverified against national standards. OSD standards as well

as national standards provide valuable guidance regardingacceptable values. The load currents measured arechecked against the current carrying capacity ofcable/motor after applying applicable rating/de-ratingfactors to identify overload condition.

o Annexures (for reference,guidelines, etc.)

This section consists of various published referencematerials that could be beneficial to the client in the area

of electrical safety. The plant electrical single line diagramand the key electrical equipment lay out diagram may alsobe attached in this section for future ready reference.

o Photographs (to highlight electricalhazards)

This is an important section, which is used to highlightelectrical hazards identified in the plant. The permission tophotograph plant sections is taken in the pre-auditmeeting. Generally, auditing agencies maintain

confidentiality of the safety audit report as well as thephotographs.

Once the photograph is attached in the report with therelevant caption, management appreciates the hazard in abetter manner than when it is expressed in text form.

Management Briefing

The management briefing at the end of safety auditing isanother crucial factor in the effectiveness of auditing

because it is the top management who needs to beconvinced about the consequences of Electrical hazards.For effective management briefing, the auditor shouldpossess a combination of effective communication skill,thorough understanding of the hazards and the capabilityto offer safe & cost-effective solution. Audits may alsoresult in questions needing policy decisions and proposalsfor capital expenditure. It is therefore important that the


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board and the senior management are seen to be theauthority for the formal audit system and have committedresources- manpower and money- to implement thechanges agreed. It is also essential that a seniormanagement representative is directly involved in the

review of the audit report leading to an action plan and insubsequent formal reviews of progress on the plan.

Consolidation of the audit is the most important part of theESA programme. If the management is not convinced ofthe seriousness /consequence of the hazard, the safetyrecommendation will not be implemented. Competentofficer (preferably, the ESA team leader) with effectivecommunication skills is ideal. Consolidation also includesgrouping the micro observations into macro levelcategorization. Macro aspects could be classified into 5

major areas:

1. Design Flaws

o Inadequate protection.o No / updated Electrical SingleLine Diagram.o Inappropriate hazardous areaclassification / selection ofelectrical equipment.o Improper lightning

protection.o Electrostatic Hazards.o Inadequate Earthing.o Selection of non-standardcables/ motors / transformers.o No passive fire protection incable passes

2. Electrical MaintenanceAspects

o Non-standard maintenancepractices.o Only documentationavailable to comply with ISOrequirement.o No periodic tests on earthingsystem, transformer oil, insulationresistance tests, etc.


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o No periodic calibration ofprotection relays/ test & measuringinstruments.o Bypassing of RCCBs (ResidualCurrent Circuit Breakers).

o Ordinary copper wires usedinstead of HRC (High RupturingCapacity) fuses.o Openings in feeders/distribution boards.o Lack of identification markson DBs (Distribution Boards),junction boxes.o Poor maintenance of flameproof equipment.

3. Training Intervention

o Lack of basic understandingof electrical hazards.o Repeated (high frequency,low severity) electrical accidents.o Electrical accidents are notinvestigated in detail.

4. Defects in Systems &Procedures

o Bypassing of electrical workpermit procedure.o Wrong tanker (carryingflammable liquids) decantingprocedure (ESD hazards).o Bypassing of the interlockingsystem for multiple power sources.

5. Management Commitment

o Employing non-competentpersons/ wrong attitude ofemployees.o Non-compliance to statutoryregulations.o Electrical safety notprioritized in the overall safetysystem.


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o Believes that Nothinghappened to us till now, so nothingis going to happen to us.o Electrical accidents are notinvestigated in detail and are

considered inevitable.o Electrical safety is perceivedas too technical to be handled bysafety department and henceconsidered to be separate. Nointerference of safety departmentin electrical activities.

Duration of Electrical Safety Audits

The duration of ESA depends on the size of the plant

/building. Normally, the pre-audit meeting, understandingthe process and electrical distribution takes almost 2 hoursand a quick round in a small plant will take another 2-3hours totaling to a half day. The initial plant visit helps theaudit team to identify areas of concern, which will beevaluated in detail during the field visit. Field visit,discussion with electrical O&M, safety officers will takealmost 80% of the audit time and is the most importantelement of the ESA programme. Reviewing the records,maintenance documents, etc. will consume approximately10% of the audit time. Pre-Audit meeting, the initial quick

plant visit, photography, and briefing management willtake the rest 10% of the total auditing time. The timerequired for report preparation is certainly time consumingand depends of the quantum of work.

Interim Report

Since the final report will take some time for preparation,an interim report containing the salient observations notedin the audit and the recommendations is sent to the clientwithin a period of 15 days. This will enable the clients top

management to take action on most critical safetyproblems without delay.

Confidentiality of Report

Generally, the safety audit agencies maintainconfidentiality of the report.


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Follow-up audit

A monitoring system is required to ensure thatrecommendations are communicated and understood thatthe required work, or changes, is implemented. Methods

for achieving this within the allotted time scale vary butwill include direct reports to senior management or toappropriate works/ projects technical committees. Thiscould be an agenda in the safety committee meetings.

Updated Electrical Safety Information Transferthrough ESAs

Temperature Detection and electrical accidentControl

Many safety conscious organizations are using non-contacttype, laser guided thermometers to detect temperaturerise in electrical panels, equipments, etc. This hotspotdetection tool if used effectively can increase reliability byidentifying potential problem areas in advance withoutinitiating a shutdown. The concept of the use ofthermometer is based on the principle that generally,electrical failures are preceded by abnormal heat build-up.Thermometers can be used for diagnostic and preventiveinspection of electrical equipment.

US study showed that 26% total electrical failures are dueto loose connections and poor terminations. Indianscenario as per an expert cannot be less than 50%.Immediate effect will be overheating of joints andterminations due to increased contact resistance.

Hotspots can form due to:

o Use of improper lugs / incomplete crimpo Poor contacto Bolts carrying currento Dirty contact surfaceo Extra Jointso Cut wire strands to accommodate smallerlugo

High temperatures (or hotspots) could indicate:


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High contact resistance Loose/ tight connections Unequal loading

Over loading

Although this versatile temperature-measuring instrumentis used in many plants, it is observed that the properinterpretation and action taken on temperatures exceedingnormal values requires improvement. A few tips fortemperature value interpretation, extracted from amanufacturers application guide are given below forguidance.

1. 30 degree centigrade + ambient indicates aserious fault condition and needs investigation.

2. Temperature difference between phases 5degree centigrade or more- a potential problem.

The temperature detection at electrical connections, etc.becomes very crucial considering the fact that the effect oftemperature on insulation life will reduce by 50% if themaximum temperature is exceeded by 10 degreecentigrade.

Protection from Electrical Arc Fires

Recently, an innovative electrical safety device called AFCI(Arc Fault Current Interrupter), designed to preventelectrical fires caused by arcing in low voltage circuits hasbeen developed in America. After the invention of GFCI(Ground Fault Current interrupter) /RCCB (Residual CurrentCircuit Breaker) forty years back, AFCIs are considered thefirst major advance in electrical protection. It is reportedthat the American government has made it compulsory toinstall AFCIs in all new American homes by 2002.

Fires in electrical wiring break out at wire/cable joints, end

terminations, etc. because of mechanical damage toinsulation, overloading, insulation deterioration, etc. resultin high temperature build-up resulting in fires. Arcinggenerates high intensity heat and expels burning particlesthat can easily ignite combustible materials. Acing faultsare supposed to have the potential of initiating fires.


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A few of the typical conditions where arc faults may startinclude:

Damaged wires Worn electrical insulation

Loose electrical connections Overheated or stressed electrical cords andwires

AFCIs are designed to detect the arcing patterns of serialand parallel or arcs to earth and to trip the circuit. It isenvisaged that this electrical safety device with its uniquearc detection circuitry would considerably controlelectrical fire accidents.

SUMMARY

Total involvement and commitment of the topmanagement is absolutely essential for the success of anysafety audit programme right from the audit initiationstage. They have to demonstrate the active support to thesafety management system by providing the requiredresources, be it manpower or materials. The topmanagement has to instruct all the relevant employees totake part in the safety audit and to provide all necessaryhelp to make the auditing successful. The managementsystem is fundamental to loss prevention. Many prudent

management are experiencing the obvious benefits fromthe concept of STEP - Safety Through EmployeeParticipation which is very crucial for the success of anysafety programme.

A properly designed, planned and executed electricalsafety audit programme can bring out many hazards thatcould save life & property. An auditor is expected to helpthe auditee to identify the potential electrical hazards, tomake the auditee understand the consequences and alsoto help them through the process of implementation of

Electrical Safety recommendations.

Safety audits are an important part of a companys controlsystem. The auditing schemes does not remove from themanagement and supervisors the necessity for regularchecking and rechecking to ensure that people under theircontrol are working in a safe manner. Their application and


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use do not remove the need for proper care andresponsibility at all levels in day-to-day operations.

An organisation instituting safety audits must define theobjectives and scope of the audit, its frequency, the

elements it should contain and the methods to be used.

An organisations culture determines the number andseverity of accidents, how they are handled and thenumber and magnitude of accidents. Japans accidentsseven times lesser than those in the US because of thedifference in culture climate in the two countries. It isnatural that the philosophy of the top managementcascades downs through the organization and reflects onevery aspect of its functions. Accepting accidents, as partof doing business is mismanagement A pragmatic

approach works better than a dogmatic one.

As some one has rightly said, Safety is good business &like most business situations, has an optimal level ofactivity beyond which are diminishing returns. If adequateinitial expenses are made on safety, plants will beinherently safe from major accidents. To conclude, themanagement system is fundamental to loss prevention andhence, Safety & Loss Prevention programme in anorganization stand or fall by the attitude of the topmanagement.

Date post:	10-Apr-2018
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Electrical Safety Auditing

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