1. Introduction
Electrical Safety Audit Service provided in a Pharmaceutical Industries Plant, which is one of the most renowned leading developers and manufacturers of Active Pharmaceutical Ingredients & High-Quality drugs making industries by unlocking the possibilities of science.
The client was facing multiple tripping issues and a blackout problem for the last 2 years. And they were unable to figure out the causes for the same. hence, they wanted to hire a subject matter expert and approached us. Â
 2. Objective
 Elegrow Technology suggested a few ways to Identify the Risk & Hazards by
- Studying & Verifying Existing Documents,
- Monitoring Safety Policy & Operation, Maintenance and Condition Monitoring Process,
- Preparation of as-Built Documents (as they didn’t have them),
- Site visits & Visual Inspection
- Testing the condition of an asset
 3. Methodology
We executed the scope in 3 stages mentioned as follows –
 Step 1: Document Verification & Preparation of as-Built Documents
(Load List, Single Line Diagram, Lightning Protection System Layout, Earthing
Layout)
Step 2: Electrical Safety Audit
- Site Visit and Visual Inspection
- Technical Discussion with the Operation and Maintenance Team
- Identification of Risk and Hazardous
Step 3: Asset Condition Testing
Power Quality Audit
Earthing System Health Assessment
LV System
Soil Resistivity
Earth Pit Resistance
Loop Impedance
Prospective Fault Current
Continuity
EHV System
Step and Touch Potential Testing
Lightning Protection System Adequacy Study (Analysis)
Partial Discharge Testing – Switchyard and Electrical Panels
Thermography – Switchyard and Electrical Panels
Electro Magnetic Induction Mapping – Overall Plant Area
Applicable Standards & Regulations
Indian Standards | ||
Purpose | Standard Number | Standard Name |
Design, O&M, Construction, Safety | NBC – 2016 | National Building Code of India – 2016 |
Safety | IS 14489: 2018 | Code of Practice on Occupational Safety and Health Audit |
Safety | IS 3043: 2018 | Code of Practice for Earthing |
Safety | IEEE 80:2015 | Guide for Safety in AC Substation Grounding |
Testing | IEEE 81:2012 | Guide for Measuring Earthing Grounding System |
Safety | IEEE 142:2007 | Recommended Practice for Grounding of Industrial and Commercial Power Systems |
Design & Installation & Maintenance | IEEE 519:2022 | IEEE Standard for Harmonic Control in Electric Power Systems |
Installation & Maintenance | IS:1255-2016 | Code of Practice For Installation and Maintenance of Power Cables Up to And Including 33 KV Rating |
Safety & Testing | IS-15652:2006 | Insulating Mats for Electrical Purposes – Specifications |
Safety | IS 884:2015 | First-Aid Hose Reel for Fire Fighting |
Safety | IS 8091:2018 | Industrial Plant Layout – Code of Safe Practice |
Safety | IS 5572:2009 | Classification of Hazardous Area – having flammable gases and vapours for Electrical Installation |
Indian Regulation | ||
Purpose | Regulation Number | Regulation Name |
Safety | CEA Regulations 2011 | Central Electricity Authority Regulations – Safety · Requirements for Construction, Operation and Maintenance of Electrical Plants and Electric Lines |
Safety | CEA Regulations 2021 | Central Electricity Authority Regulations – Measures relating to Safety and Electric Supply |
Construction | CEA Regulations 2015 | Central Electricity Authority Regulations – Technical Standards for Construction of Electrical Plants and Electric Lines |
Safety | The Electricity Act – 2020 | The Indian Electricity Act |
Safety | The Indian Electricity Rule – 2020 | The Indian Electricity Rule |
International Regulation | ||
Purpose | Regulation Number | Regulation Name |
Health and Safety | OSHA Regulation | Occupational Safety & Health Admin, Labor |
International Standards | ||
Purpose | Standard Number | Standard Name |
Safety | NFPA 70 E: 2021 | Standard for Electrical Safety in Workplace |
Maintenance | NFPA 70 B: 2019 | Recommended Practice for Electrical Equipment Maintenance |
Safety | NFPA 901: 2022 | Standard Classifications for Fire and Emergency Services Incident Reporting |
Safety | NFPA 77: 2019 | Recommended Practice on Static Electricity |
Safety | IEC 62305-1:2018 | Protection against lightning – Part 1: General principles |
Risk Assessment | IEC 62305-2:2018 | Protection against lightning – Part 2: Risk management |
Safety | IEC 62305-3:2022 | Protection against lightning – Part 3: Physical damage to structures and life hazard |
Safety | IEC 62305-4:2018 | Protection against lightning – Part 4: Electrical and electronic systems within structures |
Health and Safety | ISO 45001:2018 | Health and safety management standard |
Health and Safety | IEC 61882:2016 | Hazard and operability studies (HAZOP studies) – Application Guide |
Installation & Maintenance | IEC 60364:2022 | Electrical installations of buildings |
Installation & Maintenance | IEC 61000:2022 | Electromagnetic compatibility (EMC) |
Safety | IEC 61140:2016 | Protection against electric shocks – common aspects of installation and equipment |
Installation & Maintenance | ISO 12944-5: 2019 | Paints and Varnishes – Corrosion Protection of Steel Structures by Protective Paint Systems – Part-5-Protective Paint Systems. |
Safety | IEC 60079-10-1-2020 | Electrical Apparatus for explosive gas atmospheres – Part 10: Classification of Hazardous Areas |
Safety | IEC 60270:2000 | High-Voltage Test Techniques – Partial Discharge Measurements |
Safety | EN 61000-6-4:2019 | Electromagnetic Compatibility – Generic Standards. Emission Standard for Industrial Environments |
Safety | EN 61000-6-2:2019 | Electromagnetic Compatibility – Part 6-2: Generic Standards – Immunity Standard for Industrial Environments |
Safety | EN 61000-6-1:2019 | Electromagnetic Compatibility – Part 6-1: Generic Standards – Immunity Standard for Residential, Commercial and Light-Industrial Environments |
Safety | EN / IEC 60947-1:2021 | Low-Voltage Switchgear and Control Gear – General Rules |
Safety | IEC TS 61000-6-5:2015 | Electromagnetic Compatibility – Part 6-5: Generic Standards – Immunity for Equipment Used in Power Station and Substation Environment |
Safety | EN/IEC 61326-1:2021 | Electrical Equipment for Measurement, Control and Laboratory Use – EMC Requirements – Part 1: General Requirements |
Safety | IEC 60601-1-2: 2015 | Electromagnetic Compatibility of Medical Devices |
4. Results & Solutions
Step-1: Document Verification & Document Preparation:
Phase-1: Risk Assessment by Document Verification:
Total Documents List 30 Nos. We have found that 11 / 30 Nos. Documents require upgradation or new document preparation.
Phase-2: Risk Assessment by Document Verification – After Documents Preparation.
Total 1 / 30 Nos. The document needs to be prepared. (That’s Hazardous Area Classification Layout)
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Step-2: Risk Assessment by Visual Inspection of Entire Plant:
As per our Visual Inspection Check List for Electrical Safety:
We have found that still there 39% Risk available with respect to Visual Inspection Audit (With Detail Risk Category: Low Risk = 5%, Moderate Risk = 10% & High Risk = 18%)
Step-3: Asset Condition Testing:
Phase-1: Risk Assessment by Asset Condition Testing:
A total of 12 Nos. of Testing needs to be done periodically inside any industry as per application. And their all-testing reports must be documented and submitted to authority or government authority as & when required. We have found that only 4 Nos. of Testing done & their reports documents are available with the client. So, there is risk = 67% (8 Testing Reports not Available with respect to testing never done.)
Phase-2: Risk Assessment by Asset Condition Testing:
We have done all 12 Nos. of Testing. So, now Clients have all the updated Testing Reports. But still, we have found some abnormal points during our all testing. So, Risk Decreases from 67% to 25% with respect to Asset Condition Testing. We have given our Observations & Recommendation to the client to implement & improve the Asset condition.
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Overall Risk Assessment Summary
Before & after conducting the safety audit, the observations are shown in the following graph –
As we can see in the chart, the risk after implementation, document verification and asset condition monitoring has been reduced by implementing the required changes.
But the same has not happened in the case of the safety audit as incorporating the changes will take some time. And the results will be tracked once all the recommendations have been implemented. Hence there is not any change in the risk analysis for that factor.
Solutions: Major Observation for Improvement:
The following are a few recommendations Elegrow Technology suggested for long-term improvement and reliability.
- Documents Upgradation (Timely Basis)
- Lightning Protection System Upgradation & Implementation
- Hazardous Area Classification Layout Preparation
- Detail Cleaning & Maintenance of Electrical Panels
- Electrically Safety Rubber Mat broken
- Corrosion
- Vegetation in the Switchyard Area
5. Conclusion
 Standard & Regulation Compliance: 100% Standard & Regulations Compliance done during the Electrical Safety Audit.
 Risk Reduction:
Document Risk: Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Â Reduced from 25% to 2%
Visual Inspection Risk: Â Â Â Â Â 56% Found which can be reduced to 0% by implementing Recommendations.
Asset Condition Risk: Â Â Â Â Â Â Â Recued from 19% to 7%.
Employee Safety: Â Employee Safety will increase by Reducing the Risk. Also, be aware of them by providing additional training which can reduce the risk of accidents and injuries.
Overall Performance: Overall Performance increases by Reducing Risk, Production will Increase, Loss will decrease, Reducing breakdowns & downtime.
The document verification and as-built document preparation helped their internal team with a reduced dependency on the respective person/department. Also helped them with accurate data and allowed them to invest more time in productivity.
The client is now incorporating the recommendations from the safety audit as it is a long time process and will be carrying out asset condition tests internally by applying relevant standards as shown by Elegrow Technology.