Methodologies for Reduction of the Risks Associated with the Electrical System in the Pharmaceutical Industry.

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.  

 2. Objective

 Elegrow Technology suggested a few ways to Identify the Risk & Hazards by

1. Studying & Verifying Existing Documents,
2. Monitoring Safety Policy & Operation, Maintenance and Condition Monitoring Process,
3. Preparation of as-Built Documents (as they didn’t have them),
4. Site visits & Visual Inspection
5. 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

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)

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.

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:                  Reduced from 25% to 2%

Visual Inspection Risk:       56% Found which can be reduced to 0% by implementing Recommendations.

Asset Condition Risk:         Recued from 19% to 7%.

Employee Safety:   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.