IE Rules & Electrical Safety Audit in plant

Electric safety

1. IE Rules & Electrical Safety Audit
E.ANANDAN
MANAGER RISK SERVICES
CHOLAMANDALAM MS RISK SERVICES
23
rd
July 2009
National safety
council training
course on
“OCCUPATIONAL
SAFETY AND
HEALTH
AUDITORS”

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WHY ELECTRICAL SAFETY AUDIT
•8% of the fatalities is due to electrical reasons
•40% of fires in industries attributed to electrical reasons due to
short circuit, overload or loose connections.
•More than 15 persons die every day in India due to electrical
shock & electricity related incidents
•8076 persons died in 2007 in India . 7619 persons died in 2006
•i.e. average of 22 persons died / every day in 2007( source
National crime bureau statistics). 2.4 % of all accidental death is
due to electrocution.
•Only a detailed electrical safety audit can provide insights into
electrical system and expose major design flaws, potential
electrical hazards& slippages in maintenance system.

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PERIODICITY
•Not exceeding an interval of 5 years ( IE Rule sec.46)
•Suggested interval – once in 3 years
•Whenever there is any process change
•Whenever there is any major expansion
•OSID recommends a duration of 1 year for internal
audits

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AUDIT STRUCTURE
•PREAUDIT
•AUDIT
•POST AUDIT

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PREAUDIT
Defining scope of the audit
Collection of plant data
Formation of an effective audit team

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PRE AUDIT QUESTIONAIRE
•PROCESS DETAILS
•ELECTRICAL SLD
•MAJOR EQUIPMENT DETAILS
•DETAILS OF FLAMMABLE CHEMICALS HANDLED
•DETAILS OF PAST ELECTRICAL ACCIDENTS
•DETAILS OF ELECTRICAL MAINTENANCE

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ELECTRICAL SAFETY AUDIT-Objectives
 To carry out a systematic, critical appraisal of all
potential electrical hazards involving personnel,
plant, services and operation method
and
  To review compliance of plant electrical setup
(installation & maintenance) with reference to the
statutory regulations & applicable national &
international guidelines / standards.

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Electrical Safety Audit- Scope of Work
Physical inspection of the plant – with respect to applicable
Indian standards, Indian rules and International standards
& identification of electrical hazards
Reviewing the role of electrical safety in plant safety system
Review of protective devices in plant electrical system
Adequacy of plant lightning protection system.
Review of past electrical accidents and root cause analysis
Review of Hazardous area classification & suitability of
electrical equipments installed.
Review the EPM and check documents pertaining like test
records, work permits ,checklist, work instructions
To review hazards due to static electricity

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MAIN STANDARDS,RULES TO BE FOLLOWED
•IE Rule 1956
•Energy conservation act
•OISD Standards
•Indian standards
•API standards( for petroleum industries)
•NFPA Standards
•IEC standards

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ESA AUDITORS-GENERAL REQUIREMENTS
•Audit members should be conversant with safety audit
elements, accident investigation, safety training etc
•Ability to interpret electrical rules, standards and to
suggest simple, practical and cost effective solution
•Effective communication,competency,right attitude ,
willingness to keep updated, Openness, team work&
Perseverance.

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AUDIT
•Opening Meeting –Familiarization
•Discussion with Electrical Dept., review of key SLD
•ESA
–Walkthrough Session
–Testing (EARTH PITS,HOT SPOT,
CURRENT,VOLTAGE,HARMONICS & OTHER POWER QUALITY )
–Review of good engineering Practices
–Document & records review
•Close-Out meeting
•Final report submission within the stipulated time

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WALKTHROUGH AUDIT
•Main substation
ISOLATORS
MAINTEANCE

EARTHING
THERMOGRAPHY
EARTH PITS
CONDITION
OIL LEAK IN
CT/PTS

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IE RULE 1956 KEY PROVISIONS
•Rule enacted by Central Electricity Board under sec
37 of Indian electricity act 1910
•Last amendment on 25
th
Nov 2000

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RULE 3
•Should maintain a list of authorized persons.
•Power plants 100 MW or above should be
maintained by qualified and trained persons only
•In every registered factory with connected load
more than 250 kw , a person authorized by
management to observe safety provisions under IE
rule 1956 ( Rule 3 person)

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RULE 29
•Construction, installation, protection, operation and
maintenance of electric supply lines and apparatus
shall be of sufficient ratings for power ,insulation
and short circuit level. Should be mechanically
strong.
•Constructed in a manner to ensure safety of
humans, animals and property
•Installed equipments should confirm to ISI
standards.

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RULE 30 – SERVICE LINES & APPARATUS ON CONSUMER PREMISES
•The supplier shall ensure that his equipments, lines inside
the consumer premises shall be in safe condition and
should take precautions against danger arising from his
equipments
•Consumer is responsible for the safe custody of the
suppliers equipment inside his premises.

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RULE 35 – DANGER SIGNS & NOTICE BOARDS
•The owner shall provide skull & cross bones sign in
Hindi/English and a local language with voltage level
indication on
•Every motor, generator or transformer
•Every HV/EHV lines
•Neon illumination boards

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RULE 36 – HANDLING OF ELECTRIC SUPPLY LINES & APPARATUS
•Electricians working on lines shall be provided with PPEs
like gloves, helmets, rubber mats, shoes protecting him
from mechanical & electrical injuries

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RULE 38- CABLE FOR PORTABLE /TRANSPORTABLE
APPARATUS
•Flexible cable for portable/transportable motors, generators
& welding sets are not be used unless they are heavily
insulated and protected against mechanical injury
•3 core cables for single phase equipments and 4 core
cables for three phase equipments

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Rule 40 – STREET BOXES
•Should not allow water/gas to enter
•Should be inspected regularly
•Should be covered adequately with doors/covers to
prevent entry of gas/water and should be opened by a
special key / special appliance

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41A – CIRCUIT DISTINCTION
•For panels,equipments,structures having more than one
power feed, distinction must be made between different
power supplies

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RULE 43- PROVISONS APPLICABLE TO PROTECTIVE EQUIPMENT
•Fire buckets must be kept
•Fire extinguishers
•First aid boxes
•Gas masks for power plants > 5 MW
•Gas masks for substations > 5 MVA

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RULE 44-INSTRUCTIONS FOR RESTORATION OF PERSONS
SUFFERING FROM ELECTRIC SHOCK
•Instructions for restoration of persons suffering from
electric shock in Hindi/English & Local language shall be
affixed in every substation,generating station and where
electricity is used.
•All the authorised employees should be acquainted with
the process.
•Case study

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RULE 44A- INTIMATION OF ACCIDENT
•Telephonic intimation within 24 hours
•Written communication within 48 hours

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RULE 45- PRECAUTIONS BY CONSUMERS,OWNERS,ELECTRICAL
CONTRACTORS, WORKMEN & SUPPLIERS
•Only licensed contractors are to be employed
•Only persons with supervisory license to supervise
the work

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RULE 46
•Every installation must be periodically inspected
and tested by EI at an interval not exceeding 5 years

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RULE 47 Testing of Consumers Installation
•Supplier shall inspect & test consumer installation
•Notice to consumer for any changes to improve safety

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RULE 47 A- INSTALLATION & TESTING OF GENSETS
•Generators capacity exceeding 10 kw to be
commissioned after EI written approval only

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RULE 48 MEGGER TESTS BEFORE CONNECTION
•IR value of 1 MΩ for LV & MV circuits with 500v DC
Megger for 1 minute
•IR value of 5 MΩ for HV circuits with 2.5kV DC
Megger for 1 minute

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RULE 50 SUPPLY & USE OF ENERGY
•Isolator /switch control at point of supply by
consumer for LV /MV voltage level
•Isolators/breakers for transformers (when capacity
exceeds 2500 kVA)
•Control stations to be installed near motor

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RULE 50 A SUPPLY & USE OF ENERGY AT HIGH RISE BUILDING
( >15M)
•An emergency supply isolation switch at ground
floor installed conspicuously at a height not more
than 2.75m
•Owner should maintain electrical installations free
from shock & fire hazards and installed in
accordance with relevant code of practice
•Cable ducts should be installed with fire stop at
each floor. No other pipes should be installed
through the cable duct

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RULE 51 PROVISONS FOR MEDIUM,HIGH OR EXTRA HIGH VOLTAGE
INSTALLATIONS
•Panel boards shall have a clearance of 1 meter in
front. Backside clearance either less than 20 cm or
more than 75 cm. If backside clearance is more than
75 cm, then a passage way clear to a height of 1.8 m
shall be provided on both sides
MCC
Min 1 meter
Less than 20 cm or more than 75
cm

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RULE 61 CONNECTION WITH EARTH
•The frame of every motor, generator or electric
apparatus shall be earthed by two separate and
distinct earth leads
•Earth resistance shall be tested during dry day in
dry season atleast once in 2 years

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RULE 61A – EARTH LEAKAGE PROTECTIVE DEVICE
•Every electrical installation > 5KW should be
protected by an earth leakage protective device

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RULE 64 USE OF ENERGY AT HV/EHV LEVEL
Voltage Class Ground Clearance
(Mtrs)
Sectional
Clearance
(Mtrs)
Not exceeding11 KV 2.75 2.6
- do - 33 KV 3.7 2.8
- do - 66 KV 4.0 3.0
- do - 132 KV 4.6 3.5
- do - 220 KV 5.5 4.3
- do - 400 KV 8.0 6.5
SAFE WORKING DISTANCE

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•Substation with oil >2000 ltrs should not be located at basement
where proper oil draining arrangement is not provided
•In any substation where oil >2000 ltrs is involved, barriers of 4 hrs
fire ratings to be installed between oil filled equipments
•For equpts having oil qty>9000 ltrs oil soak pit is required
•All transformers & switchgears to be maintained as per BIS
standards and records to be kept
•Only dry type transformers should be used inside residential /
commercial buildings
•Spare oil should not be stored in substation/switch station.
RULE 64 USE OF ENERGY AT HV/EHV LEVEL

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RULE 64A
•When two or more supplies are not intended to be operated in
parallel ,interlocking is to be done.
•Buchholz,OT /WT indication & trip is to be provided for transformers
1000 kVA & above
• Transformers above 10 MVA shall be provided with differential
protection
•Generators above 100 kVA to be provided with E/F

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RULE 67 –CONNECTION WITH EARTH
•All non-current carrying metal parts associated with HV /
EHV installation shall be effectively earthed to a grounding
system ( Metal fence)
•Neutral point of every generator & transformer shall be
earthed by connecting it to the earthing system
•Earth pits are to be tested once in a year

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•Provisions be made for immediate and automatic
discharge of every static condenser on disconnection of
supply
RULE 70

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IDENTIFY THE CODE MISTAKE

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IDENTIFY THE CODE MISTAKE

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TYPICAL POINTS TO NOTE
FENCE EARTHING
FIRE SEPARATION WALL
LA CONDITION
SILICA GEL
OIL LEVEL
OTI,WTI SETTINGS
ROLLERS LOCK
BUSHINGS
TERMINAL PAD
TRANSFORMER
EARTHING
BUCHHOLZ
COOLING
ARRANGEMENT
OIL SOAK PIT
COOLING FINS
PROTECTIVE RELAYS

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ADDITIONAL POINTS
•Fence condition
•Cleanliness – growth of grass, provision of blue
metal fence
•Layout
•Earth pits condition

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MAJOR AUDIT CHECKPOINTS
A. STATUTORY COMPLIANCE

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MAJOR AUDIT CHECKPOINTS
B. SHOCK / FLASH INJURIES

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MAJOR AUDIT CHECKPOINTS
C. FIRE HAZARD

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MAJOR AUDIT CHECKPOINTS
D. ELECTRICAL SAFETY TRAINING

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MAJOR AUDIT CHECKPOINTS
E. EARTHING SYSTEM

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MAJOR AUDIT CHECKPOINTS
F. COMPETENCY & ADEQUACY OF ELECTRIAL PERSONNEL

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MAJOR AUDIT CHECKPOINTS
G.EPM PROGRAMME

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MAJOR AUDIT CHECKPOINTS
H.LIGHTNING PROTECTION SYSTEM

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MAJOR AUDIT CHECKPOINTS
I.HAZARDOUS AREA CLASSIFICATION

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MAJOR AUDIT CHECKPOINTS
J.ELECTROSTATIC HAZARDS

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MAJOR AUDIT CHECKPOINTS
K.ELECTRICAL PROTECTION SYSTEMS

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THANK YOU