electrical audit

7/24/2019 electrical audit

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MUMBAI

ELECTRICAL AUDIT REPORT

INDIAN OIL BHAVAN (H.O.)

MUMBAI

Date of Visit :

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CONTENTS

DESCRIPTION PAGE NO.

1.List of major Electrical Equipments & Electrical System

2.Executive Summary

3.ypical Eart! Electro"e

4.#$servation & %ecommen"ation

i' 11 (V V)*

ii' ransformer

iii' D+ sets

iv' ,ain Distri$ution *oar"

v' )apacitor Panel

vi' Lig!ting System

vii' Lig!ting Pole & +lo$e

viii' -) Plant & -./

ix' Pump .ouse

x' S Plants

xi' Lifts

xii' Eart!ing

xiii' Lig!tning Protection

xiv' )anteen -rea

xv' 0ee"er Pillar Panel ear ,ain +ate'

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LIST OF MAJOR ELECTRICAL EQUIPMENTS &

ELECTRICAL SYSTEM

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LIST OF MAJOR ELECTRICAL EQUIPMENTS INSTALLED IN THE BUILDING

A: SUBSTATION EQUIPMENT

A.1 11 KV VACCUM CIRCUIT BREAKER.

The building receives power supply from Reliance at 11KV, through 800

Amp. HT(11KV) Breaker of Siemens make, which under Reliance control.

The supply from Breaker is fed to Bus Bars which connected to 2 Nos. 1000

KVA 11 KV/433V Transformer of Kirlosker make

A.2 The outgoing from the VCB are connected to 2 Nos. 1000 KVA 11KV/433V

Transformer designated as:-

Transformer-1:- Flood Load, Canteen, Domestic Pumps, Lift No.1 & 2.

IT Centre, Air Conditioning Unit, Capacitor Bank 1.

Transformer-2:- Small Wing, STP, Large Wing, Lift No.4, 5 & 6, UPS

room, Capacitor Bank 2.

A.3 Transformer-1 & 2 :- L.T. Side i.e. 433 Volts are supplying to Main

Distribution Board.

Transformer-1 is connected to Main Distribution Board through 6 nos.

3.5X300 sq.mm Al. PVC Cable to MDB & 1600 Amp. ACB.

Transformer -2 is connected through 6 nos. of 3.5CX300 sq.mm Al. PVC

Cable to MDB & 1600 Amp ACB.

A.4 Main Distribution Boardis having two incomers from transformer 1&2 and

one number incomer from 500 KVA DG set.

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There are Two nos. of Bus coupler (1600 Amp. ACB) one is provided for two

incomers & one for DG set.

Section 1 of MDB is supplying power to Lift No.4, 5 &6 through 100 Amp TPN

switch, also providing power supply to Large, Small Wing & Capacitor Panel-

2 through 630 AMP, switch. 1000Amp. ACB and also to UPS changer over

through 400 Amp TPN switch.

Section 2 of MDB is supplying power to Lift No.1,2 & Freight lift through 100

Amp TPN switch, also providing power supply to 2ndfloor Micro AC & Air

Condition unit through 1000Amp TPN switch. Power supply to Canteen,

Domestic pump, IT Centre 2ndfloor & workshop is feed through 250Amp

switch. Power supply to Pantry Lift & Flood light through 63 Amp TPN

switch.

Section 3 of MDB is supplying power to Fire pump panel through 400 Amp

TPN switch, also providing power supply to Lift No.3, Building Light, Main

Gate LDB & Substation Light through 100 Amp TPN switch. Air conditioning

unit through 1000Amp TPN switch.

B. D.G. Set:-

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B.1 DG Set-1

Rating : 500KVA

Make : (Alternator- Stamford)

(Engine - Cummins)

Supplies power to Whole office Building

Cable Size 2 run of 3.5X300 Sq.mm

B.2 Generator Control Panel:-

Supplies power from DG (500KVA) connected to DG Generator Control Panel

installed in the DG Room. Breakers (ACB) are interlocked with 500 KVA DG

set & a Bus coupler for DG set of ACB 1600A in Main Distribution Board.

C Air Conditioning Units

Capacity 800 Ton/hr

There are two Nos. MCC in the A/C Plant. i.e. MCC-1 & MCC-2 for Main

AC Unit.

MCC-1 receives power from MDB Section-II, supplies power & control to

Chiller Unit 1& 2 and also to AHU Units in different floors.

MCC-2 receives power from MDB Section-I, supplies power & control to

Chiller Unit 3 & 4 and also to AHU Units in different floors.

D. Lightning & Power Supply to Sockets

D1. There are two Nos. Rising main (Bus Duct) one on Large Wing side and the

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other on the Small Wing side.

Large Wing rising main receives power from Main Distribution Feeder No. B2

through 630 Amp. MCCB.

Small Wing rising main receives power from Main Distribution Feeder No. A3

through 630 Amp. MCCB.

D2. Lightning for the Floor:-

At each floor (total 9 Nos.) rising main both Large(North) & Small(South) Wing

are tapped through 125 Amp. L&T make TPN switch.

The TPN Switch is mounted on the outer surface of the Bus duct i.e. rising

main & connected to the Bus Bars by 4CX10 sq.mm cables at the back of

the switch. The outgoing from the switch are taken in MCB DB. There is one

63 Amp, 4pole TPN MCB,

Each phase of the Bus Bars is connected trough 40/25 A RCCB. The

Outgoing is through LDB-1 & LDB-2, In LDB-1 & 2 the incoming is through

40 Amp, 4pole TPN MCB & outgoing is distributed in each phase, through

10A, 20A & 32 A Single pole MCB. The outgoing from single pole switch fuse

unit is connected to:-

a). MCB Distribution Box for light.

b). MCB Distribution Box for power supply to sockets.

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In Each Floor there are LDB-1, LDB-2, & One Emergency DB. Each floor has

different numbers of MCB distribution board.

E. Earthing

There are 36 Nos. of Earth Pit on the office premises.

F. Lightning Protection

There are 8 Nos. Air Terminal Rods Connected with 25X3 GI strips laid along

the parapet walls. On the roof 3 Nos. down conductor have been taken from

the roof G.I. Strips to the Earth Pits.

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EXECUTIVE SUMMARY

EXECUTIVE SUMMARY

ELECTRIFICATION OF HI-RISE BUILDING

An important consideration in the layout of electrical in any building or

installation is safety, besides the consideration for efficiency, convenience and

provision for future increase in load.

The fundamental requirement to achieve safety from the electrical equipment

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and associated cabling and wiring is to control the occurrence of short circuit or

fault currents in the system which results in flash-overs, burning of cable

insulation, and insulating materials of the component.

It is understood that in the electrification of HI-Rise Bldg. there would be

complexity of equipment and network of cables of various sizes right upto a

lowest size 1.5 sq.mm concealed behind the laminated walls and false ceiling

which are always prone to fire. What is therefore required is to prevent theoccurrence of any short-circuit in the system and if it does occur the same is

cleared from the circuit or system, by the protection like fuses & relays before

the wiring cables and other equipment attain a temperature which ignites the

cable insulation and other materials. For example a 1.5 sq.mm PVC insulated

copper cable can withstand only about 100 Amp. For 1 sec. before the

insulation starts melting and catches fire. The protection in the circuit,

therefore, has to be provided thr HRC fuses so that it disconnects the circuit

in less time say 100 to 200 msec .i.e. before the cable insulation melts &

catches fire.

To prevent the hazards of fire from the faults in electrical equipments it is,

therefore, imperative that the entire electrical system and installation

conforms to the following:

a). Every equipment used should be able to withstand the fault current of the

system; and where it is not so due to non-availability of the particular

rated equipment it must be protected thr HRC fuses, so that it cuts off the

circuit in the shortest possible time.

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Use of rewire able fuses in the HI-Rise Building should be totally avoided.

Only proper rated MCCB & HRC fuses to be used for the protection of

cables & equipment.

b). The loose connections to be totally avoided. All the cable terminations to be

done with proper size and type of tinned copper lugs and hardwares like

bolts, nuts, washers etc.

c). The connections to be periodically checked for tightness for which it is

imperative that enclosure used are of such size that when they are opened,

the terminals are readily accessible. Furthermore sufficient space shall be

left in the interior of the enclosure for the accommodation of external

conductor from the point of entry into the enclosures upto the

terminals(IS:4237-1967)

d). The enclosures should always be kept free from the ingress of dust, cobwebs

etc. since it leads to tracking & subsequent flash-overs. It is necessary that

after the cabling is done, all the unused holes & openings are plugged &

sealed. The equipments which are mounted outdoor shall conform to

degree of protection IP-55 and as far as possible the junction boxes

installed outdoor shall be made of aluminum or any non-corrosive

material.

e). The equipment used should be of proven quality & make. In the vulnerable

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areas, cables with elastomeric insulation i.e. EPR, silicon, CSP etc. to be

used. Such type of cables are used in railways coaches, ships etc. and do

not catch or propagate fire(Reference IOC Engg. Manual Vol-7 Part II

Chapter No.14).

f).Earthing System & Practices:-

A sound earthing system eliminates more than half of the unsafe

conditions and prevents unwanted fires. For the discharge of fault

currents, static electricity and for the operation of protective relays and

fuses, there is no short cut than to have an exacting, robust and proper

earthing system.

An Electrical Audit is a Safety Concept.It identifies the erroneous zones

(in the entire electrical installation, i.e. equipment & the system) which

may have crept into the system inadvertently during selection, erection or

subsequent to energizing/commissioning. Recommendations are made

after analyzing the deficiencies and update the electrical in its entirety.

An attempt has been made in this audit to study in detail the deficiencies

in the system, equipment, cable terminations, earthing system etc.

Recommendation to eliminate & eradicate the deficiencies are also given

which when implemented shall achieve the objective of eliminating flash-

overs and fire hazards from the electrical system.

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SUMMARY

Sl. Equipment Action Priority CategoryNo.

1. 11 KV Breaer i! Ammeter to "e c#ange $or %r&'. (

ii! Ru""er mat to "e pro)i*e* (

iii! Ca"le +i,e+ to "e mare* ((

'. %ran+$ormer+ i! Replace -%( $or %R&1 ( ii! Silica el to "e replace* (

iii! Ca"le "o/e+ to "e eart#e* (

i)! S#e* to "e pro)i*e* o)er ((

%ran+$ormer

)! Replace "ot# %ran+$ormer ((

0. Set+2 i! Routine Maintenance

enerator Panel ii! Replace 3it# Panel ((

4. MB 5Main i! Recti$y2Replace Un*er )oltage (

i+tri"ution Boar*! Relay $or

ii! Cali"rate t#e protection relay6 ((

ACB+ etc. yearly

iii! Routine Maintenance

i)! Ca"le trenc# to "e e/ten*e* ((

in *imen+ion


7. Capacitor 8 Control i! Replace lig#t o$ $ee*er No&9o$ ((

Panel panel&'

ii! :ig#er Rating Contactor o$ (

;ee*er No&< o$ panel&1

=. >ig#tning Sy+tem i! Nomenclature to >B 8 ?utgoing (( MCB to "e gi)en a+ per @oor 8

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3ing+ 3i+e.

ii! Ru""er Mat to "e place* (

ig#tning Pole+ i! ;aulte* Ca"le+ to "e replace* (

ii! Corro*e*2 Ru+te* Pole+ 8 B+ ((

to "e replace*.

iii! Eart#ing to "e connecte* (

i)! Stran*e* ca"le to terminate* ((

3it# tinne* copper lug+ o$

+uita"le type

)! Ca+t aluminum (P&77 B to ((

"e pro)i*e* $or eac# pole 8

lo"e lig#t


. AC Plant i! et ;an B to "e eart#e* (

ii! Routine Maintenance

iii! All "reaer+ to "e o)er#aule* ((

8 relay+ to "e cali"rate*

9. ;ire Pump :ou+e i! ou"le eart#ing to "e *one (

;or trolley pump.

ii! Replace* *e$ecte* Ammeter (

in+talle* in Panel+

iii! Unplugge* ca"le+ entrie+ to "e clo+e* (

i)! Routine 6maintenance o$ Pump

8 motor

1D. S% Plant i! ;or lter pump&' 8 Mono Bloc (

pump eart#ing to "e *one again

ii! Replace* *e$ecte* Ammeter (

8 Voltmeter in Panel

iii! Unplugge* ca"le+ entrie+ to "e clo+e* (

i)! Routine maintenance o$ Pump

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8 motor


11. >i$t+ i! Routine maintenance

1'. Eart#ing ii! Eart#ing +y+tem nee*+ to "e (

impro)e* a+ *etaile* out int#e recommen*ation

10. >ig#tning Protection i! Eart#ing to "e *one "y 07F= ( +trip ((

ii! Ru+te* lig#tning pole to "e replace* (

iii! Eart#ing to "e ma*e continuou+ (

14. Canteen "uil*ing i! Ammeter to "e replace* $or Panel ( ii! Panel to "e replace* (( iii! >ig#t pro)i+ion to "e pro)i*e* (

i)! re++ing o$ ca"le+ 8 t#e ca"le (( lea*+ to "e *one.

17. ;ee*er Pillar i! Ca"le i+ to "e re terminate* again ( "y proper crimping 8 3it# lug ii! Panel to "e replace* (( iii! Ca"le glan* to "e pro)i*e* ( i)! re++ing o$ ca"le+ 8 t#e ca"le (( lea*+ to "e *one.

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OBSERVATION

&

RECOMMENDATION

OBSERVATIONS AND RECOMMENDATIONS

1. 11 KV Breakers-1 No. Make Siemens.

1.1 Observations:-

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1.1.1 This Vaccum Circuit Breaker receives supply from Reliance Power through800A Breaker. Each breaker of 800A supplies to 1000 KVA Transformer

i.e. TR-1 & TR-2.

1.1.2 The breakers are installed on a separate room adjacent to DG room.

1.1.3 The Ammeter of TR-2 to be changed as, the CT ratio is 100/1 & the

installed Ammeter range is 1 to 25 A.

1.1.4 Double earthing has been provided by GI strip & same was found in goodcondition.

1.1.5 Rear Side of Breaker there is no rubber mat.

1.1.6 Cable termination were checked & same was found in healthy condition.

1.1.7 Relay setting calibration done on 14.06.15.

1.1.8 Shock treatment chart, fire extinguisher has been provided in the room,

Lighting in the room was also found adequate.

1.2 Recommendation:-

1.2.1 It is recommended that Ammeter to be change having the range of 1 to

100A for Tr-2.

1.2.2 At Rear side Rubber mat of 2mm of voltage rating 33 KV at rear side of

breaker to be provided.

1.2.3 Danger board/caution plate to be provided on the breaker.

1.2.4 Cable sizes to be stenciled with white paint on both the breakers.

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2.TRANSFORMER- 2 Nos.

Transformer (TR-1) 1000KVA, 11KV/433V, 52.5/1334A

Percentage Impedance Z = 4.95%

Make Kirlosker

Transformer (TR-2) 1000KVA, 11KV/433V, 52.5/1334A

Percentage Impedance Z = 4.99%

Make Kirlosker

2.1 Observations:-

2.1.1 Transformer I- is supplying to following area i.e. Flood Load, Canteen,

Domestic Pumps, Lift No.1 & 2. IT Centre, Air Conditioning Unit,

Capacitor Bank 1 trough Main Distribution Board. Transformer II is

supplying Small Wing, STP, Large Wing, Lift No.4, 5 & 6, UPS Room and

Capacitor Bank 2 through Main distribution board.

2.1.2 Transformer-1 is connected to Main Distribution Board through 6 nos.

3.5X300 sq.mm Al. PVC Cable to MDB & 1600 Amp. ACB.

Transformer -2 is connected through 6 nos. of 3.5CX300 sq.mm Al. PVC

Cable to MDB & 1600 Amp ACB.

2.1.3 In both the transformer, Earthing of the neutral & the body was done by

50X6 mm GI strips & the same was found in healthy condition.

2.1.4 The Transformers are installed on high concrete plinth in an open area,

behind the Main LT Panel Room,

2.1.5 Filtration of transformer oil of both the transformers has been done every

year as told by the maintenance personals.

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2.1.6 Cable terminations were checked & same was found in healthy condition.

2.1.7 WTI of Transformer-1 was found not working properly.

2.1.8 Both the Transformer was found rusted very badly.

2.1.9 Proper fencing with gate has been provided around the transformer to

avoid entry of unauthorized person.


2.2.1 It is recommended to check the di-electric strength of the oil once in a

year.

2.2.2 Silica Gel of both the transformer to be re-activated by heating & changed

when necessary.

2.2.3 WTI to be changed for Transformer-1.

2.2.4 A Shed to be provided over both the Transformer, so that rain water can

be stopped directly falling on transformer.

2.2.5 Routine maintenance as per I.O.C. Engineering Manual Vol-7 Part-I to be

done.

2.2.6 Cable Boxes both H.T. & L.T. to be earthed with main body of the

transformer

2.2.7 For long term planning it is recommended to replace both then

transformer by 1250 KVA transformer of reputed make., since the existing

transformer is 32 years old & the average life cycle has been completed.

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2.3 Healthiness Report of Transformer

Transformer was checked for healthiness at IOCL (HO) Bandra on 20,

July, 2015. During the Check up following parameters of both the

Transformers like Voltage , Current & Temperature were recorded & same

has been listed below in tabular form:-

Transformer No.1 Details As per Name Plate:-

Rating :-1000 KVA, 11/.433 KV, Dyn11, Current HV-52.5A & LV-

1334 A ,Make-Kirlosker , Year of Manufacture= 1983, Serial No.- 83LD-114/2, Impedance-4.99%.

On Dated 20.07.15

Time I/C Voltage in

Voltage

Current in

Ampere

Temperature in Celsius

OTI WTI

02:00 P.M. 405 600 40 *

02:30 P.M. 400 630 40 *

03:00 P.M. 415 560 39 *03:30 P.M. 415 540 38 *

04:00 P.M. 410 620 37 *

04:30 P.M. 415 635 38 *

05:00 P.M. 410 630 41 *

Transformer No.2 Details As per Name Plate:-

Rating :-1000 KVA, 11/.433 KV, Dyn11, Current HV-52.5A &

LV- 1334 A ,Make-Kirlosker , Year of Manufacture= 1983, Serial No 83LD-114/1, Impedance-4.99%.

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On Dated 20.07.15

Time I/C Voltage in

Voltage

Current in

Ampere

Temperature in Celsius

OTI

WTI

02:00 P.M. 400 780 38 41

02:30 P.M. 400 780 38 41

03:00 P.M. 415 740 37 40

03:30 P.M. 415 700 36 39

04:00 P.M. 410 760 38 41

04:30 P.M. 415 780 39 4205:00 P.M. 410 760 37 40

3. DG SET- 1 No:-

DG Set 500 KVA, 415V, 716 A , 1500 RPM

Make of Alternator Stamford

Make of Engine Cummins

Operation & routine maintenance being done as per the maintenance

Schedule.

3.1 Observations:-

3.1.1 500 KVA DG Set is installed in DG room, which is without acoustic

enclosure, DG set is operated through a DG panel of Narendra Switchgear

make, having 1000A ACB in incomer side. The supply is feed to Main

Distribution Board through bus coupler of 1600A, providing inter locking

with main supply.

3.1.2The DG sets has been properly installed in the DG room, cable from DG

set to DG control Panel has been laid and cable termination has been

done properly. No loose connection observed.

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3.1.3 Body earthing & neutral earthing has been provided by 50x6 mm GI strip

and connection was found healthy.

3.1.4 In DG Control panel, cable termination checked & same was found in

healthy condition.

3.1.5 Condition of Gasket of panel was found deteriorated in the DG Panel.

Neoprene type gasket shall be fitted at the door of the panel.

3.1.6 Under Voltage/Over Voltage/ Earth fault Relay installed in the DG Control

Panel, were found not in working condition.

3.1.7When the DG is in Running Condition, then there is lot of noise created

by the DG sets.


3.2.1 New DG panel to be installed having all the protection like Under

Voltage/Over Voltage/ Earth fault Relay, so that the panel can work

efficiently without any hazard.

3.2.2 For Long Run, a new DG of 630 KVA Can be installed having acoustic

enclosure as per latest CPCB norms. This will take entire load of Building

at the time of emergency.

3.2.3 It was observed there were dust & cob webs inside the panel, so it is

recommended, that from hot air blower blowing to be done in once in a

month.

3.2.4 It is recommended, that cable terminal nut bolts to be tightening to be donein once in a three month.

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4. MAIN DISTRIBUTION BOARD (MDB):-

The MDB has mainly three sections i.e. Section-I, Section-II & Section-III

coupled through Bus Coupler 1600 Amp. ACB.

Section-I consist of :-

Incomer from 1000 KVA Transformer TR-2- 1600Amp. ACB

Outgoing:-

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to Air Conditioning Plant II - 1000 Amp. SFU

to Small Wing, Large Wing & Capacitor Bank-2 - 630 Amp. SFU

to UPS changeover 2ndFloor & Spare - 400 Amp. SFU

to STP - 250 Amp. SFU

to Lift No. 4, 5 & 6 and Spare - 100 Amp. SFU

to spare - 63 Amp. SFU

Section-II consist of :-

Incomer from 1000 KVA Transformer TR-1- 1600Amp. ACB

Outgoing:-

to Air Conditioning Plant-I - 1000 Amp. SFU

to Small Wing, Large Wing & Capacitor Bank-1 - 630 Amp. SFU

to Canteen, MLTP 1 & 2, Workshop - 250 Amp. SFU

& Domestic Pump

to Lift No. 1, 2 & Freight Lift & Spare - 100 Amp. SFU

Pantry Lift & Flood Light & Spare - 63 Amp. SFU

Section-III consist of :-

Incomer from 500 KVA DG Set- 1600Amp. ACB

Outgoing:-

to Air Conditioning Plant - 1000 Amp. SFU

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to Fire Pump Panel - 400 Amp. SFU

to Lift No. 3 & Building light, Main Gate LDB - 100 Amp. SFU

& Sub station

4.1 Observations:-

4.1.1All thebreakers are of ABB make. It was reported that servicing of the

breaker are being periodically done by M/s. Spark Electrical.

4.1.2 The protection relays of the breakers are in operation. Maintenance of

MDB & other equipments being done by M/s. Spark Electrical.

4.1.3 Under voltage Relay 2 Nos. of DG section i.e. H4 feeder is found not in

working condition.


4.1.5 Condition of feeder were checked and found in healthy condition. No

heating / flash over observed / reported.

4.1.6 Shock treatment Chart, Rubber Mat, Fire Extinguishers has been provided

in the panel room. Illumination level of the room was found adequate.

4.1.7 Double earthing has been provided by GI strip for the panel & same was

found in healthy condition.

4.1.8 It was observed there were dust & cob webs inside the panel.

4.1.9 Load Current were measured in voltmeter for Tr-1 is 700 Amp. & for

Transformer Tr-2 is 600 Amp.

4.1.10 The load current capacity in several feeders were checked and found the

cables are able to carry the load current without any heating.

4.1.11 In the feeders, Phase current were checked and found the load a generally

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balanced & vary only 10%.

4.1.12 It was observed that the Cable trench were filled with cables and there is

no more space in the trench to put more cables.

4.1.13 Necessary interlocking was provided in the panel.

4.2 Recommendations:-

4.2.1 It is recommended to have the calibration of the relays done & operation of the relays/ breakers checked by Secondary injection test method through

any reliable & approved contractor/agency.

4.2.2 Cleaning of the panels interior & tightening of the connections to be done.

4.2.3 Under Voltage Relay of DG section to be changed/rectified.

4.2.4 It was observed there were dust & cob webs inside the panel, so it is

recommended, that from hot air blower blowing to be done in once in a

month.

4.2.5 It is recommended at the time of revamping the cable trench to be made of

1.2 mtr in width & 1 mtr. in depth. The cable to be dressed properly in

trench.

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5. CAPACITOR (APFC) PANEL:-

Nos. 320 KVAR each have been installed recently for the improvement of

power factor.

Make of the panels :- ABB

Capacitor :- Unistar

5.1 Observation:-

5.1.1 In each panel, there are different rating of capacitor bank feeder, capacitor

bank feeders are segregated as of 50 KVAR 2 Nos., 8 nos. of 25KVAR and

2 nos. 10 KVAR in both the panel.

5.1.2 The capacitor are brought into the circuit i.e. switched ON & OFF through

automatic P.F. correction relays mounted on the MDB.

5.1.3 The contractor used in the modules for the switching ON or OFF, were

found working satisfactory.

5.1.4 Cable terminations of banks were checked & same was found in healthy

condition.

5.1.5 Shock treatment Chart, Rubber Mat, Fire Extinguishers has been provided

in the panel room. Illumination level of the room was found adequate.

5.1.6 Double earthing has been provided by GI strip for both the panel & same

was found in healthy condition.

5.1.7 Capacitor Panel was found working condition properly and PF is being

maintained around 0.99.

5.1.8 In Capacitor Panel No.2, Feeder No-9, the Capacitor OFF button light is

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not glowing.

5.1.9 In Capacitor Panel No.1, Feeder No-7, the Capacitor contractor found

burnt.


5.2.1 In Capacitor Panel No.2, Feeder No-9, the Capacitor OFF button light top

be replaced.

5.2.2 In Capacitor Panel No.1, Feeder No-7, the Capacitor contractor to be

changed with higher rating contractor.

5.2.3 Cleaning of the panels interior & tightening of the connections to be done.

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6 LIGHTING SYSTEM:-

The lightning & power supply to different floors of the entire building is

made through 2 nos. rising mains one of the Large Wing(North) & other is

small Wing(South). At each floor the rising mains are tapped by 125Amp.

TPN switch mounted on the metal frame of the rising mains and the

terminal of the switch are connected to Bus-Bar of the rising main by cable.

The outgoing from the 100Amp. Switch is connected to a MCB DB panel.

This panel is used for phase splitting i.e. 3 phase to single phase.

Each phase of the Bus Bars is connected trough 40/25 A RCCB. The

Outgoing is through LDB-1 & LDB-2, In LDB-1 & 2 the incoming is through

40 Amp, 4pole TPN MCB & outgoing is distributed in each phase, through

10A, 20A & 32 A Single pole MCB.

In Each Floor there are LDB-1, LDB-2, & One Emergency DB. Each floor

has different numbers of MCB distribution board.

All the LDB are recently installed in each floor, the conditions of DB were

observed in good shape.

LDB

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Make ETC Energy

Incomer - 40A TPN, MCB

Outgoing - 4 Nos.-10 A, 3 Nos.- 20A, 1 No.- 32 A MCB for each phase

& 1 no, RCCB of 25A/40 A

Similar type of LDBs are installed in each floors on Large & Small Wings.

6.1 Observations :-

6.1.1 The LDBs installed in the floors are found in good condition.

6.1.2 The earthing of DBs are done by double earthing.

6.1.3 In some of the floors, frequent tripping was occurred as reported by

M/s. IOCL, in that case the RCCB was changed from 25 A to 40 A, due to

which no further tripping was reported.

6.1.4 Outdated rubber mat has been used in front of the rising mains.

6.1.5 Cable terminations were checked & same was found in health conditions.

No heating/flash over were observed/reported.

6.1.6 In LDB proper identification was not been given for each LDB according to

floor & wing.

6.1.7 Also, in each DB, identification/nomenclature for outgoing MCB were not

given for the easy of operation.

6.1.8 In LDBs no unplugged entries & dust was observed.


6.2.1 Cleaning of the DBs interior & tightening of the connections to be done.

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6.2.2 So it is recommended, that from hot air blower blowing to be done in once in a month.

6.2.3 Rubber Mat as per IS 15652, to be used for safety purpose.

6.2.4 In LDB proper identification to be given for each LDB according to floor

& wing for ease of operation & maintenance.

6.2.5 Also, in each DB, identification/nomenclature for outgoing MCB to be

given for the easy of operation.

6.2.6 Cable termination to be checked & tightened in every 3 months.

7 LIGHTNING POLE & GLOBE LIGHT :-

There are aprrox 20 Nos. lightning poles fitted with 1 X 250 Watts Metal

Halides lamps in each fitting. & 7 Nos. of lightning fitting pole fitted with

1 X 150 watts Metal Halides lamps of Bajaj & Philips make.There are

approx 51 Nos. of Dome light having 70 watt sodium vapor lamps installed

in the IOCL Office Compound.

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7.1 Observation:-

7.1.1 Dome Light in Building area, the cable laid are very old, they were found

ruptured many times, as per the information given by site personnel.

7.1.2 The sheet metal of Junction boxes are totally rusted & corroded. Terminals

hard wares are also badly rusted.

7.1.3 Cable insulation were found weak.

7.1.4 It was observed in some of the poles i.e. 5 Nos. the bottom is rusted very badly.

7.1.5 At some place, the earthing was found disconnected of lightning poles.

7.1.6 Garden Light (LED Type) of 6 Watt , some of the fitting found missing/

defective.

7.1.7 There are 8 to 10 nos. of pole which are found rusted due to which

mounting is not possible.

7.1.8 The incoming/outgoings cables mounted in the recesses at the bottom of

the poles are badly corroded/rusted which give rise to loose connection &

failure.


7.2.1 Dome Light in Building area, the cable laid over there, which are ruptured

& have less insulation , the same to be changed/replaced, so that no

Accident can take place.

7.1.2 JB conduits were found rusted, so it is recommended to replace it.

7.1.4 It is recommended to change all the poles which are rusted & defective.

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7.1.5 Earthing to be connected of lightning poles where every found

disconnected.

7.1.6 It is recommended to provide cast AL, IP-55 Junction Boxes at the base

of the poles fitted with fuses/terminal block etc.

7.1.7 The cabling to be done with gland & terminals with Cu lugs.

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8 AIR CONDITIONING PLANT:-

The New Air Conditioning Plant is installed which is nearly one year old.

There are 4 nos. of AC Plant of 200 Tonnes/Hr. Each chiller plant have

have two units each of 100 Tonnes/ Hr. The Unit receive power supply

from two new Panels installed in the Air Conditioning room.

8.1 Observation:-

8.1.1 Following Equipments has been installed in AC Plant.

Sr. No. Description Rating Make Qty.

1) Centrifugal Unit 756 KW Blue Star 4

2) Condenser Pump Motor 30 KW Kirloskar 4

3) Chiller Pump Motor 30 KW Kirloskar 4

4) MCC Panel 415 V Industrial 2

Electrical

5) JB for Condenser Pump 415V Industrial 4

Electrical

6) JB for Chiller Pump 415V Industrial 4

Electrical

7) Air handling Unit at 24

Different floor

8.1.2 All the equipments were new and recently installed, they all are in good

shape.

8.1.3 All the equipments were found Double earthing has been provided by GI

Strip/ Flexible Copper cable for both the panel & same was found in

healthy condition.

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8.1.4 There are two panels which receive power from MDB, there are two nos.

630 Amp SFU in each panel for Chiller Plant 1 to 4. And outgoing was

To Chiller pumps, motors, cooling tower & AHU Units in all the floors.

8.1.5 Emergency Stop Push Button is installed for each Condenser & Chiller

Motor.


8.1.7 The Motors for Chiller & Condenser Units were checked and found ok.

8.1.8 No problem has been observed/reported in MCC panel.

8.1.9 In front of MCC Panel( chiller 3 & 4 unit) there was no rubber mat.

8.1.10Jet Fan DB which is wall mounted having 16A three pole MCB were

found not earthed.


8.2.1 All the terminals to be checked and tightened in every three months.

8.2.2 Rubber mat to be provided in front of MCC Panel(Chiller 3 & 4)

8.2.3 Jet Fan DB to be double earthed with flexible cooper cables.

8.2.4 Regular maintenance to be done as per IOCL maintenance schedule.

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9 FIRE PUMP HOUSE :-

9.1 Observation:-

9.1.1 Following motors has been installed in Fire Pump House.


1) Fire Engine 89.5 KW Kirloskar 1

2) Hydrant Motor 60 KW Kirloskar 1

3) Sprinkler Motor 60 KW Kirloskar 1

4) Jockey Pump Motor 11 KW Kirloskar 1

5) Trolley Pump 3.7 KW Induscom 1

6) Sump Pump ----- ------ 2

9.1.2 In Fire Pump House the cable coming to Panel was not properly dressed

on the cable tray/ wall. There are lying in haphazard manner.

9.1.3 The Ammeter of Main Fire Panel and other panel installed adjacent to

Fire Panel was found not in working condition.

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9.1.4 The Jockey Pump was kept in Auto Mode & at set pressure of 7kg/cm. sq.

9.1.5 There is a proposal on one new Jockey Pump. The motor has been

brought but not yet installed.

9.1.6 The earthing of Jockey Pump, Sprinkler & Hydrant Pump were done by

25X3mm GI strips, & same was found in health condition.

9.1.7 Cable entry in terminal box of Sprinkler motor was found loose, i.e. proper

glanding is not done.

9.1.8 The condition of Fire engine was found in good shape, same is kept in

manual mode. The battery condition found healthy.

9.1.9 In DC panel for Fire Engine, unused cable entry observed at the bottom

of the gland plate.

9.1.10 The trolley pump have single body earthing.

9.1.11 In DOL starter & 16 Amp. Fuse Unit for Trolley Motor, cable entry is

without any gland. And the terminal box of motor also does not have any

gland.

9.1.12 Cable armour were found cut of Sump Pump motor.

9.1.13 Condition of Gasket of Panels were found deteriorated.


9.2.1 All the terminals of motors to be checked and tightened in every three

months.

9.2.2 All the defective Ammeter to be replaced as per the rating in Panel.

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9.2.3 Trolley Pump to be double earthed with flexible cooper cables.

9.2.4 All the cable in the Fire Pump house are to be properly dressed/cladded.

9.2.5 Proper Cable glanding to be done in all the motors terminal boxes.

9.2.6 It is advised to plug all such unused spaces/blanks by using blanker to

avoid entry of dust, lizards etc.

9.2.7 Neoprene type gasket shall be fitted at the door of the Panels.

9.2.8 Cable to be cutted & ret terminated for Sump Pump Motor.

10 ST PLANT :-

10.1 Observation:-

10.1.1 Following motors has been installed in Fire Pump House.


1) Filter Pump1-2 7.5 KW Bharat Bijlli 2

2) Carifiled Water Pump1-2 3.7 KW Toshio 2

3) Dewatering Pump 2.2 KW Bharat Bijlli 1

4) Return Sludge Pump 2.2 KW BB & Siemens 2

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5) Air Blower 3.7 KW Usha 2

6) Aerator 2.2 KW ------ 1

10.1.2 The panel of ST Plant, receives power from MDB , the Incomer has 250A

SFU & the outgoing is to Pumps, Blower etc.

10.1.3 The Ammeter & Voltmeter of Panel was found not in working condition.

10.1.4 Red & Blue Phase indicator of Panel was not glowing brightly.

10.1.5 Condition of Gasket of Panel was found deteriorated.

10.1.6 Earthing of Pumps were done by 10 sq.mm flexible copper cable.

10.1.7 Earthing for Filter Pump No.2 found disconnected & Earthing of Mono

Block Pump2(Carfiled) was done in foundation buried in motor platform.

10.1.8 In Return Sludge Pump of Siemens make the glanding of Cable terminal

were found not done.


10.2.1 All the terminals of motors to be checked and tightened in every three

months.

10.2.2 All the defective Ammeter & Voltmeter to be replaced as per the rating in

Panel.

10.2.3 Earthing for Filter Pump No.2 to be connected & Earthing of Mono

Block Pump 2(Carfiled) to be done on motor not in foundation.

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10.2.4 The Red & Blue indication lamps to be replaced in ST Panel.

10.2.5 Proper Cable glanding to be done in all the motors terminal boxes.

10.2.6 Neoprene type gasket shall be fitted at the door of the Panel.

11 LIFTS :-

11.1 Observation:-

11.1.1 Following Lifts has been installed in IOCL Building.

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Sr. No. Description Capacity Make Qty.

1) Passenger Lift 1-6 20 person Otis 6

2) Freight Lift 15 person Otis 1

3) Pantry Lift ------ Otis 1

11.1.2 All the passenger lift were well maintained. The lift license is valid.

11.1.3 The Door Sensors were found working satisfactory.

11.1.4 The Emergency Fan & light were working.

11.1.5 Necessary Control Panel & interlocking relays are of Otis make &

installed in the lift room. Lifts are being serviced & maintained by

M/s. Otis representative.


11.2.1 There is no recommendation. The Lifts are working satisfactory.

12. EARTHING & EARTHING SYSTEM:-

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The earthing system of the plant was found good. The earth pits of plant randomly checked & following observations noted-

a.Construction of the earth pit in substation area & pump house area was

found in good condition. No rusting was observed, Earth Pit Resistance was

checked on random basis & pit resistance was found in the range of 0.5 to 1.5

Ohm. The measured value of the pit resistance were found within the

acceptable range.

b. In most of the pits C type clamps used in the pits & the connection werefound ok.

c. Earth Pit Resistance is being measured and records are maintained.

d.4 Nos. of New Earth Pit has to be constructed for New installation of

transformer.

e.There are 4 Nos. of chemical earthing in front of LT Panel room. The electrode

is buried in the ground. There is no pits made for easy of maintenance.

12.1 EARTHING RECOMMENDATIONS & PRACTICES:-

Recommended practices for an earthing system to attain acceptable level

of safety:-

a.To provide a very low resistance path to ground for the discharge of

fault current, lightning current and statics charges.

b. Mechanical strength and corrosions resistance to various

environmental conditions so that the system remains intact

throughout the working life of the plant.

c.Loose contacts to be totally avoided so that there are hot spots

developed during the passage of fault current or lightning current

which can be 200KA or more.

d.Minimum Spacing between two electrodes shall be 10 meters or twice the length of the electrode.

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e.Earth grid shall be 1.5 meter away from the building column and to be

buried at a depth of 600 mm.

f.Interconnection of GI Strips in the earth grid should be done by welding

instead of bolting, and the welded portion should be painted with zinc-

rich paint (Epilux-4) or black bitumen paint to avoid rusting.

g.The connection of the grid strips with the earth electrodes shall be

made in such a way through C type clamps grouted on the side walls

of the earth pit, that it shall be possible to isolate the earth electrode

and measure its earth resistance.

h.All the earthing pits shall be interconnected so as to obtain a minimum

earth resistance of 1 ohm.

i.Equipment earthing should always be crimped in suitable lugs if done

with stranded Aluminum or GI wire ropes. Usage of solid conductor to

be avoided, as it gives rise to loose connection with crimped socket.

j.All earth connections to be checked for tightness. Loose connections or

bolted joints lead to hot spot & sparking which can become a source or

fire/explosion in the hazardous areas.

k.Rusted connections to be rectified by applying zinc-rich or black

bitumen paints.

l.All lighting fixtures made of metal should be earthed. It is necessary

that lighting fixtures installed in the plant areas shall be earthed

externally. External earthing to be done by using a 2.5 sq. mm.

stranded copper wire or 6 sq.mm. GI stranded wire.

m.The neighboring soil to the earth electrode shall be kept moist by

pouring water in the immediate vicinity of the earth electrode.

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13 LIGHTNING PROTECTION (Ref IS - 2309):-

13.1 Observation:-

13.1.1 There are 8 Nos. Air Terminal Rods Connected with 25X3 GI strips laid

along the parapet walls. On the roof 3 Nos. down conductor have been

taken from the roof G.I. Strips to the Earth Pits.

13.1.2 Lightning arrestor above machine room is found rusted.

13.1.3 Earthing strip found rusted near the incoming door of roof.

13.1.4 At some places, there is discontinuity of earthing strip, in the roof area.

13.1.5 The nos. of lightning arrestor were sufficient as per the covered area.

13.2 Recommendation :-

13.2.1 The existing earthing to be changed with 35X6 GI strip.

13.2.2 Lightning arrestor which are rusted is to be changed with new one.

13.2.3 Earthing strip to be made in continuous through out the roof area.

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14 CANTEEN AREA POWER SUPPLY:-

Panel No.1

Make - Star Engineer

Incomer from Substation -3.5 X95 sq.mm cable

Incomer switch of 125 A make L&T

Outgoing to 5 nos. SFU of 16 Amp. & through switch fuse of 63 Amp(L&T)

MCB DB in Canteen (Power):-

Incomer - 40 Amp 4 pole MCB for panel.

Outgoing 20 A, 5 Nos. 10A, 6 Nos. 32, 1 No. MCB in each phase.

14.1 Observation:-

14.1.1 It was observed in the panel that the Ammeter was not working condition.

14.1.2 No provision of lighting was provided in the panel area.

14.1.3 The way to panel was full of obstruction.

14.1.4 The dust & cob web full in the panel.

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14.1.5 Unused holes on the gland plate are not plugged.

14.1.6 The cables leads inside the boxes are not properly dressed.

14.1.7 In Fuse DB there is Bus Bar arrangement, 30 Nos. of HRC Fuse for

outgoing for distribution.

14.1.8 There are 3 feeders in the DB which are not in use, they are in

non-functional condition.


14.2.1 Panel room to be properly made with proper peripheries, show that safety

measure to be kept in mind.

14.2.2 Panel way to be cleaned, all the kitchen goods to be removed in front of the

panel.

14.2.3 Cable glanding to be provided were ever is required & the unused entries

to be plugged & sealed.

14.2.4 Cleaning is required in the panel & near by area.

14.2.5 Provision for proper lightning to be made, so that there will be adequate

light to work.

14.2.6 It is recommended that from hot air blower blowing to be done in once in a

month.

14.2.7 The dressing of cables & the cable leads to be done.

14.2.8 For, long term planning a new panel to be installed.

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15. FEEDER PILLAR PANEL (NEAR MAIN GATE):-

Main Gate DB

Incomer - of 100 A 3 pole MCB, make L&T

Outgoing to 10 nos. MCB of 32 Amp. & 40 Amp. The outgoing is to Dome

light, Cabin Light, fountain light, outdoor light.

MCB DB for Fountain (Power):-

Incomer - 40 Amp 4 pole MCB for panel.

Outgoing to fountain Starter Motor approx 10 HP.

15.1 Observation:-

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15.1.1 Incomer DB enclosure is very small, i.e. the space is less due to which

there is problem of doing maintenance.

15.1.2 Available DB is very old & the condition is very critical.

15.1.3 Heating in cable is observed in the incomer side of the cable.

15.1.4 The MCB DB was full of dust & cob web.

15.1.5 Unused holes on the gland plate are not plugged.

15.1.6 The cables leads inside the boxes are not properly dressed.

15.1.7 In Fountain DB, the space for mounting of cable terminal not in proper

Way.

15.1.8 Condition of Gasket of DB was found deteriorated.

15.1.9 Flashover observed in incoming cable terminal in Fountain DB.


15.2.1 It is recommended that the cable is to be re-terminated again by proper crimping & with lug.

15.2.2 Cable glanding to be provided were ever is required.

15.2.3 It is recommended that from hot air blower blowing to be done in once in a

month.

15.2.4 For, long term planning a new DBs to be installed so that no problem is

being faced at the time of maintenance.

15.2.5 Neoprene type gasket shall be fitted at the door of the Panel.

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15.2.6 The dressing of cables & the cable leads to be done.

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Docume!" Re#$e%

1).Document:-Documents as per Tender requirements were reviewed at IOCL

Head Office. Following Equipments Documents were reviewed as

listed below.

1.1 Earthing :-Earth resistance of earth pit in IOCL Office Compound

was taken by Spark Electrical Contractor on 03/06/2015.

The reports submitted by M/s. Spark were reviewed.

Following were theObservations:-

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1.1.1 Individual Value of Earth Pit resistance was observed from 0.4 to 0.8 ohm

for Pit No. 1 to 14.

1.1.2 Individual Value of Earth Pit resistance was observed from 0.4 to 0.8 ohm

for Pit No. 15 to 31.

1.1.3 There are 8 nos. of Earth pit at Transformer yard, the value lies from 0.4

to 1.6 2 ohm, for Pit No. 7 the resistance value is 1.3 ohm & Pit No. 8 it is

1.62 ohm.

1.1.4 There are 9 nos. of Old Earth pit at Building side, the value lies from 0.4

to 1. 2 ohm, for Pit No.6 have the maximum value of resistance was

recorded i.e. 1.2 ohm.

1.1.5 There are 6 nos. of Neutral earthing , 2 for DG & Two nos. for each

transformer, the value lies from 0.2 to .4 ohm.

2.1 Battery Charger:-Battery Charger for 11 KV Breaker was serviced by

M/s. Spark on 14.06.15 . And the report dated 16.06.15

were reviewed. Following were theObservations:-

2.1.1 Operational & Functional checks were found satisfactory.

2.1.2Condition of battery found good & there were no open entry.

3.1 LT Panel :-LT Panel servicing was done on 14.06.15 by M/s. Spark. And

the report dated 16.06.15 were reviewed. Following were the

Observations:-

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3.1.1 Cleaning, ON OFF operation of MCCB were checked & found satisfactory.

3.1.2Tightening of power & control cable was done.

3.1.3 Operating handle of MCCB of G5 i.e.( Pantry Lift) feeder were found

broken.

4.1 HT Panel :-HT Panel servicing was also done on 14.06.15 by M/s. Spark.

And the report dated 16.06.15 was issued & same was

reviewed. Following were theObservations:-

4.1.1 Cleaning, Tripping of relays were checked & found satisfactory.

4.1.2Tightening of Bus Bar was done.

4.1.3 HT Cable Termination & CT/PT connection were checked & found Ok.

5.1 Transformer:-Servicing of Transformer was done by M/s. Spark on

14.06.15 and the report dated 16.06.15 was issued & same

was reviewed. Following were theObservations:-

5.1.1 Cleaning, Tripping of relays were checked & found satisfactory.

5.1.2 HT Cable Termination were checked & found Ok.

5.1.3 Breather of both the transformer were found broken.

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5.1.4 Dielectric Test of Transformer Oil was done & the results is given below:-

Transformer Before Filtration Value After Filtration Value

Transformer-1 25 KV 60KV

Transformer-2 20 KV 60KV

6.1 HT Breaker :-Servicing of Breaker was done by M/s. Spark on



6.1.1 HT Breaker of Incomer Side & Both Outgoing side. Following test were

carried out i.e. Closing & Tripping of Breaker, Mechanical Operation,

spring charging of motor were checked & found satisfactory.

6.1.2 Indication of Relay, Breaker Tripping from Relay were found working

satisfactory.

6.1.3 Insulation Resistance in ON & OFF condition were checked and following

points were noted:-

Breakers side Phase to Phase Value Phase to Earth Value

Incomer Side 1500 M.Ohm 2000M.Ohm

Transformer-1 1000 M.Ohm 1500M.Ohm

Transformer-2 1500 M.Ohm 2000M.Ohm

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7.1 ACB in MDB :-Servicing of ACB was done by M/s. Spark on



7.1.1 Closing & Tripping of ACB, Mechanical Operation, were checked & found

satisfactory.

7.1.2 After servicing working conditions of ACBs were found satisfactory.

7.1.3 Main & Auxiliary Contacts found ok.

7.1.4 Insulation Resistance in ON & OFF condition were checked and following

points were noted:-

ACB ratings Phase to Phase Value Phase to Earth Value

ACB 1600 TR-2 200 M.Ohm 200M.Ohm

ACB 1600 B-C 100 M.Ohm 200M.Ohm

ACB 1600 TR-1 200 M.Ohm 100M.Ohm

ACB 1600 B-C RHS 200 M.Ohm 200M.Ohm

ACB 1000 B-C LHS 200 M.Ohm 200M.Ohm

8.1 Relay :-Servicing of Relays was done by M/s. Spark on 14.06.15

and the report dated 16.06.15 was issued & same was reviewed. Following were theObservations:-

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8.1.1 Relay Characteristic & functional has been checked & found ok.

8.1.2 After servicing working conditions of Relays were found satisfactory.

8.1.3 Flag indication, Alarm & Trip function of auxiliary relays were checked &

found ok.

8.1.4 Setting of different relays were done & the setting were found ok.

ForCT Ratio 100/1following settings are shown:-

Relay Ratings Setting Instantaneous Setting

Phase R 0.5 - 2.0 1.5/.2 17 A

Phase Y 0.5 - 2.0 1.5/.2 17 A

Phase B 0.5 - 2.0 1.5/.2 17 A

Earth Fault 0.1 - 0.4 0.2/.05 6.8 A



Phase R 0.5 - 2.0 1.5/.2 17 A

Phase Y 0.5 - 2.0 1.5/.2 17 A

Phase B 0.5 - 2.0 1.5/.2 17 A

Earth Fault 0.1 - 0.4 0.2/0.1 6.8 A


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Phase R 0.5 - 2.0 1.5/.2 17 A

Phase Y 0.5 - 2.0 1.5/.2 17 A

Phase B 0.5 - 2.0 1.5/.2 17 A

Earth Fault 0.1 - 0.4 0.2/0.1 6.8 A