THE PREMIER SUGAR MILLS & DISTILLERY CO. LTD., MARDAN
SOP for Electrical Management and Maintenance
Purpose:
To describe the smooth generation, transmission, distribution and preventive maintenance procedure of
electrical system for PSM. This guideline is applicable for PSM factory, Electrical Engineering personnel
who involve in this sector and have a large experience in operation and maintenance of Sugar Factory
Buildings.
Process: Depend on machine wise.
Safety:
Personal safety: Please don’t carry water, fire/fire box, salt, dust, inflammable materials, chemical and a
biological agent at substation that could cause fire hazard or illness. The Engineer/Electrician should
wear protective safety gear such as boots, gloves, apron, electrical safety glasses and earplugs to
protect him or her from Electric shocks and other environmental hazards.
Machine safety: Please follow the installation/operational manual for particular machine and
Locking/unlocking and tagging/un-tagging policy.
Energy Management:
Examples of how it is possible to save energy and costs with the help of maintenance:
•
Switching to electronic ballast and LED light. Use Energy star product with label.
•
Load management at launch time. Switching to servo motors machines.
•
Energy efficient motors to be used with synchronous belt instead of V-belt.
•
Motor input voltage shall be balanced, well lubrication & ventilation, right alignment, checks
motor temperature and ventilation, appropriate load consideration need to be maintained. Use
VVVF or VFD at motor for speed control & soft starting. Avoid idle running of any machine and
motor.
•
Insulate pipes, valves and flanges correctly and use steam traps at steam line. Repair steam and
compressed air pipe leakage.
Electrical Waste Management:
•
Place the fluorescent lights/CFL/Battery back into their original containers or the package
provided by the recycling company or waste disposal company. Label the box with
“CFL/Fluorescent light/battery: hazardous waste.”
•
Tell everyone to leave the room; open windows, allowing the room to air out for about 15
minutes. Turn off any air conditioning or heat units in the storage area.
•
Deliver the fluorescent lights/CFL/Battery to Engineering Store/PSM or Call your local recycling
company or local hazardous waste Disposal Company and ask if they offer any fluorescent light
disposal or recycling programs.
“Any HARD copies of this document are UNCONTROLLED”
Inquire as to what kinds of fluorescent bulbs they take, as some will only accept bulbs that have burned
out. Ask if there are any special boxes or labels you need to turn in your fluorescent tubes.
Methods of Electrical Maintenance:
Electrical Drawing: Update factory’s single line diagram including earthing system, Electrical Drawing of
HT, LT, PFI, MDB, SDB & SB. And machine layout drawing with proper dimension for the factory to be
update as a when required.
Lightning Protection System: Update & check Lightning Protection system diagram with earth pit after
a year.
Earthing System: Ensure only one type of earthing system and also ensure separate earthing
connection for Transformer, Generator, and Electrical System for your factory. Check & register earth
resistance half yearly for all earth pits.
Electrical Preventive maintenance Log: Keep updating your preventive maintenance log i.g.
Emergency & Exit light check monthly, Ceiling fan checking after 04months.
Cables loading: Ensure electrical cable is loaded not more than 75% of its loading capacity and prepare
DB schedule half yearly.
Cable Connection/termination: Ensure that all the cable terminations/connections are tightened firmly.
LT/MDB/SDB check quarterly. SDB, MDB, LT, HT, PFI, Cable rench/Tray/ladder: keep clean from dust and
spider net. Cable trench/Tray/ladder check quarterly.
Electrical tools & Instruments: Ensure calibrated instruments and proper insulation for all the electrical
tools used by factory electricians.
Insulation Resistance: Insulation resistance test of all the cables must be performed once every two
years cycle and recorded.
Thermographic scanning: for entire electrical system must be performed on a biannual basis and
recorded
Standard Operating Procedure For Electrical Department
(For Safety Purpose )
1. OBJECTIVE
To lay down the procedure for electrical safety.
2. SCOPE
This SOP shall be applicable for all electrical
system in the plant.
3. RESPONSIBILITY
Technician/Electrician/operator/Executives/Asst. Managers
4. ACCOUNTABILITY
HOD of Engineering
5. PROCEDURE
5.1 Do not replace a blown fuse until you are sure that the cause is identified and rectified.
5.2 Do not close any switch unless you are familiar with the circuit which it controls and knows the
reason for its being open.
5.3 Do not work on the live circuit. Make sure that all safety precautions have been taken and you are
accompanied by a second person competent to render First Aid and Artificial Respiration.
5.4 Do not touch or tamper with any electrical gear or conductor unless you have made sure that it is
ISOLATED and EARTHED.
5.5 Do not open or close switch or fuse slowly or hesitatingly. Do it quickly and positively to avoid
sparking and contact with the live circuit.
“Any HARD copies of this document are UNCONTROLLED”
5.6 Do not use wires with poor/ inadequate insulation.
5.7 Do not touch any electrical circuit when your hands are wet or bleeding from a cut or an abrasion.
5.8 Do not work on the energized circuit without
taking extra precaution such as the use of rubber hand gloves, Electrical Rubber Mats and also ensure
the circuit is properly earthed.
5.9 Do not disconnect a plug by pulling a flexible cable when the switch is on.
5.10 Do not use a fire extinguisher on electrical equipment unless it is clearly marked for that purpose.
Use DCP or CO2 type fire extinguisher.
5.11 Do not throw water on live electrical equipment in case of fire. Never use Soda Acid type fire
extinguisher for combating the electrical fire.
5.12 Do not attempt to disengage a person in contact with a live apparatus, which you can not switch
off immediately. Insulate yourself from the earth by standing on a rubber mat or dry board, before
attempting to get him clear. Do not touch his body; push him clear with a non- insulating material.
5.13 Continue artificial respiration until recovery.
5.14 Do not allow visitors and unauthorized person to touch or handle electrical or come within the
danger zone of HV apparatus.
5.15 Do not test circuit with bare fingers.
5.16 Carry out electrical inspection once in three months
5.17 Earthing
5.17.1 Earthing is required for dissipating the generated static electricity. Earthing is also provided to
detect leak current using ELCB, which disconnect the electric supply of the equipment.
5.17.2 Provide earthing to all electric equipment and where the chances of static generation exist.
5.17.3 Do not disconnect earthing connections. Do not bypass any safety gadgets installed on mains
and equipment /apparatus.
5.17.4 Check the earthing status of the equipment once in three months
“Any HARD copies of this document are UNCONTROLLED”