Learnings From Project

Sonadih2nd clinker line Project
Learning from Project
-KV Siva ram sarma
Learnings from project

1 1
Contents
A. Project construction safety

2 2
Contents
1. Electrical distribution system

2. Earthing
3. General guidelines for electrical safety
4. Specific equipment required
5. Cable laying

3 3

4 4
1. The Power will be given at one source – 3 Ph+ 1N+ 1E

2. The Internal distribution is in the Erection company scope.
3. For a construction site – Clinker line the power source should be suitable for an
operating load of 500 kW.Connected Load of 800 kW ( 2 batching plants+ aux)
4. The Voltage level to be – 415 V, 50 HZ.(Based on Indian conditions).
5. The Erection company should distribute the power in the following Voltages.
i. shop level / Main Distribution Board Level - 415 V, 3Ph+1N
ii. Sub Distribution Level –
a. 415V, 3Ph+1N – For welding machines, Water Pumps - All with
independent ELCB of 30 mA at each Out going
b. 110 V Ph- Ph – for power tools Like angle Grinders, drill Machines
and other power tools all with independent ELCB of 30 mA at each
out going.
c. Lighting
• Area Lighting – 230 V (Ph- N) with ELCB of 30 mA at the each
out going.
• Confined space – 24V(Ph- N) With ELCB of 30mA for the
Transformer incoming.
(Refer Animation in Next slide)

5 5
1. Electrical distribution system; Cont’d
230 V General area

Lighting
ELCB with 30 mA
Incoming source
MCCB
415 /110 (Ph- 230/ 24 V

Ph)Transformer transformer
Learnings from project 24 V confined

110V power tools Like
space Lighting
angle grinder etc
6 6
Protection against indirect contact can be achieved by the following
Extract from IS 3043 – Indian standard derived from IEC 364

7 7

8 8

9 9
2. Earthing
2. Earthing

10 10
2. Earthing
a. Back ground
b. Concept of Double earthing
i) In Design
ii) In construction
c. Ensuring & control methods
i) Contract stipulations
ii) Site controls during erection
d. Additional methods adopted for Electrical safety
e. Operation & maintenance of earthing system

11 11
a. Earthing !! Back ground – Learnings from Surma plant
 Electrical safety is always an area of concern considering the high potential.

 The recent fatalities in Surma (Bangladesh) reveal the importance for earthing .
 Based on the Learnings from the group Lafarge India wanted to enhance the Electrical
safety in the design & erection.

12 12
b.Concept of double earthing – Design
(Contract E 2.9 & 3.0)
Method adopted – TTNS
 The ground conductor should be redundant – 100% spare
 The Ground conductor should be preferably bare (Except electronic earthing)
Earth mat for limiting touch & step potentials in switch yard
 Separate Grounding systems for
Electrical earthing
•For Medium voltage grid resistance < 1 ohm
•For Low voltage grid resistance < 4ohm
Automation earthing
•Grid Resistance < 1ohm
 Lightning protection
Learnings from project • Grid resistance < 10 ohm
13 13
b. Concept of double earthing – Design
(Contract E 2.9 & 3.0)
 Earth conductor selected – Galvanized Iron Flat

 Ground Conductor design according to IEC.
 Grid system is with 2 runs of GI Flats buried 500 mm below ground connecting all the
respective earthing stations in the plant.
 All the transformer neutral points are grounded by two separate and distinct earthing
stations.
 All the MV & LV switch boards, JBs are also grounded by two separate ground conductors
(Local regulation)
 All the MV & LV motors are also to be grounded by two separate ground conductors (Local
regulation)

14 14
b. Concept of double earthing – In Design E2.9
Green line
Indicates
additional
requirement
Indicates additional grounding conductor/ system

15 15
b. Concept of double earthing – In Design E2.9
Indicates additional grounding conductor/ system

16 16
b. Concept of double earthing – In construction
Existing utilities
substation
Incoming
board for civil
contractor
Blending silo
LS Reclaimer area
area distribution Distribution
board board
Water Welding
Learnings from project Pump Machines
17 17
b. Concept of double earthing – In construction
 Provision double earthing stations at all the construction fronts Like LS crusher, raw mill,
coal mill, coal crusher, CF silo, Wagon tippler,kiln, clinker cooler,heat exchanger,coal crusher
 Earth pits to be prepared separately for civil construction job
 Earth pits under preparation for the mechanical erection
 Earth pits prepared for Electrical fronts
 The earthing conductor from Main distribution panels to site site distribution panels – 2 runs
of 25 x 3 GI flat.
 The earthing conductor from site distribution panels to Individual electrical equipment – 2
runs of 16 SWG Galvanized Iron wire
 All joints
Flat conductor through welding
 In Round conductor through Nut & Bolt system.
 Ground conductor 2 No should be laid along with the main power cable
 The earth resistance of individual earth station should be < 5 ohm

18 18
c. Ensuring & control - Contract stipulations
Electrical Hazards in Welding (rod and others)

Each welding machine should have double Earthing.
Each welding machine should be with individual switch
Multi welding machines with one switch is not acceptable
Return earth wire from job piece is compulsory
Animation Next slide
* Captured from contract –G3 (safety document for New projects)

19 19
c. Concept of double earthing – In construction
Welding
machine
Double Earthing for Job piece

welding
Return earth
wire
Proper Method
•Double earthing for welding machine.
•Return earth wire from job to welding machine
•No direct earthing of job

20 20
Welding
machine
Job piece
No Earthing not allowed Direct Earthing not allowed. Return

wire to welding machine is required
Double Earthing is must

21 21
Weleding
machine
Job piece
Existing
structure
Direct Earthing not allowed. Return

wire to welding machine is required

22 22

Extract from IS 3043 derived from IEC 364
23 23
c. Ensuring & control methods - Electrical Charging Approval
 Charging approval is mandatory for all electrical equipment.
 Even if it is disconnected once or the location of the equipment is changed fresh approval
need to be obtained.
 The charging approval is filled & signed by the contractor supervisor
 Lafarge Engineer will verify the charging approval at site & then approval is given.
 Safety department pastes a green color sticker
 Sample charging approval is attached next slide.

24 24
Sonadih2nd
c. Ensuring & control methods - Electrical Charging clinker line Project
Approval
Equipment charging approval (Electrical)

Certificate No : Date : Issued by :
Request reference : Date: Requested by :
Equipment Name:
Equipment location & S.No of the equipment
Incoming source / Feeder / Feeder rating
Incomer Fuse/ MCCB rating
ELCB rating / common or Individual
Incoming cable size/Type (Armoured/

Unarmoured)
Out going cable size/Type (Armoured/

Unarmoured)
Condition Cable (If flexible cable – condition of
the flexible cable) & cable route (Under ground/
Over head) If under ground burial depth>500mm.
Double earthing done / Type (GI or copper) &Size

of earth conductor
Insulation resistance (Megger value of the

equipment & cable in Mega Ohm)
Connected to earth pit NO & Earth resistance

value
Captured in SLD & Submitted
Comments / Remarks :
Approved :
(Each time a separate certificate to be issued if the location or the equipment is changed)
25 25
Sonadih2nd
c. Ensuring & control methods - Electrical Charging clinker line Project
Approval
Green sticker indicates the equipment is cleared for charging

26 26
d. Additional methods adopted for electrical safety – Part Sonadih2nd clinker
of construction line Project
contract
 All equipment are provided with residual current devices of 30 mA at the each out
going.
 All the equipment are provided with individual switches
 All the distribution cables for lighting & water pumps are laid over head
 No joint is accepted in flexible cables
 All under ground cables are with armour for mechanical protection
 Cables under ground are buried at not less than – 500mm depth
 Under ground cables are provided with mechanical protection jackets at road
crossings
 All the under ground cables are captured in drawings

27 27
e. Operation & maintenance of earthing system
 All the earth results are to be recorded after construction of the earth pits
 The Individual earth pit value should not be more than 5 ohm used for equipment
earthing not more than 10 ohm if used for lightning protection. A reading in summer is
a must as it gives the worst reading.
 For the construction sites the earth resistance to be monitored after every two months
& to be recorded.
 For the operating plant it is mandatory to conduct the earth testing at least once in a
year & to be recorded (Statutory requirement)
 During summer periodical watering of earth pits (at least once in 15 days) to be
arranged.
 As far as the earth wires are to be laid above ground (Except the earthing grid
conductor) so that any disconnection is easily identifiable.
 Splicing/ twisting joints are not allowed – only welded / bolted joints are allowed.
 If GI flats are welded the welded portions are to be provided with at least two coats of
bituminous paint and two coats of aluminum paint to avoid corrosion.

Extract from IS 3043 derived from IEC 364
28 28
3. GUIDELINES & GENERAL PROCEDURES FOR SUPPLY AND USE OF ELECTRICITY AT SITE
3. GUIDELINES & GENERAL PROCEDURES FOR SUPPLY AND USE OF ELECTRICITY AT SITE

29 29
Contents
b. Mandatory safety requirements
c. Conditions for issuing construction power supply
d. Installation
e. General
f. Protection class of construction equipment
g. LOTOTO
h. Operation & maintenance
i. Operation & maintenance of portable equipment

30 30
a. Mandatory safety requirements
• All Lafarge Mandatory safety requirements are applicable to construction site

31 31
b. Conditions for issuing construction power supply
Following safety requirement must be complied with before use of power supply.
• Contractor shall submit a list of licenced electrical staff to be posted at site.
• Provide and maintain complete installation on the load side of the supply point with regard to
the safety requirements at site.
• All cabling and installation shall comply with the appropriate statutory requirements given below
and shall be subject to approval of the LIPL- Electrical
• Where distribution boards are located at different places the submit schematic drawing
indicating all details like size of wires, Over Head or cable feeders, earthing etc., The position and
location of all equipments and switches shall be given.
• The Contractor shall make his own arrangements for main earth electrode
• Method of earthing :Installation and earth testing results shall conform to relevant I.S.
Specifications (IS-3043).

32 32
b. Conditions for issuing construction power supply cont’d
• All three phase equipment shall be provided with double earthing.
• All light fixtures and portable equipment shall be effectively earthed to main earthing.
• All 3 phase equipment are to be connected with 4 core cables out of which one core is for
earthing.
• All single phase equipment are to be connected with 3 core cables out of which one core is
for earthing.
• All Light fittings are fed with 3 core cables out of which one core is for earthing.
• All equipment are to be earthed with two no distinct & visible earthing
• No gas pipes and water pipes shall be used for earth connection.
• Neutral conductor shall not be treated as earth wire.
• The Contractor shall not connect any additional load without prior permission of LIPL -
Electrical.
• Joints in earthing conductors shall be avoided. Loop earthing of equipment shall not be
allowed. However tappings from an earth bus may be done.

33 33
b. Conditions for issuing construction power supply cont’d
•The entire installation shall be subjected to the following tests before energisation of
installation including portable equipment.
a) Insulation resistance test.
b) Earth electrode resistance.
The contractor shall submit a test report for his complete installation every 2 months or after
rectifying any faulty section in the specimen test report. One such test report for the complete
installation shall be submitted before onset of monsoon.

34 34
c. Installation
• Only persons having valid wireman’s licence/competency certificate shall be employed for
carrying out electrical work at site.The job shall be supervised by a qualified licenced
Supervisor
• Electrical equipment and installations shall be installed and maintained as to prevent

danger from contact with live conductors and to prevent fires originating from electrical
causes like short circuits, overheating etc. Installation shall not cause any hindrance to
movement of men and materials.
• Grounding conductor of wiring system shall be of corrosion-resistant material (GI/ Copper)
• Each equipment shall have individual isolating switches.
• Wires and cables shall be properly supported and an approved method of fixing shall be
adopted.
• Loose hanging of wires & cables shall be avoided.
• Lighting and power circuits shall be kept distinct and separate.
• Reinforcement rods or any metallic part of structure shall not be used for supporting wires
and cables, fixtures, equipment, earthing etc.

35 35
d. General
• All cables and wires shall be adequately protected mechanically against damages.
• In case the cable is required to be laid under ground, it shall be adequately protected by
covering the same with bricks. Plain cement Concrete (PCC)tile or any other approved means
• All armoured cables shall be properly terminated by using suitable cable glands.
• Multi stranded conductor cables shall be connected by using cable lugs/sockets. Cable lugs
shall preferably be crimped. They shall be of proper size and shall correspond to the current
rating and size of the cable.
• Twisted connections will not be allowed
• All cable glands, armouring and sheathing of electric cables, metal circuits and their fittings,
metallic fittings and other non-current carrying parts of electrical equipment and apparatus shall
be effectively grounded

36 36
d. General Cont’d
• All the Distribution Boards, Switch Fuse units, Bus bar chambers, ducts, cubicles etc. shall
have MS enclosures and shall be dust, vermin and water proof. The Distribution Boards, switches
etc. shall be so fixed that they shall be easily accessible. Changes shall be done only after the
approval of the Departmental Electrical Engineer.
• Proper enclosures/covers must be provided for protection of all the switch board, equipment
etc. against rain
• Exposed live parts of all electrical circuits & equipment shall be enclosed permanently.
• Iron clad industrial type plug outlets must be used for additional safety.
• Isolating switches / ELCBs shall be provided close to equipment for easy disconnection of
electrical equipment or conductors from the source of supply when Operation or maintenance
work has to be done on them.
•Adequate working space shall be provided around electrical equipment which require
adjustment or examination during operation
• All connections to lighting fixtures, starters or other power supplies shall be provided with PVC
insulated, PVC sheathed twin/three/four core wires to have better mechanical protection for
preventing possible damage to equipment or injury to personnel. Taped joints shall not be
allowed and the connections may be made in looping system.
• Electric starter of motors, Switches shall not be mounted on wooden boards. Only sheet steel
mounting or iron frame work shall be used.
• After installation of new electric system and or other extensive alterations to existing
installations, thorough inspection shall be made by LIPL - Electrical before the new system or
new extension is put in use.
37 37
e. Protection class of construction equipment
• All the dewatering pumps should be of IP55 protection class

• All the grinding machines should be of IP55 protection class
• All the welding machines should be properly protected from rain water. If they are to
be placed out side buildings then it should be provided with cover on three sides
( Refer animation below)
• All the drilling machines also to be of IP55 protection class if they are used out side
buildings
• All the electrical distribution boards used should be of IP55 protection class
• All the flexible cables should be double insulated
ELCB Board
Cover of 3 sides
& top
Welding
machine

38 38
f. LOTOTO
• Separate work permits shall be issued for individual group leaders working on the same
system which shall be returned after the completion of the work to Safety Supervisor and no
system shall be energized without the clearance of the respective individual group leader.
• Before any maintenance work is commenced on electrical installations / equipment, the

circuits shall be de-energized and ascertained to be dead by positive test with an approved
voltage testing device and to be locked by an individual lock by the group leaders & a permit
to be pasted on the equipment on the name of the group leaders.
• The person issuing the permits is to be authorized by the function head and he is fully aware
of the system and system de- energizing methods & the having the license issued by the local
statutory authorities.
• Switches shall be tagged out or the fuse holders withdrawn before starting the work.
Adequate precautions shall be taken in two important aspects viz.
i) That there shall be no danger from any adjacent live parts and
ii) That there shall be no chances of re-energisation of the equipments on which

the persons are working
• During final stages of electrical erection – lot of parallel activities are envisaged like – group
no load trials, loop testing for PLC , cable laying & termination
-during that period substation wise switch board attendants are required substation wise .
- Basic responsibilities include issue of electrical permits & administration of Lototo.

39 39
g. Operation & Maintenance
• All persons who work with electrical installation/equipment shall be aware of the electrical
hazards, use of protective devices and safe operational procedures.
• They shall be given training in fire fighting, first aid and artificial resuscitation techniques.
• The supervisor shall instruct the proper procedure, specify and enforce the use of necessary
protective equipment such as adequately insulated pliers, screw drivers, fuse pullers, testing
lamps and similar hand tools.
• Only wooden ladders shall be used to reach the heights in electrical work.
• No material or earth work shall be allowed to be dumped below or in the vicinity of the bare
overhead line conductors.

40 40
g. Operation & Maintenance Cont’d
•Operation of electrical equipment shall be avoided when standing on wet floor or when hands
are wet.
• Before blown fuses are replaced, the circuit shall be locked out
• When two persons are working within reach of each other, they shall never work on different
phases of the supply.
• When structural repairs, modification or painting work are to be undertaken, appropriate

measures shall be taken for the protection of persons whose work may bring them into the
proximity of live equipment/circuit.
• It shall be ensured that the insulation and wire size of extension cords are adequate for the
voltage and current to be carried.
•While tapping electricity from the socket, plug top must be used.
•It shall be ensured that no extension boards are over loaded while tapping. Only standard three
pin plugs shall be used for tapping electricity.
•Broken sockets/plugs shall be replaced immediately with good ones.
•Only joint free cables shall be used for connecting equipment/apparatus
• Floors shall be kept free from trailing electrical cables to avoid tripping hazard
• Power supply to all the machines and lighting fixture shall be switched off when not in use
• Un-authorized tapping of power by others from distribution boards under the control of the
contractor shall be prohibited at all circumstances
• No flammable materials shall be stored in any working area near the switch boards
41 41
g. Operation & Maintenance Cont’d
• Safety work permits shall be used for switching off the main feeder and equipment by the
contractor.
• “MEN ON LINE” “DO NOT SWITCH ON” “DANGER” or “CAUTION”

board as applicable shall be used during maintenance works on the electrical equipment

42 42
h. Portable electrical equipment operation & maintenance
• Portable electrical equipment shall be regularly examined, tested and maintained to ensure that
the equipment and its leads are in good order. Register shall be maintained for inspection
recording, the testing dates and results of the equipments.
• All portable appliances shall be provided with three core cable and three pin plug. The third pin
of the plug shall invariably be earthed. It shall be ensured that the metal part of the equipment
shall be effectively earthed.
• All connections to portable equipment or machines from the panel/distribution board/extension
board shall be taken using 3 core double insulated PVC flexible copper wire in one length. No
joints shall be allowed in this flexible wire. In case single length of wire is not sufficient for a
particular location then the supply can be tapped by providing another extension board
comprising of switch and socket.
• Flexible cables for portable lamps, tools, and apparatus shall be regularly examined, tested
periodically and maintained to ensure safety.

43 43
4. Specific equipment for construction site

44 44
S.No Equipment Approx cost Qty required Remark

in MINR
1 Portable DG operated Will be used for

inflatable lighting towers illumination
9 mtr improvement during
0.5 4
12 mtr deep excavations
0.7 2
21mtr 0.9 2
2 Mobile lifting towers trolley Will be used for
mounted Wah activities
Battery operated/ (Engineering
1.5 4
control)
Truck mounted

45 45
Adequate illumination plays a major role

in the construction site .
To ensure proper lighting during the
construction trolley mounted inflated
lighting towers can be used.
As these towers are having the option of
both DG & grid options they are self
sufficient to ensure uninterrupted
lighting
Typically for a green field around 6 to 8
no will help.
Approx cost – 0.5MINR each

46 46
Mobile elevated tower for addressing the wah activity like – over head cable tray & cable
laying, Light fittings installation, Street light fittings erection etc.
These mobile plat forms come with an option of battery operated/ truck mounted.
Battery operated is preferable as they are light weight(<2 ton), slow speed (4-6 kmph).
They can be lifted can be placed at PH floors for addressing the Wah jobs.
Cost of each machine – 1.5 MINR

47 47
5. Cable laying
5.Cable laying

48 48
5. Cable laying Cont’d
1. All Cables to be laid over head

2. If possible a walk way to be provided for cable laying so that future cable laying
becomes easier.
3. The cables laying through belt conveyor gantries are to be considered in side the
belt conveyor gantries.
Cable laying
area
Walk way
Height should be
sufficient to walk a
person freely >1.8 mtr
Method for cable laying through belt

Learnings from project conveyor galleries
49 49
1. In general cables inside the buildings are to be supported from the beams with
insert plates instead of on brick wall. This will avoid the construction delays &
facilitates parallel working
2. In side the building cables one floor to another floor to be taken from inside of
the building but not out side.
Floor 2
Floor 1
Method for cable laying by using the Method for cable laying from one floor to
concrete beam another

50 50
1. Where ever possible cable are to be laid along with external stair cases. This will
reduce the Wah activity.
Method for cable laying along with the stair

case

51 51
6.Lightning Protection

52 52
Content
a. General design
b. Construction site

53 53
a. General design
• Lightning protection contains the major following components – Vertical air

termination,Horizontal conductor, Down conductor & earth station
• Lightning protection is compulsory

for the building when the suggested
acceptable risk exceeds 1 in million.
Down
conductor
Horizontal
conductor
Test joint
Vertical air
termination Earth station

54 54
a. General design cont’d
• One down conductor if the base area of the structure does not exceed 100 square meter
• One down conductor+ one more down conductor for every additional 300 square meter
base area.
• One down conductor for every 30 meter perimeter (specifically for silos)
• All the down conductors are to be connected to separate earth stations as shown in the
drawing.
• Lightning protection is compulsory as per IS 2309 for all the buildings above 30 meter
height.
• The protection angle of a lightning protection system is 30 deg cone formation can be
extended up to 45 deg at less critical areas.(Refer animation in Next slide)
• The maximum earth station resistance allowed is 10 ohm.

55 55
30 deg
30 deg
Extract from IS 2309 - 1986

56 56

Lightning protection system of Sonadih line-1 (Typical plant)
57 57
b. Construction site
• At construction site the tallest equipment (Height > 30 meter) are to be protected from
lightning like
• Tower crane
• Big gantry cranes vertical boom height > 30 meter
• Lightning protection also to be provided for the construction completed buildings with a
height> 30 meter.
• They are to be connected to separate earth pits –But not Electrical equipment earth pits
• The value of the earth pits should not be > 10 ohm.
• The testing to be done after every 3 months & record of the same to be maintained.

58 58
7.Other statutory requirements

59 59
Other statutory requirements – aviation warning
• The other applicable statutory requirements are aviation warning system .

• All the construction equipment with height more than 30 meter is to be provided with
aviation warning system like
• Tower crane
• Big Gantry crane with vertical boom > 30 meter.

60 60

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Sonadih2nd clinker line Project

Learning from Project

-KV Siva ram sarma

A. Project construction safety

Learnings from project

1. Electrical distribution system

Learnings from project

1. Electrical distribution system

Learnings from project

1. The Power will be given at one source – 3 Ph+ 1N+ 1E

(Refer Animation in Next slide)

Learnings from project

230 V General area

415 /110 (Ph- 230/ 24 V

Learnings from project 24 V confined

Protection against indirect contact can be achieved by the following

Extract from IS 3043 – Indian standard derived from IEC 364

Learnings from project

Extract from IS 3043 – Indian standard derived from IEC 364

Learnings from project

1. Electrical distribution system; Cont’d

Extract from IS 3043 – Indian standard derived from IEC 364

Learnings from project

Learnings from project

b. Concept of Double earthing

c. Ensuring & control methods

ii) Site controls during erection

d. Additional methods adopted for Electrical safety

e. Operation & maintenance of earthing system

Learnings from project

 Electrical safety is always an area of concern considering the high potential.

Learnings from project

Method adopted – TTNS

 The ground conductor should be redundant – 100% spare

 The Ground conductor should be preferably bare (Except electronic earthing)

 Separate Grounding systems for

•For Medium voltage grid resistance < 1 ohm

•For Low voltage grid resistance < 4ohm

•Grid Resistance < 1ohm

Learnings from project • Grid resistance < 10 ohm

 Earth conductor selected – Galvanized Iron Flat

Learnings from project

Indicates additional grounding conductor/ system

Learnings from project

Indicates additional grounding conductor/ system

Learnings from project

 The earth resistance of individual earth station should be < 5 ohm

Learnings from project

Electrical Hazards in Welding (rod and others)

Animation Next slide

* Captured from contract –G3 (safety document for New projects)

Learnings from project

Double Earthing for Job piece

•No direct earthing of job

Learnings from project

No Earthing not allowed Direct Earthing not allowed. Return

Learnings from project

Direct Earthing not allowed. Return

Learnings from project

Learnings from project

 Charging approval is mandatory for all electrical equipment.

 The charging approval is filled & signed by the contractor supervisor