AESAP™Advanced Electrical Safety and Assessment Program
Welcome to AESAP™ - India's pioneering Advanced Electrical Safety and Assessment Program (AESAP™) sets the benchmark for electrical safety across industries, offering unparalleled expertise and a systematic approach to ensuring electrical safety compliance and risk mitigation.
AESAP™Flow Chart
AESAP™ - Advanced Electrical Safety and Assessment Program
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Phase 1 (Gap Assessment - Engineering, Safety, Maintenance)
- Assessment
- Plan & Solutions to close gaps
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Phase 2 (Detail Engineering Phase)
- Detailed Engineering for certain cases
- Detailed BOQ
- Detailed RFQ
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Phase 3 (Life-Cycle and Project Mangement for Implementation)
- Vender Indexing
- Floating of RFQ
- Poject Planning and Implementation Assurance
AESAP™Phase 1: Assessment
Global benchmarking against NFPA 70 E 2018 – To bring uniformity across sites and future ready sites.
Statuary Compliance
IER |CEA | IS | NBC | Local State BoardSystem Adequacy and compliance
28 elements developed from CEA, IER & NFPA 70E 2018Selection, installation Hardware
Engineering Review: Modeling | Calculation| Verification| ETAPMaintainability, Maintenance Practice, Healthiness
Complete LT setup, review of test, Micro level observation listingBehavior, Competency & application
Most advanced method of Electrical BBSAESAP™Statuary Compliance
This segment shall cover all elements of IER/CEA, NBC & applicable Indian Standards which shall/may impact electrical safety aspects applicable for following
Critical Elements that shall be covered
- Safety Related To Work Practices
- Establishing An Electrically Safe Work Condition
- Work Involving Electrical Hazards
- Safety-related Maintenance Requirements
- Substations, Switchgear Assemblies, Switchboards, Panelboards, Motor Control Centers, And Disconnect Switches
- Premises Wiring
- Controller Equipment
- Fuses And Circuit Breakers
- Rotating Equipment
- Hazardous (Classified) Locations
- Batteries And Battery Rooms
- Portable Electric Tools And Equipment
- Personal Safety And Protective
- Equipment
- Safety Grounding Equipment
- Safety-related Work Practices For Electrolytic Cells
- Portable Tools And Equipment.
- Safety Requirements Related To Batteries And Battery Rooms (Voltages Above 50 Volts Nominal)
- Testing, Maintenance, And Operation.
- Safety-related Work Practices: Power Electronic Equipment
- Safety-related Work Requirements: Research And Development Laboratories
Method used:
| Visual | Close Visual | Documents | Calculations | PS Analysis (ETAP) | Behaviour Observation | Measurement & Data Recording & Tests |
|---|---|---|---|---|---|---|
AESAP™System Adequacy and compliance
This section of assessment agenda would be a detailed analysis of existing systems in place which impacts electrical safety (people & assets), adequacy, implementation and behavior analysis of people involved.
The following elements are considered under detailed review.
The following elements are considered under detailed review.
- Electrical Safety & Energy Usages Safety Policy
- Updated Single Line Diagram And Accuracy
- Identification Of Circuits
- Safety & Awareness Program For Electrical Safety
- Program Elements
- Internal Risk Assessment (HIRA)
- Job Briefing And Detailing
- Training Elements And Selection Of Audience - Method & SOP
- Qualified Person Identification Of Method Of Selection /Training
- Host & Contract Employees – Rights & Responsibilities
- Use Of Energy – SOP For Different Voltage Level And Machines
- LOTO
- Work Permit
- LOTO & Work Permit Integration
- Earth Leakage Protection
- Temporary Protective Grounding Equipment
- Energized Work Condition
- De-Energized Work Condition
- Arc Flash Protection Sops & Implementation
- Personal And Other Protective Equipment – Identification, Selection, Adequacy And Behavior
- Wiring Protection And Sops For Selection, Installation And Maintainability
- Policy And Sops For Testing Of Different Electrical Equipment And Machines
- Testing Policy, Method & Sops For Portable And Handheld Equipment
- Maintenance Sops And Annual Plan – Adequacy And Benchmarking
- System In Place For Management Of Change And Review Of Events Impacting Electrical Risk
- Global Policy For Integration Of Electrical Safety At Design Stage.
- Concept, Zoning And Application Of HAC
- Specific Measures And Controls For Personnel Safety
Selection, installation Hardware: Engineering Review
This section shall cover and provide accurate calculations and modeling to confirm the ratings and selection of electrical switchgears and effect of changes made since commissioning such as derating factors, temperature etc...
It shall deliver accurate deviations for underrated conductors (Cables) and switchgears. We shall be locating cables which are either underrated in normal operation or, shall not sustain faults and may create fire scenarios, case of overloading & effect of ageing on conductor capacity. Shall consider peak demand, diversity factor, load factors etc.
It shall also define the need and type of PPEs (arc flash) required for electrical professionals to carry out their job safely.
Method used:
| Visual | Close Visual | Documents | Calculations | PS Analysis (ETAP) | Behaviour Observation | Measurement & Data Recording & Tests |
|---|---|---|---|---|---|---|
Coverage – Complete plant
Power Quality
Power quality shall be assessed based on following parameters:
- Harmonics – sinusoidal voltages or currents having frequencies that are integer multiples of the frequency at which the supply system is designed to operate
- Phase-phase/Neutral RMS voltage variations.
- Frequency variations
- Ground – Neutral RMS voltage variations.
- Load RMS current variations
- Power Factor – Improvement in power factor
This is a critical study to identify unnoticed impact of power quality on LT system – on machines & lighting.
Method used
| Visual | Close Visual | Documents | Calculations | PS Analysis (ETAP) | Behaviour Observation | Measurement & Data Recording & Tests |
|---|---|---|---|---|---|---|
Cable and wire testing (LT Only)
1) Insulation resistance (Cables and some wires)
2) Polarization index (Motors)
There are few rare methods to measure wire healthiness but those are more visual and dimension measurement based.
Sparrow shall take sample of 3 sizes of cables and 3 sizes of wire for testing by sampling of aging from worst condition areas (temperature, dust etc.)
Total number of test cases shall not exceed 20.
Method used
| Visual | Close Visual | Documents | Calculations | PS Analysis (ETAP) | Behaviour Observation | Measurement & Data Recording & Tests |
|---|---|---|---|---|---|---|
Lightning Protection
Review of existing lightning protection installed for structures & buildings for facility, tankages, switchyard etc. Estimation of Lightning risk assessment for structures & buildings for facility, tankages, switchyard etc.
Proposed modification / addition in the existing system to comply with various applicable standards with back-up support / calculation for proposed changes. (exclude BOM/BOQ) Preparation of as built drawing for existing and proposed system.
Survey and suggest surge protection for the electronic equipment like DCS / Remote Field instruments / VFDs.
Suggest Maintenance practices for the lightning protection system installed / suggested.
Provide detailed specification for the equipment needs to be installed for modification.
Standards:
- IEC 62305 Part – 1
- IEC 62305 Part – 2
- IEC 62305 Part – 3
- IEC 62305 Part – 4
Lightning & Surge Protection – Methodology
The Mesh Method:-
Established in 1838 by Maxwell, the Mesh Method is the best method adopted to protect any structure against lightning strikes.
The Rolling Sphere Method:-
In this method, a sphere of radius R (magnitude of which depends on the peak return stroke current) is rolled over the surface of the structure to determine the areas where lightning protection system shall be provided.
The Protective Angle Method:-
The Protective Angle method is also one of the best methods for lightning protection of any structure. However, it is best suited for tall structures (for example stacks, lighting masts, chimneys)
Risk Calculation & Probability Factor Table:
List of Structures in Plant Area
| Sl. No. | Description | Risk Factor (R) | Collection Area (Ac) | Probability of Strike (P) | Zone of Protection | Lightning Protection Requirement |
|---|---|---|---|---|---|---|
| 1 | A - Building | 0.19200 | 28860 m² | 1556.16 × 105 | Not Protected | Required |
| 2 | B - Building | 0.19200 | 14430 m² | 778.08 × 105 | Not Protected | Required |
| 3 | C - Building | 0.19200 | 14430 m² | 778.08 × 105 | Not Protected | Required |
| 4 | Bulk Storage Area | 0.19200 | 7200 m² | 388.23 × 105 | Not Protected | Required |
| 5 | W - Building | 0.21600 | 6680 m² | 34.45 × 105 | Partially Protected | Required |
| 6 | R - Building | 0.07200 | 1510 m² | 10.53 × 105 | Partially Protected | Required |
| 7 | H - Building | 0.04320 | 5440 m² | 66.00 × 105 | Not Protected | Required |
| 8 | K - Building | 0.04320 | 6680 m² | 18.00 × 105 | Not Protected | Required |
| 9 | Security Gate - 1 | 0.00432 | 60 m² | 0.38 × 105 | Not Protected | Not Required |
| 10 | Security Gate - 2 | 0.00432 | 160 m² | 0.38 × 105 | Not Protected | Not Required |
| 11 | Security Gate - 3 (and nearby structure) | 0.00864 | 160 m² | 0.38 × 105 | Completely Protected | Not Required |
| 12 | ETP Area - Battery Charging & Oil Storage Area | 0.00864 | 375 m² | 0.91 × 105 | Not Protected | Not Required |
3D Modelling of Buildings which requires protection:
Method used
| Visual | Close Visual | Documents | Calculations | PS Analysis (ETAP) | Behaviour Observation | Measurement & Data Recording & Tests |
|---|---|---|---|---|---|---|
AESAP™Maintainability, Maintenance Practice, Healthiness
The objectives are to review following
- Maintenance philopshy of site
- Frequency of maintenece
- SOPs
- Maintence vendor selection method & report reviews
- These area/equipmenrt shall be annalysed to sonfirm above elements and practicle suggestions
- Substations, Switchgear Assemblies, Switchboards, Panelboards, Motor Control Centers, and Disconnect Switches as per CEA, IER & NFPA 70E Article 210
- Premises wiring review as per CEA, IER & NFPA 70E Article 215
- Controller Equipment as per CEA, IER & NFPA 70E Article 220
- Fuses and Circuit Breakers as per CEA, IER & NFPA 70E Article 225
- Review of batteries and battery bank as per NFPA 70E Article 240
- Portable Electric Tools and Equipment checks as per NFPA 70E Article 245
- Earth testing & design review.
- As per IEEE 80, IS 3043.
Following test records shall be reviewed (conducting tests are not a part of this proposal) at the site to check the healthiness of electrical system.
In case some of them may not be available, Sparrow shall propose the requirement, SOPs & frequency as recommendation.
RMU/Main IC Breaker test
- RMU test with breaker test for SF6/VCB
- Gas leak detector test
- Relay tests and settings for RMU
- Mechanical/electrical operation test
- DCRM- Direct contact resistance metre test for breaker
- CT/PT Ratio test
- DC Check and Emergency tests
- IR test for cable
HT/LT Pane tests
- Insulation resistance
- Polarization index
- Winding resistance
- CT/PT Ratio and polarity test
- DCRM- Direct contact resistance meter
- Auxiliary Devices inspection
- Operating Mechanism
UPS and Battery checks and test
- Charger Settings
- Inverter Settings
- Rectifier settings
- Impedance test
- Mode operation check
- Check of all indications & cooling fans
- Moisture contamination checks
- corrosion and/or deterioration check
- Calibration/Settings of UPS parameters wherever required
- Float cum boost charger testing
DG and auxiliaries’ tests and checks
- Sizing check as per load
- Interlocking and synchronizing scheme check
- AMF panel and schematic checks
- Fuel system maintenance
- Coolant system maintenance
- Electrolyte level check
- Routine engine exercises
- Exhaust system inspection
Earth Pits & Earthing System
- Earth pit design check as per short circuit current and soil resistivity.
- Resistance check
Human safety GFCI/ELCB/ FUSES
- Checking of Ground Fault current interrupters and ELCB (we shall do a 3rd party test)
- Time setting check for tripping
- Current setting test
- Rupture time test
- Calibration records of equipment used checks
Observations for actual maintenance conditions:
Sparrow shall do a detailed site survey to observe and record a 13 element statsus report for each panel and feeders with a preapproved checklist.
MCC # 1 MILL AREA
| Description | 1A | 1B | 1C | 2A | 2B | 2C | 2D | 2E | 2F | 2G | 3A | 3B | 3C | 3D |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Obstruction to accessibility | ||||||||||||||
| Feeder identification unavailable | ||||||||||||||
| Incorrect / Improper feeder identification | ||||||||||||||
| Rear side identification unavailable | N/A | N/A | N/A | N/A | N/A | N/A | N/A | N/A | N/A | N/A | N/A | N/A | N/A | N/A |
| Incorrect rear side identification | ||||||||||||||
| Component identification unavailable | ||||||||||||||
| Component malfunctioning / damaged | ||||||||||||||
| Indicators malfunctioning / damaged | ||||||||||||||
| Cabinet door handle damaged | ||||||||||||||
| Damaged gaskets | ||||||||||||||
| No cabinet partitioning | ||||||||||||||
| Poor housekeeping | ||||||||||||||
| Excessive temperature / Poor ventilation | ||||||||||||||
| Damage / Corrosion to feeder casing | ||||||||||||||
| Component earthing unavailable/inadequate | ||||||||||||||
| Cabinet door earthing unavailable/damaged | ||||||||||||||
| Circuit diagram not displayed inside | ||||||||||||||
| Unorganized cabling | ||||||||||||||
| Cables not fastened to cabinet wall | ||||||||||||||
| Temporary cables / Damaged cables |
Method used:
| Visual | Close Visual | Documents | Calculations | PS Analysis (ETAP) | Behaviour Observation | Measurement & Data Recording & Tests |
|---|---|---|---|---|---|---|
Behavior, Competency & application
- To formulate assessment sheet: – The joint operational safety and safety culture assessment provides the organization with the opportunity to better understand the interactions between technical, human, organizational and cultural aspects, helping the organization to take actions that fully address the root causes of any identified issues.
- To identify and target areas requiring attention, and to provide advice and assistance to enhance the success of their on-going safety improvement efforts
- To plan aids in improving workplace safety, as they play a key role in developing and maintaining a high level of awareness of organizational strengths and weaknesses.
- To provide insight into how and why an organization behaves in certain ways, and thus positively impact an organization’s safety culture.
- To lay future path and formulate strategies for implementation of deviations and actions as agreed after finding approvals.
Assessment Coverage & Methodology
Assessment shall cover following –
Steps in the process
- Building partnerships
- Decision methodologies
- Implementation and Planning
- Analysis Issues
- Dissemination
Choosing & forming groups
- Choosing respondent groups basis – job, hierarchy, education, skill etc..
- Defining potential respondents: eligibility criteria
Sampling approaches
- Devising the sampling plan – Shall be shared to the client
- Probability and non-probability sampling methods
- Multi-stage cluster sampling
- Sample size requirements and parameters for calculations decision
Weighting in multi-stage sampling
- Weighting the data
- Potential bias from not weighting
- Calculating standard errors
Adapting and using questionnaires
- Time frames of key behaviours
- Informed consent
- Questionnaire administration and interview settings
- Assuring quality control
Analysis and interpretation of result
- Recommended methods of statistical analysis
- Bivariate analysis
- Multivariate analysis
- Analysis of trends in behaviour over time
- Sources of bias
Using the data collected to improve EHS efforts on electrical safety
- Packaging the data for different users
- A strategy for presenting data
- Data presentation for clarity and impact
- Indicators – Definition
Questionnaires
- For Top Management
- For Middle Management
- For Lower Level Management
- For Unskilled Workers
Survey Methodology
OBTAINING DATA
TABULATING & ANALYSING THE DATA
PLOTTING THE DATA AND PROVIDING FEEDBACK
USING THE DATA TO LAY DOWN FUTURISTIC PLAN
India’s Leading AESAP™: Advanced Electrical Safety & Risk Mitigation Across Industries
Sparrow RMS is a global safety and sustainability consultancy dedicated to building safer, more resilient, and future-ready workplaces. We deliver India’s best Electrical Safety and Assessment Program Services, providing comprehensive audits and risk assessments that integrate principles of operational excellence and corporate responsibility. Partner with us to create a lasting culture of safety and sustainability that protects your people, assets, and the environment.
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