Indian Oil Corporation Limited SAP Code:- 196073 Audit Reference:

Electrical Audit Inspection and Analysis Report 4300/4302/K02/201086/2023-2024

Date: 2023-09-21

Dealer's Name M/S SWATANTRATA SENANI BAFNA PETRO Location DHARWAD

Latitude 15.351009 Longitude 75.114551

Audit Start Time 22 September 2023 [21:28] Finalization Time 22 September 2023 [21:28]

Type of RO A District DHARWAD

Call Up Order No 28998341 Against Contract No 9591488361

Auditpr's Vendor Code : 13260797 Auditpr's Vendor Name G K ENGINEERS

Call Up Issued by DRSH BELGAUM DO Solar Available Not available

Location Contact No 9591488361 Dealer/Manager Name SWAMY

Name of Auditor/Engineer SELVA KUMARAN R Qualification of Auditor/Engineer B.E

Auditor's Competency Test Number 28021966 Auditor's Competency Test Date 14 August 2023

Power Connection TP Size of EB Incomer 16

Sanctioned Load 18 Connected Load 14.5

Class 'A' License No EA2749 Size of EB Incomer 16

Observation Details

Activity Brief Activity Observation Corrective Whether further Recommendations (if any) Capex Total
Number Action Taken corrective action (Item No, Amount
required Qty, Rate,
Amount)

1.0
Electrical Load

1.1.1 Estimation of entire load of the RO and phase wise load distribution. Necessary (8.7, 9.5,10.2) A NO
modification in load connections/distributions (In R/Y/B phase) and associated
cabling works to be recommended.

1.2.1 Wires inside the panel to be checked for proper dressing insulation rupture and loose Ok NO
connections including crimping with proper size of lugs. Observations and correction
action, if any should be recorded in detail.

1.3.1 Check for quality of state electricity board supply at Retail Outlet regarding voltage (241, 243,239) NO
fluctuation - Minimum 3 readings at 30 Minutes interval to be recorded. V(243, 247,245)
V(241, 243,244) V

1.4.1 Observations for Suitability e.g. Rating / Working Condition / Functioning of Ok NO

installed automatic Voltage Stabilizers/CVTs (if installed) should be recorded for
corrective action if any required.

1.5.1 Ensure that flameproof double compression cable glands are of correct size and fixed Ok NO
properly and firmly. (Observations if any should be recorded with reference to
make/serial number of Dispensing Unit). All damaged / oversized rubber bushes to
be recorded.

1.6.1 Check the cables are properly dressed / tagged for easy identification. Tagging / Ok NO
Ferruling to be done inside panel room at no extra cost.

1.7.1 Check for spare opening/cable entry point in the panel, to be blocked, if present. Ok NO

1.8.1 Safety Devices like ELCB/MCB are to be checked for it’s operation, rating and Ok NO
fixing properly to the panel, to be recorded.

1.9.1 Check Ammeter, Voltmeter and Selector Switches are working properly. Ok NO

1.10.1 Check for availability of safety equipments viz. Insulation Mat (Conforming to Ok NO
IS:15652:2006 having ISI Mark and visual condition), Rubber Hand Gloves for
electrical purpose (Conforming to IS:4770 having ISI Mark and visual condition),
CO2 Fire Extinguisher (Remarks on Pressure), Shock Treatment Chart.

1.11.1 Check for Danger Sign on face of panel is displayed properly. Ok NO

1.12.1 Ensure that Panel covers are securely tightened to the body of panel. Damaged Ok NO
screws to be replaced at no extra cost. (Observations if any should be recorded)

1.13.1 Removal of dust/ soot/ cobwebs/ inside the panel of DG Set, Air Compressors and Ok NO
Main electrical Panel with vacuum cleaner.

1.14.1 Checking of water accumulation inside the electrical room / cable trenches. Ok NO
Identification of cause of accumulation and Recommendation of remedial measures.

1.15.1 Check the functionality of Indicating equipments and lamps. Ok NO

1.16.1 Check for working of Emergency Shut Down during Emergency for all dispensing Not working YES ESD should be fixed properly
pumps and associated equipments and explaining/demonstration of the same to RO
personal with record keeping of training imparted.

1.17
Checking for the following Clear Spaces for power distribution panel. Automatic voltage stabiliser/UPS:
1.17.1 In front of the equipment - 1000mm Ok NO

1.17.2 Behind the equipment – 50mm (if approach is required) Ok NO

1.17.3 Behind the equipment – 200mm (if approach is not required) Ok NO

1.17.4 At sides 750mm between the equipments Ok NO

1.17.5 At sides - 200mm (if approach is not required) Ok NO

2.1.1 Check whether Earthing provided is as per Standard Drawing and as per IndianOil Ok NO
specifications

2.2
Check that earthing connections of the following equipment for continuity after opening, cleaning of the earthing joint for removal of rust/foreign materials. Any damage / shortcoming in earthing to be
recorded against each equipment.

2.2.1 Storage Tanks at two points (Record observation on availability/visibility). If not Ok NO

visible two No. of Earth Connection to be provided to the grid.

2.2.2 Dispensing Units at minimum two point Ok NO

2.2.3 Canopy Columns at least at two columns (Record observation on Ok NO

availability/visibility)

2.2.4 Yard Light Poles at minimum one point Ok NO

2.2.5 Digital Tyre inflator at minimum one point No YES Single earth connection with min
25x3mm GI flat should be
provided

2.2.6 Electrical Panel - At two points and hinged Electrical Panel Doors should have Ok NO
flexible braided connection

2.2.7 Main and Facility Signage (HMS, Monolith, Unipole, etc) at minimum one point No YES Single earth connection with min
25x3mm GI flat should be
provided

2.2.8 Decantation Points at minimum one point Ok NO

2.2.9 Air compressor (single connection for single phase and double connection for three No YES Two separate and distinct earth
phase motor) connection with min 25x3mm GI
flat should be provided

2.2.10 Transformer / DG Sets Neutral Earthing at two points (Separate earth pits for Neutral Ok NO
Earthing)

2.2.11 Air Conditioners at minimum one point Not available NO

2.2.12 Product pipelines at minimum one point every 30 m length Ok NO

2.2.13 Lightening arrestors are in place as per IS 3043 and IS 2309, at minimum two points Not available NO
with independent earth electrodes

2.2.14 Electrical Distribution Boards at minimum two points No YES Two seperate and distinct earth
connection with min 25x3mm GI
flat should be provided

2.2.15 Automation equipments (ATG,FCC, UPS, etc) at minimum one point Ok NO

2.2.16 Automatic Voltage stabilizer (single connection for single phase and double Ok NO
connection for three phase)/ CVT at minimum one point

2.2.17 STP at minimum one point Ok NO

2.2.18 Hoarding Board at minimum one point Ok NO

2.3
Measure the Earthing resistance for following by 500 V Earth tester/ Meggar and values to be recorded. The individual earth pit resistance should not be more than 2 ohms. Also check availability of SS/
Nickel-Cadmium plated Nut/Bolts. Existing value and test date to be erased on earth pit and to be written by auditor as per his test. A copy of callibration certificate of earth tester/ megger is to be enclosed in
electrical audit report.

2.3.1 Earth Pit 1 1.58 NO

2.3.2 Earth Pit 2 1.62 NO

2.3.3 Earth Pit 3 etc 1.72 NO

2.3.4 Earthing grid resistance (should be less than 1 ohm). 0.71 NO

2.3.5 Comment on overall effectiveness of the earthing system (As per IS 3043), suggest Automation earth pit YES Automation earth pit should be
for improvement if any at under ground revamped
level

2.3.6 Combined earthing grid and earthing pits resistance (should be less than 1 ohm) 0.82 NO

3.1.1 Insulation condition to be checked for all Power Cables using 500 V insulation tester/ OK NO
megger and values to be provided by vendor. A copy of callibration certificate of
insulation tester/ megger is to be enclosed in electrical audit report.

3.2.1 Check whether lugs are provided at each termination points and crimped properly Ok NO

3.3.1 If heating is observed in any cable, then cause for same to be identified and remedial Ok YES
action to be advised.

4.1.1 Check, if cable glands are available and securely fixed to the junction box (For Ok NO
Monolith, Unipole etc).

4.2.1 Check for, any loose connection /exposed wiring etc. Ok NO

5.1.1 Terminal connections of the DU motors to be checked for having proper lugs by Ok NO
opening the motor terminal box and tightened, if required. Also to check the
functionality of the motor in DUs.

5.2.1 FLP junction box inside the DU/ MPD to be checked for loose/ missing nuts and Ok NO
bolts and gasket. Proper fixing of open/ hanging/missing covers to be ensured.

5.3.1 Check and record current being drawn by DU motors against rated current by use of Ok NO
Tong Tester/ clamp on meter. The proper cooling of the motor should also be
checked.

5.4.1 Cable size for each DU motor is to be checked for adequacy and recorded. Ok NO

5.5.1 Check for dry sand filling in the gap below the Pump in Pump Island. Ok NO

5.6.1 Check the Neutral to earth voltage at the junction box. It should not exceed 4 Volt 0.9V NO

6.1.1 Observation to be recorded for the functionality of light fittings e.g. any visual 1 canopy not YES Defective light should be fixed
damages, deformation, missing Screws, damaged gaskets, water/moisture ingress, working properly
etc.

6.2
Check if following Minimum Illumination Level (Lux) shall be maintained in various areas of the RO for safety and visibility. This is to be marked on the layout drawing to be provided by IndianOil Area Lux

6.2.1 Approach Area 50 63 NO

6.2.2 Under the Canopy 150 214 NO

6.2.3 Sales/ Dealers Room 100 124 NO

6.2.4 Electrical Room 100 113 NO

7.1.1 Check MCBs and various switches in the distribution boards for proper fixing and Ok NO
operational / correct rating.

7.2.1 Check if any inflammable materials e.g. LPG Cylinders, Lube Oils, POL Samples, Ok NO
card board cartons etc. are stored in the Electrical room? If present, dealer to be
advised for clearing the Electrical room from all such materials and same to be
recorded.

7.3.1 Check whether Electrical Room is properly ventilated, clean and dry and having clear Ok NO
access to Electrical Panel?

7.4.1 30 mA ELCB is installed for all buildings having load more than 2 Kw. ELCB to be Ok NO
check for operability.

8.1.1 Check that asbestos rope is wrapped up properly to the exhaust pipe of DG set. Ok NO

8.2.1 Check the frequency of the DG Set on operation. If unacceptable fluctuations then 50.1Hz NO
recommend corrective measures.

8.3.1 Check and record output current in each phase for DG set. Ok NO

9.1.1 Preparation of cable route (Power + distribution), earth pits and Earthing Grid Ok NO
Network diagrams for existing facilities, based on site visibility and available
information at site on RO layout drawing shared by IOCL.

2.0
Earthing System

3.0
Cable Network

4.0
Main Signage

5.0
MPDs/Dispensing Units

6.0
Yard and Canopy Lighting

7.0
Sales

8.0
DG Sets

9.0
General

10.1.1 Continuous cable (without any joints) is used for AC power supply and for 12V DC Ok NO
power supply from SMPS to LED module of Monolith

10.1.2 Power supply to Monolith is provided through underground armored cable with Ok NO
tripping device

10.2.1 Connection between power supply and LED modules of Monolith is done using Not Applicable NO
proper connectors with silicon coating to prevent water ingress

10.3.1 ELCB is used for incoming power supply to Monolith Ok NO

10.4.1 Earthing is provided for Monolith structure Ok NO

 10.0
Additional Details

11.1.1 Whether dispensing hose is checked regularly with multi-meter for electrical Ok NO
continuity?

12.0
SOLAR PV INSTALLATION WITH BATTERY

12.1.1 Whether a site safety plan is prepared & implemented for solar PV installation. Not available NO

12.2.1 Whether Reinforced or double-insulated cables are laid in metallic tray or conduit. NO
(C)

12.3.1 Whether Transparent acrylic sheets are provided between the positive and negative NO
terminals and also terminal points are covered with insulating materials as well to
prevent any accidental contact after opening the box. (C)

12.4.1 Whether all interior and exterior DC conduit, enclosures, cable assemblies, junction NO
boxes, combiner boxes, and disconnectors are identified with permanent marking.
(C)

12.5.1 Whether inverter is provided with LCD touch screen or display panel for locally and NO
manually control of the main equipments.

12.6.1 Whether three phases on the AC side and positive and negative conductor on the DC NO
side are marked and identified with different colours.

12.7.1 Whether Earthing for AC and DC system are interconnected so as to have NO

equipotential system. (C)

12.8.1 Whether Surge protection device is installed to reduce surge induce failures of NO
electrical and electronic system. (C)

12.9.1 whether Suitable lightning system is provided for the solar plant. (C) NO

12.10.1 Whether Only authorised electrician is allowed to work on any PV system. (C) NO

12.11.1 Whether Fire detection, alarm and control system is provided. (C) NO

12.12.1 Whether Insulation resistance when measured with 2 kV DC insulation tester/ NO

megger for 1 minute between input circuit and ground, between output circuit and
ground. and between input and output circuit is at least 2 MEGA OHM. (Mention
date of last testing) ( C)

12.13.1 An equipotential bonding is made of copper / aluminium / stainless steel of resistivity NO

equivalent to 16mm2 copper is installed between the solar array and the “control
room”.

12.14.1 Emergency de-energisation procedure to isolate the system NO

12.15.1 Isolation of the battery bank NO

12.16.1 Isolation of the PV power inputs NO

12.17.1 Isolation of the generator set (if any) NO

12.18.1 Sign at the battery room should include “WARNING: SPARK HAZARD. Follow NO
shutdown procedure before connecting or disconnecting any equipment.”

12.19.1 List of equipment installed with rated power, models, manufacturers and quantity NO

12.20.1 Wiring Diagrams (Single line diagram with equipment information) NO

12.21.1 Data sheets (Module, batteries, charge controller and inverter) NO

12.22.1 Operating instructions (systems and components) NO

12.23.1 A checklist of what to do in case of a system failure NO

12.24.1 Emergency shutdown and isolation procedures. NO

12.25.1 Maintenance procedure and timetable NO

12.26.1 Test results and commission data NO

12.27.1 Battery record logbook NO

12.28.1 Generator set record logbook NO

12.29.1 No smoking, no open flames and no sparks are maintained around batteries. Caution NO
board is displayed.

12.30.1 Batteries are well ventilated & cap holes are open. NO

12.31.1 There is no chance of fall of tools onto the terminals or connections of battery. NO

12.32.1 Batteries are mounted onto wooden or othernon-conducting rails. NO

12.33.1 SCADA system is provided to start or stop the grid inverter. (C) NO

12.34.1 Inverter is capable of automatic start/stop and synchronisation with grid. NO

12.35.1 Inverter is provided with LCD touch screen or display panel for locally and manually NO
control of the main equipments.

12.36.1 Three phases on the AC side and positive and negative conductor on the DC side are NO
marked and identified with different colours.
 13.0
EV CHARGING STATION / BATTERY SWAPPING

13.1.1 Whether the EV charging stations socket-outlet of supply is at least 800 mm above Not available NO
the finished ground level. (C)

13.2.1 Whether a cord extension set or second cable assembly is not being used (C ) NO

13.3.1 Whether adaptors are not being used to connect a vehicle connector to a vehicle inlet. NO
(C)

13.4.1 Whether Vehicle, when parked for charging, is within 5 metre from the EV charging NO
Point.(C)

13.5.1 Whether the Maximum length of the supply lead is 5m (C) NO

13.6.1 Whether Portable socket-outlets are not in use.(C) NO

13.7.1 Whether Earth protection system is provided ( C) NO

13.8.1 Whether 30 mA Residual Current Device/ ELCB is available for EV Charging and NO
duly marked. (C)

13.9.1 Whether Cables are fitted with earth connected metal shielding with heavy NO
insulation. (C)

13.10.1 Whether Enclosure of charging stations is of fire retardant material. (C) NO

13.11.1 Whether Fire detection, alarm and control system is provided.( C) NO

13.12.1 Whether Insulation resistance is tested (Mention date of last testing) (C) NO

13.13.1 Whether Periodic test/ inspection of an EV charging station or EVSE is carried out NO
by electrical inspector/CESE in every four years. Records are maintained. (C)

13.14.1 Check availability of plug/ socket of input and output supply NO

13.15.1 Check Availability of Smoke Detector (C) NO

13.16.1 Check for water ingress inside the unit. NO

13.17.1 Machine is double earthed. (C) NO

Installed DG Sets Details

Make Model Rating Freequency [Units]

Kiloskar null 50.1

Load Distribution Details

Load Distribution Details: When Lights are OFF

R Y B

Befor Audit (KVA) 14.2 14.5 14.9

After Load Balancing (KVA) 14 14.3 1.47

Load Distribution Details: When Lights are ON

R Y B

Befor Audit (KVA) 12.2 12.5 12.9

After Load Balancing (KVA) 11.9 12.2 12.6

DU/MPD Details

Manufacturer Model DU No. Nozzle No. Product Totalizer Cable Size Cable N+E Earthing Product Remarks/ Phase Motor Motor
Reading Length Voltage at Two Points Pipeline Faulty if Current Current
JB Yes/ No Earthing any Amp. KW

GVR-DU GT2244P6EM14824HWE
5 23 MS 2541837 2.5 15 0.9 YES Yes - R 4.1 0.75
INDIA

GVR-DU GT2244P6EM14824HWE
5 26 X2 264775 2.5 15 0.9 YES Yes - R 4.1 0.75
INDIA

GVR-DU GT2244P6EM14824HWE
6 24 MS 1965081 2.5 18 0.8 YES Yes - Y 4.5 0.75
INDIA

GVR-DU GT2244P6EM14824HWE
6 25 MS 1708304 2.5 18 0.8 YES Yes - Y 4.5 0.75
INDIA

GILBARCO SIDSHD2T11C2M007 22 HSD 4799424 2.5 20 0.7 YES Yes - B 5.4 0.75

GILBARCO SIDSHD2T11C2M007 28 HSD 4380245 2.5 20 0.7 YES Yes - B 5.4 0.75

TOKHEIM TIQ2442SHPN 8 29 HSD 26122 2.5 23 1.1 YES Yes - R 5.5 0.75

TOKHEIM TIQ2442SHPN 8 30 HSD 46385 2.5 23 1.1 YES Yes - R 5.5 0.75
 TOKHEIM TIQ2442SHPN 8 31 HSD 137549 2.5 23 1.1 YES Yes - R 5.5 0.75

TOKHEIM TIQ2442SHPN 8 32 HSD 81042 2.5 23 1.1 YES Yes - R 5.5 0.75

Light Fitting Details

Item Loop No. Light No. Functioning Wattage of Illumination Reason for Rectification Cable Size Cable Length Phase KW
Yes/No ? Lamp Fixture (Lux) Non Advised
Functioning

Canopy 1 7 YES 80 213 - - 2.5 15 1 0.56

Canopy 2 7 YES 80 215 - - 2.5 20 2 0.56

Canopy 3 7 YES 80 217 - - 2.5 25 3 0.56

Canopy 4 7 YES 80 218 - - 2.5 20 1 0.56

Canopy 5 7 YES 80 211 1 light not Defective light 2.5 25 2 0.56

working should be fixed
properly

Hoarding 1 4 YES 40 67 - - 2.5 20 3 0.16

Hoarding 2 4 YES 40 65 - - 2.5 25 1 0.16

Signage 1 8 YES 40 23 - - 2.5 35 2 0.32

Yard Light 1 4 YES 100 93 - - 2.5 25 3 0.4

(Loop Wise)

Yard Light 2 4 YES 100 95 - - 2.5 30 1 0.4

(Loop Wise)

Earthing Certificate Details

M/S SWATANTRATA SENANI BAFNA PETRO

This is to certify that we have carried out the earthing testand equipment by earth tester on 21-Sep-2023, resistance in ohms (Ω) are as follows:

Tester Details: CIE200014323

Earthing Test Performed on: 21-Sep-2023

Earthing Test Valid upto: 16-Aug-2024

Next Earthing Test Due Date: 20-Sep-2024

Any Other Recommendations: Automation earth pit should be revamped

Pit Wise Earthing Readings:

Pit No. Facility (Description of Earthing Connection Grid Readings

Activity) No.
Between Shell/ Equipment & Earthing Strip Resistance of Earthing Plate/ Pipe

Point I Point II Min. Max.

Min. Max.

1 Tank 1 1 0.71 0.71 1.58 1.58

2 Tank 4 2 0.82 0.82 1.62 1.62

3 Tank 3 3 0.91 0.91 1.72 1.72

4 Tank 4 4 0.95 0.95 1.69 1.69

Photos uploaded during audit

Photos Before Audit

Unique Document Number Photograph

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Photos During Audit [When corrective action has been taken]

Unique Document Number Photograph

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