INSPECTION FOR ELECTRICAL

EQUIPMENT AT SHELL AVIATION

LOCATION: SUKKUR AIRPORT

Inspection Date: 25 June 2020

Inspection By: Mohammad Iqbal & Team.

Client: Shell Aviation, Sukkur.
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EXECUTIVE SUMMARY
This report provides an analysis and evaluation of current and prospective condition of the Terminal.
The inspection was conducted to investigate:

I. The GAP Analysis

II. Flaws in the System

III. Energy Efficient Measures

So, that it will be ensuring that precipitate failures are effectively minimized and unexpected outages
can be reduced ensuring continues power supply to the end user. These are the basic objectives which
are further classified below:

I. THE GAP ANALYSIS:

Gap refers to the space between "where we are" (the present state) and "where we want to be" (the
target state). A gap analysis may also be referred to as a need’s analysis, needs assessment or need-
gap analysis.

In engineering field, gap analysis reports are often used by project managers and process
improvement teams. The first step in conducting a gap analysis is to establish specific target
objectives by looking at the company's mission statement, strategic goals, and improvement
objectives. The next step is to analyze current processes by collecting relevant data on performance
levels and how resources are presently allocated to these processes. This data can be collected from a
variety of sources depending on what is being analyzed.

II. FLAWS IN THE SYSTEM (POWER QUALITY):

Power Quality (PQ) related issues are of most concern nowadays. The widespread use of electronic
equipment, such as information technology equipment, power electronics such as adjustable speed
drives (ASD), programmable logic controllers (PLC), energy-efficient lighting, led to a complete change
of electric loads nature. These loads are simultaneously the major causers and the major victims of
power quality problems. Due to their non-linearity, all these loads cause disturbances in the voltage
waveform.

III. ENERGY EFFICIENT MEASURES:

Here are some practices that are not simply good, they’re the best. And the ideas below are based on
best practices to trim their energy waste with nothing more invested than time.
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Improve operations and maintenance practices by regularly checking and maintaining equipment to
ensure its functioning efficiently.

Perform monthly maintenance of heating and cooling equipment to guarantee efficient operation
throughout the year.

 INTRODUCTION:

The technical issues in the process industry has become a wide concern for the management, due to
these issues most of the industries faces production losses, do not achieve their targets and effected on
the major necessities of the people. The management is responsible for dealing with these problems
and working towards solution. Accordingly, the management has tried to address this over the years by
creating policies.

Although it is not the examiner general function to question policy. It is however his responsibility to
investigate the technical issues of site, to highlight the predictive maintenance of equipment and
upgradation towards new technology. In this way examiner general can help the management to do a
better job.

The purpose of this management report was therefore to make known the findings regarding the, Gap
analysis and Energy efficiencies measures. The report was not intended to be exhaustive. In line with
inspections of this nature, the intention was to provide the reader with a general understanding of
current situation about the plant deficiencies.

The Inspection is the principal instrument by which the inspection findings are communicated to the
management of SHELL PAKISTAN.

Each inspection findings should be classified as a major control weakness, minor control weakness,
exception, observation, and violation of law.

 OBJECTIVES:

Following are the objectives:

1. To enhance Energy efficiencies measure of Electrical System i.e. Motors, lightning system and
losses and leakages in the system.

2. To indicate the Gap Analysis of the system i.e. Electrical.

3. To foresee the Predictive maintenance of equipment whether it is minor or major; so that

unexpected outages can be minimized ensuring continues power supply to the end user.
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PRIORITY STANDARD
S. No. DESCRIPTION FINDINGS REMARKS
LEVEL S
1 Earthing Pits
LT Room earth pit

No finding of any fault.

Newly constructed
IEC 60364
1.1 no any observation. Low
Earth Pit=1.3 ohm BS 7430

MCC Panel Earth pit

Cover Broken Cover will be IEC 60364

1.2 Low
Earth Pit=0.2 ohm changed. BS 7430

Pit for Tanks

Tank Earthing pit=0.3 New earth pit is to IEC 60364
1.3 Low
ohm be constructed. BS 7430
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2 Electrical Motors
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Decanting Motor (7.5 HP) Single core cable is used Multi core cable is
instead of multi core suggested.
cable.
Use proper gasket
The cables & connectors & fastening.
are not labeled.
Use appropriate
Terminal box is in bad cable glands
condition because (explosion proof are
gasket and other fittings recommended).
are not used.
Use termination kit
Cable glands are not for connections/
used instead pipes are joints.
directly inserted in the
2.1 HIGH API 610
Junction box. Provision for
local/remote
Cables are not properly operation with ESD
terminated on the may be carried out.
motor terminal (e.g.
lugs/sleeves/marking
etc. are not used).

No local-remote
provision is available at
MCC Panel.

No ESD is provided in
case of any emergency.

2.2 Loading Motor (7.5 HP) Single core cable is used Multi core cable is HIGH API 610
instead of multi core suggested.
cable.
Use proper gasket
& fastening.
The cables & connectors
are not labeled. Use appropriate
cable glands
Terminal box is in bad (explosion proof are
condition because recommended).
gasket and other fittings
are not used. Use termination kit
for connections/
Cable glands are not joints.
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used instead pipes are

directly inserted in the Provision for
Junction box. local/remote
operation with ESD
Cables are not properly
should be installed.
terminated on the
motor terminal (Jumper
Provision for
wires are used instead
Star/Delta starting
of delta links).
is not available at
Access to motor is not MCC panel.
easy due to the
presence of piping Wires should be
network. connected to
No local-remote operate Star/Delta
3 MDB / LDB Panel
3.1 Corrosion is observed at Faulty components HIGH IEC 60439
terminals, Screws, & proper BS 5420
Enclosure, etc. termination with BS 6121
IEC 60364
de-rusting should
Fault Indication lamps be carried out.
are burnt out.
Rubber lining must
No phase marking is be installed.
observed on cable
cores. Appropriate cable
glands should be
Terminations of cables used with proper
dressing & clamping
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are not as per standard of cables.

(e.g. Lugs, sleeves,
marking, etc.). Labeling of items/
components to be
Sharp edges are found carried out.
on DB housing.

Cable glands are not

used.

Cables are not properly

4 dressed
Motorand Control
hooked up.Panel

4.1 Loading motor is Star / Delta circuit HIGH IEC 60439

running on DOL mode. should be installed BS 5420
No provision of Star / for one motor. BS 6121
Delta circuit.
Panel sealing is
Decanting motor is required with IP
running on Star / Delta class 55.
mode.
Rubber Lining is
Enclosure was in dirty required on sharp
condition. edges to avoid cable
damage.
Sharp edges found on
DB housing. Installation of glands
according to cable
Cable glands are size along with the
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missing. proper dressing.

Cable was not properly Labeling of DB is

dressed and hooked up. required.

DB is not properly
sealed.
5 Electrical LT Room
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LT room walls and floor

are deteriorated.

The condition of the LT

room is badly affected
by severe weather
conditions because of
the metal sheet on the
rooftop.

Space in the room is

limited.

The Switchboard and Refurbishment of

Switchroom are poorly Electrical room with
protected against the masonry or
5.1 rodents/insects or dust. concealed rooftop, HIGH IEC 60364
proper ventilation &
Major cracks observed emergency lights
on the walls. must be installed.

The electrical conduit is

not as per standard
practice.

No ventilation/ exhaust
are provided in the
electrical room.

The room lighting is

normal but emergency
lighting is not installed.
6 Change Over Switch
Switch is found burst.
System to be
Generator Cable and restored with a
IEC 60439
Changeover to MDB new Manual-
HIGH BS 6121
6.1 Cable is disconnected. change-over or
BS 5420
Automatic-change-
Main Cable is directly
over.
connected in MDB.