The rising concern for safety in India
The concern for safety in India is on the rise due to an alarming increase in electric hazards, such as short circuits and fire accidents, which have resulted in a significant number of fatalities. Vivek Yadav, Executive Vice President, Havells India, shared distressing statistics, stating, "Electrocution accidents is one of the top reasons for death occurring commonly in India. As per the National Crime Records Bureau (NCRB) statistics, at least 3,000 people die every year in electric power-related accidents in the country."
Shreegopal Kabra, Managing Director, RR Kabel, identified the unprecedented surge in electricity demand due to rapid urbanisation, infrastructure development, and industrial growth as one major the reasons behind these accidents. This surge exerts strain on electrical systems, increasing the likelihood of overloads and short circuits. Bhushan Sawhney, Executive President and Chief Business Officer, Polycab India Ltd., highlighted the risks associated with this situation. He explained that inadequate power generation leads to unstable power supply and voltage fluctuations, which can cause sudden spikes or drops in voltage. This, in turn, stresses electrical equipment, distribution infrastructure, and escalates the risk of short circuits.
The need to meet the escalating demand for electricity often results in compromised quality and the use of counterfeit or substandard equipment, which are sold at lower prices. In 2019, India recorded 10,915 deaths due to fire accidents, a majority of which arose from electrical short circuits because of the use of substandard wires. Ramachandran V, Director and COO of V-Guard Industries Ltd., emphasised, "Many people in India use low-quality electrical wiring to save money, which can be dangerous and increase the risk of electrical short circuits."
In addition to financial considerations, Ramachandran also identified lack of awareness and education about electrical safety as a contributing factor. He stated, "Many consumers or electricians are not aware of the best wiring practices and potential risks and dangers of electrical short circuits and do not know how to prevent them."
Mitigating risks and safeguarding employee well-being
According to data from the Central Electricity Authority (CEA), nearly 40 per cent of workplace fatalities can be attributed to electrical hazards. Consequently, it is crucial for manufacturers to prioritise the training of their employees, enabling them to recognise and report incidents. Ramachandran, for instance, highlighted the safety measures implemented. He says, "V-Guard employees are trained on safety procedures and how to identify and avoid hazards. Training is conducted on an ongoing basis, and employees are required to demonstrate their knowledge and understanding of safety procedures." Even Kabra, emphasised RR Kabel's commitment to encouraging employee participation in reporting safety concerns and near-miss incidents. He referred to ongoing training programs, safety drills and workshops, as "investments" for the future. Moreover, companies commonly employ the Hazard Identification and Risk Assessment (HIRA) approach to identify potential hazards, evaluate their likelihood and severity, and assess the resulting consequences. A team of experts, including engineers, safety professionals, and operators conduct regular HIRA at the workplace. Risk assessments by considering the likelihood and severity of the hazard, as well as the potential consequences of an accident, help in focussing on the significant areas for safety improvement.
In addition to a proactive management safety review team who approves policies and safety standards, reviews safety performances and the effectiveness of safety procedures, Vivek Yadav described, "100 per cent of Havells workers are covered by occupational health and safety management system. Targeted safety placards, posters and signboards are placed at strategic locations, to raise awareness and to reinforce that safety is everyone's responsibility."
Acknowledging the inherent dangers posed by substandard products and unsafe working conditions, cable and wire manufacturing companies prioritise rigorous compliance with their certifications. Prominent companies have disclosed their commitment to adhering to ISO 14001 (Environmental Management System) in relation to their environmental impact. Furthermore, they strictly adhere to ISO 45001 (Occupational Health and Safety Management System) to safeguard the health and well-being of their workforce, and ISO 50001 (Energy Management System) to effectively manage energy resources. Additionally, companies uniformly comply with ISO 9001:2015 to ensure efficient quality management practices.
Customer safety
Due to a significant lack of awareness in the country, it is essential to establish a robust customer support system that can guide users through proper installations, maintenance, and provide important guidelines. Prominent companies including Polycab India and RR Kabel prioritise customer safety by providing detailed product documentation, user manuals and installation guides, to offer clear instructions on the correct installation, usage, and maintenance of their products.
Moreover, they organise awareness workshops and collaborate with industry partners to train electricians, contractors, and end-users. These initiatives aim to promote safe practices and raise awareness about electrical safety, ultimately contributing to the establishment of stringent norms for electrical fire safety and gearing a collective effort towards building a fire-safe nation.
Ramachandran emphasised V Guard's proactive approach to customer safety sharing, "We provide online resources, such as videos and FAQs, to help customers better understand our products and how to use them safely. Additionally, we have a dedicated customer support team that is available to answer any questions or concerns that customers may have about our products."
Intelligent cables
There are several challenges that arise during the manufacturing process of cables and wires. The integration of Internet of Things (IoT) and other technological advancements has the potential to enhance the reliability of electrical systems, reduce downtime, and mitigate the risk of electrical hazards. Sawhney expressed Polycab's commitment to advancing its operations, "We actively explore the integration of IoT into our products and solutions. These technologies enable us to develop smart cables and wires that can monitor electrical parameters, detect potential hazards such as overheating or power fluctuations, and provide real-time data for preventive maintenance."
The sector is flourishing as technologies are incorporated into various aspects of manufacturing. Ramachandran V shared one such advancement in the manufacturing process of building wires products, which involves the use of advanced insulation materials with superior insulation resistance, high flame retardancy, and improved heat resistance. These materials can effectively prevent short circuits. The Director emphasised, "We are the pioneer to use triple extrusion insulation, to ensure that our cables and wires are manufactured to the highest standards of quality and safety."
Fire safety components are essential for all structures, but they are particularly critical for highrise buildings due to unique concerns related to accessibility, evacuation, and smoke control. This issue becomes even more relevant in India's landscape, which is experiencing rapid urbanisation and infrastructure development. In this context, Kabra highlighted RR Kabel's efforts to address this issue by stating, "Electrical accidents can be avoided by using high quality fire-resistant wiring and cables. Our cables and wires are manufactured using technologically advanced machinery and each tested wire undergoes stringent tests at our in-house NABL laboratory."
Safe disposal and recycling
The discussion of environment safety is not far-fetched when talking about the safety in the cables and wires manufacturing industry. With the growing demand for electrical products, it becomes imperative to address the environmental impact associated with the production process. Companies operating in this industry have taken significant steps to tackle this challenge head-on, implementing robust systems to handle waste materials generated during manufacturing.
Companies like V Guard begin working towards this goal with measures to reduce scrap generation in the first place. The company works towards optimising production processes and using environment-friendly materials where feasible.
Effective waste management systems within manufacturing facilities encompass proper segregation, storage, and disposal of waste materials. Polycab India takes stringent efforts in this regard and prioritises recycling and reuse of waste materials to minimise environmental impact. The company works alongside authorised recycling partners who specialise in the recycling of specific materials, ensuring their safe and sustainable treatment.
What does a safe future hold?
The premise of a safe future as Kabra highlights entails, "Cables that are sustainable for both, the consumer and the environment adhering to international standards and quality."
To achieve this vision, companies including Havells and Polycab are manufacturing cables which are fire-resisitant, they are promoting the use of Halogen-free flame retardant (HFFR) insulated wires since they do not emit hazardous gases, and clear smoke. Further, "The low intensity visible white smoke HFFR is more effective during fire outbreaks since it reduces the amount and density of the smoke, which makes exiting a space easier for occupants as well as increases the safety of firefighting operations during any fire accident," shared Vivek Yadav.
There is an increasing demand for energy-efficient cables that reduce power losses. In addition to this need of increasing efficiency, there is a gathering momentum which propels decreasing carbon impact. Consequently, the future will witness a shift towards wiring solutions that facilitate the efficient transmission and distribution of clean energy. Furthermore, smart cables enabling realtime monitoring, early fault detection, and remote control capabilities will play a pivotal role in shaping future infrastructure, the Polycab CBO shared.
In lieu of the government's substantial investments in infrastructure development, India is facing an increasing demand for electricity.
As smart homes become increasingly popular in India, they drive the demand for a special variety of cables and wires. Smart homes use a variety of sensors and devices that are connected to the internet, and this requires high-quality cables and wires that can handle high-speed data transfer. Ramachandran V also brought to light the impact that the EV industry will create on this sector. According to him, "Electric vehicles require high-power cables that can carry the high currents required for charging. The electric vehicle market is growing at a good pace in India, and this is driving demand for high-quality cables for charging electric vehicles."
