ELECTRICAL SAFETY INSPECTION REPORT

Transcription

1 ELECTRICAL SAFETY INSPECTION REPORT APPLE KNITWEAR LTD. House 1, Road 1, Horinchala, Konabari, Gazipur GPS Coordinate: , Factory List: Apple knitwear Ltd. Inspected by Report Generated by : Md. Assaduzzaman : Md. Assaduzzaman Inspected on: October 25, 2016

2 SUMMARY The Factory was surveyed for electrical safety by Stichting Bangladesh Accord Foundation. The purpose of the survey was to identify significant electrical safety issues and to provide recommendations for remediation based on applicable standards specified by the Accord. Electrical Safety Audit is a methodical approach to evaluate potential electrical hazards and to recommend suggestions for improvement. The scope of this initial electrical safety inspection was limited to the review and identification of major electrical safety issues. The inspection did not include identification of minor deficiencies, which would be further dealt with as part of follow-up inspections. The information in this electrical safety inspection report was obtained during a visit to the facility and during discussion with local factory management. Services performed by the auditors are conducted in a manner consistent with that level of care and skill generally exercised by members of the engineering and auditing profession. However, an effort has made to discover all meaningful areas under the stipulated time available. In evaluating subject site, Inspector relies in good faith on information provided by factory management or employees. The Inspector assumes that the information provided is factual, accurate and accepts no responsibility for any deficiency, misstatement or inaccuracies contained in this report as a result of omission or misrepresentation of any person interviewed or contacted. The findings and recommendations in this report are not intended to imply, guarantee, ensure or warrant compliance with any government regulations. Additionally, the results do not imply in any way that compliance with the findings or recommendations as stated in this report will eliminate all risks or exposures not referred to in this report do not exist. Compliance with the findings and recommendations stated in this report does not relieve the factory owner from obligation to comply with specific project requirements, industry standards, or the provisions of any local government regulations. Apple knitwear Ltd. factory is established in its 4 story (G +3) rented building. As reported by the Factory Management, the building was constructed before 2005 and still under construction and the production began in September During the time of the Inspection, the factory accommodated a total of approx. 250 (single shifts) workers working on regular basis. The four storied (G+3) i.e. factory building is 48 feet tall and has a total floor area of approx sqft. Page 2 of 16

3 FINDINGS AND RECOMMENDATIONS The table below summarizes the major electrical hazards identified during the walk through inspection. Recommendations have been provided to each finding. The implementation schedule shall be developed by the factory to remediate each of the findings. The specific timing of improvements, including any requested extensions due to design / installation constraints, shall be submitted to the Accord for an approval. FINDING E - 1 DOCUMENTATION Electrical Single Line Diagram (SLD) is unavailable in the factory As built Electrical SLD must be prepared; it must have factory's whole electrical installation information. FINDING E - 2 LIGHTNING PROTECTION SYSTEM Lightning Protection System (LPS) drawing is unavailable Factory has to design Lightning Protection System (LPS) for the whole factory (where the Risk index is more than 40). Once a LPS is designed properly, installation must be done accordingly. Page 3 of 16

4 FINDING E - 3 TESTING & PERIODIC MAINTENANCE Insulation resistance record (cable information) doesn't match with field Field information must be reflected in the record and significantly lower sized cables' record shall be avoided FINDING E - 4 TESTING & PERIODIC MAINTENANCE Earth Pit resistance record doesn't match with field Adequate number of earth pits must be ensured (if it's lower in numbers) and record must be made accordingly. FINDING E - 5 TESTING & PERIODIC MAINTENANCE Thermography survey record is unavailable. Hot spots have been observed at some points. Thermography survey must be done at least twice in a year. Hot spots must be removed as soon as possible. P1 REMEDIATION TIME FRAME: IMMEDIATE Page 4 of 16

5 FINDING E - 6 DOCUMENTATION Electric safety training program has not initiated/conducted. Electrical safety training and awareness program for the electrical personnel must be initiated. It is a periodic task which factory has to continue to improve overall electrical safety situation for the staffs. FINDING E - 7 DOCUMENTATION 1) Personal Protective Equipment (PPE) for Electrical Work is not available. 2) Uninsulated electrical tools are used for breakdown and preventive maintenance 1) Personal Protective Equipment (PPE) must be arranged by the factory management team for the safety of their employee and worker. 2) For maintenance purposes all the electrical tools shall be properly insulated and these insulations shall be checked periodically. P3 FINDING E - 8 DOCUMENTATION There is no programmed schedule for periodical inspection & testing of electrical equipment. An electrical maintenance program shall be prepared which will include inspections and testing of the electrical systems (preventive and proactive) P3 Page 5 of 16

6 FINDING E - 9 GENERATOR ROOM Generator room is filled with debris (or used as temporary storage) Generator room must be kept neat and clean. REMEDIATION TIME FRAME: 1 MONTH FINDING E - 10 GENERATOR ROOM Lead acid battery terminals are left open & kept on wooden board Lead acid battery terminals must be covered/capped and rust must be checked and cleaned, use non-flammable case/shelf to store battery. FINDING E - 11 GENERATOR ROOM Water spillage has been observed in generator room. Any kind of water spillage/leakage must be stopped; and generator must be kept always dry. Page 6 of 16

7 FINDING E - 12 GENERATOR ROOM Generator body has been earthed by inadequate/improper sized (type) cable Two separate and distinct earth connection must be provided over generator. Equipment earthing cable size must be increased. The earth cable size shall be less than or equal to half of the phase cable (depends on fault clearing time). You may use equivalent sized bare copper conductor. FINDING E - 13 GENERATOR ROOM Mechanical guard is not provided to the rotating part of the generator. Provide adequate mechanical guard on the rotating part. P1 FINDING E - 14 EARTHING SYSTEM Pedestrian fan is using for generator cooling purpose Avoid using pedestrian/ceiling fan in generator room for cooling purpose; ensure adequate ventilation (cross ventilation) for the generator room Page 7 of 16

8 FINDING E - 15 CABLE & CABLE SUPPORTS Service cables from Grid network has inadequate support (or excessively sagged) Power service cables must be draw using cable tray/ladder (in case of overhead drawing); covering is required for LT cables. FINDING E - 16 Panel doors are not connected with earth. All metal installation which are part electrical system must be connected with earth to avoid electrical shock or electrocution. REMEDIATION TIME FRAME: 1 MONTH FINDING E - 17 No/Inadequate rubber (insulation) mat at the working area of distribution board/panel. Electrical insulation (not less than 3 mm thick in case of rubber mat) at the working area of each electrical installation (Transformer/LT panel/mdb/db/sdb/ other manual operated machineries) must be ensured. Page 8 of 16

9 FINDING E - 18 Distribution boards have no clear identification markings. All distribution boards, switchboards, sub main boards and switches shall be marked clearly for proper identification. FINDING E - 19 Loop connection has been used powering multiple circuits through MCB/MCCBs. Any kind of looped power connection must be avoided from electrical installation. REMEDIATION TIME FRAME: 1 MONTH FINDING E - 20 Multiple cables connected/terminated at the bus bar using single cable lug. Each power cable must be terminated at any point using single cable lug. Page 9 of 16

10 FINDING E - 21 Multiple cables (came from different electrical consumers) terminated at MCCB terminals/ Busbar. Each electrical circuit must be terminated at single MCB/MCCB and busbar terminals. FINDING E - 22 Cables terminated at electrical bus bar/mccb without cable lugs Terminate all the power/earth/neutral cable with proper sized cable lug FINDING E - 23 Oversized circuit breakers or Circuit breakers are not adjusted accordingly Adjust or replace all the MCCBs/MCBs according to cable ampacity (connected load). Avoid using different sized cable at the terminals P1 Page 10 of 16

11 FINDING E - 24 Unterminated live wire is kept inside the electrical panel/cable tray. All the unterminated live power cables must be removed as soon as possible. P1 REMEDIATION TIME FRAME: 1 MONTH FINDING E - 25 Cables in service are joined (splicing) between terminations. Splicing in the power cables shall be avoided; in unavoidable cases splicing must be made following proper guidance. FINDING E - 26 Phase barrier/separators are missing in the MCCB/MCB Phases must be separated by insulator (a rubber type no-flammable materials shall be used for it) P3 Page 11 of 16

12 FINDING E - 27 Earth lead cable/earth Continuity Conductor size is inadequate/undersize Earth lead cable/ Earth Continuity Conductor (ECC) must be resized by half of the phase cable. Cable size shall be selected depending on the CB's response time and phase cables' size. FINDING E - 28 Distribution Board's top/bottom is left open (typical issue) Each electrical distribution board/panel must be properly sealed to avoid ingression of fluffs; but an adequate ventilation system must also be ensured. FINDING E - 29 CABLE & CABLE SUPPORTS Power cables entering into or exiting from Distribution board/panel are not properly fixed. Power cables entering into or exiting from distribution board/panel must be fixed through Panel base/top plate using proper sized cable glands (metal/pvc). Page 12 of 16

13 FINDING E - 30 Inadequate working space around (or in front of) board/panels and access to the board/panels is obstacles At least 1 meter (or equal to the width of board/panel, whichever is higher) working clearance must be maintained in front of each electrical board/panel FINDING E - 31 Electrical distribution box/panels are full of fluffs (lint/dirt) Each electrical distribution board/panel must be properly sealed to avoid ingression of fluffs; but an adequate ventilation system must also be ensured. P3 REMEDIATION TIME FRAME: 1 MONTH FINDING E - 32 Combustible materials kept near distribution panel. In front of each distribution board, there shall have at least 1.07 m clearance around it. REMEDIATION TIME FRAME: 1 MONTH Page 13 of 16

14 FINDING E - 33 Distribution panel & PFI are not fixed with base properly. Firmly grout the panels permanently with foundation bolts. REMEDIATION TIME FRAME: 1 MONTH FINDING E - 34 CABLE RACEWAY & TRENCH Cable channel/duct terminals are left open for ingression of lint, dust or fluffs. cable ducts must be properly sealed to avoid ingression of any foreign particles. P3 REMEDIATION TIME FRAME: 1 MONTH FINDING E - 35 CABLE RACEWAY & TRENCH Wooden cable channel/ducts is used for power cable distribution. Metal type cable tray (perforated one is preferred) shall be used for distributing power cables Page 14 of 16

15 FINDING E - 36 CABLE RACEWAY & TRENCH Maintenance movement is obstacled due to improper cable channel/duct. Covered cable duct (close to floor-slab) must be equal to working floor height. If not, extended area must be sloped at both sides to avoid obstacle. P3 FINDING E - 37 CABLE RACEWAY & TRENCH Heat source (or exposed steam line) is adjacent to electrical installations (cable channel/duct) Heat source (or steam line) must be kept at least 0.9 meter apart from any electrical installation. In unavoidable case heat source, shall be covered by proper and adequate insulator. FINDING E - 38 EARTHING SYSTEM Manually operated machines (may have chance to be touched by operator/user) have no earth connection. Each manually operated machine (may have chance to be touched by user/operator) must have earth connection. Cable selection shall be made according to CB response and circuit's power demand. P1 Page 15 of 16

16 FINDING E - 39 WIRING SYSTEM Hazardous lights in store room / storage areas are uncovered. hazardous lights in store room / storage areas shall be covered by proper type material; or non-hazardous lights shall be installed in these areas. P1 FINDING E - 40 BOILER & COMPRESSOR Flexible PVC pipe is used to cover power and signal cable for boiler Power and signal cable for boilers shall be distributed using proper type insulator to avoid damage of cables. Page 16 of 16