ELECTRICAL SAFETY INSPECTION REPORT

Transcription

1 ELECTRICAL SAFETY INSPECTION REPORT ABSS HIGH TECH SWEATER LTD. Kalameshar, Board Bazar, Gazipur. Factory List: ABSS HIGH TECH SWEATER LTD. Inspected by Report Generated by : Hossain Shah Aarif : Mobassear Ul Islam Inspected on : May 10, 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 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. ABSS High Tech Sweater Ltd. factory is established in its six 1 story buildings/sheds. Right at this moment ground floor is used as production floor, Office, store & utility purpose. Building is owned by factory; as reported by the Factory Management, the building was constructed in early 2007 and the production began in During the time of the Inspection, the factory accommodated a total of approx. 200 (one shift) workers working on regular basis. Page 2 of 18

3 1. 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. Draw as built electrical SLD & electrical layout drawing mentioning all required information and get it reviewed by Accord. FINDING E - 2 HOTSPOT Hot spots at terminations inside panel. Thermographic inspection record is unavailable. Arrange periodic inspection & thermal scan at least twice in a year to identify the overloading, loose connection, unbalanced load which may cause the excessive heatrise and take action accordingly. However, quickly correct such points. P1 Page 3 of 18

4 FINDING E - 3 EARTHING SYSTEM Earth Pit resistance record is unavailable. All earthling systems shall be tested for resistance on any dry day not less than once in every two years. A record of every earth test made and the result shall be kept for not less than two years and shall be available to the Inspector when required. FINDING E - 4 SAFETY TRAINING Electric safety training program is not initiated/conducted. Electrical safety training and awareness program for the electrical personal and workers must be initiated and recorded according to NFPA 70E. FINDING E - 5 TESTING & PERIODIC MAINTENANCE Insulation resistance test of electrical cables is not performed. Insulation resistant test of all the cables (Higher than 16rm) must be performed once every 2-year cycle and recorded (this must require a complete power shut off). Page 4 of 18

5 FINDING E - 6 TESTING & PERIODIC MAINTENANCE Transformer Oil Test report is unavailable. Check the transformer oil condition by performing oil test. Do it once in a year and keep the record. FINDING E - 7 WIRING SYSTEM Drop out fuse is replaced by wire. Install the drop out fuse. FINDING E - 8 GENERATOR ROOM (1) Generator output cables (laid on floor) are not protected and supported. (2) Panel base plates removed to allow cable entry. (1) If possible route all the power cable through overhead cable tray. Or ensure adequate protection for power cables arranging cable trench(ladder type) with checkered plate. Do not make any arrangement that obstacle personnel's movement within working clearance. (2) Panel base plates must be installed, at all time, and cables entering panel must be firmly fixed with cable gland. Page 5 of 18

6 FINDING E - 9 GENERATOR ROOM Inadequate sized earth cable connected to generator frame. Two separate and distinct earth connection must be provided over generator. Generator body must have earth connection with half of phase conductor/ follow manufacturer/ suppliers recommendation. FINDING E - 10 CABLE RACEWAY & TRENCH Power cable is covered by sand in the cable trench (or cable trench is filled with sand). If it is designed keeping Power cable under sand, it s OK; otherwise remove sand from cable trench avoiding physical damage. FINDING E - 11 TRANSFORMER ROOM Lint and dust deposited on transformer top Keep transformer top always neat and clean. Page 6 of 18

7 FINDING E - 12 TRANSFORMER ROOM Transformer Body earthling is inadequate. Two separate and distinct earth connection & one separate and distinct Neutral connection must be provided for Transformer. Transformer body must have earth connection with half of phase conductor/ follow manufacturer/suppliers recommendation. FINDING E - 13 TRANSFORMER ROOM Inadequate space around transformer for performing maintenance work. Ensure minimum 1.07m working space around the transformer (and related electrical installations). FINDING E - 14 CABLE & CABLE SUPPORTS Power cables entering to or exiting from Distribution board/panel are not properly fixed & supported. Power cables entering to or exiting from distribution board/panel must be fixed through Panel base/top plate using cable glands (metal/pvc). Use ladder type cable tray to support cables. Page 7 of 18

8 FINDING E - 15 EARTHING SYSTEM Panel door has no earth connection. All metal panel doors shall have earth connection with a 4 rm earth cable. FINDING E - 16 Distribution board/panel is filled with fluffs (lint/dust) (1) Keep always clean inside all the distribution boards/panels. Seal them properly and ensure adequate ventilation. FINDING E - 17 No/Inadequate rubber (insulation) mat on the working are of distribution board/panel. Put electrical insulation (rubber mat) on the working area of each electrical installation (Transformer/LT panel/mdb/db/sdb/ other manual operated machineries). Page 8 of 18

9 FINDING E - 18 WIRING SYSTEM Cables terminated at electrical bus bar/ MCCB without cable lugs. Terminate all the power/earth/neutral cable with proper sized cable lug. P1 FINDING E - 19 SUBSTATION ROOM Change Over Switch contacts smeared with bearing grease. Instead of bearing grease, thin layer of contact grease must be used for lubrication of Changeover-Switch contacts. FINDING E - 20 SAFETY INSTRUCTION No instruction for CPR (Cardiopulmonary Resuscitation)/Electrical shock restoration is absent at the panel boards. Hang this instruction(cpr) near all electrical equipment (LT panel, MDB, FDB, DB, SDB) on a visible location. Page 9 of 18

10 FINDING E - 21 WIRING SYSTEM Phases are imbalanced. In three phase outgoing circuits all the phases shall be balanced. Calculate each phase's load and redistribute loads to make phases balanced. FINDING E - 22 WIRING SYSTEM Cables in service are joined (splicing) between terminations. Joints of cable shall be avoided. For unavoidable cases, existing cables with joints must be spliced using butt splicing kits and then should be insulated with electrical tapes. Joints must be supported and protected. FINDING E - 23 EARTHING SYSTEM Dedicated neutral/ecc is not provide for each circuit. Provide dedicated neutral & ECC for each circuit. Page 10 of 18

11 FINDING E - 24 EARTHING SYSTEM Manually operated machines/motors have no earth connection. Connect and ensure all the manually operated machines/motors with earth P1 FINDING NO: E - 25 WIRING SYSTEM Cables are hanging without proper support. Use cable tray/ladder to support cables at anywhere to keep cable out of tension. FINDING E - 26 CABLE RACEWAY & TRENCH Cable duct is left open. Cover it with electrical graded materials, clean it at certain interval and keep records of cleaning. Page 11 of 18

12 FINDING E - 27 STORAGE LIGHT Light in store room / storage areas is uncovered. Lights in store room / storage areas shall be covered. P1 FINDING E - 28 INDICATOR LAMP Indicator light/electrical element is mounted without control device. Indicator light/electrical element should be connected with control device such as fuse or MCB. FINDING E - 29 BATTERY Battery terminals are left open. Use insulated rubber cap to cover all the battery terminals Page 12 of 18

13 FINDING E - 30 LIGHTNING PROTECTION SYSTEM Lightning Protection System(LPS) has not installed yet Design and Install LPS for your factory REMEDIATION TIME FRAME: 4 MONTHS FINDING E - 31 Multiple cables terminated at MCCB terminals/ Bus bar. Terminate each power cable at single terminal and use proper sized cable lug. P1 FINDING E - 32 Distribution Board's top/bottom/back is left open (typical issue) Seal each distribution board's top/bottom; and use cable glands holding/supporting cables. Also seal the unwanted gland holes. Page 13 of 18

14 FINDING E - 33 Loop connection has used powering multiple MCBs/MCCBs. Eliminate loop cables, use single cable for each MCBs/MCCBs. You may use bus bar to avoid multiple termination. P1 FINDING E - 34 Power bus bar/mccb are installed congested; and power cables touch opposite phased bus bar. Ensure that no power cable touches bare bus bar. Use insulated bus bar (just covering existing bus bar by heat shrink) FINDING E - 35 WOODEN SUPPORT Wooden support used for electrical installation/element. Replace wooden support and it is preferable to fix each electrical devices with noncombustible support. Page 14 of 18

15 FINDING E - 36 BOILER & CMPRESSOR Compressor is on wheels. Fix the device with floor/baseplate. FINDING E - 37 Panel/Distribution boxes are inaccessible or cannot be opened to perform any maintenance work. Take necessary initiative thus every panel/distribution board can be easily accessible FINDING E - 38 EARTHING SYSTEM Earth lead cable/earth Continuity Conductor size is inadequate/undersize Resize earth lead cable/ecc for LT panel/mdb/db; follow BNBC 2006 Part 8 chapter 2 section 2.8 for sizing your earthling cables (Usually ECC should be equal to the half of the respective phase cable). Page 15 of 18

16 FINDING E - 39 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 FINDING E - 40 CABLE & CABLE SUPPORTS HT cables laid on substation room floor. Use a cable tray to ensure adequate support. This must not be routed/supported through the equipment' working clearance area. FINDING E - 41 Circuit is drawn from bus bar without/bypassing Circuit breaker or any protective means. For distribution board, along with the main circuit breaker all outgoing circuits shall have individual outgoing circuit breaker. P1 Page 16 of 18

17 FINDING E - 42 Three phase MCCB connected to control two phases or less. Check and redesign the requirements to control the circuits. If three phase control is not required, then replace with suitable control devices. FINDING E - 43 No permanent identification found at the panel boards. All distribution boards shall be marked permanently, as the case may be, provided a unique ID number (e.g. MDB-1). FINDING NO: E - 44 EARTHING SYSTEM Neutral earthling is not separated from body earthling of the electrical system. Need to improve the earthling system for the whole electrical system so that Neutral earthling is separated from body earthling of the electrical system. Page 17 of 18

18 FINDING NO: E - 45 EARTHING SYSTEM Earth pits are not identifiable. Identify each earth pit and mark it for periodic maintenance purpose. FINDING NO: E - 46 DOCUMENTATION There is no programmed schedule for periodical inspection & testing of electrical equipment. Develop an electrical maintenance program that includes inspections and testing of the electrical systems (preventive, proactive and breakdown maintenance) Page 18 of 18