ELECTRICAL SAFETY INSPECTION REPORT WARN KNIT FASHION Chanmari, Fatullah, Narayanganj- 1400 GPS Coordinate:23.634239,90.496801 Inspected by Report Generated by : Noman Saber Khan & Shaik Muhammed Wasi : Noman Saber Khan & Shaik Muhammed Wasi Inspected on: December 4, 2016
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. Warn Knit Fashion factory is established in its 6 storied (G +5) building and a separate utility shed. The building is rented by Factory Management for 2 years and owned as personal property as reported by building management. Right now, 3 rd and 4 th is used as Warn Knit Fashion. 5 th Floor is used by difference factory named ARS Printing. Ground, 1 st and 2 nd floor is occupied by another factory named as Sun Knitwear. The building was constructed in 2004 as personal properties and the production began in November 2014. During the time of the Inspection, the factory accommodated a total of approx. 100 (Regular shift) workers working on regular basis. 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. Page 2 of 12
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 TESTING & PERIODIC MAINTENANCE Insulation resistance test of electrical power cables is not performed Insulation resistant test of all the cables must be performed once every 2-year cycle and recorded (this must require a complete power shut off) FINDING E - 3 TESTING & PERIODIC MAINTENANCE Thermography survey record is unavailable. Hot spots have been observed at some points. Thermography survey must be done and recorded at least twice in a year. Hot spots must be removed. Page 3 of 12
FINDING E - 4 TESTING & PERIODIC MAINTENANCE Earth Pit resistance record is unavailable. Number of earth pits must be increased; and all those shall be identifiable. And all earthing 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 - 5 DOCUMENTATION Electric safety training program is 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 - 6 LIGHTNING PROTECTION SYSTEM Lightning Protection System (LPS) installation is not done. 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 asap. Page 4 of 12
FINDING E - 7 SUBSTATION ROOM Lead acid battery terminals are filled with rust and left open. Lead acid battery terminals must be covered/capped and rust must be cleaned. P3 FINDING E - 8 SUBSTATION ROOM Wooden cable channel/ducts are used for power cable distribution. Metal type cable tray (perforated one is preferred) shall be used for distributing power cables P3 FINDING E - 9 Cable channels are filled with fluffs (Lint/ dust). Cable channels must be kept neat and clean; these must be sealed properly thus no scope of ingression of fluffs. Page 5 of 12
FINDING E - 10 Power Cables are hanging without proper support. Power cables must be supported by cable tray (ladder- where needed). Outdoor arrangement must be covered. FINDING E - 11 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 - 12 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. Page 6 of 12
FINDING E - 13 Power cables entering or exiting from Distribution board/ panel are not properly fixed. Power cables entering or exiting from distribution board/panel must be fixed through Panel base/top plate using proper sized cable glands (metal/ PVC). P3 FINDING E - 14 Generator output cables (laid on floor) are not protected and supported Service cables from generator must be supported at its own breaker's terminal and with cable tray. FINDING E - 15 Magnetic ballast found inside the cable channel. Magnetic ballast shall not be kept inside of cable channel. Page 7 of 12
FINDING E - 16 MCCBs are not adjusted per load demand. All the MCCBs must be adjusted per cable current ampacity/load current; if adjustment is not possible, replacement will be the only way. FINDING E - 17 Panel doors are not connected with earth. All metal installation which are part of electrical system must be connected to earth to avoid electrical shock or electrocution. FINDING E - 18 Phase barrier/separators are missing in MCCBs Phases must be separated by insulator (a rubber type no-flammable materials shall be used for it) Page 8 of 12
FINDING E - 19 Distribution Board's top/bottom are not properly sealed (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 - 20 Multiple cables (came from different electrical consumers) terminated at MCCB terminals Each electrical circuit must be terminated at single MCB/MCCB terminals. FINDING E - 21 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 (LT panel / MDB / DB / SDB/ other manual operated machineries) must be ensured. Page 9 of 12
FINDING E - 22 Loop connection has been used powering multiple circuits through MCB/ MCCBs. Loop Connections shall be removed from entire electrical system. FINDING E - 23 Multiple cables connected in the MCCB terminal bus bar through single lugs. Each cable must be connected in the MCCB terminal / bus bar through single lugs. FINDING E - 24 Instruction for CPR (Cardiopulmonary Resuscitation) or Electrical shock restoration is not present CPR instruction shall be hanged near all electrical installations (LT panel, MDB, FDB, DB, SDB) at visible location Page 10 of 12
FINDING E - 25 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 - 26 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 per CB response and circuit's power demand. FINDING E - 27 EARTHING SYSTEM 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. Page 11 of 12
FINDING E - 28 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. FINDING NO: E - 29 BOILER & COMPRESSOR Electric boiler. motor has inadequate /no earthing connection Each electrical installation must have proper earth connection. REMEDIATION TIME FRAME: 1 MONTH FINDING NO: E - 30 GENERATOR ROOM Generator Body and neutral has no earth connection. Adequate earthing connection for generator/ transformer body and generator neutral (consult with your generator supplier) shall be ensured. Page 12 of 12