ELECTRICAL SAFETY INSPECTION REPORT - …electrical safety inspection report liberty fashion wears...

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ELECTRICAL SAFETY INSPECTION REPORT

LIBERTY FASHION WEARS LTD.

PLOT 101, MOUZA, TENGURI, ZIRANI, BAZAR, SAVAR, DHAKA

GPS Coordinates: 23.994748 N, 90.252709 E

Inspected by : Banna Kasemi & Jahidur Rahman Report Approved by : Rob Wayss

Inspected on: March 22, 2017

of 24 Liberty Fashion Wears Ltd.

ELECTRICAL SAFETY INSPECTION REPORT

LIBERTY FASHION WEARS LTD.

PLOT: 101, MOUZA, TENGURI, ZIRANI, BAZAR, SAVAR, DHAKA

1. INTRODUCTION

The Factory was inspected for electrical safety by Stichting Bangladesh Accord

Foundation. The purpose of the initial electrical safety inspection was to identify

significant electrical safety issues and to provide recommendations for remediation

based on applicable standards specified by the Accord.

Electrical Safety inspection 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.

2. LIMITATIONS

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.

3. DEFINITION

3.1. TIME FRAME

The amount of time being allocated based on the remediation work volume of the

electrical issues considering the feasibility and ideal status of materials, capital and

working condition. Criticality and priority level of the issue is not taken into


consideration. It is bound only for the particular finding unless mentioned ‘typical’, shall

include the whole typical findings.

3.2. PRIORITY LEVEL

3.2.1 Electrical issues related to code violation and/or non-conformity with codes possessing immediate fire hazard, direct threat to human safety, shall be considered as P1 Level of priority. The execution of remediation works shall commence immediately without compromising with any other issues and must strictly complete within the allocated remediation time frame. It shall include only the critical issues

3.2.2 Electrical issues related to code violation and/or non-conformity with codes, protection of electrical switchgears and equipment, spatial arrangement and location of switchgears and equipment, design and drawings, shall be considered as P2 Level of priority. The execution of remediation work of P2 shall commence along with or soon after the P1 level remediation work has commenced. It shall include only the moderately-critical issues.

3.2.3 Electrical issues related to violation of code and/or non-conformity with codes, workmanship of operation and maintenance and obsolete technology of electrical system, shall be considered as P3 Level of priority. The execution of remediation work of P3 shall commence along with or soon after the P2 level remediation work has commenced. It shall include only the non-critical issues.

3.2.4 It doesn’t take into consideration the remediation time frame and feasibility of remediation. It doesn’t take into consideration the capital, materials and working environment.

4. GENERAL BUILDING INFORMATION

1. Factory Name : LIBERTY FASHION WEARS LTD.

2. Factory Address : PLOT 101, MOUZA TENGURI, ZIRANI, BAZAR, SAVAR, DHAKA

3. Accord ID : 10048

4. Inspection participants

: Md. Masud Rana

Electrical Engineer

Tel: +8801725365777

Email: [email protected]

5. BUILDING DATA

A. General

Liberty Fashion Wears Ltd. (LFWL) factory is comprised of 29 building structures (RCC

constructions and pre-fabricated steel constructions). The list of all structures is

provided in Figure 1 below.


Figure 1: List of all structures of LFWL premises.

FLOOR LAYOUT INFORMATION

The factory has a total floor area of approx. 436,075 sq. ft. Figure 2 shows the layout

plan of the factory premises. Figure 3 shows floor layout plan of the 1st floor (sewing

section).


Figure 2: Factory layout plan

Figure 3: Floor layout plan (for building 26 in Figure 1)

ELECTRICAL SYSTEM & UTILITY INSTALLATION INFORMATION

Liberty Fashion Wears Ltd factory premise is connected to grid (BREB) supply, which

is the main source of power supply tapped from 11kV OH line and delivered through

HT cable, protected by 11 kV DO fuse and 630A VCB with an HT switchgear panel.


The 11kV supply is stepped down by 1250 kVA x 1 no, 11/0.415kV, 3 phase power

transformer installed in substation located in ground floor of the utility building

(Building No.28). Electrical system and utility installation information at a glance:

Query Information Remarks

Grid Electricity Supplier REB

Sanctioned Load 700 kW

Number of Transformers 1

Capacity of each transformer 1250 kVA

Transformer location in the

factory

Substation located in utility building

isolated from production building

Building No.28

in Fig. 1

Transformer owned by factory Yes, and maintained by factory

HT switch gear HT switchgear is located near the

transformer

Number of Generator 2

Capacity of each Generator 1x1000 kVA, 1x400 kVA Diesel fuel

Generator location in the factory Utility building isolated from

production building

Building No.28

and 29 in Fig. 1

Number of Compressors 5

Capacity of each Compressor 1x22 kW, 3x12 kW, 1x Unknown

capacity

Number of Boilers 3

Capacity of each Boilers 2 ton (gas), 3 ton (gas and furnace oil),

5 ton (not in operation)

Total no. of LT panel 1

Total no. of Distribution boards 21

Power distribution system All through Cabling using cable tray,

ladder, channel, duct.

Illumination system Tube light shed

Number of manual changeovers 3

Number of synchronizer N/A

Number of Automatic transfer

switch 1

Substation room location Utility building isolated from

production building

Building No.28

in Fig. 1


B. ELECTRICAL PRACTICES IN OPERATION AND MAINTENANCE

Maintenance and Operations are done by in-house electrical and maintenance

team of the tenant factory. Maintenance of major equipment like transformers,

generators, and boilers are sometimes outsourced to service centers.

There were no maintenance electrical design & drawings, programs, logs and

maintenance schedules of the factory’s electrical facilities.

6. LIGHTNING PROTECTION RISK ASSESSMENT

A. For RCC building with RCC roof of structure #26 of Figure 1.

Calculation Of Risk Index Factor (BNBC 2006) Index A Use of Structure

Small and medium size factories, workshops and laboratories

6

Index B Type of Construction Reinforced concrete with nonmetal roof 2

Index C Contents or Consequential Effects

Industrial buildings with especially susceptible contents 5

Index D Degree of Isolation Structure located in an area with a few other structures or trees of similar height 5

Index E Type of Terrain Flat terrain at any level 2

Index F Height of Structure 9 – 15 m 4

Index G Lightning Prevalence Over 21 21

Total Risk Index of the building 45

Requirement of installing LPS Yes

B. For shed buildings (structure#11 of Figure 1)

Calculation Of Risk Index Factor (BNBC 2006) Index A Use of Structure

Small and medium size factories, workshops and laboratories

6

Index B Type of Construction Steel frame encased or reinforced concrete with metal roof 5

Index C Contents or Consequential Effects

Industrial buildings with especially susceptible contents 5

Index D Degree of Isolation Structure located in an area with a few other structures or trees of similar height 5

Index E Type of Terrain Flat terrain at any level 2

Index F Height of Structure 9 – 15 m 4

Index G Lightning Prevalence Over 21 21

Total Risk Index of the building 48

Requirement of installing LPS Yes

It is necessary to design and install LPS.


7. 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.

FINDING NO: E - 1

CATEGORY: DOCUMENTATION

FINDING:

Electrical Single Line Diagram (SLD) is unavailable for the factory.

RECOMMENDATION:

As built Electrical SLD must be prepared and it must include the factory's entire electrical installation information.

PRIORITY: P2

REMEDIATION TIME FRAME: 2 MONTHS

FINDING NO: E - 2

CATEGORY: LIGHTNING PROTECTION SYSTEM

FINDING:

Lightning Protection System (LPS) is not installed.

RECOMMENDATION:

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.

PRIORITY: P1



FINDING NO: E - 3

CATEGORY: SUBSTATION ROOM

FINDING:

Inadequate working space around transformer for performing maintenance work.

RECOMMENDATION:

Minimum working space (1.07m) around the transformer (and related electrical installations) must be maintained.

PRIORITY: P2


FINDING NO: E - 4


FINDING:

Transformer Arcing horn/s are missing/not installed yet.

RECOMMENDATION:

Transformer arcing horn must be installed with proper alignment.

PRIORITY: P2

REMEDIATION TIME FRAME: 1 MONTH

FINDING NO: E - 5


FINDING:

Transformer Silica gel is discolored.

RECOMMENDATION:

Silica gel shall be changed; or reuse can be done, if color regains after sundry.

PRIORITY: P2



FINDING NO: E - 6


FINDING:

Oil leakage from transformer has been observed.

RECOMMENDATION:

Oil leakage from transformer must be stopped and top of transformer must also be kept clean.

PRIORITY: P2


FINDING NO: E - 7


FINDING:

No working separation between LT (Low Tension) panel/s and HT (High Tension) unit/s (Transformer, HT switchgear).

RECOMMENDATION:

A working separation between LT and HT must be ensured. A brick wall will do it; and adequate working clearance (1.07m) and ventilation must be ensured.

PRIORITY: P1


FINDING NO: E - 8

CATEGORY: GENERATOR ROOM

FINDING:

Generator output cables (laid on floor) are not protected and supported.

RECOMMENDATION:

Service cables from generator must be supported at its own breaker's terminal and with cable tray.

PRIORITY: P2



FINDING NO: E - 9

CATEGORY: GENERATOR ROOM

FINDING:

Lead acid battery terminals are left open.

RECOMMENDATION:

Lead acid battery terminals must be covered/capped and rust must be checked and cleaned.

PRIORITY: P3


FINDING NO: E - 10


FINDING:

11kV power cables laid on substation room floor which makes obstacle in the working areas.

RECOMMENDATION:

HT cables shall be rerouted avoiding obstacles in the working areas of electrical installations.

PRIORITY: P2


FINDING NO: E - 11

CATEGORY: WIRING SYSTEM

FINDING:

Power cable is buried in the concrete floor.

RECOMMENDATION:

Power cables must not be buried in the concrete. A cable trench shall be constructed or routing power cables.

PRIORITY: P2



FINDING NO: E - 12

CATEGORY: DISTRIBUTION BOARD/PANEL

FINDING:

Distribution boards have no clear identification markings.

RECOMMENDATION:

All distribution boards, switchboards, sub main boards and switches shall be marked clearly for proper identification.

PRIORITY: P3


FINDING NO: E - 13


FINDING:

Panel base plates are removed to allow cable entry.

RECOMMENDATION:

Panel base plates must be installed, and in place at all times, and cables entering panel must be firmly fixed with cable gland.

PRIORITY: P2


FINDING NO: E - 14


FINDING:

Electrical distribution box/panels are full of fluffs (lint/dirt).

RECOMMENDATION:

Each electrical distribution board/panel must be properly sealed to avoid ingression of fluffs; but an adequate ventilation system must also be ensured.

PRIORITY: P2



FINDING NO: E - 15

CATEGORY: EARTHING SYSTEM

FINDING:

Earth lead cable/Earth Continuity Conductor size is inadequate/undersize

RECOMMENDATION:

Earth lead cable/ Earth Continuity Conductor (ECC) must be resized according to BNBC-2006 article 2.8, Table 8.2.11. Cable size shall be selected depending on the phase cables' size.

PRIORITY: P2

REMEDIATION TIME FRAME: 2

MONTHS

FINDING NO: E - 16


FINDING:

Power bus bars are installed congested; and power cables touch other phase bus bar/s.

RECOMMENDATION:

Power bus bar must be installed with adequate clearance between two bars. (not less than 2-3 inch for LV depends on panel connected load) Cables must not touch opposite bus bars in any case.

PRIORITY: P2


FINDING NO: E - 17


FINDING:

Phase barrier/separators are missing in MCCBs.

RECOMMENDATION:

Phases must be separated by insulator (a rubber type, no-flammable materials shall be used for it).

PRIORITY: P3



FINDING NO: E - 18


FINDING:

MCCBs are not adjusted per load demand.

RECOMMENDATION:

All the MCCBs must be adjusted per connected load and connected cable current ampacity/load current; if adjustment is not possible, replacement is required.

PRIORITY: P1


FINDING NO: E - 19


FINDING:

Panel/distribution boxes are inaccessible or cannot be opened to perform maintenance work.

RECOMMENDATION:

Each electrical distribution board/panel must be easily accessible.

PRIORITY: P1


FINDING NO: E - 20


FINDING:

Cables inside distribution board are disorganized.

RECOMMENDATION:

Cables inside each distribution board shall be well organized to avoid misleading during any troubleshooting.

PRIORITY: P3


MONTHS


FINDING NO: E - 21


FINDING:

Panel doors are not connected with earth.

RECOMMENDATION:

All metal installation which are part of electrical system must be connected to earth to avoid electrical shock or electrocution.

PRIORITY: P2


FINDING NO: E - 22


FINDING:

Power cables are bent excessively.

RECOMMENDATION:

Power cables must be installed as straight as possible. The conductor shall not be bent to a radius less than 8 times the overall diameter for non-shielded conductors or 12 times the overall diameter for shielded or lead-covered conductors. For multi-conductor or multiplexed single-conductor cables having individually shielded conductors, the minimum bending radius is 12 times the diameter of the individually shielded conductors or 7 times the overall diameter, whichever is greater. PRIORITY: P2


FINDING NO: E - 23


FINDING:

Inadequate working space around (or in front of) board/panels and access to the board/panels is obstructed.

RECOMMENDATION:

At least 1.07 meter (or equal to the width of board/panel, whichever is higher) working clearance must be maintained in front of each electrical board/panel. Door opening shall be at least 90 degrees.

PRIORITY: P3



FINDING NO: E - 24


FINDING:

Multiple cables (came from different electrical consumers) terminated at MCCB terminals/ Busbar.

RECOMMENDATION:

Each electrical circuit must be terminated at single MCB/MCCB terminals.

PRIORITY: P2


FINDING NO: E - 25


FINDING:

No/inadequate rubber (insulation) mat at the working area of distribution board/panel.

RECOMMENDATION:

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.

PRIORITY: P3


FINDING NO: E - 26


FINDING:

Loop connection has been used powering multiple circuits through MCB/MCCBs.

RECOMMENDATION:

No loop connection shall be used; each single cable shall be terminated using cable lug (flat/I) at each terminal. Combo bus bar may be used (but incoming cable size must meet the rated capacity)

PRIORITY: P2



FINDING NO: E - 27


FINDING:

MCCB/MCB is installed without any enclosure.

RECOMMENDATION:

Each MCCB/MCB must be enclosed by proper type material. the material must be 18 SWG graded or thicker.

PRIORITY: P2


FINDING NO: E - 28


FINDING:

Instruction for CPR (Cardiopulmonary Resuscitation) or Electrical shock restoration is not present.

RECOMMENDATION:

CPR instruction shall be hung near all electrical installations (LT panel, MDB, FDB, DB, SDB) at visible location.

PRIORITY: P3


FINDING NO: E - 29


FINDING:

Circuit is drawn from bus bar without any protective means.

RECOMMENDATION:

Each electrical circuit must be drawn from distribution board busbar using a proper type protection arrangement (MCCB/MCB).

PRIORITY: P2


MONTHS


FINDING NO: E - 30


FINDING:

Cable connected to busbar/MCCB/MCB terminal without cable lug.

RECOMMENDATION:

Each electrical circuit must be terminated at single busbar/MCB/MCCB terminals using cable lug.

PRIORITY: P2


FINDING NO: E - 31


FINDING:

Burning signs are visible at the terminal

RECOMMENDATION:

Need to check the connected load, Check the thermal issue. Need to replace the burnt cable and lugs immediately.

PRIORITY: P1


FINDING NO: E - 32

CATEGORY: CABLE & CABLE SUPPORTS

FINDING:

Power Cables are hanging without proper support.

RECOMMENDATION:

Power cables must be supported by cable tray (ladder- where needed). Outdoor arrangement must be covered.

PRIORITY: P2



FINDING NO: E - 33


FINDING:

Cables in service are joined (splicing) between terminations.

RECOMMENDATION:

Splicing in the power cables shall be avoided; in unavoidable cases splicing, must be made following proper guidance.

PRIORITY: P2


FINDING NO: E - 34

CATEGORY: CABLE & CABLE SUPPORTS

FINDING:

Excess cables coiled and kept unsupported at the back of panel.

RECOMMENDATION:

Unsupported/unprotected power cables must be supported/protected by cable tray/ladders (If it is HT cable, rearrangement shall be made rather than trimming)

PRIORITY: P3


FINDING NO: E - 35


FINDING:

Electrical power cables are not identified properly.

RECOMMENDATION:

Proper identification (by using cable marker, tag, colored heat shrink) shall be done on major power cables used in the system according to SLD.

PRIORITY: P3



FINDING NO: E - 36


FINDING:

Magnetic ballast found inside the cable channel/duct.

RECOMMENDATION:

Magnetic ballast shall not be kept inside of cable channel/duct.

PRIORITY: P2


FINDING NO: E - 37


FINDING:

MCCB/MCB inside panel board is not fixed at base.

RECOMMENDATION:

MCCB/MCB must be fixed at base with proper support.

PRIORITY: P2


FINDING NO: E - 38


FINDING:

Distribution Board's top/bottom is left open (typical issue).

RECOMMENDATION:

Each electrical distribution board/panel must be properly sealed to avoid ingression of fluffs; but an adequate ventilation system must also be ensured. Gland shall be used, where required.

PRIORITY: P2



FINDING NO: E - 39


FINDING:

Connection is taken from broken power socket without plug.

RECOMMENDATION:

In case of taking any connection from power source, appropriate plug should be used.

PRIORITY: P2


FINDING NO: E - 40


FINDING:

Hazardous lights in store room / storage areas are uncovered.

RECOMMENDATION:

Hazardous lights in store room / storage areas shall be covered by proper type material; or non-hazardous lights shall be installed in these areas.

PRIORITY: P2


FINDING NO: E - 41


FINDING:

Manually operated machines (may have chance to be touched by operator/user) have no earth connection.

RECOMMENDATION:

Manually operated each 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.

PRIORITY: P1



FINDING NO: E - 42

CATEGORY: TESTING & PERIODIC MAINTENANCE

FINDING:

Uninsulated electrical tools are used by maintenance personnel in the factory.

RECOMMENDATION:

For maintenance purposes, all the electrical tools shall be properly insulated and these insulations shall be checked periodically.

PRIORITY: P2


FINDING NO: E - 43


FINDING:

Hot Spots were observed at several points.

RECOMMENDATION:

Hot spots must be eliminated from entire electrical system and shall be always carried forward.

PRIORITY: P1


FINDING NO: E - 44


FINDING:

Electric safety training program has not initiated/conducted.

RECOMMENDATION:

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 the overall electrical safety situation for the staffs.

PRIORITY: P3



FINDING NO: E - 45


FINDING:

Earth pits are not identifiable.

RECOMMENDATION:

Each earth pit shall be properly identifiable and marked for periodic maintenance.

PRIORITY: P3


FINDING NO: E - 46


FINDING:

Insulation resistance test of electrical power cables is not performed.

RECOMMENDATION:

Insulation resistance test of all the cables (you can avoid less than 25 sq.mm) must be performed once every 2 years and recorded (this requires a complete power shut off).

PRIORITY: P2


FINDING NO: E - 47


FINDING:

Earth Pit resistance record is unavailable.

RECOMMENDATION:

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.

PRIORITY: P2



FINDING NO: E - 48


FINDING:

Thermography scanning report is unavailable.

RECOMMENDATION:

Thermography survey must be done and recorded at least twice in a year.

PRIORITY: P2


FINDING NO: E - 49


FINDING:

Transformer Oil Test (dielectric strength test) report is unavailable.

RECOMMENDATION:

Transformer oil test (dielectric strength test for oil) shall be done once in a year.

PRIORITY: P2


FINDING NO: E - 50

CATEGORY: DOCUMENTATION

FINDING:

There is no programmed schedule for periodical inspection & testing of electrical equipment.

RECOMMENDATION:

An electrical maintenance program shall be prepared which will include inspections and testing of the electrical systems (preventive and proactive)

PRIORITY: P3


ELECTRICAL SAFETY INSPECTION REPORT - …electrical safety inspection report liberty fashion wears...

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