ELECTRICAL SAFETY INSPECTION REPORT MTM...

Factory ListMTM Garments Ltd.

Inspected by: Hemlal DahalReport Generated by: Hemlal Dahal

Inspected on 01 November 2015

ELECTRICAL SAFETY INSPECTION REPORT

15934/16004, Chanpara, Medical Road, Uttarkhan, Dhaka, Bangladesh.

MTM Garments Ltd.

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1MTM Garments Ltd.

SUMMARY

The Factory was surveyed for electrical safety by Woosun Energy and Construction Co., Ltd. (WEC).The purpose of the survey was to identify significant electrical safety issues and to providerecommendations for remediation based on applicable standards specified by the Accord.The scope of this initial electrical safety inspection was limited to the review and identification of majorelectrical safety issues. The inspection did not include identification of minor deficiencies, which wouldbe further addressed as part of follow up inspections.

MTM Garments Ltd. factory is established in 1 building plus utility buildings, and is owned by thefactory. The main building is a 2 storied structure comprising the concrete portion in the front foroffices and substation, and steel framed structure at the rear for production. There are two othersingle storied sheds used by the factory. One of the sheds is a rented concrete structureaccommodating the dining and daycare facilities while the other shed is a makeshift hut housingThe factory was constructed in 2013, production started in 2014, and during the inspection thenumber of workers was approximately 400.

Table below summarizes the major electrical safety issues identified during the inspection.Recommendations have been provided to address each issue. The implementation schedule shallbe 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 theAccord for approval.

7

FINDING NO.CATEGORY:

P-28 Weeks


P-24 Weeks


P-22 Weeks

PRIORITY:

FINDINGS AND RECOMMENDATIONS:

REMEDIATION TIMEFRAME:

E-1

PRIORITY:REMEDIATION TIMEFRAME:

E-2

Design Drawings and RecordsFINDING:Electrical as-built Single Line Diagram (SLD) is unavailable.

RECOMMENDATION:Have a qualified engineer create an as-built electrical SLD mentioning all the required information, and get itreviewed & approved by Accord.

E-3


Design Drawings and RecordsFINDING:Thermographic scanning of the entire electrical system has not been tested and recorded.

RECOMMENDATION:Thermographic scanning for the entire electrical system must be performed on a bi-annual basis andrecorded.

Design Drawings and RecordsFINDING:Instruction for CPR (Cardiopulmonary Resuscitation) or Electrical shock restoration is not present in most ofthe electrical facilities.

RECOMMENDATION:Hang this first aid and CPR instructions near all electrical equipment (LT panel, MDB, FDB, DB, SDB) on avisible location.

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MTM Garments Ltd. 2


P-24 Weeks


P-36 Weeks


P-28 Weeks



Service LineFINDING:Excess HT cables coiled and kept haphazardly at theback of HT panel.

RECOMMENDATION:HT cable bends must be avoided such that no stress isimposed on the insulation of the cable. Rearrange thecables using cable tray/ladder and latch the additionalcable with the tray/ladder. Alternatively, retrieve theexcess cable back on the ground and lay it undergroundas per prescribed standards for cable safety andprotection.

Maintenance Manager or Safety Officer must keep accurate records and ensure that they reflect actual factoryday to day operations.

PRIORITY:

E-5


E-6

E-4

Haphazard HT cable coil

Service Line

HT cable laid over the LT cables and cable trench is leftopen.

RECOMMENDATION:

HT & LT cables laid mixed-up

FINDING:

Lay the HT cable and LT cables separately on cabletray/support and provide covers for the trench (made ofnon combustible material preferably metal) to protect thecables’ insulation from physical damage as well asprevent entering debris, dust and lint.

PRIORITY:

Design Drawings and RecordsFINDING:Maintenance records don’t reflect actual factory circumstances; the records do not detail out all the electricalequipment/machinery.

RECOMMENDATION:

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MTM Garments Ltd. 3


P-12 Weeks


P-14 Weeks


P-24 Weeks

PRIORITY:

E-9

FINDING:Generator exhaust pipe terminated inside the generatorroom.

Exhaust pipe terminated inside room

RECOMMENDATION:Extend the existing exhaust pipe out of the generatorroom to ensure the exhaust fumes can leave theenclosure.

E-7

E-8

Generator


Batteries on floor

Empty oil cup

Generator

Batteries are laid directly on concrete floor.

RECOMMENDATION:

FINDING:

Generator Battery must be placed and encased on thebattery stand made of non-combustible material (may besteel fabricated).

TransformerFINDING:Oil cup of transformer breather is empty.

RECOMMENDATION:Ensure the breather oil cup is filled with transformer oilto the required level as instructed by the manufacturer.



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MTM Garments Ltd. 4


P-12 Weeks


P-11 Week


P-28 Weeks

E-10


Generator

Ensure two dedicated and distinct earthing connectionsfor generator body (consult with your generatorsupplier).

Generator body not earthed

GeneratorFINDING:Battery terminals are left open.

RECOMMENDATION:


Provide insulating cover to the battery terminal toprevent short circuit due to falling foreign metal on it.

Open battery terminals

Distribution Boards & PanelsFINDING:

FINDING:Generator body is not provided with earthingterminal/connection.

RECOMMENDATION:


Gland holes left open

E-11

E-12

Gland holes in panel left open (Typical issue).

RECOMMENDATION:Provide cable gland according to the respective cablesize for cable entry and exit so that the cables are notstressed on the sharp edges of the hole of panels.Provide covers (of non-combustible material) if anyadditional gap remains after installing cable glands.

PRIORITY:

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MTM Garments Ltd. 5


P-11 Week


P-11 Week


P-14 Weeks

RECOMMENDATION:Identify the cause of hot spots and take actionaccordingly. Arrange periodic inspection & thermal scanto identify the overloading, loose connection, unbalancedload which may cause the excessive heat-rise.

Distribution Boards & Panels

High temperature detected at cable termination point ofcontrol/protective devices inside PFI panel.


Hot spot at MCCB termination bar

E-14


High temperature

Distribution Boards & PanelsFINDING:Hot spot detected at outgoing cable of MCCB insideMDB-4 panel, 64 degree Celsius.

PRIORITY:


E-13

Live MCCB

RECOMMENDATION:Identify the cause of high temperature and take actionaccordingly. Arrange periodic inspection & thermal scanto identify the overloading, loose connection, unbalancedload which may cause the excessive heat-rise.

FINDING:Control device mounted on wall without enclosure.


RECOMMENDATION:Protective devices should be encased in metal casingmade of 20 SWG thickness metal sheets or in astandard enclosure supplied by manufacturer to preventingression of dust, lint and yarn.

E-15

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MTM Garments Ltd. 6


P-11 Week


P-26 Weeks


P-36 Weeks

Mismatch in incoming and outgoing cables (size) atMCCB inside MDB 4 panel board.



No base plate and compression glands are installed atthe bottom (cable entry/exit point) of panel (Typicalissue).

RECOMMENDATION:Provide panel base plate and cable gland according tothe respective cable size for cable entry and exit so thatthe cables are not stressed at the termination point andon the sharp edges of the hole of panels.

Mismatched terminating cables/MCCB


Multiple cable termination




Cables must be terminated using individual lugaccording to the respective cable size and shall beterminated on busbar individually.

No base plate and cable glands

E-16

E-17

E-18

Incoming and outgoing cables terminating at MCCBmust be of same size. Check the connected load andprovide respective cable sizes and appropriately ratedMCCB. Replacing the existing MCCB if required.

RECOMMENDATION:

FINDING:Multiple cables terminated using single lug at the busbar(Typical issue).

RECOMMENDATION:

FINDING:

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MTM Garments Ltd. 7


P-14 Weeks


P-24 Weeks


P-14 Weeks

FINDING:Panel doors not connected with earth bond (Typicalissue).



Distribution Boards & PanelsFINDING:Phase barrier/separators between different phases arenot installed (Typical issue).

RECOMMENDATION:Provide earth connection for body and doors of metallicdistribution boards using green cables preferably braidso that the metallic door remains at zero potential all thetime.

Panel body not earthed

No door earth bond

Electrical panel enclosure or body not connected toearth (Typical issue).

No phase separators

RECOMMENDATION:Panel enclosure including its door must be connected toearth using green cables preferably earth braid so thatthe metallic door remains at zero potential all the time.Practice earth continuity test to insure earth continuity topanel and loads enclosure and keep record.

E-20

E-21

PRIORITY:


PRIORITY:

RECOMMENDATION:Phase barriers between different phases must beinstalled to avoid arc flashing. Standard separatorsprovided by the MCCB manufacturer must be used.

E-19Distribution Boards & Panels


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MTM Garments Ltd. 8


P-24 Weeks


P-26 Weeks


P-36 Weeks

Panel labels & circuit diagram not provided

Distribution Boards & PanelsFINDING:Wires/cables not drawn swiftly/neatly inside panel(Typical issue).

RECOMMENDATION:

Cable & Cable SupportFINDING:


Organize all the power cables or wires securely andneatly. Install slotted PVC channels for routing wires andcables inside the panel.

Wires not drawn swiftly


E-22

E-23

Cables must be drawn, arranged swiftly & latched firmlyat a regular interval on adequate support (tray/ladder).The cable trench must be covered with a suitable coverpreferably made of steel checkered plate.

REMEDIATION TIMEFRAME:Cables disorganized and not protected


Cables in electrical room trench laid haphazardly andnot protected (open).

RECOMMENDATION:

Provide/hang circuit diagrams of panels/boards in everypanel. (Provide identification and warning notice in frontevery electrical panel. Include voltage level on the noticeand any precautions if required for special case).

No identification and circuit diagrams on control panels(Typical issue).

PRIORITY:

E-24

RECOMMENDATION:

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MTM Garments Ltd. 9


P-28 Weeks


P-26 Weeks


P-16 Weeks

PRIORITY:

Cable & Cable SupportFINDING:

Generator output cables not supported

Cable & Cable SupportFINDING:Cable raceways are open; excessive combustiblematerials (dust/lint/yarn) deposit on cable and insideraceway (Typical issue).


RECOMMENDATION:


E-25

Cables not protected

Cable & Cable SupportFINDING:Generator output cables not supported/protected andlaid directly on concrete floor and improper trench.

Thoroughly clean the combustible materials to avoid firehazard and maintain a periodic cleaning schedule.Provide appropriate cover on the top and ends toprevent further ingress.

Open cable raceway; dust accumulated excessively


Cable passed through permanent wall not protected.

RECOMMENDATION:Cables must be encased in steel pipe (conduit) whenpassed through the wall and seal the unused openingsafter the passage of conduit by fire rated materials.

E-26

E-27

RECOMMENDATION:Where possible, route all the power cable throughoverhead cable tray otherwise provide covered cabletray to support and protect the cables from physicaldamage.

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MTM Garments Ltd. 10


P-12 Weeks


P-24 Weeks


P-24 Weeks

Wiring/FittingsFINDING:Lighting and lighting circuits in storage area.

RECOMMENDATION:

Lighting in storage area

EarthingFINDING:Earth pits are not identifiable.

Install the MET in a metal casing and mount it at least 18inches above the floor to make it free from dust and wetfloor.

Open METPRIORITY:

No identification of pits

Earthing


Main earthing terminal (MET) not encased.



Clearly identify each earth pit, and mark it for periodicmaintenance purposes.

Electrical circuits & fittings installed inside storage roomsmust be removed as required by fire safety regulationsin order to reduce the risk of catching fire due to shortcircuit.

RECOMMENDATION:

FINDING:

PRIORITY:

E-30

RECOMMENDATION:

E-28

E-29

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P-14 Weeks


P-18 Weeks

Transformer not adequately earthed

Lightning ProtectionFINDING:Lightning Protection System (LPS) needed but has notbeen installed.

PRIORITY:

Lightning protection not provided

RECOMMENDATION:Transformer body should be earthed with two separateand distinct connections to earth with better earthcontinuity.

E-32

RECOMMENDATION:Design and Install LPS for your factory; Factory have tosubmit LPS design to Accord before starting installation.


E-31Earthing

FINDING:

PRIORITY:

Transformer body connected to one earth connection.


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