ELECTRICAL SAFETY INSPECTION...

ELECTRICAL SAFETY INSPECTION REPORT

AHSIAR FASHIONS LTD

Shovapur, Rajfulbaria, Savar, Dhaka, Bangladesh

Factory List:

1. Ahsiar Fashions Ltd.

Inspected by: Hemlal Dahal

Report Generated by: Hemlal Dahal

Inspected on March 6th 2015

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Ahsiar Fashions Ltd.

SUMMARY

Ahsiar Fashions Ltd. factory is established in a 3-storied (G+2) owned building at Shovapur, Savar, Dhaka.

The ground and 1st floors of the building are of similar size, and the 2

nd floor is much smaller. The building

was constructed as industrial structure in 2007 and the factory started production in 2012. The factory had

approximately 370 workers at the time of inspection.

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 provide recommendations 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 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.

Table below summarizes the major electrical safety issues identified during the inspection.

Recommendations have been provided to address each issue.

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.

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FINDINGS AND RECOMMENDATIONS

FINDING NO: E- 1

CATEGORY: DESIGN, DRAWINGS & RECORDS

FINDING: Electrical Single Line Diagram (SLD) has inadequate information which has no effectiveness.

RECOMMENDATION: Prepare SLD more informative thus anyone can understand it, and, get it reviewed by Accord.

PRIORITY: P2

REMEDIATION TIMEFRAME: 12 WEEKS

FINDING NO: E- 2


FINDING: Thermographic scanning of the entire electrical system has not been performed.

RECOMMENDATION: Thermographic scanning of the entire electrical system must be performed twice in a year.

PRIORITY: P2


FINDING NO: E- 3


FINDING: Insulation resistance test of electrical equipment is not performed.

RECOMMENDATION: Insulation resistance test of all power cables (up to Floor distribution board or SDB) must be performed in a periodic manner and recorded.

PRIORITY: P2


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FINDING NO: E- 4


FINDING: Earth Pit resistance record is unavailable.

RECOMMENDATION: Record earth pit resistances for all the earth pits, and do it once a year.

PRIORITY: P2


FINDING NO: E- 5


FINDING: Electric safety program is not initiated.

RECOMMENDATION: Electrical safety training and awareness program for the electrical personnel and workers must be initiated and recorded.

PRIORITY: P2


FINDING NO: E- 6


FINDING: Instruction for CPR (Cardiopulmonary Resuscitation) or Electrical shock restoration is missing.

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

PRIORITY: P2


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FINDING NO: E- 7


FINDING:

Maintenance records are unavailable for total electrical installations.

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

PRIORITY: P2


FINDING NO: E- 8

CATEGORY: LIGHTNING PROTECTION & EARTH

FINDING: Lightning Protection System (LPS) needed but has not been installed.

RECOMMENDATION: Design and install Lightning Protection System (LPS) in the factory; the LPS designs must be submitted to Accord before starting installation.

PRIORITY: P1


FINDING NO: E- 9

Aerial service cables not supported

CATEGORY: SERVICE LINE

FINDING:

Overhead aerial service cables are not supported (typical issue).

RECOMMENDATION: Overhead service cables must be supported by suitable means from the transformer to the building (must be supported on catenary wire).

PRIORITY: P2


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FINDING NO: E- 10

Service cable not supported on wall

CATEGORY: SERVICE LINE

FINDING: Service cables drawn loose on building wall and not supported (typical issue).

RECOMMENDATION: Service cables drawn along wall must be supported on cable tray, clamping at regular intervals.

PRIORITY: P2


FINDING NO: E- 11

Generator room not identified

CATEGORY: GENERATOR ROOM

FINDING: No identification and signs for generator room including high Voltage danger signs.

RECOMMENDATION: Every equipment & enclosure within which a nominal voltage exceeding 230 volts exits must have a visible warning notice (of durable material) mentioning maximum voltage and must be identified clearly.

PRIORITY: P2


FINDING NO: E- 12

Inadequate working clearance


FINDING:

Inadequate working clearance around the generators.

RECOMMENDATION: Working clearance around each generator should be 1.07m. If multiple generators are installed then the gap between two generators must be equal to the width of bigger generator.

PRIORITY: P1


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FINDING NO: E- 13

Single frame earthing looped for panel too


FINDING: Inadequate generator frame earthing (typical issue).

RECOMMENDATION: Ensure minimum two earthing connection for generator body (consult with your generator supplier).

PRIORITY: P1

REMEDIATION TIMEFRAME: 1 WEEK

FINDING NO: E- 14

Output cables not supported


FINDING: Generator output cables (laid on floor) are not protected and supported (typical issue).

RECOMMENDATION: Install a cable tray/ladder or duct or cable trench with checkered plate cover on floor, at safe location ranging from generator terminal (output) box to panel to support the generator output cables. Do not make any arrangement that obstructs personnel's movement within working clearance.

PRIORITY: P2


FINDING NO: E- 15

Generator batteries placed direct on floor


FINDING: Generator batteries are kept directly on concrete floor.

RECOMMENDATION: Use non-flammable case/shelf to keep/store battery.

PRIORITY: P2


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FINDING NO: E- 16

Fuel barrel near DG set in generator room.


FINDING: Combustible materials and reserve fuel stored in the generator room.

RECOMMENDATION: Remove all the combustible and flammable materials from generator room.

PRIORITY: P1


FINDING NO: E- 17

Insulation mat not provided

CATEGORY: DISTRIBUTION & LT PANELS

FINDING: No/Inadequate rubber (insulation) mat on the working area of distribution board/panel (typical issue).

RECOMMENDATION: Put electrical insulation (rubber mat) on the working area of each electrical installation (Transformer/LT panel/MDB/DB/SDB/ other manual operated machineries).

PRIORITY: P1


FINDING NO: E- 18

Circuit diagrams missing for panels

CATEGORY:DISTRIBUTION & LT PANELS

FINDING: Circuit diagrams are not hung on the panels (typical issue).

RECOMMENDATION: Provide/hang circuit diagrams of panels/boards in every panel.

PRIORITY: P2


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FINDING NO: E- 19

MCCB main switch mounted without enclosure


FINDING: Control/protective device mounted on wall without enclosure; cables terminating on it are drawn haphazardly and without support.

RECOMMENDATION: Electrical control/protective devices should be encased in metal casing made of 20 SWG thickness sheet metal. Cables should be supported on trays, preferably metallic, and adequately clamped and neatly arranged.

PRIORITY: P1


FINDING NO: E- 20

Main LT panel bottom is left open


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

RECOMMENDATION: Seal each panel/distribution board's top/bottom; and use cable glands holding/supporting cables.

PRIORITY: P2


FINDING NO: E- 21

Phase barriers not used at MCCB terminals


FINDING: Phase barrier/separator has not been installed (typical issue).

RECOMMENDATION: Install phase separators between different phases of MCCBs. Standard separators provided by the MCCB manufacturer must be used; also terminate cables by proper sized cable lugs and cover cable lugs by heat shrink.

PRIORITY: P2


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FINDING NO: E- 22

Cable excessively bent


FINDING: Cables terminating at MCCB are excessively bent (typical issue).

RECOMMENDATION: Avoid power cable bending in electrical system;

in unavoidable case bend cables without any

stress but not less than 135 degree.

PRIORITY: P2


FINDING NO: E- 23

Wires/cables disorganized


FINDING: Wires/cables inside distribution board are disorganized (typical issue).

RECOMMENDATION: Organize all the power cables securely and neatly inside distribution board to prevent from electrical hazards. Install slotted PVC channels for routing wires and cables inside the panel.

PRIORITY: P2


FINDING NO: E- 24

Frame/body not connected to earth


FINDING: Electrical panel frame/body does not have earth connection (typical issue).

RECOMMENDATION: Frame/body of all electrical panels and manually operated machines must be connected to earth.

PRIORITY: P1


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FINDING NO: E- 25

Door earth bond missing


FINDING: Panel doors are not connected with earth bond (typical issue).

RECOMMENDATION: All the metal panel doors shall have earth

connection by at least 4rm earth cable.

PRIORITY: P1


FINDING NO: E- 26

Multiple cables terminating at busbar inside panel


FINDING: Multiple cables/wires terminated at busbar (typical issue).

RECOMMENDATION: Terminate the cables/wires at busbar/MCB/MCCB firmly and by proper sized cable lugs.

PRIORITY: P2


FINDING NO: E- 27

Hot spot inside panel (PFI panel)


FINDING: Hot spot is found inside the panel (typical issue).

RECOMMENDATION: Check the connection and measure the connected load. If necessary, replace the breaker.

PRIORITY: P1


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FINDING NO: E- 28

Cable trench partly open and partly tiles covered

CATEGORY: CABLE & CABLE SUPPORTS

FINDING: Cables not protected in open trench; trench partly covered with floor tiles.

RECOMMENDATION: Cables in floor trench must be protected by providing adequate cover; preferably with metallic checkered plate (tiles must be avoided).

PRIORITY: P2


FINDING NO: E- 29

Unsupported cables in PVC conduits


FINDING: Cables not drawn in orderly; not supported, and not protected (typical issue).

RECOMMENDATION: Provide covered metallic tray/ladder/riser to support and protect the cables. Cables must be laid in an orderly manner into cable tray/ladder and neatly dressed and firmly installed or tied.

PRIORITY: P2


FINDING NO: E- 30

Cables not supported - COS in generator room


FINDING: Power cables entering to or exiting Distribution board/panel are not properly supported/fixed (typical issue).

RECOMMENDATION: Power cables entering or exiting the distribution board/panel must be fixed through Panel base/top plate using cable glands (metal/PVC). Cable trays/ladders should be used to support the cables.

PRIORITY: P2


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FINDING NO: E- 31

Cables not protected


FINDING: Cables passing through walls are not protected (typical issue).

RECOMMENDATION: Cables/wirings passing through permanent wall must be protected installing pipes and remaining gaps must be sealed with fire resistant materials.

PRIORITY: P2


FINDING NO: E- 32

Cables not supported and protected


FINDING:

Cables in flexible PVC pipe directly clipped on wall are not supported (typical issue).

RECOMMENDATION: Cable tray/raceway(instead of flexible pipes) should be installed to support the cables throughout the length.

PRIORITY: P2


FINDING NO: E- 33

Inadequate working clearance

CATEGORY: BOILER & COMPRESSOR

FINDING: Inadequate working clearance around the Boiler.

RECOMMENDATION: Working clearance around each generator should be 1.07m. If multiple generators are installed then the gap between two generators must be equal to the width of bigger generator.

PRIORITY: P1


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FINDING NO: E- 34

Wiring in Flexible PVC pipe around Boiler

CATEGORY: BOILER & COMPRESSOR

FINDING: Wiring in flexible PVC pipe is used around vertical boiler surfaces.

RECOMMENDATION: Wires close/attached to boiler must be protected from external heat. If it is unavoidable use metallic flexible conduit, and power cables must be kept at least 0.9m from hot areas.

PRIORITY: P1


FINDING NO: E- 35

IPS battery placed direct on floor

CATEGORY: EQUIPMENT &MACHINE

FINDING: Batteries are kept directly on concrete floor (typical issue).

RECOMMENDATION: Use non-flammable case/shelf to keep/store battery.

PRIORITY: P2


FINDING NO: E- 36

Open battery terminals

CATEGORY: EQUIPMENT &MACHINE

FINDING: Battery terminals are left open.

RECOMMENDATION: Use insulated rubber cap to cover all the battery terminals.

PRIORITY: P2


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FINDING NO: E- 37

MCB is controlling large exhaust fan

CATEGORY:EQUIPMENT & MACHINE

FINDING: Large exhaust fans in production floors are directly controlled by the MCB (typical issue).

RECOMMENDATION: Use Direct On Line (DOL) switch to stop auto start after power failure and connect each individual fan frame with earth.

PRIORITY: P2


FINDING NO: E- 38

Earth pit unmaintained and unidentified

CATEGORY: LIGHTNING PROTECTION & EARTH

FINDING: Internal electrical system earth pit not installed, earth pits are not identifiable.

RECOMMENDATION: Install earth pit for electrical system and interconnect it with the generator earthing. Clearly identify each earth pit, and mark it for periodic maintenance purposes.

PRIORITY: P2


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