ELECTRICAL SAFETY INSPECTION...

ELECTRICAL SAFETY INSPECTION REPORT

DENIM FASHIONS LTD.

Sataish Road, Tongi, Gazipur-1712, Bangladesh

Factory List:

1. Denim Fashions Ltd.

Inspected by: Pema Wangdi

Report Generated by: Pema Wangdi

Inspected on March 14th 2015

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Denim Fashions Ltd.

ELECTRICAL SAFETY INSPECTION REPORT

DENIM FASHIONS LTD.

1. INTRODUCTION

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.

2. LIMITATIONS

The information in this electrical safety inspection report was obtained during a visit to the facility

and during interviews with local factory management. It has not been possible to provide

independent verification for all the information and data collected, and, therefore, WEC cannot

accept general responsibility for omissions or errors arising from inaccuracies in this report from the

information obtained.

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

issue 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

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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: Denim Fashions Ltd.

2. Factory Address: Sataish Road, Tongi, Gazipur-1712, Bangladesh

3. Accord ID: 12109

4. Inspection participates:

Sariful Islam DGM (Admin, HR & Compliance) FLORENCE GROUP Mob: +880 1712262738 Email: [email protected] Abdullah Farouq Company Secretary FLORENCE GROUP Phone: +880 1721885353 Email: [email protected]

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Denim Fashions Ltd.

5. BUILDING DATA

A. General

The Denim Fashions Ltd. factory is established in its two buildings. The building 1 is one

storied and the other one is a two storied building. They have production in the one storied

building only.

As reported by the Factory Management, both the buildings were constructed in 2013 and the

factory started their production in the same year. The buildings have been formally approved

for industrial purpose. During the time of the Inspection, the factory accommodated a total of

about 630 workers working on regular basis only in the third floor.

The buildings utilization is as detailed below:

Building 1: Cutting, Finishing, Sewing, Boiler, Generator, Substation, Store

Building 2:

Ground Floor: Warehouse, Fire Hydrant, Medical room, Childcare

First Floor: Dining, Sample Room, Office, Prayer Room

B. Floor Layout Information

The one storied (G) factory building is 4.5m tall and has a total floor area of 2,323sqm. Figure

1 shows the floor plan of the building 1:

Figure1: Floor plan of the building 1

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Denim Fashions Ltd.

C. Electrical System

The Denim Fashions Ltd. factory premises is connected to grid (DESCO) supply, which is the

main source of power supply tapped from 11kV OH line and delivered through HT cable,

protected by DO fuse and LBS. The 11kV supply is stepped down by 250kVA, 11/0.415kV, 3

phase power transformer installed in building 1.

The factory has a diesel generators (350 kVA) operated during grid failure and a diesel

generator (63kVA) dedicated for fire hydrant.

The output from the transformer and the generator are controlled by MCCB connecting to the factory’s electrical system through various combination of manual changeover switch. The factory does not have an as built electrical single line diagram, which is mandatory for safe

operation and maintenance of the electrical system. Upon discussion with the factory

management, they readily agreed to make an as built electrical single line diagram consulting a

competent electrical engineer.

Figure 2: Electrical single line diagram.

D. Electrical Installations

The factory generally must follow cabling systems supported in cable trays and cable duct,

from the mains to the load centers (production floors and other buildings).

However, in some production area at Denim Fashions Ltd. the cable ducts supporting cables

were not installed in complete sets with accessories like bents, junctions and covers.

The power cables from the MDB in the electrical substation to the distribution boards located in

various floors of the factory are encased in PVC flexible pipe, drawn in shallow cable trench

covered with concrete and sand.

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The Figure 3 shows the power cables supported in aluminum cable tray and PVC conduit to

distribute power to the various production floors.

Figure 4 shows the aluminum tray system used to support power cables for the power

distribution in the production floors.

The factory’s internal wiring systems consist of PVC conduit wiring and aluminum duct systems

though often, the PVC flexible conduits are extended for loads which are modified later. Power

distributions to work tables in production floors (sewing, cutting and finishing floors) are

supported with MS cable ducts performing functions of wiring ducts. The cable ducts are often

left open and wires joints are found during random checks.

Figure 3: PVC conduit and Aluminum tray.

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Figure 4: Aluminum tray.

E. Operation and Maintenance

Maintenance and Operations is done by in-house electrical and maintenance team of the

factory. However, the maintenance of major equipment like transformer, generator and boilers

are outsourced to the service centers.

Inspecting teams were presented with the maintenance programs, logs and maintenance

schedule of the factory’s electrical facilities; however, the factory did not have a detailed

maintenance schedule.

The cable duct supporting cables has not been cleaned for quite some time as a result it was

covered with dust and lint. In some areas the service cables encased in the flexible PVC

conduits were not supported.

The cables ducts installed in the production floors were not installed in full set. The

management was positive and assured that the wiring without conduit under the working tables

and uncovered cable duct, in various production floors will be done as per the code.

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6. LIGHTNING PROTECTION RISK ASSESSMENT

There is no proper lightning protection system in the building. The calculation of the risk index

for lightning protection for this building is below.

Recommendation:

The total risk index figure being over 40, hence, lightning protection system is required. Select an

appropriate lightning protection system and install it at the highest point of the building structure.

Sl.no. Index category Index Figure

A Usage of Structure 6

B Type of construction 5

C Contents or consequential effects 5

D Degree of isolation 5

E Type of area and terrain 2

F Height of structure 4

G Lightning prevalence 21

Total index Figure 48

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7. FINDINGS AND RECOMMENDATIONS

The table below summarizes the major electrical safety issues identified during the 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 NO: E-1

CATEGORY: DESIGN, DRAWINGS & RECORDS

FINDING: Electrical Single Line Diagram (SLD) has inadequate information, and thus is unusable.

RECOMMENDATION: Prepare an accurate SLD with all necessary information, so any experienced person will then be able to understand the system.

PRIORITY: P2

REMEDIATION TIMEFRAME: 12 WEEKS

FINDING NO: E-2


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


FINDING NO: E-3


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


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FINDING NO: E-4

CATEGORY: LIGHTNING PROTECTION

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

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

PRIORITY: P2


FINDING NO: E-5


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-6


FINDING: Earth pits are not identifiable.

RECOMMENDATION: Identify each earth pit and mark it for periodic maintenance purpose.

PRIORITY: P2


FINDING NO: E-7


FINDING: Earth Pit resistance record is unavailable.

RECOMMENDATION: Record earth pit resistance for all the earth pit and do once in a year.

PRIORITY: P2


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FINDING NO: E-8


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

RECOMMENDATION: Hang this instruction near all electrical equipment (LT panel, MDB, FDB, DB, SDB) on a visible location.

PRIORITY: P2


FINDING NO: E-9


FINDING: Maintenance records don’t reflect actual factory circumstances, the records are totally inaccurate.

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-10


FINDING: Transformer Oil Test report is unavailable.

RECOMMENDATION: Check the transformer oil condition by performing oil test, this must be done twice a year and records kept.

PRIORITY: P1


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FINDING NO: E- 11

The HT service cable.

CATEGORY: SERVICE LINE

FINDING: HT service cable dropping from pole is not protected near the base of the pole, above ground level.

RECOMMENDATION: HT cable dropping from HT pole must be protected in steel pipe of required size at least 2m from the ground level to protect the cable from any physical damage.

RIORITY: P1

REMEDIATION TIMEFRAME:10 WEEKS

FINDING NO: E-12

Power transformer.

CATEGORY: TRANSFORMER ROOM

FINDING: Transformer guarded with wire mesh fencing.

RECOMMENDATION: Construct a separate room for the transformer by constructing barrier (brick) walls (fire rated wall) up to the ceiling; the minimum area of the transformer room should be 10-13sqm (according to BNBC 2006, Section-2.6.3).

PRIORITY: P2


FINDING NO: E- 13

CATEGORY: SERVICE LINE

FINDING: HT cable laid over the LT cables.

RECOMMENDATION: HT cable and LT cables must be laid separately in the cable trench covered by checkered plate or concrete slab.

PRIORITY: P1


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HT and LT service cable.

FINDING NO: E- 14

The transformer room.

CATEGORY: CABLE & CABLE SUPPORT

FINDING: Secondary cables laid on the floor.

RECOMMENDATION: Secondary cables must be laid in a cable trench covered by rigid (checkered plate/concrete slabs).

PRIORITY: P2


FINDING NO: E- 15

The breather.


FINDING: Oil cup below transformer breather is empty.

RECOMMENDATION:

Breather oil cup must be filled with transformer oil to required level as instructed by the manufacturer.

PRIORITY: P2


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FINDING NO: E- 16

Cables in transformer room.


FINDING: Cables passing through wall not protected and remaining gaps after passage of cables through wall not sealed.

RECOMMENDATION: Install covered cable tray or rigid pipe for passing cables and it should be prevailed throughout the permanent wall to protect cable insulation from damage and the remaining gaps must be sealed with fire rated materials.

PRIORITY: P1


FINDING NO: E- 17

HT cable.


FINDING: HT cable in electrical room not supported.

RECOMMENDATION: Install the cable tray or ladder with cover to provide mechanical support to the HT cable.

PRIORITY: P1


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FINDING NO: E-18

Arching horns.


FINDING: Transformer Arcing horn has not been installed.

RECOMMENDATION: Install transformer arcing horn with proper alignment (keep at least a 2 inch gap between two horns).

PRIORITY: P1


FINDING NO: E- 19

Working space around the transformer.


FINDING: Inadequate space around the transformer.

RECOMMENDATION: Keep adequate clearance (not less than 1.07 meter, preferably) around the transformer.

PRIORITY: P1


FINDING NO: E- 20

PFI panel.

CATEGORY: SWITCH BOARD & PANELS

FINDING: Hot spot has been detected inside the PFI panel.

RECOMMENDATION: Periodic thermal scanning must be carried out. The cause of the hot spot must be rectified.

PRIORITY: P1

REMEDIATION TIMEFRAME:1 WEEK

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FINDING NO: E- 21

Power cables.


FINDING: Cables buried under the concrete.

RECOMMENDATION: Cables must be laid in the cable trench covered by checkered plate or concrete slab.

PRIORITY: P1


FINDING NO: E- 22

MCCB enclosure.

CATEGORY: GENERATOR ROOM

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

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

PRIORITY: P2


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FINDING NO: E- 23

PVC flexible pipes.


FINDING: Cables drawn in PVC flexible conduit entering panels are not supported.

RECOMMENDATION: Cables drawn in PVC flexible conduit entering panels must be firmly supported on cable tray or duct.

PRIORITY: P2


FINDING NO: E- 24

Distribution board.

CATEGORY: SWITCH BOARD & PANELS

FINDING: Panel doors not connected with earth bond.

RECOMMENDATION: All metal panel doors must have an earth connection of at least 4 rm earth cable.

PRIORITY: P2

REMEDIATION TIMEFRAME:1 WEEK

FINDING NO: E- 25

Distribution panel.

CATEGORY: SWITCH BOARD & PANEL

FINDING:

Phase barrier/separator between different phases are not installed.

RECOMMENDATION: Phase barrier between different phases supplied by the breaker manufacturer must be installed to avoid arc flashing.

PRIORITY: P1


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FINDING NO: E- 26

The generator and IPS batteries.

CATEGORY: GENERATOR ROOM

FINDING: Generator exciter and IPS batteries not encased and it’s terminals not insulated.

RECOMMENDATION: Keep the Batteries inside a metal casing (acid proof) and insulate its terminal by insulating material to protect it from short circuit which may occur due to falling foreign material on it.

PRIORITY: P2


FINDING NO: E- 27

Distribution panel.


FINDING: Panel not provided with earth busbar (earth strip).

RECOMMENDATION: Earth bus bar should be installed inside all panels with earthing connection as per BNBC.

PRIORITY: P2


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FINDING NO: E- 28

Transformer frame earth.


FINDING: High earth loop impedance measured.

RECOMMENDATION: Check the earthing connection and rectify as required.

PRIORITY: P1


FINDING NO: E- 29

Generator room.

CATEGORY:GENERATOR ROOM

FINDING: Generator cables laid on floor without protection.

RECOMMENDATION: Cables must be protected in cable tray/ladder with covers.

PRIORITY: P2


FINDING NO: E- 30

Generator room.


FINDING: Generator frame not earthed.

RECOMMENDATION: Two separate and distinct earth connection (2 SWG) must be provided for the generator.

PRIORITY: P1


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FINDING NO: E- 31

Cable duct.

CATEGORY:CABLE & CABLE SUPPORT

FINDING: Ducts under the work tables not covered and cables inside it are randomly placed.

RECOMMENDATION: Provide cover for the duct, made of noncombustible material preferably metallic sheet to prevent dust and lint entering in it. The cables within the duct must be properly arranged.

PRIORITY: P2


FINDING NO: E- 32

Exhaust fan.

CATEGORY:EQUIPMENT & MACHINE

FINDING: Large exhaust fans in production floors are directly controlled by the MCB.

RECOMMENDATION: Large exhaust fans must be connected through control device such that it will not restart automatically when power is restored.

PRIORITY: P2


FINDING NO: E- 33

Boiler room.


FINDING: Power and control wiring of boiler are carried through flexible PVC pipe.

RECOMMENDATION: Use industrial graded (heat resistant) pipe for control and power wiring of boiler.

PRIORITY: P2


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FINDING NO: E- 34

DOL starter.


FINDING: DOL starter not fixed in the upright position.

RECOMMENDATION: The DOL starter must be firmly fixed to a support in upright position.

PRIORITY: P2


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