INITIAL ELECTRICAL ASSESSMENT REPORTsfi.fairfactories.org/sfi_dev_files/1/Audit_Files/PKG -...

INITIAL ELECTRICAL ASSESSMENT REPORT(EAR)

Factory Name: PKG - SML Packaging Solutions Bangladesh Limited

Address: SFB 2 Adamjee EPZ, Siddergonj, Narayangonj,Siddhirgonj Dhaka Bangladesh

Assessor: Shaheedullah

Date: 22 Feb 2017

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The Alliance for Bangladesh Worker Safety /18

Introduction to the Report

The following report contains a site profile and summary of non-conformities identified during an onsite assessment commissioned by theAlliance for Bangladesh Worker Safety (Alliance) and conducted by a third-party Qualified Assessment Firm (QAF). The assessment wasconducted against the Alliance for Bangladesh Worker Safety Assessment Protocols (APs) and Fire Safety and Structural Integrity Standard,which is harmonized with the factory assessment guidelines developed by Bangladesh University of Engineering and Technology (BUET) forthe Bangladesh National Tripartite Plan of Action (NTPA). The goal of the Alliance process is to provide clear and practical technicalrequirements by which Bangladeshi Ready Made Garment (RMG) Factories producing for Alliance members may be consistently and fairlyevaluated for fire, structural, and electrical safety in a non-duplicative manner. Each assessment will prompt action plans that will be used byRMG factories to systematically and sustainably improve safety conditions for garment workers. Beyond tracking and reporting on actionsteps taken in a transparent manner, the Alliance organization and its members will seek to further support factory improvements throughtechnical assistance, training, implementation support for functional Worker Committees, and in some cases financial assistance and wagesupport for workers if factories are closed for remediation.

The contents of the report do not constitute a guarantee of compliance with the applicable laws, the Alliance Standard or the absolute orcontinued safety against fire, electrical and/or structural integrity issues that may lead to injury or loss of life. The report is designed to providea non-exhaustive summary of risk issues, based on a limited sampling and duration of time onsite by the named QAF. Neither the QAF northe Alliance can certify or guarantee the quality, outcome, or effectiveness of actions taken in response to the report.

For more information and report feedback please go to: www.bangladeshworkersafety.org.

FactoryName:

PKG - SML Packaging Solutions Bangladesh Limited

Address: SFB 2 Adamjee EPZ, Siddergonj, Narayangonj, Siddhirgonj DhakaBangladesh


Date: 22 Feb 2017



GENERAL INFORMATION

General Information

Factory Name: PKG - SML Packaging Solutions Bangladesh Limited

Address: SFB 2 Adamjee EPZ, Siddergonj, Narayangonj, Siddhirgonj Dhaka Bangladesh

Country: Bangladesh

Province: Dhaka

City: Siddhirgonj

Zip Code: 1431

Audit Duration: 2 Days

Re-Audit: Re-Audit After 0 Months

Draft Report Date : 22 February 2017

Final Report Date : 02 March 2017

Are all action items fromprevious assessmentcomplete? :

N/A

Buildings in Complex : There are 5 buildings / sheds in the complex. Out of 5 buildings/sheds, 2 are production buildings and 3 areancillary buildings/sheds. Name of production buildings are: 1) 4-storied R.C. Main Production Building. 2) 1-storied woven Shed.

Is the building(s) ownedor rented by theFactory?:

Owned

Number of BuildingLevels (Stories) :

1) 4-storied R.C. Main Production Building: 4 story above grade. 2) 1-storied woven Shed: 1 story abovegrade.

Approximate BuildingArea (SF) :

1) 4-storied R.C. Main Production Building about 97,500 sft 2) 1-storied woven Shed: 4,500 sft.

Date of BuildingConstruction :

1) 4-storied R.C. Main Production Building: 2007-2009. 2) 1-storied woven Shed: 2013.

Date of Last BuildingRenovation/Addition :

No sign of renovation and addition has been noticed.

Ancillary Structures inComplex :

3 Nos. 1) 1-storied utility shed (Sub-station and Generator room). 2) 1-storied outdoor shed-1 (ETP, Chemicalwarehouse and Electrical room). 3) 1-storied outdoor shed-2 (BEPZA-LT panel room).

Approximate AncillaryStructures Area (SF) :

1) 1-storied utility shed (Sub-station and Generator room): about 2,094 sft. 2) 1-storied outdoor shed-1 (ETP,Chemical warehouse and Electrical room): about 755 sft. 3) 1-storied outdoor shed-2 (BEPZA-LT panel room):

FactoryName:




Date: 22 Feb 2017



350sft.

Number of Occupants : Total = 514 Persons.

Provide brief descriptionof the electrical systemfor each building.:

Service Line: BEPZA. FDB: 08 nos. MTS: 06 nos. LV: 03 nos. DB: 01 nos. A/C, DB: 04 nos. A/C W: 03 nos.SSDB: 10 nos. LDB: 26 nos. AVR: 04 nos. SDB: 19 nos. HT Panel (630A VCB): 2 nos. COS: 04 nos (400A),01 nos (800A), 01 nos (630A). Transformer: 5nos (250KVA: 04 nos & 1250KVA: 01 nos). PFI: 05 nos(750KVAR: 01 nos, 150KVAR: 04 nos). LT Panel: 01 nos. Generator: 03 nos (350KVA: 01 nos, 313KVA: 01nos, 650KVA: 01 nos. Lift: 01 nos. Fuel Tank Capacity: 200 Ltr.

Physical location ofSubstation? :

Outside of production building.

What equipment/loadsdoes the UPS serve? :

Emergency Exit light

FactoryName:




Date: 22 Feb 2017



ASSESSMENT FINDINGS

Electrical System Information

Question: Are as-built electrical drawings indicating information such as panel and circuitlocations throughout the building(s) available for review?

Priority Level: High

Non-Compliance Level: 3

Description: As-built electrical drawings do not reflect actual installation.

Source of Findings: Document Review: Documents do not match with actual installation.

Suggested Plan ofAction:

Have a qualified electrical engineer develop an as-built single line diagramdetailing key components and capacity of the electrical system.

Suggested DeadlineDate:

30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.3.7

Electrical System Maintenance

Question: Is a periodical Insulation Resistance Measurement Program established andrecorded?

Priority Level: Medium


Description: Insulation Resistance Measurement test program is not established orrecorded.

Source of Findings: Document Review: No IR test program was recorded.


Develop an Insulation Resistance Measurement Program that ensuresdeterioration of insulation resistance will be identified quickly. Testing shouldbe in compliance with InterNational Electrical Testing Association (NETA). Alltransformers, switchgears etc. shall be subject to an insulation resistancemeasurement test to ground after installation but before any wiring isconnected. Insulation tests shall be made between open contacts of circuitbreakers, switches etc. and between each phase and earth.


30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.13.4 Insulation Tests and 10.13.8Electrical Inspections

Question: Are thermographic scans of electrical equipment completed at least everythree years?

FactoryName:




Date: 22 Feb 2017





Description: Thermographic scans of electrical equipment is not completed at least everythree years.

Source of Findings: Document Review: Thermographic scan report was not found.


Complete thermographic scans at least on a three year cycle. Thermographicscans should be completed in accordance with the Standard for InfraredInspection of Electrical Systems & Rotating Equipment and NFPA70B or acomparable standard.


30 Apr 2017

Standard: Alliance Standards Part 10 Section 10.13.8 Electrical Inspections

Question: Transformers do not contain harmful substances such as PCBs.



Description: No testing documentation was provided during inspection.

Source of Findings: Document Review: No document was found.


Consider replacing transformers with harmful substances to reduce healthhazards.


30 Apr 2017

Standard: Not Applicable

Question: Are periodic safety inspections of the electrical system components completedand documented?



Description: Periodic safety inspections of the electrical system components are notdocumented.

Source of Findings: Document Review: No documentation was found.


Establish a periodic inspection program to ensure the electrical systems arefree from damage, debris, dirt, lint, etc. Maintain records concerninginspections and follow up actions.


30 Apr 2017

FactoryName:




Date: 22 Feb 2017



Standard: Alliance Standard Part 10 Section 10.13 Inspection and Testing and Part 13Section 13.6 Housekeeping

Question: A transformer oil analysis is routinely completed on main service transformers.

Priority Level: Low


Description: No testing documentation was provided during inspection.

Source of Findings: Document Review: No document was found.


Complete an oil analysis on applicable transformers at appropriate intervalsbased on voltage and power.


30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.13.8 Electrical Inspections

Electrical System Conditions

Question: Light fixtures without protective covers are not installed in storage areas or inany area where the Inspector of the Factories Rules (1.5.3.5) Part 53 disallowsthese fixtures.



Description: Light fixtures without protective covers are installed in storage areas.

Source of Findings: Photograph: Light fixtures without protective covers in storage areas.


"Remove light fixtures without protective covers from storage areas or anyarea where the Inspector of the Factories Rules (1.5.3.5) Part 53 disallowsthese fixtures."


31 Mar 2017

Standard: Alliance Standards Part 10 Section 10.15 Naked Lights

Question: Do switchboards and/or distribution boards have a minimum clearance of 1 m(39 in) in front?



Description: Switchboards and/or distribution boards do not have a minimum clearance of 1m (39 in) in front. Location: DB/offset.

Source of Findings: Photograph: No minimum clearance.

FactoryName:




Date: 22 Feb 2017




Provide minimum clearance of 1 m (39 in) in front of all panel boards inaccordance with the Alliance requirement.


15 Apr 2017

Standard: Alliance Standards Part 10 Section 10.7 Main Switch, Switchboards and MetalClad Switchgear

Question: Are all switchboards and/or distribution boards metal enclosed with a deadfront construction?



Description: All switchboards and/or distribution boards are not metal enclosed with a deadfront construction. Location: LV-01.

Source of Findings: Photograph: No dead front constructed metal.


Provide switchboards and/or distribution boards with metal enclosed deadfront construction.


15 Apr 2017


Question: Are switchboards and/or distribution boards installed in compliant locations?



Description: Distribution boards are not installed in compliant locations. Location: DB/offset.

Source of Findings: Photograph: DB is not in a compliant locations.


Relocate distribution boards to suitable locations for operation andmaintenance.


30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.7 Main Switch, Switchboards and MetalClad Switchgear

FactoryName:




Date: 22 Feb 2017



Question: Is electrical wiring/cables sized according to capacity of circuit breakers (Nohigher rated circuit breakers with lower rated wiring)?



Description: Higher rated breaker is found with lower rated cable. Location: LV-01.

Source of Findings: Photograph: Higher rated breaker with lower rated cable.


Consult with a qualified Electrical Engineer and ensure electrical wiring/cablesare sized according to capacity of circuit breakers. Provide electricalwiring/cables of proper size according to capacity of circuit breakers. Higherrated circuit breakers are not allowed with lower rated wiring.


15 May 2017

Standard: Alliance Standard Part 10 Section 10.3.1 Electrical Connections.

Question: No multi looping of wiring/cables observed at circuit breakers withinswitchboards and/or distribution boards.



Description: Multi looping of cables was observed at circuit breaker and busbar withinswitchboards. Location: LDB-W-01.

Source of Findings: Photograph: Multi looping of cables are observed.


Survey all distribution boards to identify all locations of multi looping of cables.Remove multi looping of wiring/cables at circuit breakers within switchboardsand/or distribution boards. Make separate connection from bus bar forindividual circuits.


30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.3 Electrical Wiring and Cabling

Question: Is a readily accessible single point of disconnect provided for each mainelectrical service feed?



Description: Readily accessible single point of disconnect is not provided for each mainelectrical service feed. Location: LDB-3E-03

Source of Findings: Photograph: No readily accessible single point of disconnect.

Suggested Plan of Provide readily accessible single point of disconnect for each main electrical

FactoryName:




Date: 22 Feb 2017



Action: service feed.


30 Apr 2017

Standard: BNBC 2.7.5 Main Switch and Switchboards

Question: Wiring systems are selected and erected so that no damage is caused by theingress of water.



Description: Wiring systems are erected allowing ingress of water. Location: LDB-01-E-04.

Source of Findings: Photograph: Wiring systems are erected allowing ingress of water.


Relocate distribution boards to suitable locations for operation andmaintenance.


30 Apr 2017

Standard: Alliance Standards Part 10 Section 10.3.4.3 Presence of Water

Question: Are all internal components of switchboards and/or distribution boards properlyconcealed (No missing circuit breaker or knockout covers)?



Description: Internal components of distribution boards are not properly concealed.Location: All Panel boards.

Source of Findings: Photograph: Internal components of DB are not properly concealed.


Provide covers or blanks to conceal all live internal components ofswitchboards and/or distribution boards.


31 Mar 2017

Standard: Alliance Standard Part 10 Section 10.3.9 Sub-Distribution Boards

Question: Do switchboards and/or distribution boards have clear identification markings?



Description: Distribution boards have no clear identification markings. Location: All panelboards.

Source of Findings: Photograph: No marking in DB.

FactoryName:




Date: 22 Feb 2017




Provide clear and permanent identification marks on all distribution boards,switchboards, sub main boards and switches and post proper caution/dangersignage in all electrical panel boards.


30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.7 BNBC Part 8 Section 2.11.5.4

Question: Do switchboards and/or distribution boards have capacity information labels?



Description: Distribution boards have no capacity information labels. Location: All panelboards.

Source of Findings: Photograph: No capacity information labels in DBs.


Provide capacity information labels (Maximum current rating, number of circuitbreakers, rated capacity of circuit breaker, etc.) for Switchboards and/ordistribution boards. Display panel schedule on panel door (inner side) printedon a sheet made of non-combustible material.


30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.7 Main Switch, Switchboards And MetalClad Switchgear and 10.13.7 Inspection of the Installation

Question: Are switchboards and/or distribution boards provided with physical means toprevent the installation of more over current devices than that number forwhich the panel board was designed, rated, and listed.



Description: Distribution boards are not provided with a physical means to prevent theinstallation of more over current devices than that number for which the panelboard was designed, rated and listed. Location: All panel boards.

Source of Findings: Photograph: No physical means for DBs.


Verify the existing load does not exceed the panel rating. For switch boardsand/or distribution boards, provide the physical means to prevent theinstallation of more over current devices than that number for which the panelboard was designed, rated, and listed following NFPA 70 section 408.54.


30 Apr 2017


FactoryName:




Date: 22 Feb 2017



Question: Are electrical wiring/cables properly identified?



Description: Electrical wiring/cables are not properly identified. Location: All panel boards.

Source of Findings: Photograph: No identification for Electrical wiring/cable.


Provide identification of wires/cables by separate color coding, marking tape,tagging, or other approved means.


30 Apr 2017

Standard: Bangladesh Electricity Rules 1937 Rule 51 and 56

Question: The substation room has adequate ventilation.



Description: The substation room does not have adequate ventilation.

Source of Findings: Photograph: The substation room does not have adequate ventilation.


Provide means of ventilation for the substation room. Consult a qualifiedelectrical engineer to determine the required ventilation rates based on theinstalled equipment.


30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.13.7.1 Inspection of SubstationInstallations.

Question: The substation room has adequate illumination levels.



Description: The substation room does not have adequate illumination levels.

Source of Findings: Photograph: The substation room does not have adequate illumination levels.


Provide additional light fixtures to increase illumination levels provided in theBNBC.


15 Apr 2017

Standard: Alliance Standard Part 10 Section 10.13.7.1 Inspection of SubstationInstallations.

FactoryName:




Date: 22 Feb 2017



Question: Stranded conductors having a nominal cross-sectional area 6mm2 or greaterare provided with cable sockets. Conductors below 6 mm2 without cablesockets, all strands at the exposed ends are soldered together or are crimpedusing suitable sleeve or ferrules.



Description: Stranded conductors having a nominal cross-sectional area 6mm2 or greaterare not provided with cable sockets. Location: SDB-01-W-04.

Source of Findings: Photograph: Cable lugs not used.


Provide proper cable lugs for for connecting cable with circuit breaker orbusbar.


30 Apr 2017

Standard: Alliance Standards Part 10 Section 10.3.8.3 Cable Ends

Question: Cable joints are through porcelain/PVC connectors with PIB tape woundaround joint.



Description: Improper cable joints were found. Location: Every floor.

Source of Findings: Photograph: Improper cable joints.


Provide cable joints through porcelain/PVC connectors with PIB tape woundaround joint before placing the cable in the box in accordance with AllianceStandard Section 10.3.8.4.


30 Apr 2017

Standard: Alliance Standards Part 10 Section 10.3.8.4 Cable Joints

Question: Is all electrical wiring/cable properly terminated at its point of termination (Noun-terminated wires, lugs are provided at terminals, etc)?



Description: Electrical cables are not properly terminated. Location: DB-U-01.

Source of Findings: Photograph: Electrical cables are not properly terminated.


Provide proper termination of all wiring in accordance with the Alliancestandard. No un-terminated wires or cables are allowed.

FactoryName:




Date: 22 Feb 2017




30 Apr 2017

Standard: Alliance Standards Part 10 Section 10.3.9.2 Wiring of Sub-distribution Boards

Question: Are junction boxes and other electrical devices provided with covers?



Description: Junction boxes are not provided with covers. Location: Near of FDB-W-04.

Source of Findings: Photograph: No cover for the Junction boxes.


Provide adequate covers for junction boxes and other electrical devicesaccording to Alliance Standard.


31 Mar 2017

Standard: Alliance Standard Part 10 Section 10.3.5 and 13.6.2

Question: Mechanical guards are provided for electrical equipment and wiring wherenecessary.



Description: Mechanical guards are not provided for electrical equipment and wiring wherenecessary. Location: In front of SDB-01-W-04.

Source of Findings: Photograph: No Mechanical guards.


Survey all locations to identify missing mechanical guards. Provide mechanicalguards for electrical equipment where necessary.


31 Mar 2017

Standard: Alliance Standard Part 10 Section 10.3 Electrical Wiring and Cabling, 10.6.5Cables, and 10.7 Main Switch, Switchboards And Metal Clad Switchgear

Question: Are electrical insulation mats provided in front of substation, switchboardsand/or distribution boards?

Priority Level: Low


Description: Properelectrical insulation mats are not provided in front of substation switchboardsand distribution boards. Location: All panel boards.

FactoryName:




Date: 22 Feb 2017



Source of Findings: Photograph: Insulation mats are provided.But not proper sized.


Provide electrical insulation mats in front of distribution boards.


30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.13.7 Inspection of the Installation.

Question: Required equipment and safety signage is posted within the room.

Priority Level: Low


Description: Required equipment and safety signage is not posted within the room.

Source of Findings: Visual Assessment: There is no safety signage in the substation room.


"Indoor electrical installations that are accessible to unqualified persons shallbe made with metal-enclosed equipment. Switchgear, unit substations,transformers, pull boxes, connection boxes, and other similar associatedequipment shall be marked with appropriate caution signs. Entrances to roomsand other guarded locations that contain exposed live parts shall be markedwith conspicuous warning signs forbidding unqualified persons to enter.Caution, warning, danger signs or labels should meet the followingrequirements: (1) The marking shall adequately warn of the hazard usingeffective words and/or colors and/or symbols. American National StandardsInstitute ANSI Z535.4-2011, Product Safety Signs and Labels, providesguidelines for suitable font sizes, words, colors, symbols, and locationrequirements for labels. (2) Shall be permanently affixed to the equipment orwiring method and shall not be hand written. Exception, portions of labels ormarkings that are variable, or that could be subject to changes, shall bepermitted to be hand written and shall be legible. (3) The label shall be ofsufficient durability to withstand the environment involved. ANSI Z535.4-2011,Product Safety Signs and Labels, provides guidelines for the design anddurability of safety signs and labels for application to electrical equipment"


31 Mar 2017

Standard: Alliance Standard Part 10 Section 10.3.7, Section 10.7.3, and 10.13.7, NFPA70 Chapter 1 Article 110.21, and Bangladesh Electricity Rules of 1937 Rule 46

Question: Phase separators are provided between terminals on circuit breakers.

Priority Level: Low


Description: Phase separators are not provided between terminals on circuit breakers.Location: LV-01.

Source of Findings: Photograph: Phase separators are not provided.

FactoryName:




Date: 22 Feb 2017




Install phase separators between terminal connections. Verify phaseseparators are installed at all remaining locations.


30 Apr 2017

Standard: Alliance Standard Part 10 Section 10.3.1 Electrical Connections

Question: Signage indicating the prohibition of light fixtures without protective covers isinstalled at required locations.

Priority Level: Low


Description: Signage indicating the prohibition of light fixtures without protective covers isnot installed at required locations.

Source of Findings: Photograph: Signage indicating the prohibition of light fixtures withoutprotective covers is not installed at required locations.


"Light fixtures without protective covers (otherwise known as naked lights)shall not be allowed in storage areas or in any area where the Inspector of theFactories Rules (1.6.3.7) Part 53 disallows these fixtures. Install signs postedin Bengali and English, indicating this prohibition at all entrances to theseareas."


31 Mar 2017

Standard: Alliance Standards Part 10 Section 10.15 Naked Lights

Emergency Power System

Question: Is the generator room properly ventilated



Description: The generator is not room properly ventilated.

Source of Findings: Photograph: No proper ventilation system.


Provide the generator room with significant amount of ventilation and fittedwith a number of ceiling fans. Appropriate type and number of firefightingequipment must be installed inside the generator room.


15 Apr 2017

Standard: Alliance Standards Part 10 Section 10.8.4 Generator Room

FactoryName:




Date: 22 Feb 2017



Question: Is the generator frame earthing (grounding) provided at two separate points?



Description: Generator frame earthing (grounding) is not provided at two separate points.

Source of Findings: Photograph: Generator frame earthing.


Provide generator frame earthing at two separate points with proper size ofconductors and sufficient number of earth electrodes.


15 Apr 2017

Standard: Alliance Standard 10.8.2.2

Question: Is the generator room properly illuminated?



Description: The generator room is not properly illuminated.

Source of Findings: Photograph: No proper illumination.


Provide proper illumination in generator room.


15 Apr 2017

Standard: Alliance Standards Part 10 Section 10.8.4 Generator Room

Question: Are inspection, maintenance, and testing procedures of the emergencygenerator being completed and documented?

Priority Level: Low


Description: Inspection, maintenance, and testing procedures for the emergency generatorare being documented, but not in Accordance with all requirements.

Source of Findings: Document Review: No proper document was found.


"Establish a routine maintenance and testing program for the emergencygenerator. The program shall be based on all of the following: (1)Manufacturer's recommendations (2) Manufacturer's Instruction manuals (3)Requirements of NFPA 110 Chapter 8"


30 Apr 2017

FactoryName:




Date: 22 Feb 2017



Standard: NFPA 110 Chapter 8

Question: Are inspection, maintenance, and testing procedures of the UPS beingcompleted and documented?

Priority Level: Low


Description: Inspection, maintenance, and testing procedures of the UPS are not beingcompleted and documented.

Source of Findings: Document Review: No documentation was found for Inspection, maintenance,and testing of IPS.


"Establish an inspection testing, and maintenance program for theUninterruptable Power Supply (UPS) and associated components. Theprogram must based on the following: (1) Manufacturer's recommendations (2)Manufacturer's instruction manuals (3) Minimum Requirements of NFPA 111Chapter 8 (4) Minimum Requirements of NFPA 70B Chapter 28"


30 Apr 2017

Standard: Alliance Standard Part 13 Section 13.11 NFPA 111 Chapter 8 NFPA 70BChapter 28

Lightning Protection System

Question: Is a lightning protection system installed on the building?



Description: Lightning protection system is not properly installed on the building.

Source of Findings: Photograph: Lightning protection system.


Have a qualified electrical engineer design a lightning protection systemaccording to the BNBC requirements. Have a licensed electrician install thedesigned system.


31 May 2017

Standard: Alliance Standards Part 10 Section 10.11 Lightning Protection. Calculate RiskIndex to determine if required.

FactoryName:




Date: 22 Feb 2017



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