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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Denim Fashions Ltd.
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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Denim Fashions Ltd.
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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Denim Fashions Ltd.
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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Denim Fashions Ltd.
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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Denim Fashions Ltd.
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
CATEGORY: DESIGN, DRAWINGS & RECORDS
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
REMEDIATION TIMEFRAME: 8 WEEKS
FINDING NO: E-3
CATEGORY: DESIGN, DRAWINGS & RECORDS
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
REMEDIATION TIMEFRAME: 8 WEEKS
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Denim Fashions Ltd.
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
REMEDIATION TIMEFRAME: 12 WEEKS
FINDING NO: E-5
CATEGORY: DESIGN, DRAWINGS & RECORDS
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
REMEDIATION TIMEFRAME: 8 WEEKS
FINDING NO: E-6
CATEGORY: DESIGN, DRAWINGS & RECORDS
FINDING: Earth pits are not identifiable.
RECOMMENDATION: Identify each earth pit and mark it for periodic maintenance purpose.
PRIORITY: P2
REMEDIATION TIMEFRAME: 8 WEEKS
FINDING NO: E-7
CATEGORY: DESIGN, DRAWINGS & RECORDS
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
REMEDIATION TIMEFRAME: 8 WEEKS
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Denim Fashions Ltd.
FINDING NO: E-8
CATEGORY: DESIGN, DRAWINGS & RECORDS
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
REMEDIATION TIMEFRAME: 8 WEEKS
FINDING NO: E-9
CATEGORY: DESIGN, DRAWINGS & RECORDS
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
REMEDIATION TIMEFRAME: 8 WEEKS
FINDING NO: E-10
CATEGORY: DESIGN, DRAWINGS & RECORDS
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
REMEDIATION TIMEFRAME: 8 WEEKS
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Denim Fashions Ltd.
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
REMEDIATION TIMEFRAME: 10 WEEKS
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
REMEDIATION TIMEFRAME: 10 WEEKS
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Denim Fashions Ltd.
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
REMEDIATION TIMEFRAME:5 WEEKS
FINDING NO: E- 15
The breather.
CATEGORY: TRANSFORMER ROOM
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
REMEDIATION TIMEFRAME:5 WEEKS
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Denim Fashions Ltd.
FINDING NO: E- 16
Cables in transformer room.
CATEGORY: 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
REMEDIATION TIMEFRAME: 5 WEEKS
FINDING NO: E- 17
HT cable.
CATEGORY: TRANSFORMER ROOM
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
REMEDIATION TIMEFRAME:4 WEEKS
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Denim Fashions Ltd.
FINDING NO: E-18
Arching horns.
CATEGORY: TRANSFORMER ROOM
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
REMEDIATION TIMEFRAME:2 WEEKS
FINDING NO: E- 19
Working space around the transformer.
CATEGORY: TRANSFORMER ROOM
FINDING: Inadequate space around the transformer.
RECOMMENDATION: Keep adequate clearance (not less than 1.07 meter, preferably) around the transformer.
PRIORITY: P1
REMEDIATION TIMEFRAME:10 WEEKS
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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Denim Fashions Ltd.
FINDING NO: E- 21
Power cables.
CATEGORY: CABLE & CABLE SUPPORT
FINDING: Cables buried under the concrete.
RECOMMENDATION: Cables must be laid in the cable trench covered by checkered plate or concrete slab.
PRIORITY: P1
REMEDIATION TIMEFRAME:10 WEEKS
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
REMEDIATION TIMEFRAME:5 WEEKS
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Denim Fashions Ltd.
FINDING NO: E- 23
PVC flexible pipes.
CATEGORY: CABLE & CABLE SUPPORT
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
REMEDIATION TIMEFRAME:5 WEEKS
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
REMEDIATION TIMEFRAME:2 WEEKS
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Denim Fashions Ltd.
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
REMEDIATION TIMEFRAME:5 WEEKS
FINDING NO: E- 27
Distribution panel.
CATEGORY: SWITCH BOARD & 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
REMEDIATION TIMEFRAME:5 WEEKS
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Denim Fashions Ltd.
FINDING NO: E- 28
Transformer frame earth.
CATEGORY: TRANSFORMER ROOM
FINDING: High earth loop impedance measured.
RECOMMENDATION: Check the earthing connection and rectify as required.
PRIORITY: P1
REMEDIATION TIMEFRAME:5 WEEKS
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
REMEDIATION TIMEFRAME:5 WEEKS
FINDING NO: E- 30
Generator room.
CATEGORY:GENERATOR ROOM
FINDING: Generator frame not earthed.
RECOMMENDATION: Two separate and distinct earth connection (2 SWG) must be provided for the generator.
PRIORITY: P1
REMEDIATION TIMEFRAME:5 WEEKS
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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
REMEDIATION TIMEFRAME:5 WEEKS
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
REMEDIATION TIMEFRAME:5 WEEKS
FINDING NO: E- 33
Boiler room.
CATEGORY:GENERATOR 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
REMEDIATION TIMEFRAME:5 WEEKS
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Denim Fashions Ltd.
FINDING NO: E- 34
DOL starter.
CATEGORY: SWITCH BOARD & PANEL
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
REMEDIATION TIMEFRAME:2 WEEKS
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