ELECTRICAL SAFETY INSPECTION REPORTaccord.fairfactories.org/accord_bgd_files/1/Audit_Files/12753.pdf · Page 3 of 17 Abir Fashions FINDINGS AND RECOMMENDATIONS FINDING NO: E- 1 CATEGORY:

ELECTRICAL SAFETY INSPECTION REPORT

ABIR FASHIONS

Kutubail, Fatullah (Post Office Road), Narayangonj, Bangladesh

Factory List:

1. Abir Fashions

Inspected by: Pema Wangdi & Mamun

Report Generated by: Pema Wangdi

Inspected on August 30th 2014

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Abir Fashions

SUMMARY The Abir Fashions factory is established in five adjoined buildings and a shed. Building 1, 2, 3, 4 and 5

are 7(G+6), 4(B+G+2), 4(B+G+2), 3(G+2) and 2(G+1), storied respectively. Most of the production

activities take place in building 1. All five buildings including the shed are owned by the factory.

As reported by the Management of the factory, the buildings were constructed in 2005, 2007, 2007,

2007 and 2011 respectively. The factory started its production in building 1 in the year 2007. The

building has been formally approved for industrial purpose. During the time of the Inspection, the

factory accommodated a total of about 1015 workers working on regular basis.

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 will be further addressed 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. An 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 approval.

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Abir Fashions

FINDINGS AND RECOMMENDATIONS

FINDING NO: E- 1

CATEGORY: DESIGN, DRAWINGS & RECORDS

FINDING: 1. As-built electrical SLD, wiring layout designs and drawings, machine layouts are not prepared

2. Thermo graphic scanning of the entire electrical system has not been performed

3. Electric safety program is not initiated

4. Factory does not have maintenance report.

5. Factory does not have insulation test report.

RECOMMENDATION:

1. The factory must have As-built electrical SLD with electrical wiring layout designs and drawings.

Any changes in load, protection system, conductors, Generation and supply system must be

reflected in the As-built SLD and drawings.

2. Thermo graphic scanning of the entire electrical system must be performed on tri-annual basis

and recorded

3. Electrical safety training and awareness program for the electrical personal and workers must be

initiated and recorded

4. Factory must have maintenance report.

5. Factory must have insulation test report.

PRIORITY: P3

REMEDIATION TIMEFRAME: 5 WEEKS

FINDING NO: E- 2

Transformer room

CATEGORY: TRANSFORMER ROOM

FINDING: Transformer is not separated from substation by barricaded wall.

RECOMMENDATION:

Construct fire rated brick wall up to the ceiling around the transformer to separate it from other occupancy and install louvers and exhaust fan for cooling the transformer room.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 3

Transformer room

CATEGORY: SERVICE LINE

FINDING: HT cable laid over the LT cables.

RECOMMENDATION: HT and LV cables must be laid in different trays to avert the crossover.

RIORITY: P2

REMEDIATION TIMEFRAME:10 WEEKS

FINDING NO: E- 4

Changeover switch

CATEGORY: SWITCH BOARD & PANELS

FINDING: Openings in the changeover switch top and base cover plate.

RECOMMENDATION: Cables must be firmly fixed and terminated using cable glands and enter through base/gland plates. The panels must be protected from intrusion of large insects and animals (mice, lizards, snakes).

PRIORITY: P2


FINDING NO: E- 5

Power transformer


FINDING: Transformer breather not installed.

RECOMMENDATION: Transformer breather must be installed to prevent ingress of moisture into transformer oil.

PRIORITY: P1


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Abir Fashions

FINDING NO: E- 6

LT panels in the electrical room


FINDING: Panel base plates removed to allow cable entry. (Typical)

RECOMMENDATION: Install the base/top plate (metal) with the provision of gland fixation for cable entry.

PRIORITY: P2


FINDING NO: E- 7

Main distribution panel


FINDING: Insufficient working clearance around the panel.

RECOMMENDATION: Panels must be rearranged in such a way that the opening of door of any panel must not be obstructed others panel. Provide 1 m clearance around LT panel for easy operation and maintenance.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 8

Motor power cables


FINDING: Cables encased in flexible pipes are not supported and protected.

RECOMMENDATION: The rigid pipes/tray should be used for surface wiring instead of using flexible pipes and it should be properly supported (clamped with saddle, at regular interval of 600 mm).The pipes shall run vertically or horizontally, shall never at angle.

PRIORITY: P3


FINDING NO: E- 9

Generator frame earth

CATEGORY: GENERATOR ROOM

FINDING: High earth loop impedance measured.

RECOMMENDATION: Check the earthing connection (for loose connections) and rectify as required.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 10

Exhaust fan in the production floor

CATEGORY: EQUIPEMENT & 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- 11

Cable trench in the generator room

CATEGORY: LIGHTNING PROTECTION & EARTH

FINDING:

Cover of cable trench made of combustible materials (wooden plank).

RECOMMENDATION: Remove all combustible covers. Metallic cover (checkered plate) should be provided on cable trench to prevent risk of spreading fire due to short circuit.

PRIORITY: P2


FINDING NO: E- 12

Generator control panel

CATEGORY: GENERATOR ROOM

FINDING: Cables entering/exiting the generator control panel from top plate without gland.

RECOMMENDATION: Provide cable gland according to the respective cable size for cable entry and exit so that the cables are not stressed on the sharp edges of the gland holes of the panel. Provide covers (of noncombustible material) if any additional gap remains after installing cable glands.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 13

Generator and AVR panel


FINDING: Generator and AVR panel base plates removed to allow cable entry.

RECOMMENDATION: Provide cover made of noncombustible material preferably metallic sheet along with cable gland same as the cable size at the cable entry and exit so that it prevents the ingression of lint and dust through entry and exit hole of the panel board.

PRIORITY: P2


FINDING NO: E- 14

Protective device mounted on wall

CATEGORY: CABLE & CABLE SUPPORT

FINDING: MCBs and MCCB mounted on wall without proper enclosure.

RECOMMENDATION: MCBs and MCCB (electrical devices) mounted on wall must be encased in metal enclosure made of steel sheet of thickness 20 SWG.

PRIORITY: P1


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Abir Fashions

FINDING NO: E- 15

Boiler room


FINDING:

Cables passing through walls are not protected through the wall and not supported near entry point(s).

RECOMMENDATION:

Cables passing through permanent walls must be protected with rigid conduits/pipes and supported near entry point. The remaining opening must also be sealed with fire rated material.

PRIORITY: P2


FINDING NO: E- 16

Distribution board in the production floor


FINDING: Three phase MCCB connected to control two phases or less.

RECOMMENDATION: Check and redesign the requirements to control the circuits. If three phase control is not required, then replace with suitable control devices.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 17

Cable duct made up of wood


FINDING: Wooden channel used as cable duct.

RECOMMENDATION: Disconnect the electric supply and remove the wooden channel. Install cable channel made of noncombustible material preferably metal to safely support and protect the cables.

PRIORITY: P2


FINDING NO: E- 18

PVC flexible conduit


FINDING: Cables/wires passing through floor are not protected and remaining gaps around the cable/wiring are not sealed. The cable ladder or riser is not installed for feeding power from the substation located in the ground floor to the upper production floors.

RECOMMENDATION: Cables/wirings passing through floor must be protected installing covered cable tray/raceway/rigid pipes and remaining gaps must be sealed with fire resistant materials. The flexible PVC conduit must be replaced with cable tray/raceway to support the cable throughout its length.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 19

Distribution board in the production floor


FINDING: Multiple wires installed in single lug/terminal. (Typical)

RECOMMENDATION: Terminate each cable proving individual lug according to the cable size. Multiple cables shall not be terminated on a single point of the bus-bar.

PRIORITY: P2


FINDING NO: E- 20

The distribution board in the production floor

CATEGORY: SWITCH & PANEL BOARDS

FINDING: Multiple cables terminating into MCCB terminal.

RECOMMENDATION: Multiple cables connecting to MCCB terminal must be avoided. Individual protective device must be provided for the protection of each circuit/load.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 21

Distribution panel in the production floor

CATEGORY: SWITCH & PANEL BOARDS

FINDING: Distribution panel not connected to earth. Panel doors not connected with earth bond. (Typical)

RECOMMENDATION:

Provide earth connection for body and doors of metallic distribution boards using green cables preferably braid so that the metallic door remains at zero potential all the time.

PRIORITY: P2


FINDING NO: E- 22

Aluminum cable duct in the production floor.


FINDING: Open cable ducts used.

RECOMMENDATION: Provide cover on cable ducts made of non-combustible material preferably metallic sheet to protect the cables’ insulation from physical damage as well as prevent the ingress of debris, dust and lint.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 23

Distribution panel in the production room

CATEGORY: SWITCH BOARD & PANEL

FINDING: Multiple cables terminated at a single point of the bus bar. (Typical)

RECOMMENDATION: Avoid multiple connections. Terminate individual cables at individual point of bus bar. Provide copper cable-socket, copper nut-bolt, and copper washer for termination

PRIORITY: P2


FINDING NO: E- 24

The wiring in the storage room and production floor

CATEGORY: WIRING

FINDING: Wires drawn along the wall and floor without conduit.

RECOMMENDATION: The PVC/rigid pipe (instead of flexible conduit) must be used for wiring and must be continuous through-out its length, properly supported (clamped with saddle, at regular interval of 600 mm).The conduit shall run vertically or horizontally, shall never at angle.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 25

Distribution panel in the production floor.


FINDING: The cables drawn in PVC flexible conduits are drawn along with water pipe line.

RECOMMENDATION: The cable drawn along the flexible PVC conduit must be drawn in aluminum channel. The aluminum channel must be separated from water line with minimum 0.9 meter.(900 mm)

PRIORITY: P2


FINDING NO: E- 26

Compressor room


FINDING: Cables encased in flexible pipes not supported and it’s drawn along the CGI sheet.

RECOMMENDATION: Install cable tray or rigid pipe to route and protect the cables. The flexible PVC conduit must not be drawn along the CGI sheet.

PRIORITY: P1

REMEDIATION TIMEFRAME:1 WEEK

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Abir Fashions

FINDING NO: E- 27



FINDING: Cables connecting to MCCB inside panel without cable lugs.

RECOMMENDATION: Cables shall be connected to terminals only by cable lugs according to cable size.

PRIORITY: P2

REMEDIATION TIMEFRAME:1 WEEK

FINDING NO: E- 28

Distribution panel in the compressor room


FINDING: Insufficient working space around the panel.

RECOMMENDATION: Panels must be rearranged in such a way that the opening of door of any panel must not be obstructed others panel. Provide 1 m clearance around LT panel for easy operation and maintenance.

PRIORITY: P2


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Abir Fashions

FINDING NO: E- 29



FINDING: Cables terminated to bus bar without lugs.

RECOMMENDATION: Terminate cables to bus bar by using proper sized lugs and punch the lugs by proper hand puncher or hydraulic puncher. Periodic inspection is needed to keep all the contacts tight.

PRIORITY: P2


FINDING NO: E- 30

The wiring inside the PVC conduit

CATEGORY: WIRING

FINDING: Wires exposed while extending from the main conduit to the other. (Casing capping T junction not installed)

RECOMMENDATION: Provide PVC pipe to support and protect the cables throughout its length. Wiring exposed between different wiring systems may be prevented by selecting appropriate adapter to connect two wiring system.

PRIORITY: P2

REMEDIATION TIMEFRAME:5WEEKS

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Abir Fashions

FINDING NO: E- 31

Compressor room.

CATEGORY: BOILER & COMPRESSOR ROOM

FINDING: Compressor input cables drawn in the flexible PVC conduit laid on floor without protection.

RECOMMENDATION: Use steel pipe/cable tray to ensure the mechanical protection of the cable laid on floor otherwise cable insulation may damage due to falling object or stepping of occupants onto it.

PRIORITY: P2


Documents

ELECTRICAL SAFETY INSPECTION REPORTaccord.fairfactories.org/accord_bgd_files/1/Audit_Files/12753.pdf · Page 3 of 17 Abir Fashions FINDINGS AND RECOMMENDATIONS FINDING NO: E- 1 CATEGORY: