ELECTRICAL SAFETY INSPECTION REPORT A & B OUTERWEAR LTD. Plot # 29-30, CEPZ, Chittagong, Bangladesh. Factory List: 1. Inspected by: Al-Amin Report Generated by: Al-Amin Inspected on March 7 th 2015
SUMMARY The factory is established in owned three building and four shed. Building-1 is three storied; Building-2 is two storied and building three is one storied. Building-1 was constructed in 2010 and production started in same year. Building-2 was constructed in 2011 and production started in same year. Building-3 was constructed in 2011. The factory had approximately 1114 workers. 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. Page 2 of 12
FINDINGS AND RECOMMENDATIONS FINDING NO: E- 1 Thermographic scanning of the entire electrical system has not been performed. Thermographic scanning of the entire electrical system must be performed twice in a year. FINDING NO: E-2 Electrical Single Line Diagram (SLD) is unavailable. Have a qualified engineer to create an as-built electrical SLD, mentioning all the required information, and get it reviewed by Accord. REMEDIATION TIMEFRAME: 12 WEEKS FINDING NO: E- 3 Insulation resistance test of electrical equipment is not performed. Insulation resistant test of all the cables must be performed once every 2 year cycle and recorded (this must require a complete power shut off). Page 3 of 12
FINDING NO: E- 4 Electric safety program is not initiated. Electrical safety training and awareness program for the electrical personnel and workers must be initiated and recorded. FINDING NO: E- 5 Factory does not have maintenance record. Maintenance Manager or Safety Officer must keep accurate records and ensure that they reflect actual factory day to day operations. FINDING NO: E- 6 Transformer Oil Test report is unavailable. Check the transformer oil condition by performing oil test, this must be done twice a year and recorded. FINDING NO: E- 7 Earth Pit resistance record is unavailable. Record earth pit resistances for all the earth pits, and do it once a year. Page 4 of 12
FINDING NO: E-8 Instruction for CPR (Cardiopulmonary Resuscitation) or Electrical shock restoration is not present. Hang this first aid and CPR instructions near all electrical equipment (LT panel, MDB, FDB, DB, SDB) on a visible location. FINDING NO: E- 9 CATEGORY: CABLE & CABLE SUPPORTS Wire is used in place of DO fuse and HT cables dropping from 11kV OH line not supported firmly to the pole. Replace the wire with standard DO fuse and the HT cable dropping from 11kV pole must be firmly fixed to the pole with supports and clamps. HT cable protected by DO fuse, dropping from pole. FINDING NO: E- 10 CATEGORY: TRANSFORMER ROOM No separation between LT panels and HT units (transformer, HT switchgear). Make a brick built separation between LT and HT units; ensure that after making separator you have adequate ventilation (cross ventilation) and working clearance around each electrical equipment. PRIORITY: P3 REMEDIATION TIMEFRAME: 16 WEEKS 315 kva transformer in substation. Page 5 of 12
FINDING NO: E- 11 CATEGORY: TRANSFORMER ROOM HT cable laid over the LT cables. Cables of different voltage levels must be separated in different trays. HT and LT cable. FINDING NO: E- 12 CATEGORY: TRANSFORMER ROOM No space around transformer for performing maintenance work. Ensure a minimum 1.07m working space around the transformer. REMEDIATION TIMEFRAME: 16 WEEKS 500 kva transformer in substation. FINDING NO: E- 13 CATEGORY: TRANSFORMER ROOM Oil leakage has been observed from transformer. Stop oil leakage from transformer and keep top of transformer clean. 500 KVA transformer Page 6 of 12
FINDING NO: E- 14 CATEGORY: TRANSFORMER ROOM Silica gel inside the breather is replaced by pebbles. Remove the pebbles from breather and replace it by silica gel after thorough cleaning of breather. The oil cup attached to breather must be filled by clean transformer oil. Transformer breather FINDING NO: E- 15 CATEGORY: EARTHING SYSTEM Impedance of main earthing of factory electrical system is very high (255.7 ohms) Check properly may be loose connection is one of the cause. Main earthing busbar. FINDING NO: E- 16 No base plate and compression gland, excessive dust, lint and debris deposit underneath the panel (typical issue). Dust, lint and debris must be thoroughly cleaned to avoid fire hazard. Provide covers (of noncombustible material) if any additional gap remains after installing cable glands. LT panel. Page 7 of 12
FINDING NO: E- 17 Cable connected MCCB without Lug. (Typical issue) Cable must be connected to MCCB by cable lug. MCCB inside the LT panel. FINDING NO: E- 18 Cable connected to busbar without lug (typical). Cables must be connected to busbar with proper size of cable lug. Bus bar inside the LT panel FINDING NO: E- 19 CATEGORY: EARTHING SYSTEM Earthing system of LT panel is not properly done. (Typical) Every panel must be used earthing busbar. Inappropriate earthing Page 8 of 12
FINDING NO: E- 20 CATEGORY:CABLE & CABLE SUPPORTS Cable passes through wall are not protected and not supported. Cable must be supported by cable tray and remaining gap is must be sealed. Distribution cables FINDING NO: E- 21 Phase barrier/separator not installed (typical issue). Put a purposely made phase separator (rubber type) between two phases; also terminate cables by proper sized cable lugs and cover cable lugs by heat shrink. Cables terminating at MCCB in panel on production floor. FINDING NO: E- 22 CATEGORY: CABLE & CABLE SUPPORTS Cables are covered by lint and dust. Thoroughly clean the combustible materials. Suggested to include in routine cleanliness/maintenance work. Distribution cables Page 9 of 12
FINDING NO: E- 23 CATEGORY: WIRINGS Cable duct/channels have excessive lint/dust (typical issue). Clean all the cable channels/ducts and cover them with checkered/perforated plates. Cable raceways in production floor. FINDING NO: E- 24 Hot spots detected at termination point of MCCB due to loose connection. (72 degree) Arrange periodic inspection & thermal scan to identify the overloading, loose connection, unbalanced load which may cause the excessive heat-rise and take action immediately REMEDIATION TIMEFRAME: 4 WEEKS Hot spot inside distribution board. FINDING NO: E- 25 Multiple cable termination at a terminal of MCCB (typical issue). Multiple cables connecting at a MCCB terminal must be disconnected. Existing multiple circuits may be distributed through bus bars. REMEDIATION TIMEFRAME: 2 WEEKS Cable terminating at MCCB in panel. Page 10 of 12
FINDING NO: E- 26 Cables inside distribution board is disorganized. Organize all the power cables securely and neatly inside distribution board to prevent from electrical hazards. Panel on ground floor. FINDING NO: E- 27 Power cables are bent excessively (typical issue). Avoid power cable bending in electrical system; in unavoidable case bend cables without any stress but not less than 135 degrees. Cable terminating at MCCB inside distribution board. FINDING NO: E- 28 Multiple cables connected in the busbar through a single lug (typical issue). Every cable must be connected to the busbar through its own single lug (one lug per cable). REMEDIATION TIMEFRAME: 4 WEEKS Wires terminating at busbar inside panel. Page 11 of 12
FINDING NO: E- 29 MCCB without enclosure and mounted on wooden plank. Remove the wooden plank. Provide standard MCCB protective enclosures. REMEDIATION TIMEFRAME: 4 WEEKS Cables terminating at MCCB. Page 12 of 12