ELECTRICAL SAFETY INSPECTION REPORT - …bangladeshaccord.org/wp-content/uploads/Fulpur-Knit-Garments-Ltd... · ELECTRICAL SAFETY INSPECTION REPORT FULPUR KNIT & GARMENTS LTD 1/1

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ELECTRICAL SAFETY INSPECTION REPORT

FULPUR KNIT & GARMENTS LTD

1/1 Sataish, Tilargati Road, Tongi

GPS Co-ordinate: 23.916162, 90.370541

Inspected by : Shafi Md. Imran & Shaik Muhammed Wasi Report Generated by : Shafi Md. Imran

Inspected on: August 16, 2016

Page 2 of 17 FULPUR KNIT & GARMENTS LTD, ID 12399

SUMMARY

The Factory was surveyed for electrical safety by Stichting Bangladesh Accord

Foundation. 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.

Electrical Safety Audit is a methodical approach to evaluate potential electrical hazards

and to recommend suggestions for improvement. 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.

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.

Fulpur Knit & Garments Ltd factory is established in its 4 storied production buildings of

RCC construction (Knitting, Cutting, Sewing and Finishing) with 1 adjacent tin shed room

for generator. As reported by the Factory Management, the production building was

constructed in around December, 2008 and the production began in around January

2009. During the time of the Inspection, the factory accommodated a total of 145 workers

working in this factory in single shift.

Fulpur Knit & Garments Ltd factory premise 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 11 kV DO fuse. The 11kV supply is stepped down by250 kVA x 1 no,

11/0.415kV, 3 phase power transformer installed in substation located in ground floor of

main production building. Electrical system and utility installation information at a glance:

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 sometimes outsourced to the service centers.

Inspecting teams were presented with no maintenance programs, logs and maintenance

schedule of the factory’s electrical facilities; however, the factory need to have a detailed

maintenance schedule.


FINDINGS AND RECOMMENDATIONS

The table below summarizes the major electrical hazards identified during the walk

through 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: DOCUMENTATION

FINDING:

Electrical Single Line Diagram (SLD) is unavailable.

RECOMMENDATION:

Draw as built electrical SLD mentioning all required information by qualified engineer and get it reviewed by Accord.

PRIORITY: P2

REMEDIATION TIME FRAME: 3 MONTHS

FINDING NO:

E - 2

CATEGORY: TESTING & PERIODIC MAINTENANCE

FINDING:

Thermography scanning report is unavailable.

RECOMMENDATION:

Keep a thermography scanning record of your electrical system at least twice a year.

PRIORITY: P2



FINDING NO:

E - 3


FINDING:

(1) Earth Pit resistance record is unavailable. (2) Earth pits are not identifiable

RECOMMENDATION:

(1) All earthing systems shall be tested for resistance on any dry day not less than once in every two years. A record of every earth test made and the result shall be kept for not less than two years and shall be available to the Inspector when required. (2) Identify each earth pit and mark it for periodic maintenance purpose. PRIORITY: P2


FINDING NO:

E - 4


FINDING:

Insulation resistance test of electrical cable is not performed

RECOMMENDATION:

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).

PRIORITY: P2


FINDING NO:

E - 5


FINDING:

Electric safety training program is not initiated/conducted.

RECOMMENDATION:

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

PRIORITY: P2



FINDING NO:

E - 6


FINDING:

Transformer Oil Test report is unavailable.

RECOMMENDATION:

Check the transformer oil condition by performing oil test. Do it once in a year and keep the record.

PRIORITY: P2


FINDING NO:

E - 7

CATEGORY: LIGHTNING PROTECTION SYSTEM

FINDING:

Lightning Protection System (LPS) has not installed.

RECOMMENDATION:

Design and Install LPS for your factory.

PRIORITY: P1


FINDING NO:

E - 8

CATEGORY: CABLE & CABLE SUPPORTS

FINDING:

HT Cable dropping from 11kV OH line is not firmly supported to the pole.

RECOMMENDATION:

HT cable dropping from 11kV pole must be firmly fixed to the pole with supports and clamps.

PRIORITY: P3



FINDING NO:

E - 9

CATEGORY: GENERATOR ROOM

FINDING:

Generator body has been earthed by inadequate sized (type) cable.

RECOMMENDATION:

Two separate and distinct earth connection must be provided over generator. Generator body must have earth connection with half of phase conductor. Or follow manufacturer/supplier’s recommendation.

PRIORITY: P3

REMEDIATION TIME FRAME: 1 MONTH

FINDING NO:

E - 10


FINDING:

Generator output cables (laid on floor) are not protected and supported.

RECOMMENDATION

If possible, route all the power cable through overhead cable tray. Or ensure adequate protection for power cables arranging cable trench with checkered plate. Do not make any arrangement that obstacle personnel's movement within working clearance.

PRIORITY: P2


FINDING NO:

E - 11


FINDING:

Storage in generator room

RECOMMENDATION:

Remove all the unused materials from the generator room. Establish a routine cleaning program as a part of regular maintenance to keep the electrical room dust and vermin proof as well as preventing spread of fire.

PRIORITY: P2



FINDING NO:

E - 12

CATEGORY: SUBSTATION ROOM

FINDING:

No separation between LT panels and HT units (Transformer, HT switchgear).

RECOMMENDATION:

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: P2


FINDING NO:

E - 13


FINDING:

Cables are laid on floor without any support.

RECOMMENDATION:

Provide cable tray inside cable drain and cover it by checkered plate.

PRIORITY: P2


FINDING NO:

E - 14


FINDING:

Substation room has inadequate ventilation.

RECOMMENDATION:

Ensure/Arrange cross ventilation substation room; You may use fire damper if you have to keep any opening on the corridors/egress path/exit.

PRIORITY: P1



FINDING NO:

E - 15


FINDING:

Transformer Breather oil cup is empty.

RECOMMENDATION:

Fill the transformer breather oil cup by transformer oil.

PRIORITY: P2


FINDING NO:

E - 16


FINDING:

Oil leakage has been observed from transformer.

RECOMMENDATION:

Stop oil leakage from transformer and keep clean top of transformer.

PRIORITY: P1


FINDING NO:

E - 17

CATEGORY: DISTRIBUTION BOARD/PANEL

FINDING:

No rubber (insulation) mat on the working area of distribution board/panel.

RECOMMENDATION:

Put electrical insulation (rubber mat) on the working area of each electrical installation (Transformer/LT panel/MDB/DB/SDB/ other manual operated machineries). PRIORITY: P2



FINDING NO:

E - 18


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


FINDING NO:

E - 19


FINDING:

Phase barrier/separator has not installed.

RECOMMENDATION:

Put purposely made phase separator (rubber type) between two phases; also terminate cables by proper sized cable lugs and cover cable lugs by heat shrink.

PRIORITY: P2


FINDING NO:

E - 20


FINDING:

Circuits are drawn from bus bar without Circuit breaker or any protective means.

RECOMMENDATION:

For distribution board, along with the main circuit breaker all outgoing circuits shall have individual outgoing circuit breaker.

PRIORITY: P2



FINDING NO:

E - 21


FINDING:

Panel doors are not connected with earth.

RECOMMENDATION:

All metal panel doors shall have earth connection by at least 4 mm² earth cable.

PRIORITY: P2


FINDING NO:

E - 22


FINDING:

Distribution boards are filled with fluffs (lint/dust).

RECOMMENDATION:

Keep always clean inside all the distribution boards/panels. Seal them properly and ensure adequate ventilation.

PRIORITY: P3


FINDING NO:

E - 23


FINDING:

Multiple cables terminated at MCCB terminals/ Bus bar.

RECOMMENDATION:

Terminate each power cable at single terminal and use proper sized cable lug.

PRIORITY: P2



FINDING NO:

E - 24


FINDING:

Cables terminated at electrical bus bar/MCCB without cable lugs.

RECOMMENDATION:

Terminate all the power/earth/neutral cable with proper sized cable lug.

PRIORITY: P2


FINDING NO:

E - 25


FINDING:

Multiple cables connected in the bus bar through single lug.

RECOMMENDATION:

Each cable must be connected in the bus bar through single lug.

PRIORITY: P2


FINDING NO:

E - 26


FINDING:

Oversized circuit breakers or Circuit breakers are not adjusted accordingly.

RECOMMENDATION:

Adjust or replace all the MCCBs/MCBs according to cable ampacity (connected load). Avoid using different sized cable at the terminals.

PRIORITY: P2



FINDING NO:

E - 27

CATEGORY: Choose an item.

FINDING:

Light in store room / storage areas is uncovered.

RECOMMENDATION:

Lights in store room / storage areas shall be covered.

PRIORITY: P2


FINDING NO:

E - 28


FINDING:

The compressors installed temporarily.

RECOMMENDATION:

Compressors must be locked to prevent compressor from unintentional movement during operation.

PRIORITY: P3


FINDING NO:

E - 29


FINDING:

MCB are hanged without support.

RECOMMENDATION:

MCB shall be supported and fixed properly.

PRIORITY: P2



FINDING NO:

E - 30


FINDING:

MCB is installed without any enclosure.

RECOMMENDATION:

Need to provide electrical graded enclosure.

PRIORITY: P2


FINDING NO:

E - 31

CATEGORY: CABLE & CABLE SUPPORTS

FINDING:

Cables are hanging without support. Cable terminals may be in tension.

RECOMMENDATION:

Use cable tray/ladder to support cables at anywhere to keep cable out of tension.

PRIORITY: P2


FINDING NO:

E - 32


FINDING:

Distribution board does not have permanent Identification markings (typical).

List of circuit or SLD of existing circuits are not available in each electrical panel board.

RECOMMENDATION:

Provide clear and permanent identification marks in all distribution boards. List of circuit or SLD of existing circuits shall be available for each electrical panel board.

PRIORITY: P3



FINDING NO:

E - 33

CATEGORY: BOILER & COMPRESSOR

FINDING:

Wiring has done using flexible PVC cable around vertical boiler surface.

RECOMMENDATION:

Wires close/attached to boiler must be protected from external heat. In unavoidable case use metal type flexible pipe. Again Power cable should keep 0.9m apart from hot area.

PRIORITY: P2


FINDING NO:

E - 34

CATEGORY: BOILER & COMPRESSOR

FINDING:

Motor not firmly fixed on the foundation/frame.

RECOMMENDATION:

Motor shall be fixed firmly on the concrete floor.

PRIORITY: P3


FINDING NO:

E - 35

CATEGORY: WIRING SYSTEM

FINDING:

Cables in service are joined (splicing) improperly between terminations.

RECOMMENDATION:

Existing cables with joints must be spliced using butt splicing kits and then should be insulated with electrical tapes. Joints must be supported and protected.

PRIORITY: P2



FINDING NO:

E - 36

CATEGORY: CABLE RACEWAY & TRENCH

FINDING:

Cable duct/channels are filled with fluffs (Lint/dust) and not covered.

RECOMMENDATION:

Clean all the cable channels/ducts; then cover them (you may use checkered / perforated plate at the bottom). And after each maintenance, keep record.

PRIORITY: P2


FINDING NO:

E - 37


FINDING:

Wooden cable channel/ducts used for power distribution.

RECOMMENDATION:

Replace wooden cable channel/ducts by non-combustible material (iron, aluminum etc.). Ensure that the metal structure has connection.

PRIORITY: P2


FINDING NO:

E - 38

CATEGORY: EARTHING SYSTEM

FINDING:

Earth lead cable/Earth Continuity Conductor size is inadequate/undersize.

RECOMMENDATION:

Resize earth lead cable/ECC for LT panel/MDB/DB; follow BNBC 2006 Part 8 chapter 2 section 2.8 for sizing your earthing cables (Usually ECC should be equal to the half of the respective phase cable).

PRIORITY: P2



FINDING NO:

E - 39


FINDING:

Panel/Distribution boxes are inaccessible or cannot be opened to perform any maintenance work.

RECOMMENDATION:

Take necessary initiative thus every panel/distribution board can be easily accessible.

PRIORITY: P2


FINDING NO:

E - 40


FINDING:

Cables passing through wall/floor slab are not protected at the entry/exit point(s).

RECOMMENDATION:

Cables passing through permanent wall/floor slab must be protected. Seal the opening by fire rated material protecting power cables thus no smoke can pass through this.

PRIORITY: P2


FINDING NO:

E - 41


FINDING:

Personal Protective Equipment (PPE) for Electrical Work is not available.

RECOMMENDATION:

Personal Protective Equipment (PPE) must be arranged by the factory management team for the safety of their employee and worker

PRIORITY: P1



FINDING NO:

E - 42


FINDING:

There is no programmed schedule for periodical inspection & testing of electrical equipment.

RECOMMENDATION:

Develop an electrical maintenance program that includes inspections and testing of the electrical systems (preventive, proactive and breakdown maintenance)

PRIORITY: P3


Documents

ELECTRICAL SAFETY INSPECTION REPORT - …bangladeshaccord.org/wp-content/uploads/Fulpur-Knit-Garments-Ltd... · ELECTRICAL SAFETY INSPECTION REPORT FULPUR KNIT & GARMENTS LTD 1/1