electrical safety inspection...

ELECTRICAL SAFETY INSPECTION REPORT

TARATEX FASHION LTD.

North Augh Para, Tongi, Gazipur

Factory List:

1. Taratex Fashion Ltd.

Inspected by: Luv Kumar Chhetri

Report Generated by: Luv Kumar Chhetri

Inspected on August 6th 2014

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Taratex Fashion Ltd.

ELECTRICAL SAFETY INSPECTION REPORT

TARATEX FASHION 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

3.1.1. 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

3.1.2. 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.

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3.1.3. 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 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.

3.1.4. 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: Taratex Fashion Ltd.

2. Factory Address: 6/1, NAimuddin Mollah Road, North Augh Para, Tongi,Gazipur,

Bangladesh

3. Accord ID: 10071

4. Inspection participates:

5. BUILDING DATA

A. General

Taratex Fashion Ltd. factory is housed in a G+5 storied rented factory building with total floor

area of 12744.72sqm and height 23.77m. The building was constructed in 2009; production

starts from 2012 and has 1000 workers presently working in the factory.

The building and floor wise utilization are as follows: GF: Dining, Child care, Warehouse, substation, Generator, Boiler and wastage godown F1: Finishing, Finished goods, Packing & Office F2: Cutting section, Medical & office F3: Sewing, Sample & Idle Machine area F4: Sewing (Only 50% occupied) F5: Under construction

Md. Anwar Hossain Asst. Manager Taratex Fashion Ltd. Mob: +88 01833317659 Email: [email protected] Md. Sarwar Jawarddar Electrical In-charge Taratex Fashion Ltd. Mob: +88 01833317667 Email: [email protected]

mailto:[email protected]

mailto:[email protected]

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B. Floor Layout Information

The figures below show factory site and machine layout plan:

Figure 1: Factory layout plan

Figure 2: 2nd floor machine layout plan Figure 3: 3rd Floor layout plan

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C. Electrical System

The main source of power for the factory is from DESCO. The 11KV power is step down to

415V by 1,250 kVA, oil filled, Betelco make transformer located at the ground floor of the

building. To meet the power requirement during the load shading, they have one 320 kVA,

Caterpillar make diesel generator which runs approximately for an hours a day. The two

supplies are selected from manual change over switches located inside control room near

substation. The power supply from COS is fed to Main control panel and then to individual

distribution board in each floor for further supply to SDBs.

Figure 4: 1250 kVA transformer

Figure 5: 320 kVA diesel generator

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D. Electrical Installations

11KV underground armoured HT cable is drawn from the OH line to HT meter and then to HT

breaker. Power cable is laid underground protected with GI pipe at the road crossing. HT cable

is partially laid on floor inside the HT panel room and partially in cable duct.

Both HT and LT have adequate protections; VCB on HT and ACB on LT side while MCCBs are

adequately installed for protections in each control panel, distribution panel and sub-

distribution panels.

LT cable inside control room is partially laid in duct and on cable tray while; it is laid in GI duct

inside production floors. Aluminium channel is being used for wiring support above the work

bench and GI channels below work bench with power socket mounded for machine

connections. In addition, concealed wiring and PVC surface wiring are also being done.

Figure 6: GI duct

Figure 7: Aluminium wiring duct

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E. Operation and Maintenance

Daily operation and maintenance of the electrical installations in the factory are carried out by

in-house by seven technical personnel. The schedule maintenance record sheet is maintained

for each installation as shown in figure 8 below.

As reported, the major maintenance of generator is looking after by BanglaCAT while for the

rest of the installations is outsourced to ENCON.

Figure 8: Schedule Inspection Chart

6. LIGHTNING PROTECTION RISK ASSESSMENT

Calculation of risk index for lightning protection

Sl.no. Index category Index Figure

A Usage of Structure 6

B Type of construction 2

C Contents or consequential effects 2

D Degree of isolation 5

E Type of area and terrain 2

F Height of structure 8

G Lightning prevalence 21

Total index Figure 46

Recommendation:

The total risk index figure being more than 40, hence, lightning protection system is required and

the factory has installed five lighting protections.

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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: As-build electrical Single Line Diagram (SLD) is not correct while, wiring layout design drawing is not prepared.

RECOMMENDATION: The factory must have corrected as-build 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-build SLD and drawings.

PRIORITY: P2

REMEDIATION TIMEFRAME: 10 WEEKS

FINDING NO: E- 2


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

RECOMMENDATION: Thermo graphic scanning of the entire electrical system must be performed on tri-annual basis and recorded.

PRIORITY: P2


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FINDING NO: E- 3


FINDING: Electric safety program is not initiated.

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

PRIORITY: P2


FINDING NO: E- 4

UG power cable lying on floor

CATEGORY:SERVICE LINE

FINDING: 11KV UG power cable partially laid on floor inside control room.

RECOMMENDATION: Underground power cable should be protected adequately in cable duct to full length.

PRIORITY: P2

REMEDIATION TIMEFRAME:24 WEEKS

FINDING NO: E- 5

Cable sleeve not provided

CATEGORY:SERVICE LINE

FINDING: No cable sleeve provided at the entry of 11KV UG power cable inside the electrical room. Cable not protected.

RECOMMENDATION: Cables must be drawn through cable sleeve at the wall crossing and the remaining opening must be sealed with fire rated material.

PRIORITY: P3


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FINDING NO: E- 6

Empty breather oil cup

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: 1 WEEK

FINDING NO: E- 7

Low oil level

CATEGORY: TRANSFORMER ROOM

FINDING: Oil level in transformer conservator tank is below the minimum requirement.

RECOMMENDATION: Transformer oil must be filled to the required level after shutdown.

PRIORITY: P2


FINDING NO: E- 8

Oil leakage from transformer


FINDING: Oil leakage from the transformer.

RECOMMENDATION:

Leakage must be identified during maintenance and repaired it as soon as possible. Preferably, Assign supplier company to take necessary steps as soon as possible

PRIORITY: P2

REMEDIATION TIMEFRAME:1 WEEK

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FINDING NO: E- 9

Leakage current collector connected to transformer body


FINDING: The leakage current collector of HT power cable is connected to the transformer body.

RECOMMENDATION: Leakage current collector of HT power cable should be grounded individually.

PRIORITY: P2


FINDING NO: E- 10

Transformer body connected to only one earth.


FINDING: Transformer body connected to only one earth. The earth wire connected to transformer body is not as per standard size.

RECOMMENDATION: Transformer body should be provided with two earth connection and should be done with solid Cu/GI wire or strip.

PRIORITY: P2


FINDING NO: E- 11

Cable termination without cable thimble

CATEGORY: TRANSFORMER ROOM

FINDING: Earth cable terminating at earth bar without lugs.

RECOMMENDATION: Provide appropriate size cable thimble/lugs for terminating the cable at the earth bar

PRIORITY: P3


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FINDING NO: E- 12

No rubber mat inside transformer room.


FINDING: Rubber mat not provided inside the transformer room.

RECOMMENDATION: Adequate rubber mat should be provided inside the transformer room and inside the control panel room.

PRIORITY: P3


FINDING NO: E- 13

Earth bonding missing

CATEGORY: SWITCH BOARD & PANELS

FINDING: Panel doors not connected with earth bond.

RECOMMENDATION: Panel door(s) must be connected with earth bond connecting frame and door.

PRIORITY: P3


FINDING NO: E- 14

Panels mounted directly on floor


FINDING: Panels are installed directly on concrete floor without base/plinth. No adequate space between floor and earth bar.

RECOMMENDATION: Panels must be mounted with base/plinth on the concrete floor. To avoid live parts coming in contact with water and easy operation and maintenance. (Base / Plinth can be supplied by the manufacture).

PRIORITY: P3


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FINDING NO: E- 15

Phase barrier missing


FINDING: Barrier/separators between different phases are not installed.

RECOMMENDATION: Install separators between different phases of MCCB. Standard separators provided by the MCCB manufacturer must be used.

PRIORITY: P3


FINDING NO: E- 16

Panel base plate not provided.


FINDING: Panel base plate removed to allow entry and exit of cables.

RECOMMENDATION: Make circular hole at the base plate and 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 hole of panels. Provide covers (of noncombustible material) if any additional gap remains after installing cable glands

PRIORITY: P3


FINDING NO: E- 17

Opening on wall not sealed

CATEGORY: CABLE & CABLE SUPPORT

FINDING: Opening on wall for cable tray left open

RECOMMENDATION: All openings on wall made for cable route must be sealed adequately with non-combustible material.

PRIORITY: P3


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FINDING NO: E- 18

PVC surface conduit unsupported

CATEGORY: WIRING

FINDING: PVC surface conduits are not supported adequately on wall.

RECOMMENDATION: Surface conduit must be supported adequately by clamp/saddle at regular interval.

PRIORITY: P3


FINDING NO: E- 19

PVC flexible conduit used in boiler room

CATEGORY: BOILER ROOM

FINDING: PVC flexible conduit used in boiler room. Flexible conduit hanging and not protected.

RECOMMENDATION: Steel flexible/spiral conduit should be use in boiler room. The conduit must be supported adequately or use rigid conduit for cable protections.

PRIORITY: P2


FINDING NO: E- 20

Wires exposed from different wiring system

CATEGORY: WIRING

FINDING: Wires exposed while transiting from concealed wiring to surface conduit wiring (Typical)

RECOMMENDATION: Provide circular junction box at the transitional point. Wires must be protected throughout the entire length in a wiring system.

PRIORITY: P3


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FINDING NO: E- 21

MCCBs installed closely


FINDING: Spacing around the MCCBs narrow and crowded inside panel.

RECOMMENDATION: Check and assess the distribution system. Additional panel may be installed to reduce cable load in the existing panel.

PRIORITY: P3


FINDING NO: E- 22

Wires exposed from concealed wiring.

CATEGORY: WIRING

FINDING: Wires are exposed from concealed wiring (Typical)

RECOMMENDATION: Conduit must be provided to full length of wiring. Use appropriate conduit at the surface to protect the wires.

PRIORITY: P2


FINDING NO: E- 23

Deposit of lint on MCCB


FINDING: Deposit of lint and dust on the surface of MCCB and cable inside the distribution panel.

RECOMMENDATION: Clean inside panels periodically. Electrical installations should be free from lint and dust. All panels must be vermin proof.

PRIORITY: P1

REMEDIATION TIMEFRAME: IMMEDIATELY

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FINDING NO: E- 24

Ends of wiring duct left open

CATEGORY: CABLES & CABLE SUPPORT

FINDING: MS wiring dust below work bench not covered at ends. Excess deposit of lint inside wiring ducts.

RECOMMENDATION: Wiring duct must be closed from all ends to prevent ingression of lint and dust. Clean the ducts regularly as normal operation and maintenance.

PRIORITY: P1


FINDING NO: E- 25

Aluminium channel open from top and ends.


FINDING: Aluminium channel is open from top and end cover not provided. Wiring duct has deposit of lint and dust.

RECOMMENDATION: Wiring duct must be covered from top and ends should be sealed to prevent the ingression of lint and dust. Clean the wiring duct regularly.

PRIORITY: P2

REMEDIATION TIMEFRAME:8WEEKS

FINDING NO: E- 26

Improper wiring joints


FINDING: Wire/cable joints in wiring systems are not properly done and not protected adequately. Insulation done with plastic tape.

RECOMMENDATION: Wires/cable must be terminated at terminals or use appropriate jointing. PIB tape and heat-shrink tubes may be used for insulation.

PRIORITY: P2


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FINDING NO: E- 27

Ceiling fan connected without ceiling rose

CATEGORY: WIRING

FINDING: Ceiling fan connection done without ceiling rose.

RECOMMENDATION: Ceiling fan and ceiling fittings should be connected from ceiling rose.

PRIORITY: P3


FINDING NO: E- 28

Deposit of lint inside socket box


FINDING: Deposit of lint and dust inside the power socket box.

RECOMMENDATION: Power socket must be installed properly to prevent ingression of lint and dust. Clean the box and check frequently.

PRIORITY: P2

REMEDIATION TIMEFRAME:4WEEKS

FINDING NO: E- 29

Cable exposed from the floor


FINDING: Cables are exposed from the floor while transiting from surface conduit to concealed under floor (Typical).

RECOMMENDATION: Provide cable protections at the base of the wall. Cable must be protected to full length.

PRIORITY: P3


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FINDING NO: E- 30

Inconsistency in MCCB rating


FINDING: Inconsistency between the reading and rating of MCCB installed.

RECOMMENDATION: Measurement should be taken during the peak load time and accordingly replace high current rated MCCB with appropriate one.

PRIORITY: P2


FINDING NO: E- 31

Flexible conduit not supported adequately

CATEGORY: WIRING

FINDING: Surface wiring in PVC flexible conduit not supported adequately.

RECOMMENDATION:

Surface conduit should be supported adequately at regular interval with clamp/saddle.

PRIORITY: P3


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