electrical safety inspection report - accord...

ELECTRICAL SAFETY INSPECTION REPORT

ALIF GARMENTS Ltd, Dhaka, Bangladesh

Prepared for:

JANUARY 14, 2014

Accord – Bangladesh RMG Electrical Safety Inspection Alif Garments Ltd. PAGE 1

SUMMARY

The seven-story factory housing Alif Textiles Ltd. & Hexa Garments Ltd. located in Dhaka, Bangladesh was surveyed for Electrical Safety on 06 December 2013 by Woosun Energy and Construction Co Ltd. This summary identifies the critical and major deficiencies that were identified during the inspection as documented in the Electrical Safety Inspection Report, dated 14 January 2014, submitted to the Accord.

The factory building was surveyed 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 inspection was limited to the review and identification of critical and 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 1 summarizes the critical and major electrical safety issues identified during the inspection. Recommendations have been provided to address each issue. Reference photos are provided in Attachment 1.

An implementation schedule shall be developed by the factory to remediate each of the findings in Table 1. The specific timing of improvements, including any requested extensions due to design / installation constraints, shall be submitted to the Accord for approval.


Table 1. Findings and Recommendations

No. Category Finding Recommendation Timeline Photo

Ref

E-1 Transformer and service line

The service lines (cables) from pole mounted outdoor transformer to 6th floor are strung without support and protection against harsh weather.

The cables must be weather resistant and supported with steel wire. It is recommended that the cables be drawn underground from pole to the factory building.

Within 3 months

E.1

E-2 Service line from another pole mounted transformer is drawn on the 2nd floor unsupported.

The cables must be weather resistant and supported with steel wire. It is recommended that the cables be drawn underground from pole to the factory building.

Within 3 months

E.2

E-3 The remaining opening after passing the service cables through wall on 6th floor is not sealed.

The openings must be sealed corresponding to the fire rating required in the compartment/room after the cables re-drawn.

Within 3 months

E.3

E-4 440KVA Diesel Generator set

Generator is located at the ground floor left of entrance with door opening towards the entrance.

Refer to fire safety recommendations; change the door opening to avoid the main entrance.

Within 3 months

E.4

E-5 Cables entering/leaving the terminal box are connected without cable gland and base pate.

Cables terminating must be fixed using cable glands and the terminal box base must be closed with gland plates.

Within 3 months

E.5

E-6 Cables are laid directly on concrete floor.

Cables run on floors must be protected and supported on cable trays or in trenches.

Within 3 months

E.6

E-7 Panels Cables entering or leaving panels are connected directly to MCCBs without supports.

Cables entering or leaving panels must be firmly fixed/supported at the base plate using cable glands

Within 3 months

E.7



Ref

E-8 Spacing between different phases and bus bars are too close and sign of arcing is seen (main panel)

The copper bus bars may be redesigned and insulated to prevent arcing between different phases and earthed parts.

Within 3 months

E.8

E-9 Cables in panels are dressed with sharp bends.

Cables and wires in panels must be dressed and fixed to panel safely without stress.

Within 6 months

E.9

E-10 Flexible PVC conduit used to cover wiring inside and outside panels

Cables must be supported on cable trays/ladders or raisers and fixed firmly on the wall.

Within 6 months

E.10

E-11 Bus bar chamber (panel) is too congested and does not have adequate space inside for maintenance.

The bus bar panel must be designed in accordance to the number of cables connecting and the rating of the bus bar.

Within 3 months

E.11

E-12 Phase barrier between different phases are not installed in MCCBs

Phase barriers between different phases for voltage exceeding 230 volts must be installed.

Within 3 months

E.12

E-13 Wiring inside panels are extended through mid -span joints or repaired with PVC insulation tapes.

Joints must be avoided and wires damaged must be repaired by soldering and insulated such that it has sufficient electrical and mechanical strength. It is recommended that joints and repairing1 (when the conductor is damaged) must be avoided.

Within 3 months

E.13

E-14 Receptacles Two socket outlets are connected through a circuit.

Socket outlets must be connected with separate circuit and connected with earth.

Within 6 months

E.14

1 Repairing wiring for damaged conductor is not permitted. Repair of damaged insulation may be permitted if the engineer verifies that the wire has

adequate electrical insulation and mechanical strength after repairing.



Ref

E-15 Fluorescent light fittings are not covered (connections and fitting wiring) and connections are exposed.

Light fittings must be safely installed and all live parts must be covered. All metal parts/frames must be earthed.

Within 3 months

E.15

E-16 Fans and lights are extended from the same wiring and fan locations.

Every lighting circuit must not be connected/loaded more than the designed rating2. The joints must be looped at the terminals3.

Within 6 months

—

E-17 Wiring & Cables Cables laid on floors/ceilings or walls are not protected.

Cables run on floors must be supported on cable trays or laid in trenches. Cables on walls must be supported on ladder or raisers.

Within 3 months

E.16

E-18 Cables and wirings are run through stairways.

Main cables passing through different floors must be separated through service shaft or enclosed in corresponding fire rated enclosures as per the compartment/room it passes through. It is recommended that stairways not be used as electrical shafts.

Within 3 months

E.17

E-19 Wiring is drawn out from the conduit junction boxes for modification / extension of wirings.

Practice of extending existing wiring must stopped4 and all modifications must be re-wired, by safe practices, to avoid joints in wires.

Within 3 months

E.18

2 Each lighting circuit must not be connected with more than 800W.

3 Mid-span joints must be avoided in circuits (between switch & light fittings or between fittings connected in parallel.

4 Any additional points must be connected through new wiring from the distribution panel either the existing supports or installing additional supports.



Ref

E-20 Wooden ducts, without cover, are used as wiring supports in the production floors. Some insulation damages (probably by rats) can be seen in wiring.

Wooden ducts must be replaced with safe factory fabricated ducts. The ducts may be designed such that the wirings supported in it are safe and protected from dust and external damages.

Within 3 months

E.19

E-21 Wires are joined (mid-span and Tee joints) are made in wooden ducts and repaired/insulated using PVC insulation tape.

Joints in cable ducts must be avoided and where PVC insulation are to be repaired (minor damages), it must be insulated and tested (IR measurement).

Within 3 months

E.20

E-22 Wiring in boiler room is not protected from external heat.

Wirings in boiler room must be protected from external heat5. Wires must not be joined other than at the designated terminals. Terminals boxes must be covered to protect from dust and physical damages besides risk of electric shock to the operators.

Within 6 months

E.21

E-23 Connection in terminal box is not protected and not maintained (box cover open) regularly.

Cables and wiring must be firmly fixed to the devices and protected/supported to prevent damages (aging of insulator) due to heat from boiler.

Within 3 months

E.22

E-24 Wiring inside boiler control panels is not dressed and protected.

Wiring inside boiler control panel must be checked and maintained on regular basis. The wiring after maintenance must be redressed safely.

Within 3 months

E.23

5 Wiring must be protected from external heat by enclosing in heat resistant covers, placing at safe distance on supports or using heat rated cables/wires.



Ref

E-25 Extension of wiring and additional wires are drawn in flexible conduit and not supported. PVC conduits are not firmly supported/fixed with saddles.

PVC flexible conduits must not be used for permanent wirings6 and when used in short points, must be supported/fixed on wall/ceiling at regular intervals to avoid stress.

Within 6 months

E.24

E-26 Transitions between different wiring systems are not covered or adapted for proper joints.

Wiring system must be consistent and try to use single system from distribution board to load points. All additional points must be wired in separate conduit/duct, without crossing existing wirings.

Within 6 months

E.25

E-27 The openings left after passing the main cables through walls are not sealed.

The opening (excess) remaining after passing the cables must be sealed such that it meets the fire resistant specifications.

Within 3 months

E.26

E-28 Conduit wiring systems crossing building expansion joints without expansion joints.

Conduit wiring must avoid crossing expansion joints and where it is unavoidable, conduit expansion joints must be used.

Within 3 months

E.27 9332

E-29 Earth systems Mid-span and tee joints are made in earth conductors.

Joint in earth conductors (mid-span and tee) must be avoided. All earth connections must be distributed from earth strips installed in panels.

Within 3 months

E.28 9413

6 PVC flexible must not be used in industrial wiring of permanent nature. Where unavoidable, the flexible conduit selected must be industrial grade.



Ref

E-30 Panels and metal parts of electrical appliances/devices used are not earthed.

All panels must be connected to earth at least at two points for guaranteed earth connection. All metal parts of electrical appliances and devices must be connected to earth. Panel doors and other metal parts used must be connected with earth bond.

Within 6 months

—


ATTACHMENT 1 – PHOTOGRAPHS OF FINDINGS/ISSUES


Photo E.1 – Service Line cables, entering factory building at 6th Floor, without supports

Photo E.2 – Second service cables, entering building at 1st floor, without supports

Photo E.3 – Opening after service cable passed through wall not sealed

Pole mounted transformer

2nd

Service cable entering 1

st floor


Photo E.4 – Generator room door opening to main stair ways at ground floor

Photo E.5 – Cables in the generator terminal box directly supported at the terminations

Photo E.6 – Cables in Generator room laid directly on concrete floor


Photo E.7 – Cables not supported with glands and base plates in panels

Photo E.8 – Bus bars in panels without maintaining safety clearances (typical)

Photo E.9 – Cables and wirings in Panels stressed and not arranged safely (typical)


Photo E.10 – Flexible PVC conduits are used to protect wires and cables

Photo E.11 – Bus Bar panel without maintaining safety clearances (typical)

Photo E.12 – Phase barrier plates not installed in MCCB (typical)


Photo 13 – Single fire alarm bell provided on each floor

Photo E.14 – Two socket outlets connected to a circuit

Photo E.15 – Fitting connections (fluorescent light) not covered


Photo E.16 – Cables on floors and wall not supported and not protected (typical)

Photo E.17 – Cables in stair ways (not service shaft)

Photo E.18 – Wiring extended from conduit junction box (with joints) (typical)


Photo E.19 – Wooden ducts supporting wirings are not covered. Conductor insulation damaged by rats (inset)

Photo E.20 – Wire joints in duct (typical)

Photo E.21 – Wiring and cables in boiler room not protected from external heat (typical)


Photo E.22 – Connection of devices in Boiler room not protected and fixed (typical)

Photo E.23 – Wiring inside boiler control panel not arranged/dressed (typical)

Photo E.24 – Conduit wirings (flexible/rigid) on ceilings and walls not fixed adequately (typical)


Photo E.25 – Transition between different wiring systems not safe (typical)

Photo E.26 – Gaps not sealed/protected after wirings passed through walls and ceilings (typical)

Photo E.27 – Conduit wiring crossing expansion joints

Expansion joints


Photo E.28 – Earth conductor joints (typical)

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