electrical safety inspection report arcorp denim ltd

Factory List

Arcorp Denim Ltd.

Inspected by: Hemlal Dahal

Report Generated by: Hemlal Dahal

Inspected on Saturday, October 10, 2015

ELECTRICAL SAFETY INSPECTION REPORT

Kumkumari, Gauripur, Ashulia, Savar, Dhaka, Bangladesh.

Arcorp Denim Ltd.

SUMMARY

The factory was constructed in 2008, production started in 2015, and during the inspectionthe number of workers was approximately 585.

Arcorp Denim Ltd. factory is established in 1 building, and is rented by the factory. Thefactory has a utility shed adjacent to the main building and it accommodates the Generator,Compressor, Transformer and HT/LT switchgears. A section of the factory building is asshown in Figure 1.

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 addressed as part of follow up inspections.

Table below summarizes the major electrical safety issues identified during theinspection. Recommendations have been provided to address each issue. Theimplementation schedule shall be developed by the factory to remediate each of thefindings. The specific timing of improvements, including any requested extensions due todesign/installation constraints, shall be submitted to the Accord for approval.

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Arcorp Denim Ltd. 1

7

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

6 Weeks

Design Drawings and Records

FINDING:

Insulation resistance test of power cables is not performed.

RECOMMENDATION:

Insulation resistance test of all power cables (up to Floor distribution board or SDB) must be performed in a periodic manner and recorded.

PRIORITY:

FINDINGS AND RECOMMENDATIONS:

REMEDIATION TIMEFRAME:

E-1

PRIORITY:


E-2


FINDING:

Thermographic scanning of the entire electrical system has not been tested and recorded.

RECOMMENDATION:

Thermographic scanning for the entire electrical system must be performed on a bi-annual basis and recorded.

E-3

PRIORITY:



FINDING:

Electrical Single Line Diagram (SLD) is unavailable.

RECOMMENDATION:

Have a qualified engineer create an as-built electrical SLD mentioning all the required information, and get it reviewed & approved by Accord.

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Arcorp Denim Ltd. 2

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

2 Weeks

Record earth pit resistances for all the earth pits, and do it once a year.


FINDING:

Instruction for CPR (Cardiopulmonary Resuscitation) or Electrical shock restoration is not present in some of the electrical facilities.

RECOMMENDATION:

Hang this first aid and CPR instructions near all electrical equipment (LT panel, MDB, FDB, DB, SDB) on a visible location.

Check the transformer oil condition by performing oil test, this must be done twice a year and recorded.


FINDING:

Earth Pit resistance record is unavailable.


FINDING:

Electric safety training program is not conducted.

RECOMMENDATION:

E-5


PRIORITY:


PRIORITY:

PRIORITY:

RECOMMENDATION:

Electrical safety training and awareness program for the electrical personnel and staff must be initiated and recorded .


FINDING:

Transformer Oil Test report is unavailable.

RECOMMENDATION:

PRIORITY:


E-6

E-7

E-4


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Arcorp Denim Ltd. 3

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

RECOMMENDATION:

Clearly identify each earth pit, and mark it for periodic maintenance purposes.


FINDING:

Maintenance records don’t reflect actual factory circumstances; the records do not detail out all the electrical equipment/machinery.

RECOMMENDATION:

Maintenance Manager or Safety Officer must keep accurate records and ensure that they reflect actual factory day to day operations.

Earthing

FINDING:

Earth pits are not identifiable.

PRIORITY:


E-10

E-9

FINDING:HT cable passed through permanent wall not protected.

HT cable passing through wall not protected

RECOMMENDATION:The HT cable must be encased in steel pipe (conduit) when passed through the wall and seal the unused openings after the passage of conduit by fire rated materials.

E-8

PRIORITY:


Service Line

PRIORITY:


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Arcorp Denim Ltd. 4

FINDING NO.

CATEGORY:

P-3

4 Weeks

FINDING NO.

CATEGORY:

P-2

12 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

E-11


Service Line

HT cable bends must be avoided such that no stress is imposed on the terminating of the cable or insulation of the cable. Rearrange the cables using cable tray/ladder and latch the additional cable with the tray/ladder.

Live cable coil kept at the back of transformer

Transformer

FINDING:Transformer room congested.

RECOMMENDATION:

PRIORITY:


Maintain a sufficient working space (preferably 1.07 meters) around the transformer or assign a qualified engineer to design a required transformer room according to BNBC, Section-2.6.3.

Congested Transformer room

Transformer

FINDING:

FINDING:Excess HT cables coiled on pole/coiled and kept at the back of transformer

RECOMMENDATION:

PRIORITY:


Unprotected HT cables in transformer room

E-12

E-13

11kV cable in to transformer room is laid in open floor trench without any protection.

RECOMMENDATION:Install the cables tray or duct with cover (metallic) for the protection of the cable laid on floor trench. Ensure the cables are tightly latched inside the ladder/tray and provide covers made of non-combustible material preferably metallic sheet to protect the cables’ insulation from any physical damage as well as prevent the ingress of debris, dust and lint.

PRIORITY:

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Arcorp Denim Ltd. 5

FINDING NO.

CATEGORY:

P-1

2 Weeks

FINDING NO.

CATEGORY:

P-1

2 Weeks

FINDING NO.

CATEGORY:

P-2

6 Weeks

RECOMMENDATION:Establish a routine cleaning program to avoid deposit of combustible materials like dust/lint.

Generator

Silica gel deteriorated and oil cup empty.


Dirt deposit and oil spillage on transformer top

E-15

PRIORITY:


Empty Breather oil cup

Transformer

FINDING:Excessive dust and lint deposit on transformer and its surrounding area.

PRIORITY:

Transformer

FINDING:

E-14

Cables in flexible PVC pipe laid directly on floor

RECOMMENDATION:Repair/replace the breather, replace with new silica gel and breather oil cup must be filled with transformer oil to the required level as instructed by the manufacturer.

FINDING:Cables terminated to generator output box are directly laid on the floor.

PRIORITY:


RECOMMENDATION:If possible route all the cable through an overhead cable tray/ladder. Cable on the floor must be protected by providing covered cable tray/ladder/trench to avoid physical damage to cable insulation.

E-16

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Arcorp Denim Ltd. 6

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

No identification and circuit diagrams on control panels.

Distribution Boards & Panels

PRIORITY:


Phase barrier/separators between different phases are not installed or locally manufactured phase separators used.RECOMMENDATION:Phase barriers between different phases must be installed to avoid arc flashing. Standard separators provided by the MCCB manufacturer must be used.


Cable sizes not coordinated with MCCB & load


FINDING:

PRIORITY:


PRIORITY:


Incoming and outgoing cables terminating at MCCB must be of same size. Check the connected load and provide respective cable size.

MCCBs without phase separators; cable colour coding not maintained

Identification and circuit diagrams not provided

E-17

E-18

E-19

Provide/hang circuit diagrams of panels/boards in every panel. (Provide identification and warning notice in front every electrical panel. Include voltage level on the notice and any precautions if required for special case).

RECOMMENDATION:

FINDING:Mismatch in incoming and outgoing cables (size) at MCCB in a panel (typical).

RECOMMENDATION:

FINDING:

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Arcorp Denim Ltd. 7

FINDING NO.

CATEGORY:

P-3

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING:Cables laid randomly in cable trench.


PRIORITY:


Cable & Cable Support

FINDING:Gap around Bus Bar Trunking (BBT) passing through ceiling/floor/wall not closed.


FINDING:

PRIORITY:

RECOMMENDATION:Seal all the penetrations using appropriate fire rated material and ensure the Bus Bar Trunking (BBT) does not get damaged during sealing work.

RECOMMENDATION:Rearrange the cables by drawing them swiftly and fastening them on the support, a cable ladder or a cable tray.

Unsupported power cables entering/exiting the distribution panels

Cables laid randomly and without protection

Cables in PVC flexible conduit entering/exiting panels are not supported.

Gap dug for passing BBT riser left open

RECOMMENDATION:Wiring/cabling in PVC flexible conduit entering or exiting panels must be supported on cable tray/ladder and be firmly fixed at the panel (base / top) using socket and check nuts.

E-21

E-22

PRIORITY:


E-20


___________________________________________________________________________________________

Arcorp Denim Ltd. 8

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-2

4 Weeks

FINDING NO.

CATEGORY:

P-1

2 Weeks

Unsupported cable/wire extension from BBT

Earthing

FINDING:Generator frame connected to one earth connection.

RECOMMENDATION:

PRIORITY:


E-23

E-24


FINDING:

Power cables of boiler carried through flexible PVC pipe

Cables extended from BBT breaker to distribution boards must be supported on trays/risers (rigid pipes may be used when passing through concrete).

Cable from busbar Trunking (BBT) in electrical shaft, extended to different levels (floors) are not supported.

Boiler & Compressor Room

FINDING:


Generator frame should be earthed with two separate and distinct connections to earth with better earth continuity.

Only one earth connection provided to Generator frame

PRIORITY:


PRIORITY:

Power and control wiring of boiler are carried through flexible PVC pipe.

RECOMMENDATION:Use industrial graded (heat resistant) conduit for control and power wiring of boiler.

RECOMMENDATION:

E-25

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Arcorp Denim Ltd. 9

FINDING NO.

CATEGORY:

P-2

2 Weeks

FINDING NO.

CATEGORY:

P-2

2 Weeks

FINDING NO.

CATEGORY:

P-1

6 Weeks

Lightning Protection

FINDING:Lightning Protection System(LPS) needed but has not been installed.

RECOMMENDATION:

Roof top of the factory building with no LPSREMEDIATION TIMEFRAME:

Exposed battery terminals

Equipment & Machines

FINDING:Input power cable drawn for machine laid on floor unprotected.

PRIORITY:


RECOMMENDATION:

Design and Install LPS for your factory; Factory have to submit LPS design to Accord before starting installation.

Equipment & Machines

FINDING:Battery terminals are left open.

Use Steel/covered cable tray pipe for carrying cables laid on the floor drawn from distribution/switch board to machines. Use industrial graded flexible pipe where the steel pipe unable to bend.

Power cables connecting machines laid directly on floor

PRIORITY:


E-26

E-27

PRIORITY:

RECOMMENDATION:Use insulated rubber cap to cover all the battery terminals.

E-28

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Arcorp Denim Ltd. 10

electrical safety inspection report arcorp denim ltd

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