electrical safety inspection report york …yorkbd.com/accord/york_fashion_electrical.pdf · the...

Factory ListYork Fashion Ltd.

Inspected by: DawaReport Generated by: Dawa

Inspected on 28 October 2015

ELECTRICAL SAFETY INSPECTION REPORT

Plot # S-12 & 13, BSCIC Industrial Area, Baburhat, Chandpur, Dhaka, Bangladesh.

York Fashion Ltd.

1 INTRODUCTIONThe 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 providerecommendations 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 majorelectrical safety issues. The inspection did not include identification of minor deficiencies, which wouldbe further addressed as part of follow up inspections.

2 LIMITATIONSThe information in this electrical safety inspection report was obtained during a visit to the facility andduring interviews with local factory management. It has not been possible to provide independentverification for all the information and data collected, and, therefore, WEC cannot accept generalresponsibility for omissions or errors arising from inaccuracies in this report from the informationobtained.The findings and recommendations in this report are not intended to imply, guarantee, ensure or warrantcompliance with any government regulations. Additionally, the results do not imply in any way thatcompliance with the findings or recommendations as stated in this report will eliminate all risks orexposures not referred to in this report do not exist. Compliance with the findings and recommendationsstated in this report does not relieve the factory owner from obligation to comply with specific projectrequirements, industry standards, or the provisions of any local government regulations.

3 DEFINITION3.1 Time Frame

The amount of time being allocated based on the remediation work volume of the electrical issueconsidering the feasibility and ideal status of materials, capital and working condition. Criticality andpriority level of the issue is not taken into consideration. It is bound only for the particular finding unlessmentioned ‘typical’, shall include the whole typical findings.

3.2 Priority Level3.2.1 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 ofremediation works shall commence immediately without compromising with any other issues and muststrictly complete within the allocated remediation time frame. It shall include only the critical issues

3.2.2 Electrical issues related to code violation and/or non-conformity with codes, protection of electricalswitchgears and equipment, spatial arrangement and location of switchgears and equipment, designand drawings, shall be considered as P2 Level of priority. The execution of remediation work of P2 shallcommence along with or soon after the P1 level remediation work has commenced. It shall include onlythe moderately-critical issues

3.2.3 Electrical issues related to violation of code and/or non-conformity with codes, workmanship ofoperation and maintenance and obsolete technology of electrical system, shall be considered as P3Level of priority. The execution of remediation work of P3 shall commence along with or soon after theP2 level remediation work has commenced. It shall include only the non-critical issues.

3.2.4 It doesn’t take into consideration the remediation time frame and feasibility of remediation. It doesn’ttake into consideration the capital, materials and working environment.

ELECTRICAL SAFETY INSPECTION REPORTYork Fashion Ltd.

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1York Fashion Ltd.

4 GENERAL INFORMATION

Factory Name: York Fashion Ltd.

Inspected on: October 28, 2015

Factory Address: Plot # S-12 & 13,BSCIC Industrial Area,Baburhat,Chandpur,Dhaka,Bangladesh.

Factory ID: 12298

Inspection Participants: Gazi Salah UddinManager-Marketing & MerchandisingYork Fashion [email protected]

AKM. AktaruzzamanCoordinator-Technical & Compliance DevelopmentYork Fashion [email protected]

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2York Fashion Ltd.

55.1

5.2

Number ofFloors

Area ofBuilding Height of Building

2 3,800 sq. m 7.00 m211

BUILDING DATAYork Fashion Ltd. factory is established in 1 building plus utility buildings, and is owned by thefactory. York Fashion Ltd. factory is designed as a 8 storied (G+7) building but had beenconstructed up to 2nd floors (G+1) at the time of inspection.

The factory was constructed in 2013, production started in 2013, and during the inspection thenumber of workers was approximately 300.

The building and shed utilization is as detailed below:

Figure 1: Ground floor plan of factory building.

Building

Main BuildingUtility Building-1Utility Building-2Extended shed

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3York Fashion Ltd.

Ground floor: (30 Workers)

1st floor: (270 Workers)

Ground floor: (5 Workers)

1st floor:

Ground floor:

Ground floor: Generator (60kVA).Extended shed

Boiler

Main Building

Utility Building-1

Utility Building-2

Transformer, Generator, Security room.

Compressor.

Store, Bonded Warehouse, Cutting, Finished goods store,Dining, Daycare, Doctor room,Offices.Sewing, Finishing, Maintenance room, Spot removing room,Finishing area.

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4York Fashion Ltd.

5.3 Electrical System:York Fashion Ltd. gets its grid power from REB. There is 1 generator used as backup power. Thegenerator and transformer setup is as below.The 11kV OH line which is protected by a DO fuse and delivered through a HT cable to thesubstation. The outputs from transformer and generator are fed to the factory's electrical systemthrough a combination of Auto-Transfer Switches (ATS). The 60kVA diesel generator installed inthe extended shed is used only for the fire pump.The inspecting team found a slight mismatch in SLD provided and actual installation. The issuehas been raised to the factory management for necessary changes. The SLD of substation aspresented by factory officials is as shown in Figure 2.

Figure 2: SLD of substation.

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5York Fashion Ltd.

Transformer #1Owner Factory ownedLocation Floor mounted transformer in the substationTransformer Type Oil immersed typeArrangement 1 three-phase transformerSingle phase or 3 phase 3Primary Voltage (kV) 11.0 kVSecondary Voltage (kV) 0.44 kVCapacity 1,000 kVANetwork System 3 Phase, 4-Wire

Generator #1Generator Type DieselCapacity 250 kVARated Voltage 440 VNumber of hours/day 4Backup or Main supply Backup power

5.4 Electrical Installation

The cable raceway system in one of the production floor is as presented in Figure 3.

The cabling systems in the factory are mostly supported in cable raceways made of aluminumchannels above the working tables. However, some sections of distributions are made throughsurface PVC conduit and concealed conduit wires.

Figure 3: Electrical Installation on the factory floor.

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6York Fashion Ltd.

5.5 Operation and Maintenance:

Figure 4: MDB maintenance record.

The factory has no qualified engineers, 1 certified electrician, and 1 non-certified electrical staff onits electrical maintenance team. The factory does not keep adequate maintenance records, andmaintenance of major equipment is carried out by the supplier.

The maintenance record as presented by the factory officials is presented in Figure 4.

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7York Fashion Ltd.

6

Sl.no. Index category Index Figure

A Usage of Structure 6B Type of construction 4C Contents or consequential effects 5D Degree of isolation 2E Type of area and terrain 2F Height of structure 2G Lightning prevalence 21

Total index figure 42

Recommendation:

LIGHTNING PROTECTION RISK ASSESSMENTThere is no adequate lightning protection system in the building, and there is no LPS drawing for thesystem. The calculation of the risk index for lightning protection for this building is below.

The total risk index figure is more than 40; hence a lightning protection system is required. An LPSdrawing must be drawn up

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8York Fashion Ltd.

7

FINDING NO.CATEGORY:

P-26 Weeks


P-24 Weeks


P-26 Weeks

E-3

PRIORITY:REMEDIATION TIMEFRAME:

Design Drawings and RecordsFINDING: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 andrecorded.

Design Drawings and RecordsFINDING: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 aperiodic manner and recorded.

E-1


E-2

Design Drawings and RecordsFINDING:Electrical Single Line Diagram (SLD) does not comply with the actual installation.

RECOMMENDATION:Assign a qualified engineer to develop an as-built drawing according to the actual installation.

FINDINGS AND RECOMMENDATIONS:Table below summarizes the major electrical safety issues identified during the inspection.Recommendations have been provided to address each issue. The implementation schedule shallbe 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 theAccord for approval.

REMEDIATION TIMEFRAME:PRIORITY:

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9York Fashion Ltd.


P-24 Weeks


P-24 Weeks


P-28 Weeks


P-26 Weeks

Design Drawings and RecordsFINDING:No details found in maintenance record.

RECOMMENDATION:

FINDING:Earth Pit resistance record is unavailable.

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

FINDING:Electric safety training program is not conducted.

RECOMMENDATION:Electrical safety training and awareness program for the electrical personnel and staff must be initiated andrecorded.

Design Drawings and RecordsFINDING:Transformer Oil Test report is unavailable.

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

PRIORITY:

Design Drawings and Records

REMEDIATION TIMEFRAME:

E-4


E-6

E-7

PRIORITY:

E-5



PRIORITY:

Maintenance Manager or Safety Officer must keep accurate records and ensure that they reflect actual factoryday to day operations. It must include all the electrical parameters with complete detail.

Design Drawings and Records

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10York Fashion Ltd.


P-36 Weeks


P-34 Weeks


P-22 Weeks

HT cable coiled around HT panel in substation.

Service Line

HT cable on floor, unprotected.

RECOMMENDATION:

FINDING:

HT cable must be supported & protected in coveredcable tray/ladder or trench to protect cable insulation. HTcable must be drawn swiftly without bends or withpermissible bending radius and must be protected in fulllength.


Service Line


E-8


Transformer

FINDING:HT cable passing along building wall notsupported/protected.

HT cable entering transformer room.

Breather oil cup must be filled with transformer oil to therequired level as instructed by the manufacturer.

Transformer breather.

RECOMMENDATION:Install cable tray/ladder or provide saddle to support &protect HT cable through wall. The cable must be firmlylatched at regular interval (600mm) to the supportprovided.

E-9

E-10

FINDING:Oil cup below transformer breather empty.

RECOMMENDATION:

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11York Fashion Ltd.


P-12 Weeks


P-11 Week


P-12 Weeks

RECOMMENDATION:Generator Battery must be placed on acid proof batterystand (may be steel fabricated).

PRIORITY:

GeneratorFINDING:

E-13

250kVA D.G set in substation.

E-11

E-12

Oil spilled on generator frame.

RECOMMENDATION:Generator frame and floor in generator room must bekept free from water and oil spillage. Clean the oilspillage and include it in the scheduled maintenancerecord.

PRIORITY:


GeneratorFINDING:Wiring in flexible PVC conduit attached to generator.

RECOMMENDATION:


Wires installed near/attached to generator body must beprotected from external heat & moisture by metallic heatresistant conduit

250kVA D.G set in substation.

GeneratorFINDING:


Generator battery placed on a pile of bricks and woodenboard.

60kVA D.G set battery in extended shed.

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12York Fashion Ltd.


P-22 Weeks


P-24 Weeks


P-36 Weeks

FINDING:

E-15

E-16

Provide panel base plate and cable gland according tothe respective cable size for cable entry and exit so thatthe cables are not stressed at the termination point andon the sharp edges of the hole of panels.

RECOMMENDATION:

FINDING:Cables connection without cable lugs (typical issue).


RECOMMENDATION:Cables connecting to magneticcontactor/MCB/MCCB/busbar must be connected firmlyproviding proper sized cable lugs.

HT panel in substation.PRIORITY:REMEDIATION TIMEFRAME:

Cable terminating at MCCB.

Distribution Boards & Panels

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

No panel base plate (typical issue).

RECOMMENDATION:If possible route all the cable through an overhead cabletray/ladder. Cable on the floor must be protected byproviding covered cable tray/ladder/trench to avoidphysical damage to cable insulation.


Generator output cable.

E-14


Generator

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13York Fashion Ltd.


P-1

4 Weeks


P-24 Weeks


P-24 Weeks

E-19Distribution Boards & Panels

FINDING:Panel doors not connected with earth bond (typicalissue).

RECOMMENDATION:

E-17

E-18

RECOMMENDATION:Phase barriers between different phases must beinstalled to avoid arc flashing. Standard separatorsprovided by the MCCB manufacturer must be used.

Locally fabricated phase barrier.PRIORITY:

Inside distribution panel on production floor.


HT panel in substation.

Distribution Boards & PanelsFINDING:

PRIORITY:


Provide earth connection for body and doors of metallicdistribution boards using green cables preferably braidso that the metallic door remains at zero potential all thetime.

FINDING:


Locally fabricated Phase barrier/separators used (typicalissue).

Multiple cables terminated at single point in busbar(typical issue).

RECOMMENDATION:Cables must be terminated using individual lugaccording to the respective cable size and shall beterminated on busbar individually.


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14York Fashion Ltd.


P-24 Weeks


P-210 Weeks


P-26 Weeks


RECOMMENDATION:

RECOMMENDATION:Provide/hang circuit diagrams of panels/boards in everypanel. (Provide identification and warning notice in frontevery electrical panel. Include voltage level on the noticeand any precautions if required for special case). It mustbe marked "Lighting" or "Power" as the case may be.


Multiple cables connecting to MCCB terminal must beavoided. Individual protective device must be providedfor the protection of each circuit/load.

Multiple cables terminating into MCCB terminal (typicalissue).


MDB-1 on ground floor.

Panels below stair case (typical issue).

LT Panel in substation.

RECOMMENDATION:Panels located below stairs must be relocated to safeplace to prevent obstruction during emergency asrequired by fire safety regulations.

E-20

E-21

PRIORITY:

E-22


Multiple cable termination at MCCB terminal.

FINDING:No identification and circuit diagrams on control panels(typical issue).



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15York Fashion Ltd.


P-26 Weeks


P-22 Weeks


P-18 Weeks

Cable raceway installed close to steam line (typicalissue).

RECOMMENDATION:Ensure the ironing steam line is properly insulated andmaintain a safe distance between electrical facilities andsteam line (0.9 meters) (Accord Building Standard10.3.4.2).

E-24

Cable trench near MDB-1 with trench cover heldopen.


E-25

Dust/lint & construction materials inside cable trench(typical issue).

RECOMMENDATION:

Ironing steam line & cable raceway.

PRIORITY:

Thoroughly clean the combustible materials (dust/lint &construction materials) to avoid fire hazard. Must beincluded in periodic cleaning.

Cable & Cable SupportFINDING:



Cable must be drawn through a rigid conduit(steel/HDPE pipe) to protect cable insulation. Theremaining gaps after the passage of cables must besealed with fire resistance materials.

Cable exiting generator room.

E-23

PRIORITY:

Cable & Cable SupportFINDING:Cable not adequately protected while passing throughbuilding wall (typical issue).

RECOMMENDATION:

Cable & Cable SupportFINDING:

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16York Fashion Ltd.


P-16 Weeks


P-24 Weeks


P-22 Weeks

E-26

E-27

PRIORITY:

RECOMMENDATION:Make an arrangement to provide a safe distancebetween electrical facilities (wirings) and steam tube(Accord Building Standard 10.3.4.2).

E-28

Provide extra protection by drawing the cables in rigidPVC/HDPE/steel conduit till existing cable trench toavoid physical damage to cable insulation. Theprotection provided must be clamped with saddle atregular interval (600mm).

Cable & Cable SupportFINDING:Steam tube attached to wiring in flexible PVC conduit(typical issue).

Use steel pipe to ensure the mechanical protection ofthe cables/wires laid on floor otherwise cable insulationmay damage due to falling object or stepping ofoccupants onto it.

Machine connection on production floor.


Ironing steam line & wiring in flexible PVC conduit.

Cable & Cable SupportFINDING:Cable/wire for machine connection laid directly on floorwithout adequate protection (typical issue).


RECOMMENDATION:

Motor output cable.REMEDIATION TIMEFRAME:

Cable & Cable SupportFINDING:Cables in flexible PVC conduit on floor.

RECOMMENDATION:

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17York Fashion Ltd.


P-16 Weeks


P-24 Weeks


P-22 Weeks

RECOMMENDATION:

FINDING:

E-30

RECOMMENDATION:

E-29


Electrical circuits and fittings installed inside storagerooms must be removed as required by fire safetyregulations. Remove the lighting connections fromstorage area to reduce the risk of catching fire due toshort circuit.


Compressor wheels not locked.

Cable & Cable SupportFINDING:Lighting in storage area (typical issue).

RECOMMENDATION:Compressor wheels must be removed (to install on floor)or locked to prevent unintentional movement duringoperation/earthquake.


E-31

Both phase & neutral cables of final circuit must run fromDB up to Switchboard without joints. Under thecircumstance where this is not possible, cable jointsmust be realized through porcelain or PVC connectorswith PIB tape wound around.

Wire joint inside cable trench.

Boiler & Compressor RoomFINDING:

PRIORITY:

Storage area.

Wiring/Fittings

Wires joint is not proper (typical issue).

Compressor machine on production floor.PRIORITY:

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18York Fashion Ltd.


P-22 Weeks


P-22 Weeks


P-24 Weeks

Earth conductor should be laid through rigid PVC orsteel conduit (on wall/floor at safe location) and it shouldbe supported or clammed at regular interval.

Earth conductor in substation.

Install the MET in a metal casing and mount it at least 18inches above the floor to make it free from dust and wetfloor.

MET in substation.PRIORITY:REMEDIATION TIMEFRAME:

RECOMMENDATION:

PRIORITY:

Earthing

RECOMMENDATION:

E-33

E-34Earthing

FINDING:Main earthing terminal (MET) not encased (typicalissue).

FINDING:Earthing conductor are laid on the floor (typical issue).


REMEDIATION TIMEFRAME:IPS battery on ground floor.

E-32

RECOMMENDATION:Use insulated rubber cap to cover all the batteryterminals.

PRIORITY:

Equipment & MachinesFINDING:Battery terminals are left open.

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19York Fashion Ltd.


P-24 Weeks


P-22 Weeks


P-112 Weeks

Lightning ProtectionFINDING:

EarthingFINDING:


E-36

E-37

Transformer metal fence not provided with earthconnection.

RECOMMENDATION:Earth connection with required sized cable should beconnected to the metallic fence for ensuring safety tooperator/apparatus.

Lightning Protection System (LPS) needed but has notbeen installed.

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


EarthingFINDING:Open earth loop measured (typical issue).

RECOMMENDATION:


Check for loose earthing-connection. Reconnect wireand check the continuity of earthing wire (if the value iswithin required level, less then 1 Ohm).

PFI panel in substation.

E-35

Transformer guarded with metal fence.

Highest point of factory building.

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20York Fashion Ltd.

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