electrical safety inspection...

ELECTRICAL SAFETY INSPECTION REPORT

HAMID SWEATER LTD.

Dapa, Fatullah, Narayangonj, Bangladesh

Factory List:

1. Hamid Sweater Ltd.

Inspected by: Nazmul Huda

Report Generated by: Nazmul Huda

Inspected on February 28th 2015

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Hamid Sweater Ltd.

SUMMARY

The Hamid Sweater Ltd. factory is a seven (G+6) storied building. The building was constructed in 1993, and factory began production in 1994. The building has been approved for factory building. During the inspection the factory had approximately 742 workers.

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.

Table below summarizes the major electrical safety issues identified during the inspection.

Recommendations have been provided to address each issue.

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.

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Hamid Sweater Ltd.

FINDINGS AND RECOMMENDATIONS

FINDING NO: E- 1

CATEGORY: DESIGN, DRAWINGS & RECORDS

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 by Accord.

PRIORITY: P1

REMEDIATION TIMEFRAME: 12 WEEKS

FINDING NO: E- 2

CATEGORY: MAINTENANCE TEST/ DOCUMENTATION

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.

PRIORITY: P2


FINDING NO: E- 3

CATEGORY: MAINTENANCE TEST/ DOCUMENTATION

FINDING: Insulation resistance test of electrical equipment is not performed.

RECOMMENDATION: Insulation resistant test of all the cables must be performed once every 2 year cycle and recorded (this requires a complete power shut off).

PRIORITY: P2

REMEDIATION TIME FRAME: 10 WEEKS

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Hamid Sweater Ltd.

FINDING NO: E- 4

CATEGORY: EARTHING SYSTEM

FINDING: Earth Pit resistance record is unavailable.

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

PRIORITY: P2


FINDING NO: E- 5

CATEGORY: TRAINING

FINDING: Electric safety training program is not initiated.

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

PRIORITY: P2


FINDING NO: E- 6

CATEGORY: DESIGN, DRAWINGS & RECORDS

FINDING: No detailed maintenance record.

RECOMMENDATION: A detailed maintenance record must be maintained for all the electrical installations.

PRIORITY: P2


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Hamid Sweater Ltd.

FINDING NO: E- 7

CATEGORY: DOCUMENTATION

FINDING: Instruction for CPR (Cardiopulmonary Resuscitation) or Electrical shock restoration is not present.

RECOMMENDATION: Hang this instruction near all electrical equipment (LT panel, MDB, FDB, DB, SDB) on a visible location.

PRIORITY: P3


FINDING NO: E- 8

CATEGORY: Lightning Protection & Earth

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

RECOMMENDATION: Design and install Lightning Protection System (LPS) in the factory; the LPS designs must be submitted to Accord before starting installation.

PRIORITY: P1


FINDING NO: E- 9

Bypassing the DO fuse.

CATEGORY: SERVICE LINE

FINDING: Protective fuse not provided at overhead HT

tapping point.

RECOMMENDATION: Overhead tapping point must be protected by

standard HT Fuse instead of using wire strip.

PRIORITY: P1


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Hamid Sweater Ltd.

FINDING NO: E- 10

Transformer area is not properly separated.

CATEGORY: TRANSFORMER ROOM

FINDING: Transformer area is not properly separated from substation room.

Recommendation: Barrier walls between transformer and other panels must be installed. The walls must be fire resistant and should have height up to the ceiling. The wall should have the provision for necessary ventilation and fire rated door on required side.

PRIORITY: P2


FINDING NO: E- 11

Power transformer breather.

CATEGORY: TRANSFORMER ROOM

FINDING: Transformer Silica gel is discolored, and breather oil cup is empty.

Recommendation: Replace silica gel by a new one; or dry it under sun and reuse it, if color regains. Fill the transformer breather oil cup with transformer oil

PRIORITY: P2


FINDING NO: E- 12

Improper illumination in substation room.

CATEGORY: SUBSTATION ROOM

FINDING: Substation room has inadequate illumination.

Recommendation: Ensure adequate illumination in the substation room thus any maintenance can be done comfortably (150 lux should be maintained).

PRIORITY: P2

REMEDIATION TIMEFRAME: 1 WEEK

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Hamid Sweater Ltd.

FINDING NO: E- 13

Cable trench filled with sand.

CATEGORY: CABLE & CABLE SUPPORTS

FINDING: Power cable is covered by sand in the cable trench.

Recommendation: If the cable trench is designed to be covered with sand, the trench may be left as is; otherwise remove sand from cable trench to avoid physical damage to the power cable.

PRIORITY: P2


FINDING NO: E- 14

Earth Pit not identified.

CATEGORY: EARTHING SYSTEM

FINDING: Earth pits are not identifiable (typical).

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

PRIORITY: P3


FINDING NO: E- 15

One point frame earthing at generator.

CATEGORY: GENERATOR ROOM

FINDING: Generator frame connected to one earth connection.

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

PRIORITY: P2


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Hamid Sweater Ltd.

FINDING NO: E- 16

No cover on battery terminal.

CATEGORY: BATTERY

FINDING: Battery terminals are left open.

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

PRIORITY: P2


FINDING NO: E- 17

Access limited to panel.

CATEGORY: DISTRIBUTION BOARD & PANEL

FINDING: Distribution board is not installed in compliant location (typical issue).

RECOMMENDATION: Install distribution boards in compliant locations so that operation is not hampered due to limited access.

PRIORITY: P2


FINDING NO: E- 18

List and diagram of circuit not available.


FINDING: Circuit directory (SLD) and clear identification of the panel are not present (typical issue).

RECOMMENDATION: Ensure each distribution board is provided with a circuit list giving diagram of each circuit which it controls and the current rating for the circuit and size of fuse element. Provide clear and permanent identification marks in all distribution boards.

PRIORITY: P2


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Hamid Sweater Ltd.

FINDING NO: E- 19

Inadequate rubber mat in front of the panel.


FINDING: Inadequate rubber (insulation) mat on the working are of distribution board (typical issue).

RECOMMENDATION: Put adequate 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- 20

No earthing connection at panel door.


FINDING:

Panel doors are not connected with earth (typical issue).

RECOMMENDATION: All metal panel doors must have an earth connection of at least 4rm earth cable.

PRIORITY: P1


FINDING NO: E- 21

Standard phase separator missing.


FINDING: Phase barrier/separator not installed (typical issue).

RECOMMENDATION: Put a 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: P1


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Hamid Sweater Ltd.

FINDING NO: E- 22

Un-terminated wire.


FINDING:

Un-terminated wire present inside the panel.

RECOMMENDATION: Remove unneeded wires from the panel.

PRIORITY: P1


FINDING NO: E- 23

Splicing cable joints found inside panel.


FINDING: Wires in panel are spliced and insulated with PVC insulating tapes (typical issue).

RECOMMENDATION: Use PVC or porcelain cable connector and PIB tape wound around it for joining cables inside panel.

PRIORITY: P2


FINDING NO: E- 24

Cable terminating at MCB.


FINDING: Multiple cables terminated at MCB terminals (typical issue).

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

PRIORITY: P1


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Hamid Sweater Ltd.

FINDING NO: E- 25

Cable terminating a single point of bus bar.


FINDING: Multiple cables are connected in a single point bus-bar (typical issue).

RECOMMENDATION: Terminate each power cable at single terminal on bus bar and use proper sized cable lug.

PRIORITY: P2


FINDING NO: E- 26

MCB is broken.


FINDING: Broken MCB is used inside the distribution board.

RECOMMENDATION: Broken MCB terminals must be replaced with a new one.

PRIORITY: P1


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Hamid Sweater Ltd.

FINDING NO: E- 27

Burning sign inside the panel.


FINDING: Burning sign at MCCB inside distribution board.

RECOMMENDATION: Arrange periodic inspection & thermal scan to identify the overloading, loose connection, unbalanced load which may cause the excessive heat-rise and take action accordingly.

PRIORITY: P1


FINDING NO: E- 28

Cable termination without lugs.


FINDING: Multiple cables terminated at electrical busbar/MCB without cable lugs (typical issue).

RECOMMENDATION: Terminate all the power/earth/neutral cable with proper sized cable lug. Every cable must be connected to a single MCB.

PRIORITY: P2


FINDING NO: E- 29

Undressed cable present inside the panel.


FINDING: Cables inside distribution board are disorganized.

RECOMMENDATION: Organize all the power cables securely and neatly inside distribution board to prevent from electrical hazards.

PRIORITY: P3


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Hamid Sweater Ltd.

FINDING NO: E- 30

Improper cable bent inside the panel.


FINDING: Power cables are bent excessively.

RECOMMENDATION: Avoid power cable bending in electrical system; in unavoidable case bend cables without any stress but not less than 135 degree.

PRIORITY: P2


FINDING NO: E- 31

No ceiling rose used to connect ceiling fan (connected by splicing joint).

CATEGORY: WIRINGS

FINDING: No ceiling rose used to connect ceiling fan (connected by splicing joint) (typical issue).

RECOMMENDATION: Need to use ceiling rose for connection.

PRIORITY: P3


FINDING NO: E- 32

Multiple connections through one socket outlet.

CATEGORY: WIRINGS

FINDING: Multiple connections through one socket outlet (typical issue).

RECOMMENDATION: Need to provide single connection through single socket.

PRIORITY: P2


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