ELECTRICAL SAFETY INSPECTION REPORT.

Transcription

1 ELECTRICAL SAFETY INSPECTION REPORT. KAROTOA APPARELS LTD., TATKHANA ROAD, DHAKA, BANGLADESH. Factory List: 1. Inspected on May 14, 2014

2 ELECTRICAL SAFETY INSPECTION REPORT. KAROTOA APPARELS LTD., TATKHANA ROAD, DHAKA 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 will be further addressed 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 hazards, risks or exposures or that hazards, 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. GENERAL BUILDING INFORMATION 1. Factory Name : 2. Factory Address : 3. Accord ID : 4. Inspection Participants :, Tatkhana road, Dhaka, Bangladesh Niaz Uddin Ahmed (RANA) (Director Operation),, Ph: , rana_karotoa@outlook.com, ranatun@taraspinning.com Soboj (Maintenance Officer),, Ph : Page 2 of 15

3 5. Building Data a. General: The factory is established in a five storied (G+4) building and a shed. Thebuilding, reportedly, has completed the construction in 2008.The factory began production in2009. The building was approved for industrial purpose and the factory during survey, reportedly had about 200 workers working on regular basis. The floor wise occupancy details are: Ground floor: Cutting section and storage. 1st floor: Finishing section and office. 2nd floor: Finishing section. 3rd floor: Sewing section. 4th floor: Sewing section. b. Floor Layout Information: Thefactory s ground floor plan is presented in Figure 1. Most of the activities of the factory is in the main building. The first floor plan of the mainbuilding which is used for cutting and storage is presented in Figure 2. The building has similarfloor layout for the other floors. Figure 1: Ground floor layout plan for building. Page 3 of 15

4 Figure 2: First floor layout plan for building c. Electrical System: The factory premises is connected to grid (REB) supply, tapped from 11kV OH line and delivered through HT cable, protected by DO fuse. The 11kV supply is stepped down by 200kVA and 11/0.415kV. The 3 phase power transformer installed on the two polesof 11kV. The transformer is controlled and protected by DO fuse installed at 11 kv side. Theoutput from the transformer is controlled by MCCB connecting to the factory electrical system through a manual change over switch. Figure 3: Power transformer 200 KVA, 11/0.415 KV, oil type The factory has one diesel generator sets (150kVA), operated during grid failure and D.G set of 150 kva is located at separate shed and is connected to LV panel through a mechanical change over switch. Page 4 of 15

5 Figure 4: Diesel generator of 150 kva for backup power d. Electrical Installations: The factory generally followed cabling systems supported in trays and raceways, mostly fabricated at site from MS angles and flats, from the mains to the load centers (production floors and other buildings). However, the trays and raceways supporting cables are not installed. The cables connecting between LT control panel and transformer is laid externally on the walls of building is shown in Figure 5. Figure 5: LT overhead line Laid externally on the walls of building. The factory internal wiring systems generally are in concealed wiring systems though often, the concealed wiring points are extended for loads modified later. Power distributions to work tables in production floors (sewing, cutting and finishing floors) are supported and wooden box is used as wiring ducts. The ducts are often left open and wires joints are found during random checks. Page 5 of 15

6 Figure 6: Wooden box used for laying wires. The LT control panel and changer over switch are located under star case of first floor. Figure 7:LT control panel e. Operation and Maintenance: The is operated & maintained by in-house electrical and maintenance team. However the maintenance of major equipment like transformer, generator(s) and boilers are outsourced to the service centers. Factory officials, accompanying electrical inspecting team, presented the inspectors with the maintenance programs, logs and maintenance schedule of the factory electrical facilities, no detailed schedule was presented. Cable raceways and trays supporting cables are not maintained regularly as debris, dust and lint deposited on it looks to have not cleaned for long time. Cables and wiring inside panels are not arranged and are loosely hanging. Communication wires bunched in cut open flexible PVC conduits, at few places are laid along the electrical wiring/cables and often cross the electrical facilities. Page 6 of 15

7 Figure 8: Cables laid with PVC hose to upper floor level. Page 7 of 15

8 4. FINDINGS AND RECOMMENDATIONS Table below summarizes the major electrical safety issues identified during the inspection. Recommendations have been provided to address each issue. An 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 approval. E- 1 CABLE & CABLE SUPPORTS Combustible materials covering power cables. Combustible materials covering power cables must be removed. Electrical cables are joined inside the wooden cable tray and filled with dust. E- 2 TRANSFORMER ROOM No protection between the transformer and surrounding area. Increase the height of the existing brick wall around the transformer(s) to provide barrier to surrounding areas. Transformer mounted on the pole and service line is tapped from here E- 3 TRANSFORMER ROOM Loose transformer frame earth. Transformer frame earth must be checked and reconnected firmly with properly sized washers. Transformer frame earthing is not connected properly to earth. Page 8 of 15

9 E- 4 TRANSFORMER ROOM Arcing horns on HT bushings of transformer, not installed. Missing pairs of arcing horn must be installed. Arcing horns on transformer are missing. E- 5 SERVICE LINE Service cables run on walls are not supported. Cables supported on external walls must be laid horizontal/vertical to the wall, supported in cable trays/ladder. Service cables run on building wall E- 6 SERVICE LINE Joints in service cables. Damaged service cables must be repaired using standard repair kits and protected against further damages. Page 9 of 15 Cables are connected with insulators on the pole

10 E- 7 SERVICE LINE Overhead service cables are not supported. Overhead cables must be firmly fastened at both ends. Overhead cables, connected with transformer E- 8 SERVICE LINE Cable entering electrical room, through wall & fence, is not protected. Cables passing through permanent walls must be protected in steel pipes and remaining holes around the pipe must be sealed. LT cables entering the electrical room through wall E- 9 SWITCH BOARD & PANELS Distribution Board(s) installed near exit. Existing panel installed near exit may be relocated to prevent obstruction to emergency exits, as required by fire safety regulations. Distribution boards installed near exit and under the star case of first floor. Page 10 of 15

11 E- 10 SWITCH BOARD & PANELS Gland holes in cable base plates left open. Unused gland holes in base plates or top cover must be sealed with blanking plates or plugs. Cables entering COS panel E- 11 SWITCH BOARD & PANELS Burnt sign visible at terminal(s) inside panel. Check and tighten connections. Overloading may be one of the causes. Cables connected with MCCB Within 1 Month E- 12 SWITCH BOARD & PANELS Cable inside panel touching bare bus bar. Cables inside panel must be securely fastened, through ducts or by ties, to avoid crossing live parts. Cables inside the panel are connected with the busbar Page 11 of 15

12 E- 13 SWITCH BOARD & PANELS Barrier/separators between different phases are not installed. Install separators between different phases of MCCB. Standard separators provided by the MCCB manufacturer must be used. Within 1 Month MCCB, installed inside a panel E- 14 SWITCH BOARD & PANELS Cables entering panel with entry holes forcefully punched. Cable must be reconnected to the panel through designated entry plates (bottom or top) and securely fastened with cable glands. Cables entering COS panel E- 15 SWITCH BOARD & PANELS Neutral bus in the panel not used (terminated). The neutral busbar installed inside panel must be used to terminate and distribute neutral wires of the circuits distributed from the panel. Cables entering COS panel Within 1 Month Page 12 of 15

13 E- 16 SWITCH BOARD & PANELS Three phase MCCB connected to control two phases or less. Check and redesign the requirements to control the circuits. If three phase control is not required, the control devices suitable for the purpose may be selected (replaced). MCB and MCCB are installed inside a panel E- 17 SWITCH BOARD & PANELS Cables looped at the MCCB to extend supply to other SDBs. Extending main supply to SDBs from the MCCB must be avoided. The main panel may be redesigned with busbar systems to distribute branches to other sub-panels. Cables connected to MCCBs to connect each other E- 18 SWITCH BOARD & PANELS Distribution panel not connected to earth. All panel frame in the factory must be connected to earth, if not specifically designed for unearthed system. Distribution panels not connected to earth(typical). Within 1 Month Page 13 of 15

14 E- 19 GENERATOR ROOM Cables terminating to generator output terminal box are laid on floor. Cable terminating at Generator output terminal box must be supported on riser and protected. Existing cables laid on floor may be installed in cable trench or on trays. Cables terminating from generator output terminal box E- 20 GENERATOR ROOM Inadequate working space around the generators. Expand the existing generator room to provide safe working space. Generator placed inside the utility room E- 21 GENERATOR ROOM Storage in generator room. Remove reserved fuel and other combustible items stored in the generator room. Oil barrel are kept in generator room Within 1 Month Page 14 of 15

15 E- 22 BOILER & COMPRESSOR ROOM Wirings in boiler room are drawn in flexible PVC conduit. Heat resistant conduits may be used to protect wirings. Wirings for boiler are drawn in flexible PVC hose conduit. Within 1 Month E- 23 BOILER & COMPRESSOR ROOM Wiring and cables installed in boiler room are not protected. All electrical installations, including wiring and cable works must be protected against heat from the boiler by supporting and separating at safe distance. wiring and cables installed in boiler room are not protected from excessive heat. E- 24 BOILER & COMPRESSOR ROOM MCBs and contactors are not fixed firmly on the panel board, inside boiler control panel. MCB, contactor and other devises used in panel must be firmly fixed and protected from touching unintentionally to other live parts. MCBs and contactors are not fixed firmly on the DIN rail inside the panel board and wiring not properly arranged. Page 15 of 15