ELECTRICAL SAFETY INSPECTION REPORT

Transcription

1 ELECTRICAL SAFETY INSPECTION REPORT ADVANCE WORLD LIMITED Lalkha Shair Char, Fatullah, Narayanganj, Dhaka, Bangladesh Factory List: 1.. Inspected by: Sherub Tenzin & Md. Moin Hasan Report Generated by: Sherub Tenzin & Md. Moin Hasan Inspected on August 7 th 2014

2 SUMMARY The Advance World Ltd. factory is established in a five (G+4) storied building, and the main building is shared with Advance Flexopack Industries. The building was constructed in 2002 and the production began in The three (G+2) storied building for generators and transformers was constructed in The building is rented and has been formally approved for industrial purpose. There are 249 number of labors employed in the factory. 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. 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. Page 2 of 12

3 FINDINGS AND RECOMMENDATIONS FINDING NO: E- 1 CATEGORY: DESIGN, DRAWINGS & RECORDS 1. Typical electrical SLD is prepared 2. Thermo graphic scanning of the entire electrical system has not been performed 3. Insulation resistance test of electrical equipment is not performed 4. Electric safety program is not initiated 1. The factory must have As-built electrical SLD with electrical wiring layout designs and drawings. Any changes in load, protection system, conductors, Generation and supply system must be reflected in the As-built SLD and drawings. 2. Thermo graphic scanning of the entire electrical system must be performed on tri-annual basis and recorded 3. Insulation resistant test of all the cables must be performed once every 5 year cycle and recorded 4. Electrical safety training and awareness program for the electrical personal and workers must be initiated and recorded PRIORITY: P1 REMEDIATION TIMEFRAME: 5 WEEKS FINDING NO: E- 2 CATEGORY: SERVICE LINE HT cable in electrical room not protected and supported. Install the cable tray or ladder with cover to provide mechanical support to the HT cable. XLPE cable inside Transformer room REMEDIATION TIMEFRAME: 3 WEEKS Page 3 of 12

4 FINDING NO: E- 3 CATEGORY: CABLES & CABLE SUPPORT HT cable laid over the LT cables. Segregate the HT cable and LT cables separately on a cable tray/ladder and provide covers made of non-combustible material preferably metal to protect the cables insulation from physical damage as well as prevent entering debris, dust and lint. PRIORITY: P Power cables in electrical room FINDING NO: E- 4 CATEGORY: GENERATOR ROOM Inadequate working space around the generators and used as storage room. Existing generator room should have sufficient working clearance around the generator (1 meter preferably) and storage material must be relocate to other place. Generator room REMEDIATION TIMEFRAME: 3 WEEKS FINDING NO: E- 5 CATEGORY: GENERATOR ROOM Panel not readily accessible Remove the obstacle from the access-way of the panel. Every item of installation shall be arranged so as to facilitate its operation, inspection, maintenance & access. Access of the panels must be kept obstacle free for easy operation & maintenance Storage in front of Change over switch Page 4 of 12

5 FINDING NO: E-6 CATEGORY: SWITHBOARD AND PANEL MCCB fixed on wall without any protection and installed on Wood plank. MCCB must be protected, installing it into a metallic enclosure of minimum 20 SWG thicknesses.wooden planks must be removed from the panel and then fix the MCCB on metal rail inside panel. REMEDIATION TIMEFRAME: 2 WEEKS MCCB and control devices mounted on the wall FINDING NO: E- 7 CATEGORY: CABLE AND SUPPORT Cables terminating at changeover not supported and acute bend found. Cables terminating at distribution boards must be supported in risers and protected throughout its length till the panel base or top plate. Rearrange the cables to avert acute bend. Cables in flexible PVC drawn from Changeover switch FINDING NO: E- 8 Openings in the panel top cover plate. Panel top cover plate must be installed to prevent the ingress of lint/dust into the panel. Install ladder/tray to support the cables. Make circular hole at the base plate/top plate of panels and provide cable gland according to the respective cable size for cable entry and exit so that the cables are not stressed on the sharp edges of the hole of panels. Provide covers (of noncombustible material) if any additional gap remains after installing cable glands. Cables entering panel board Page 5 of 12

6 FINDING NO: E- 9 Cables are not properly arranged inside panel. Assign an electrical engineer to determine the capacity of the installation and redesign the wirings of the panel. If the wirings and loads exceed the capacity of the panel, install additional panel. Establish a load management program for avoiding any installation exceeding its capacity in future. Install PVC wiring duct inside the panel to latch the haphazard cables inside the duct. Panel door held open and cables terminating at MCCB termination point FINDING NO: E- 10 CATEGORY: TRANSFORMER ROOM Oil leakage from the transformer. Leakage must be identified during maintenance and repaired it as soon as possible. Preferably, Assign supplier company to take necessary steps as soon as possible. Transformer radiator FINDING NO: E- 11 CATEGORY: CABLE AND SUPPORT Flexible PVC conduit wiring not supported. Use rigid PVC pipe for surface and exposed wiring throughout the whole lengths. Flexible conduit must not be used for long point wiring (except for special wirings). Wiring inside flexible PVC supported on the wall Page 6 of 12

7 FINDING NO: E- 12 CATEGORY: EQUIPEMENT & MACHINE Motor is not firmly fixed on the foundation/frame. Motor must be fixed firmly on the concrete floor (base slab may be built). Motor in production floor FINDING NO: E- 13 Multiple cables terminated at a single point of the bus bar. Avoid multiple connections. Terminate individual cables at individual point of bus bar. Provide copper cable-socket, copper nut-bolt, and copper washer for termination Cables terminating at bus bar strips inside panel FINDING NO: E- 14 The opening of the wall after passing cable not sealed. The openings remaining after passage of the wiring system should be sealed according to the degree of fire resistance prescribed for the respective element of building. Remaining passage of wiring after passing cables Page 7 of 12

8 FINDING NO: E- 15 CATEGORY: WIRINGS Wires connected to bus bar without using cable lug. Cables shall be connected to terminals only by soldered/welded lugs according to the size of the respective cables. Proper crimping tools must be used to punch the cable lug. Cables terminating at bus bar strips FINDING NO: E-16 CATEGORY: CABLE AND SUPPORT Damaged PVC flexible conduit. Damaged conduit must be replaced and supported, clamped using saddle at regular interval (600 mm preferably). Flexible PVC fixed to the wall in production floor FINDING NO: E-17 CATEGORY: WIRINGS Cable duct is not covered Disconnect electric supply of the duct and clean the duct. Provide cover made of noncombustible material preferably metal on the duct to prevent ingression of dust and debris into the duct. Establish a routine maintenance cleaning program for all the channels, ducts and distribution boards. Wiring duct in production floor Page 8 of 12

9 FINDING NO: E-18 CATEGORY: WIRINGS Cables terminating at panel are not firmly fixed. Install the cable tray/ladder/ duct up to the cable entry of the panel in order to support the cables. Ensure the cables are tightly latched with the ladder and provide covers made of noncombustible material preferably metallic sheet to protect the cables insulation from any physical damage as well as prevent ingress of debris, dust and lint. Cables in flexible PVC entering panel board FINDING NO: E-19 CATEGORY: WIRINGS Temporary connections tapped from the LT panel. Temporary connection done by twisting with the conductor should be removed as soon as possible. PRIORITY: P1 Sparking from temporary wire connection FINDING NO: E-20 CATEGORY: TRANSFORMER ROOM Silica gel in transformer breather, discolored. Shutdown the transformer and replace silica gel. Establish a routine inspection program to avoid such occurrence in future. Breather attached to the transformer conservator tank Page 9 of 12

10 FINDING NO: E-21 CATEGORY: TRANSFORMER ROOM Transformer breather damaged. Install new transformer breather. Oil cup below transformer breather FINDING NO: E-22 Hot spots at capacitor bank inside PFI panel. Arrange periodic inspection & thermal scan to identify the overloading, loose connection, unbalanced load which may cause the excessive heat-rise and take action accordingly. Thermal imager showing Hot spot infront of PFI panel FINDING NO: E-23 Capacitor bank and MCCB placed outside panel. Capacitor bank and MCCB must be placed inside PFI panel board to prevent from physical damage to the equipment or prevent any electrical hazard. Capacitor bank and MCCB laid on floor beside PFI panel Page 10 of 12

11 FINDING NO: E-24 Earth conductor drawn from control panel has leakage current. (4.09 Amps) Earth and neutral point should be terminated at separate point and insulation damaged also might be checked. Earth ground clamp meter showing leakage current FINDING NO: E-25 Earth continuity not found. Check the noted earthing cable and ensure the earth continuity is okay. Periodic earth continuity test should be performed to ensure earth continuity of the installation/equipment. Earth ground clamp meter showing open looped(over Loaded) FINDING NO: E-26 Multiple cables terminating to MCCB in panel. Multiple cables connecting at a MCCB terminal must be removed. Individual circuit breaker must be used for each load according to the respective cable-size. Cables terminating at MCCB Page 11 of 12

12 FINDING NO: E-27 CATEGORY: WIRINGS Wires in panel are spliced and insulated with PVC insulating tapes. For every cable joint, PVC connector must be provided with PIB tape wound around the joint. Twisted joint connection inside panel FINDING NO: E-28 CATEGORY: LIGHTNING PROTECTION & EARTH Lightning protection system is not installed in the factory. Assign an electrical engineer to design lightning protection system for the factory. REMEDIATION TIMEFRAME: 5 WEEK Rooftop Page 12 of 12