ELECTRICAL SAFETY INSPECTION REPORT REDPOINT JACKETS LTD, DHAKA, BANGLADESH January 14, 2013
Redpoint Jackets Ltd. PAGE 1 SUMMARY The four-story factory housing Redpoint Jackets Ltd. located in Dhaka Export Processing Zone, Dhaka, Bangladesh was surveyed for Electrical Safety on 08 December 2013 by Woosun Energy and Construction Co Ltd. This summary identifies the critical and major deficiencies that were identified during the inspection as documented in the Electrical Safety Inspection Report, dated 13 January 2014, submitted to the Accord. The factory building was surveyed 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 inspection was limited to the review and identification of critical and 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 1 summarizes the critical and major electrical safety issues identified during the inspection. Recommendations have been provided to address each issue. Reference photos are provided in Attachment 1. An implementation schedule shall be developed by the factory to remediate each of the findings in Table 1. The specific timing of improvements, including any requested extensions due to design / installation constraints, shall be submitted to the Accord for approval.
Redpoint Jackets Ltd. PAGE 2 Table 1. Findings and Recommendations No. Category Finding Recommendation Timeline E-1 500kVA, 11/0.415 kv, Transformer separated with metal Transformer must be separated Power Transformer rails around the transformer. with fire barrier walls to protect against damages to generators and panels during emergency, E-2 Empty oil container attached below the breather (silica gel container). E-3 Neutral earth connected to transformer body earth. E-4 Silica gel in the transformer breather turned pinkish white. E-5 Raised cable channel/trenches in substation room are covered with rubber mat. Portion of the cables are laid directly on the concrete floor. such as transformer failure. The container must be filled with oil at required level (manufacturer s instruction) to trap moistures/dust entering transformer. Neutral earth must be connected to earth at the main earth strip. All earth connections in substation must be distributed from an earth strip. Silica gel must be regularly checked and replaced when necessary to prevent moisture ingression in transformer oil. Cables must either be laid in trenches below floor level 1 protected with covers or supported on cable tray/raceways. Cables must be protected and supported throughout its length. Within 6 Within 6 Photo Ref E.1 E.2 E.3 E.4 E.5 1 Cable channel/trenches raised above floor level are not a standard practice in industrial floors. In case the local standards permit to such installation, it must be protected with metallic covers and the walls of the channel must be grouted to the floor.
Redpoint Jackets Ltd. PAGE 3 No. Category Finding Recommendation Timeline E-6 Panels Openings are cut from sides, top Wirings and cables entering panel or bottom to enable cable and must be fixed using glands wiring entry into panels. (cables) and sockets (conduits) and must remain sealed to prevent dust and rats (small animals) E-7 Connection to motors and electrical appliances are not firmly fixed. Often glands are not used. E-8 Wiring inside panels (Main & Sub- Distribution panels) are haphazardly arranged and does not follow specific route. E-9 Wirings (smaller conductors) used for long points and supported on cable trays and raisers are not supported. E-10 Multiple wires are connected at a point crimped using a single ferrule (socket). E-11 Base/gland plates of the panels are removed to let the cable enter. Top covers of come panels are removed to let the cable enter/leave. entering panel and damaging it. Wiring / connection to electric motors and other appliances must be firmly fixed using cable glands and lugs. All wirings/cables inside panel must be arranged and route through safe spaces. Smaller wires or conductors used for wiring and supported on cable trays / raceways must be protected against external impacts 2. Each wire must individually be crimped with lug/socket and connected separately on the bars (earth or the current carrying conductor). Panels must be closed from all sides to prevent dust and varmint from entering. Cable ends must be firmly fixed at the base or gland plates using cable glands. Unused holes must be closed again by dummy or plugs. Photo Ref E.6 E.7 E.8 E.9 E.10 E.11 2 The smaller wires and conductors rum on cable trays / raceways must be protected by enclosing in conduits or bunching & covering. When ladder type trays are used, the wires must be supported in conduits.
Redpoint Jackets Ltd. PAGE 4 No. Category Finding Recommendation Timeline E-12 Phase barrier between different Phase barriers between different phases are not installed. phases must be installed to E-13 Wiring inside panels re repaired and joined for extensions. E-14 Cables & Wiring Systems Metal channels without covers are used to support wirings in production floors. E-15 Flexible PVC conduits used to support cables/wires connecting between different ducts are joined (tee) without junction box/tee. E-16 11kV (HT) Cables laid directly on concrete floor (not supported and unprotected). E-17 Leakage current collector of 11kV power cable connecting to earth is joined to extend connection. prevent flashover/arcing. Wires must be continuous and all repairs must be carried out in accordance to the standard requirement and minimum requirement by the cable manufacturers. Metal channels installed as ducts to support wirings at the production floor to distribute supply to various appliances must be covered and supported firmly. The joints must be avoided wherever possible and all extensions must be made by cables. If flexible conduits of adequate grade and specifications, the joints (if unavoidable) must be realized through commercially available junction 3 box or tee. Cables on ground level must be laid in cable trenches supported and protected from physical damages. Leakage current collector may be connected to the clamp from where it can be extended to earth connection point. Within 6 Within 6 Photo Ref E.12 E.13 E.14 E.15 E.16 E.17 3 If conduit joints are unavoidable, all joints or Tee must be realized through junction boxes but the wiring/cables must not be joined.
Redpoint Jackets Ltd. PAGE 5 No. Category Finding Recommendation Timeline E-18 Wooden frames (locally made) are Cables in ladders must be Within 6 used to hold/support cables in tied/fixed on the ladders at the place through walls and ladders. steps (bars) and cables on walls must be supported on ladder/raiser E-19 Cables leading from cable supports to the panels are not supported. E-20 Cables supported on cable trays are repaired. E-21 Remaining opening after the cables have passed through walls are not protected / sealed. E-22 Wiring in flexible PVC conduits is extended from panel to ducts without supports. or cable trays. Cable trays or supports must be extended till the panel and cable lead connecting to panels must be protected 4 Cables must not have mid-span joints between the two designated points of connection 5. In case of insulation repairs, shrink tubes (near cable ends) must be used and special tapes (repairs far from ends) must be used 6. Remaining holes/gaps after cables(s) have passed through the walls must be covered or sealed with specifications required by the fire safety. Flexible PVC conduit must not be used for long extensions/points and must be supported and protected. Photo Ref E.18 E.19 E.20 E.21 E.22 4 Cable lead connecting between the cable supports to the panels may be protected in industrial grade flexible conduit and supported firmly. 5 If unavoidable due to long span/length of cable between the two points, joints must electrically and mechanically meet the standards without compromising the minimum requirement for cable joints by the cable manufacturers. 6 Section of the cable (near) joints must be mechanically protected firmly fixing on the supports on both sides of the joints.
Redpoint Jackets Ltd. PAGE 6 No. Category Finding Recommendation Timeline E-23 PVC Pipes (100 150mm dia) are Wiring ducts must be designed to used as wiring ducts in production meet safety and electrical floors. standards for industrial use. PVC conduits must not be used as ducts when points for appliances are distributed at various points in E-24 Wiring in flexible PVC conduits on walls (approaching distribution panels) are not supported/fixed on walls. E-25 Earth Earth strip/bar in substation has multiple earth wire conductors terminating at a point. E-26 Earth connection joined at midspan (tapping) to extend earth connections to other equipment. E-27 Boiler Room Wiring and cables used to connect devices and equipment in boiler room are not protected against external heat. the floor. Wiring approaching distribution panels may be extended in the same system (duct or conduits) and flexible conduit must be limited to short lead before entering the panel. The conduits on walls must be firmly fixed and supported. Each earth conductor must be connected to earth strip/bar independently to avoid loose connection and increased joint resistance. Earth connection (conductor) must be connected from distribution to equipment without joints or looped at appropriate points All cables or the wiring used in boiler room must be protected from external heat from boiler. Within 6 Photo Ref E.23 E.24 E.25 E.26 E.27
Redpoint Jackets Ltd. PAGE 7 ATTACHMENT 1 PHOTOGRAPHS OF FINDINGS/ISSUES
Redpoint Jackets Ltd. PAGE 8 1000kVA 500kVA Photo E.1 Transformer fenced with GI Pipe rails Photo E.2 Oil container attached below breather to trap dust and moisture is empty
Redpoint Jackets Ltd. PAGE 9 Photo E.3 Earth looped from transformer body earth Photo E.4 Silica gel in transformer breather turned pinkish white
Redpoint Jackets Ltd. PAGE 10 Photo E.5 Channel/Cable Trench raised above floor level covered with rubber mat. Portion of the cables laid directly on the concrete floor (typical in substation) Photo E.6 Panels cut open for cable entry and not sealed /covered (typical)
Redpoint Jackets Ltd. PAGE 11 Photo E.7 Connections for motor (equipment) not firmly connected (typical) Photo E.8 Wiring inside sub-distribution panel, haphazardly arranged and not safely routed (typical)
Redpoint Jackets Ltd. PAGE 12 Photo E.9 Smaller wires or conductors laid on ladder type cable tray without protection (typical) Photo E.10 Multiple wires in panels connected to a terminal crimped using a lug or socket (typical) Photo E.11 Panels top (left) and bottom (right) covers removed for cable entry
Redpoint Jackets Ltd. PAGE 13 Photo E.12 Phase barriers between different phases not installed in many of the MCCBs Photo E.13 Cables/wires in panels joined and repaired Photo E.14 Metal channels used for wiring ducts in factory floors without covers
Redpoint Jackets Ltd. PAGE 14 Photo E.15 Flexible PVC conduit joint without junction boxes Photo E.16 11kV (HT) cables laid directly on concrete floor
Redpoint Jackets Ltd. PAGE 15 Photo E.17 Leakage current collector from HT cable end termination joined Photo E.18 Cables supported by wooden frame on walls and cable raisers (typical) Photo E.19 Cables leading from cable supports to panels are not supported
Redpoint Jackets Ltd. PAGE 16 Photo E.20 Cables repaired in mid-span (typical) Photo E.21 Remaining holes/gaps after passing cables through walls are left open Photo E.22 Flexible PVC conduit used to for connection from panel to ducts / cable trays (typical)
Redpoint Jackets Ltd. PAGE 17 Photo E.23 PVC conduit used as duct to support wiring in production floors. Duct ends not sealed (inset) Photo E.24 Wiring in PVC flexible conduit near panels not supported Photo E.25 Multiple earth conductors terminated at a point on earth strip/bar
Redpoint Jackets Ltd. PAGE 18 Photo E.26 Earth conductor joined to extend earth connection to other equipment Photo E.27 Wirings and cables used in boiler room not protected from external heat