EQUIVALENT INITIAL ELECTRICAL SAFETY ASSESSMENT

Transcription

1 EQUIVALENT INITIAL ELECTRICAL SAFETY ASSESSMENT Factory 50-60, Dakkhin Panishail. N.K. Link Road, Kashimpur, Gazipur Gazipur 08 May 2014 The Alliance for Bangladesh Worker Safety Page 1/23

2 08 May 2014 Introduction to the Report The following report contains a site profile and summary of non-conformities identified during an onsite assessment commissioned by the Alliance for Bangladesh Worker Safety (Alliance) and conducted by a third-party Qualified Assessment Firm (QAF). The assessment was conducted against the Alliance for Bangladesh Worker Safety Assessment Protocols (APs) and Fire Safety and Structural Integrity Standard, which is harmonized with the factory assessment guidelines developed by Bangladesh University of Engineering and Technology (BUET) for the Bangladesh National Tripartite Plan of Action (NTPA). The goal of the Alliance process is to provide clear and practical technical requirements by which Bangladeshi Ready Made Garment (RMG) Factories producing for Alliance members may be consistently and fairly evaluated for fire, structural, and electrical safety in a non-duplicative manner. Each assessment will prompt action plans that will be used by RMG factories to systematically and sustainably improve safety conditions for garment workers. Beyond tracking and reporting on action steps taken in a transparent manner, the Alliance organization and its members will seek to further support factory improvements through technical assistance, training, implementation support for functional Worker Committees, and in some cases financial assistance and wage support for workers if factories are closed for remediation. The contents of the report do not constitute a guarantee of compliance with the applicable laws, the Alliance Standard or the absolute or continued safety against fire, electrical and/or structural integrity issues that may lead to injury or loss of life. The report is designed to provide a non-exhaustive summary of risk issues, based on a limited sampling and duration of time onsite by the named QAF. Neither the QAF nor the Alliance can certify or guarantee the quality, outcome, or effectiveness of actions taken in response to the report. For more information and report feedback please go to: The Alliance for Bangladesh Worker Safety Page 2/23

3 08 May 2014 GENERAL INFORMATION General Information Factory Country: Province: City: Bangladesh Dhaka Gazipur Zip Code: Audit Duration: Re-Audit: 1 Days Re-Audit After 0 Months Draft Report Date : Final Report Date : Are all action items from previous assessment complete? : Buildings in Complex : Is the building(s) owned or rented by the Factory?: Number of Building Levels (Stories) : Approximate Building Area (SF) : Date of Building Construction : Date of Last Building Renovation/Addition : N/A There are 3 buildings in the factory premises out of which one is five story main production building and two are ancillary buildings. The buildings are named as: 1) Five Story Main Building, 2) Single Story Utility shed-1, 3) Single Story Utility shed-2. Owned 1) Five Story Main Building: Building height (est occupied floor level): m or ft [Height up to roof: m or ft], Stories above grade: 5, Stories below grade: 0, Occupied levels: 5, 2) Single Story Utility shed-1: Building height (est occupied floor level): 15 cm or 0.50 ft above grade [Height up to roof: 3.05 m or 10 ft], Stories above grade: 1, Stories below grade: 0, Occupied levels: 1, 3) Single Story Utility shed-2: Building height (est occupied floor level): 15 cm or 0.50 ft above grade [Height up to roof: 3.65 m or 12 ft], Stories above grade: 1, Stories below grade: 0, Occupied levels: 1. Total area of buildings in the factory premises: sft. Building wise breakdown as follows: 1) Five Story Main Building: Sft (Ground floor: Sft, 1st floor: Sft, 2nd floor: Sft, 3rd floor: Sft, 4th floor: Sft), 2) Single Story Utility shed-1: 400 Sft, 3) Single Story Utility shed-2:200 Sft. Factory personnel informed the date of construction as follows: 1) Five Story Main Building: Finished in-2002, 2) Single Story Utility shed-1: Finished in-2003, 3) Single Story Utility shed-2: Finished in ) In front of Single Story Utility shed-2 civil works on going. The Alliance for Bangladesh Worker Safety Page 3/23

4 08 May 2014 Ancillary Structures in Complex : Approximate Ancillary Structures Area (SF) : Number of Occupants : Provide brief description of the electrical system for each building.: Physical location of Substation? : What equipment/loads does the UPS serve? : 1) Single Story Utility shed-1, 2) Single Story Utility shed-2. 1) Single Story Utility shed-1: 400 Sft, 2) Single Story Utility shed-2: 200 Sft. Total number of occupants: ) Five Story Main Building: 2257 (Ground floor: 150, 1st floor: 472, 2nd floor: 600, 3rd floor: 650, 4th floor: 425), 2) Single Story Utility shed-1: 4, 3) Single Story Utility shed-2: 3. Source of power REB, Transformer 630 KVA, Generator-2 Nos. (560 KVA, 92 KVA), COS-2Nos, Distribution Boards (DB) 17 Nos. Ground floor, front right side of the building. UPS served Computer. IPS served fire alarm, emergency lighting, exit signage. The Alliance for Bangladesh Worker Safety Page 4/23

5 08 May 2014 ASSESSMENT FINDINGS Electrical System Information Are as-built electrical drawings indicating information such as panel and circuit locations throughout the building(s) available for review? Non-Compliance Level: Alliance Standard Part 10 Section Electrical System Maintenance Have workers that operate and maintain the electrical system received electrical safety training? Is training documentation on site? Non-Compliance Level: Reference NFPA 70e for example Is a periodical Insulation Resistance Measurement Program established and recorded? A periodical Insulation Resistance Measurement program has not been established. The Alliance for Bangladesh Worker Safety Page 5/23

6 08 May 2014 Document Review: No periodical Insulation Resistance Measurement program. Develop an Insulation Resistance Measurement program that ensures deterioration of insulation resistance will be identified quickly. Testing should be in compliance with International Electrical Testing Association (NETA). All transformers, switchgears etc. shall be subject to an insulation resistance measurement test to ground after installation but before any wiring is connected. Insulation tests shall be made between open contacts of circuit breakers, switches etc. and between each phase and earth. Alliance Standard Part 10 Section Insulation Tests and Electrical Inspections Is the electrical switchgear and panel boards inspected on an annual basis to ensure that the equipment is installed in accordance with the listed ratings? The electrical switch-gear and panel boards are not inspected on an annual basis to ensure that the equipment is installed in accordance with the listed ratings. Document Review: No annual inspection record for electrical switchgear and panel boards. Inspect electrical switchgear and panel boards on an annual basis to ensure that the equipment are in good working condition. Alliance Standards Part 10 Section Electrical Inspections Are thermographic scans of electrical equipment completed at least every three years? Thermographic scans of electrical equipment are not completed. Document Review: No Thermographic scans for electrical equipment. Complete Thermographic scans, at minimum, on a three year cycle. Thermographic scans should be completed in accordance with the Standard for Infrared Inspection of Electrical Systems & Rotating Equipment. The Alliance for Bangladesh Worker Safety Page 6/23

7 08 May 2014 Alliance Standards Part 10 Section Electrical Inspections Transformers do not contain harmful substances such as PCBs. There is no document to review the whether transformers contain harmful substances or not. Document Review: There is no document to review whether the transformers contain harmful substances. Consider replacing transformers that contain harmful substances to reduce health hazards. Not Applicable Are periodic safety inspections of the electrical system components completed and documented? Periodic safety inspections of the electrical system components are not completed. Document Review: No periodic safety inspections of the electrical system. Establish a periodic inspection program to ensure the electrical systems are free from damage, debris, dirt, lint, etc. Maintain records concerning inspections and follow up actions. Alliance Standard Part 10 Section Inspection and Testing and Part 13 Section 13.6 Housekeeping A transformer oil analysis is routinely completed on main service transformers. Low Transformer oil analysis is not routinely completed on main service transformers. Document Review: Transformer oil analysis is not routinely completed. The Alliance for Bangladesh Worker Safety Page 7/23

8 08 May 2014 Complete an oil analysis on applicable transformers at appropriate intervals based on voltage and power. Alliance Standard Part 10 Section Electrical Inspections Electrical System Conditions The substation room has the required fire rating/protection and is physically separated from the remainder of the building. The substation room has no required fire rating, protection and is not physically separated from the remainder of the building. Photograph: No fire rating, protection and physical separation for substation room. Consult with an expert fire protection engineer and make sure the substation room is fire rated with physically separated from rest of the building as per Alliance standard. Alliance Standard Part 3 Section Are all switchboards and/or distribution boards metal enclosed with a dead front construction? Distribution boards are metal enclosed without dead front construction. Location: All distribution boards. Photograph: Metal enclosed without dead front construction. Distribution boards are metal enclosed without dead front construction. Alliance Standards Part 10 Section 10.7 Main Switch, Switchboards and Metal Clad Switchgear The Alliance for Bangladesh Worker Safety Page 8/23

9 08 May 2014 Indications of overheating, overloading, or signs of burning were not observed. Indications of overheating, and signs of burning were observed. Location:SDB -1, 1st Floor; DB-5, 3rd Floor; COS-1 Substation, LT-1, Substation, PFI-1, Substation DB-01,Ground Floor; DB-09, 4h Floor. Photograph: Indications of overheating and signs of burning were observed. Find out the cause of overheating, signs of burning and take proper action. Alliance Standard Part 10 Section Is electrical wiring/cables sized according to capacity of circuit breakers (No higher rated circuit breakers with lower rated wiring)? Electrical wiring, cables are not sized according to capacity of circuit breakers. Document Review: er rated circuit breakers with lower rated wiring. Consult with a qualified Electrical Engineer and ensure electrical wiring/cables are sized according to capacity of circuit breakers. Alliance Standard Part 10 Section Electrical Connections. All metal in the building is connected to the building earthing/grounding system such as metal rebar in concrete, metal frame of building, or metal water pipe. Non-Compliance Level: 2 All metal in the building is not connected to the building earthling system such as metal rebar in concrete, metal frame of building, or metal water pipe. Photograph: Not all metal in the building is connected to the building earthing. Connect all metal in the building to the building earthing/grounding system such as metal rebar in concrete, metal frame of building, or metal water pipe. The Alliance for Bangladesh Worker Safety Page 9/23

10 08 May 2014 Alliance Standard Part 10 Section Earthing Do switchboards and/or distribution boards have a minimum clearance of 1 m (39 in) in front? Non-Compliance Level: 1 Distribution boards are not provided with adequate clearance. Location: DB- 10, 4th Floor, DB -8, 3rd Floor, DB -6, 2nd Floor, DB -3, 1st Floor Photograph: Inadequate clearance in front of distribution boards. Provide clearance of at least 1 m (39 in) in front of switchboards and/or distribution boards. Alliance Standards Part 10 Section 10.7 Main Switch, Switchboards and Metal Clad Switchgear Are switchboards and/or distribution boards installed in compliant locations? Non-Compliance Level: 1 Distribution boards are not installed in compliant locations (access limited). Location: DB-10, 4th Floor; DB -8, 3rd Floor; DB -6, 2nd Floor; DB -3, 1st Floor. Photograph: Distribution boards installed in improper location. Install distribution boards in compliant locations so that operation is not hampered due to limited access. Alliance Standard Part 10 Section 10.7 Main Switch, Switchboards and Metal Clad Switchgear Wiring systems are selected and erected so that no damage is caused by the ingress of water. Non-Compliance Level: 1 Wiring systems are not selected and erected considering the effect of damage caused by ingress of water. Location: 2nd Floor, near window. The Alliance for Bangladesh Worker Safety Page 10/23

11 08 May 2014 Photograph: Damage due to ingress of water. Ensure wiring systems are selected and erected so that no damage is caused by the ingress of water. Alliance Standards Part 10 Section Presence of Water Power and telecommunication or antenna cables are led in separately. Power and antenna cables are not led in separately. Photograph: Power and antenna cables are not separated. Lead telecommunication or antenna cables separately to the main point of service. Power and telecommunications cables must have separate entrance. Alliance Standards Part 10 Section Service Entry Are all switchboards and/or distribution boards properly grounded (earthed)? Distribution boards are not properly grounded (earthed). Location: DB -7, sample section, 2nd Floor. Photograph: Inadequate grounding. Provide grounding (earthing) for Switchboards and/or distribution boards. Alliance Standard Part 10 Section Circuit and System Earthing Do switchboards and/or distribution boards have capacity information labels? Distribution boards have no capacity information labels. Location: All distribution boards. The Alliance for Bangladesh Worker Safety Page 11/23

12 08 May 2014 Photograph: No capacity information labels found. Provide capacity information labels (Maximum current rating, no of circuit breakers etc.) in distribution boards. Alliance Standard Part 10 Section 10.7 Main Switch, Switchboards And Metal Clad Switchgear and Inspection of the Installation Are switchboards and/or distribution boards free of dust and debris? Distribution boards are not free of dirt. Location: DB-10, 4th Floor; DB -8, 3rd Floor; DB -6, 2nd Floor; DB -3, 1st Floor. Photograph: Dirt found in distribution boards. Ensure distribution boards free from dirt. Alliance Standard Part 10 Section Enclosures Are switchboards and/or distribution boards provided with physical means to prevent the installation of more over current devices than that number for which the panel board was designed, rated, and listed. Distribution boards are not provided with physical means to prevent the installation of more over current devices than that number for which the panel board was designed, rated, and listed. Location: All Distribution board. Photograph: No means to prevent the installation of more over current devices. Ensure switchboards and/or distribution boards provided with physical means to prevent the installation of more over current devices than that number for which the panel board was designed, rated, and listed. Alliance Standards Part 10 Section 10.7 Main Switch, Switchboards and Metal Clad Switchgear The Alliance for Bangladesh Worker Safety Page 12/23

13 08 May 2014 Each circuit is provided with a dedicated neutral. Each circuit is not provided with a dedicated neutral. Location: All Distribution Boards. Photograph: No dedicated neutral for each circuit. Provide dedicated neutral for each circuit. Alliance Standards Part 10 Section 10.3 Electrical Wiring and Cabling Are lighting and receptacle (socket) circuits segregated? Lighting and socket circuits are not separated. Document Review: Lighting and socket circuits are not separated. Lighting and socket circuits must be separated at the noted locations. Have a qualified electrician separate the lighting and sockets into separate circuits. Alliance Standard Part 10 Section Are electrical wiring/cables properly identified? Electrical wiring, cables are not properly identified. Location: All Distribution boards, switch board. Photograph: Electrical wiring, cables are not identified. Ensure the means of identification is obtained by separate color coding, marking tape, tagging, or other approved means. Bangladesh Electricity Rules 1937 Rule 51 and 56 The Alliance for Bangladesh Worker Safety Page 13/23

14 08 May 2014 Stranded conductors having a nominal cross-sectional area 6mm2 or greater are provided with cable sockets. Conductors below 6 mm2 without cable sockets, all strands at the exposed ends are soldered together or are crimped using suitable sleeve or ferrules. Cable sockets are not provided for stranded conductors. Location: All distribution boards. Photograph: Cable socket are not provided. Provide cable sockets for stranded conductors having a nominal crosssectional area 6mm or greater. Alliance Standards Part 10 Section Cable Ends Cable joints are through porcelain/pvc connectors with PIB tape wound around joint. Improper cable joints were found. Location: Iron Section, 4th Floor; Sewing Section 4th Floor; SDB -6, 4th Floor; DB -8, 3rd Floor; DB -9, 3rd Floor; Cable Tray 2nd Floor; DB -5, 2nd Floor. Photograph: Improper cable joints were found. Ensure cable joints through porcelain/pvc connectors with PIB tape wound around joint. Alliance Standards Part 10 Section Cable Joints Is all electrical wiring/cable properly terminated at its point of termination (No un-terminated wires, lugs are provided at terminals, etc)? Electrical cable is not properly terminated. Location: 4th Floor Sewing section, SDB -3, Bartic Section. Photograph: Un-terminated wires found. Ensure all electrical wiring/cable properly terminated at its point of termination. The Alliance for Bangladesh Worker Safety Page 14/23

15 08 May 2014 Alliance Standards Part 10 Section Wiring of Sub-distribution Boards Are all internal components of switchboards and/or distribution boards properly concealed (No missing circuit breaker or knockout covers)? Non-Compliance Level: 2 Internal components of switchboards and distribution boards are not properly concealed. Location: DB-8, 3rd floor, 2nd Floor, Sewing Section; 1st Floor, Finishing. Photograph: Internal components are not properly concealed. Provide covers or blanks to conceal all live internal components of switchboards and/or distribution boards. Alliance Standard Part 10 Section Sub-Distribution Boards Lighting fixtures are supported from the structure and seismic bracing is installed as required. Non-Compliance Level: 2 Lighting fixtures are not supported properly. Location: 1st floor, finishing area. Photograph: Lighting fixtures are not supported properly. Ensure Lighting fixtures are supported from the structure and seismic bracing is installed as required. Alliance Standards Part 10 Section Lighting Fittings Electrical connections at equipment, fixtures, etc are properly secured. Non-Compliance Level: 2 Electrical connections at equipment, fixtures, etc. are not properly secured. Location: Boiler Room The Alliance for Bangladesh Worker Safety Page 15/23

16 08 May 2014 Photograph: Electrical connections are not secured. Ensure electrical connections at equipment, fixtures, etc. are properly secured. Alliance Standards Part 10 Section Electrical Connections Are junction boxes and other electrical devices provided with covers? Non-Compliance Level: 2 Junction boxes and other electrical devices are not provided with covers. Location: 2nd Floor (ceiling) Photograph: Inadequate electrical cover. Provide adequate covers for junction boxes and other electrical devices. Alliance Standard Part 10 Section and Mechanical guards are provided for electrical equipment and wiring where necessary. Non-Compliance Level: 2 No mechanical guards are provided for electrical equipment where necessary. Location: 3rd floor, sewing section Photograph: No mechanical guards. Provide mechanical guards for electrical equipment where necessary. Alliance Standard Part 10 Section 10.3 Electrical Wiring and Cabling, Cables, and 10.7 Main Switch, Switchboards And Metal Clad Switchgear The Alliance for Bangladesh Worker Safety Page 16/23

17 08 May 2014 Conduit expansion fittings are used for conduit runs that span a building expansion joint. Non-Compliance Level: 1 Conduit expansion fittings are not used for conduit runs that span a building expansion joint. Photograph: Conduit expansion fittings not found. Use conduit expansion fittings for conduit runs that span a building expansion joint. Alliance Standards Part 10 Section Expansion Joints Are there additional areas of non-compliance to report? Non-Compliance Level: 1 There are no additional areas of non-compliance to report. Visual Assessment: There are no additional areas of non-compliance to report. N/A Not Applicable Are electrical insulation mats provided in front of substation, switchboards and/or distribution boards? Low Non-graded electrical insulation mats are provided in front of substation and distribution boards. Photograph: Non-graded mats provided in front of substation and distribution boards. Provide electrical graded insulation mats in front of distribution boards. The Alliance for Bangladesh Worker Safety Page 17/23

18 08 May 2014 Alliance Standard Part 10 Section Inspection of the Installation. Required equipment and safety signage is posted within the room. Low Required equipment and safety signage is not posted within the room. Visual Assessment: Required equipment and safety signage is not available. Indoor electrical installations that are accessible to unqualified persons shall be made with metal-enclosed equipment. Switchgear, unit substations, transformers, pull boxes, connection boxes, and other similar associated equipment shall be marked with appropriate caution signs. Entrances to rooms and other guarded locations that contain exposed live parts shall be marked with conspicuous warning signs forbidding unqualified persons to enter. Caution, warning, danger signs or labels should meet the following requirements: (1) The marking shall adequately warn of the hazard using effective words and/or colors and/or symbols. American National Standards Institute ANSI Z , Product Safety Signs and Labels, provides guidelines for suitable font sizes, words, colors, symbols, and location requirements for labels. (2) Shall be permanently affixed to the equipment or wiring method and shall not be hand written. Exception, portions of labels or markings that are variable, or that could be subject to changes, shall be permitted to be hand written and shall be legible. (3) The label shall be of sufficient durability to withstand the environment involved. ANSI Z , Product Safety Signs and Labels, provides guidelines for the design and durability of safety signs and labels for application to electrical equipment Alliance Standard Part 10 Section , Section , and , NFPA 70 Chapter 1 Article , and Bangladesh Electricity Rules of 1937 Rule 46 Phase separators are provided between terminals on circuit breakers. Low Phase separators are not provided between terminals on circuit breakers. Location: All Distribution Boards. Except DB -11. Photograph: No phase separators. Install phase separators between terminal connections. Verify phase separators are installed at all remaining locations. Alliance Standard Part 10 Section Electrical Connections The Alliance for Bangladesh Worker Safety Page 18/23

19 08 May 2014 Signage indicating the prohibition of light fixtures without protective covers is installed at required locations. Low No signage indicating the prohibition of light fixtures without protective covers is installed at required locations. Visual Assessment: No signage indicating the prohibition of light fixtures without protective covers. Ensure signage indicating the prohibition of light fixtures without protective covers is installed at required locations. Light fixtures without protective covers (otherwise known as naked lights) shall not be allowed in storage areas or in any area where the Inspector of the Factories Rules disallows these fixtures. Install signs posted in Bengali and English, indicating this prohibition at all entrances to these areas. Alliance Standards Part 10 Section Naked Lights Emergency Power System Is the generator room properly rated and physically separated from the remainder of the building? Generator room is not properly rated but is physically separated from the remainder of the building. Photograph: Generator room is not rated. Consult with an expert fire protection engineer and make sure the generator room is fire rated as per Alliance standard. Alliance Standards Part 10 Section Generator Room Is the generator room clean and free of dirt, debris, and improperly stored materials? Non-Compliance Level: 1 Generator room is not clean. The Alliance for Bangladesh Worker Safety Page 19/23

20 08 May 2014 Photograph: Generator room is not clean. Ensure the generator room clean and free of dirt, debris. Alliance Standards Part 10 Section Generator Room Is the generator room properly ventilated Non-Compliance Level: 1 Generator room is not properly ventilated. Photograph: Inadequate ventilation. Provide means of ventilation for the generator room. Consult a qualified electrical engineer to determine the required ventilation rates based on the installed equipment. Alliance Standards Part 10 Section Generator Room Are cable trenches properly covered? Non-Compliance Level: 1 Cable trenches are not covered properly. Photograph: No cable trench cover. Provide adequate cover on cable trench. Alliance Standard Part 10 Section Inspection of the Installation Is the generator frame earthing (grounding) provided at two separate points? Generator frame earthing (grounding) is not provided at two separate points. Photograph: Inadequate generator frame earthing. The Alliance for Bangladesh Worker Safety Page 20/23

21 08 May 2014 Provide two separate points earthing (grounding) provided for generator. Alliance Standard Is the generator room appropriately sized in order to properly access the generator to perform routine maintenance activities? The size of generator room is not appropriate. Photograph: Inadequate generator room size. Ensure appropriate size for generator room in order to properly access the generator to perform routine maintenance activities. Alliance Standard Part 10 Section Generator Room Are inspection, maintenance, and testing procedures of the UPS being completed and documented? Low Non-Compliance Level: 2 Inspection, maintenance, and testing procedures of the UPS and IPS are not completed. Document Review: No documentation on UPS and IPS testing and maintenance. Establish an inspection testing, and maintenance program for the Uninterruptable Power Supply (UPS) and associated components. The program must based on the following: (1) Manufacturer's recommendations (2) Manufacturer's instruction manuals Alliance Standard Part 13 Section NFPA 111 Chapter 8 NFPA 70B Chapter 28 Lightning Protection System The lightning protection ground terminals are bonded to the building or structure grounding. The Alliance for Bangladesh Worker Safety Page 21/23

22 08 May 2014 The lightning protection ground terminals are not bonded to the building or structure grounding. Visual Assessment: The lightning protection ground terminals are not bonded to the building or structure grounding. Consult with an expert engineer to have details design and drawing of lightning protection system and ensure your building is secured. Alliance Standards Part 10 Section Lightning Protection The air termination network vertical and horizontal conductors are appropriately spaced. Non-Compliance Level: 2 No design and document found to verify, the air termination network vertical and horizontal conductors are appropriately spaced. Photograph: Inadequate spacing. Consult with an expert electrical engineer and prepare drawing for lightning protection including risk index and make sure your system is secured against lightning. Alliance Standards Part 10 Section Lightning Protection The appropriate number of down conductors are installed based on the building size. Non-Compliance Level: 2 No such design and drawing found to identify number of down conductors installed based on the building size. Visual Assessment: Inadequate down conductor found. Consult with an expert electrical engineer to make sure system has appropriate numbers of down conductors installed based on the building size. The Alliance for Bangladesh Worker Safety Page 22/23

23 08 May 2014 Alliance Standards Part 10 Section Lightning Protection The Alliance for Bangladesh Worker Safety Page 23/23