INITIAL ELECTRICAL ASSESSMENT REPORT (EAR)

Transcription

1 INITIAL ELECTRICAL ASSESSMENT REPORT (EAR) Factory Name: Plot 33-35, Dhaka (EPZ), Savar Savar Dhaka Bangladesh 06 Jul 2014 The Alliance for Bangladesh Worker Safety Page 1/19

2 06 Jul 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 2/19

3 06 Jul 2014 GENERAL INFORMATION General Information Factory Name: Country: Province: City: Bangladesh Dhaka Savar Zip Code: 1349 Audit Duration: Re-Audit: 1 Days Re-Audit After 0 Months Draft Report Date : 07/07/2014 Final Report Date : 07/10/2014 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 : Ancillary Structures in N/A There are 9 Buildings: 1) Main Building (Actor Sporting Limited); 2) Shed -1 (Boiler, Generator and Sub Station); 3) Shed-2 (Workers Dining); 4) Shed-3 (Wastage Store); 5) Shed-4 (Accessories store and Laser); 6) Shed-5 (Cap Visor and Prayer Room); 7) Shed-6 (Child Care); 8) Shed-7 (Fire Control Room); 9) Shed -8 (Security Shed). Owned There are 9 Buildings: 1) Five story main building (Actor Sporting Limited); 2) Single story shed -1 (Boiler, Generator and Sub Station); 3) Single story shed-2 (Workers Dining); 4) Single story shed-3 (Wastage Store); 5) Single story shed-4 (Accessories store and Laser); 6) Single story shed-5 (Cap Visor and Prayer Room); 7) Single story shed-6 (Child Care); 8) Single story shed-7 (Fire Control Room); 9) Single story shed-8 (Security Shed) There are 8 Ancillary Buildings: 1) Shed -1 (Boiler, Generator and Sub Station); 2) Shed-2 (Workers Dining); The Alliance for Bangladesh Worker Safety Page 3/19

4 06 Jul 2014 Complex : Approximate Ancillary Structures Area (SF) : 3) Shed-3 (Wastage Store); 4) Shed-4 (Accessories store and Laser); 5) Shed-5 (Cap Visor and Prayer Room); 6) Shed-6 (Child Care); 7) Shed-7 (Fire Control Room); 8) Shed -8 (Security Shed) Number of Occupants : 1751 Provide brief description of the electrical system for each building.: Physical location of Substation? : What equipment/loads does the UPS serve? : 11KV service feed of Bangladesh Export Processing Zone (BEPZA) to 2500KVA Oil Type Transformer via one number Tension (HT) Panel, total captive power capacity of 1000KVA provided by one number 1000KVA Diesel Generator, electrical power is distributed via one number Low Tension (LT) Panel, one number Change Over Switch (COS), one number Power Factor Improvement (PFI) Panel and forty four numbers Distribution Boards (DB). Substation is located in Shed-1. IPS serves emergency lights, exit lights and fire alarms. The Alliance for Bangladesh Worker Safety Page 4/19

5 06 Jul 2014 ASSESSMENT FINDINGS Electrical System Maintenance Have workers that operate and maintain the electrical system received electrical safety training? Is training documentation on site? Non-Compliance Level: 2 Workers that operate and maintain the electrical system have received electrical safety training but not documented on site. Document Review: No documentation of electrical safety training was found. Develop and implement an electrical safety program. Include key topics such as lock out tag out procedures, personal protective equipment requirements, etc. Reference NFPA 70e for example program requirements. Reference NFPA 70e for example Is a periodical Insulation Resistance Measurement Program established and recorded? Periodical Insulation Resistance Measurement Program is not established. Document Review: No document of periodical insulation measurement program was found on site. 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 Are thermographic scans of electrical equipment completed at least every three years? The Alliance for Bangladesh Worker Safety Page 5/19

6 06 Jul 2014 Thermographic scans of electrical equipment have not been completed. Document Review: No document of thermographic scans was found. Complete thermographic scans at least on a three year cycle. Thermographic scans should be completed in accordance with the Standard for Infrared Inspection of Electrical Systems & Rotating Equipment or a comparable standard. Alliance Standards Part 10 Section Electrical Inspections Transformers do not contain harmful substances such as PCBs. No document regarding PCB containment of transformer was found on site that confirms that the transformer does not contain harmful substances such as PCBs. Document Review: No document regarding PCB containment of transformer was found on site. Consider replacing transformers with harmful substances to reduce health hazards. Not Applicable A transformer oil analysis is routinely completed on main service transformers. Low Transformer oil analysis has not been completed on main service transformer. Document Review: No document of transformer oil analysis was found on site. Complete an oil analysis on applicable transformers at appropriate intervals based on voltage and power. Alliance Standard Part 10 Section Electrical Inspections The Alliance for Bangladesh Worker Safety Page 6/19

7 06 Jul 2014 Electrical System Conditions 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. All metal in the building is not connected to the building earthing system such as metal rebar in concrete, metal frame of building, or metal water pipe. Location: Throughout the building. Visual Assessment: Not all metal in the building is connected to the building earthing. Connect all metal in the building to the building earthing system such as metal rebar in concrete, metal frame of building, or metal water pipe. Alliance Standard Part 10 Section Earthing Indications of overheating, overloading, or signs of burning were not observed. Non-Compliance Level: 2 Signs of burning were observed. Location: DB-8, Ground floor, Main Building Indications of overheating were observed at some locations during thermography. Location: 1) PFI Right, Ground floor-78.0 C 2) PFI middle, Ground floor-77.9 C 3) PFI Left, Ground floor-78.3 C 4) DB-1-Ext-1, Ground floor-74.7 C 5) DB-2, Ground floor-88 C 6) DB-5, Ground floor-80 C 7) SDB-3, Ground floor, EMB-91.1 C 8) SDB-4, 1st floor-82.2 C 9) SDB-3/2, 1st floor C 10) SDB-3, 1st floor-76.4 C 11) SDB-2, 1st floor-73 C 12) DB-1, 1st floor-72.1 C 13) DB-2, 1st floor-73.6 C 14) SDB-3/2, 1st floor-76.3 C 15) DB- 1, 2nd floor-78.9 C 16) SDB-4, 2nd floor-70.2 C 17) Compressor control panel, Ground floor-71.2 C Note: Detail thermography report is uploaded here under General Information section namely ' Thermography of Actor Sporting Ltd (Garment Division) Photograph: Indications of overheating and signs of burning were found. Find out the cause of overheating, signs of burning and take proper action. Alliance Standard Part 10 Section The Alliance for Bangladesh Worker Safety Page 7/19

8 06 Jul 2014 Light fixtures without protective covers are not installed in storage areas or in any area where the Inspector of the Factories Rules ( ) Part 53 disallows these fixtures. Non-Compliance Level: 2 Light fixtures without protective covers are installed in storage areas. Location: Fabric store, Ground floor; Finish good store, 1st floor. Photograph: Without protective cover light fixtures installed in storage areas. Ensure light fixtures without protective covers are not installed in storage areas or in any area where the Inspector of the Factories Rules disallows these fixtures. Alliance Standards Part 10 Section Naked Lights Do switchboards and/or distribution boards have a minimum clearance of 1 m (39 in) in front? Distribution boards are not provided with adequate clearance. Location: SDB- EM, Embroidery Section, Ground floor. Photograph: Inadequate clearance in front of distribution board. Provide clearance of at least 1 m (39 in) in front of distribution boards. Alliance Standards Part 10 Section 10.7 Main Switch, Switchboards and Metal Clad Switchgear Are all switchboards and/or distribution boards metal enclosed with a dead front construction? Distribution boards are metal enclosed without dead front construction. Location: LT panel,substation Room,Shed-1. Photograph: No dead front construction. Ensure distribution boards are metal enclosed with a dead front construction. The Alliance for Bangladesh Worker Safety Page 8/19

9 06 Jul 2014 Alliance Standards Part 10 Section 10.7 Main Switch, Switchboards and Metal Clad Switchgear Are switchboards and/or distribution boards installed in compliant locations? Distribution board is not installed in compliant locations (access limited). Location: SDB-EM, Embroidery Section, Ground floor. Photograph: Distribution board 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 No circuits are drawn for loads without the incorporation of a overcurrent protection device (circuit breaker). Circuits are drawn for loads without the incorporation of an overcurrent protection device (circuit breaker). Location: DB-3-Ext, Ground floor; SDB-1, Ground floor. Photograph: No protection device. Ensure overcurrent protection device (circuit breaker) for each and every loads. Alliance Standards Part 10 Section 10.9 Protection of Circuits The Alliance for Bangladesh Worker Safety Page 9/19

10 06 Jul 2014 Is electrical wiring/cables sized according to capacity of circuit breakers (No higher rated circuit breakers with lower rated wiring)? Electrical cables are not sized according to capacity of circuit breakers(circuit Breaker :40A SP MCB, connected cable: 6rm BYA) Location: SDB-4, Level-3, Main Building; DB-8, Level-3, Main Building. Photograph: er rated circuit breakers with lower rated wiring. Consult with a qualified Electrical Engineer and ensure electrical wiring are sized according to capacity of circuit breakers. Alliance Standard Part 10 Section Electrical Connections. No multi looping of wiring/cables observed at circuit breakers within switchboards and/or distribution boards. Multi looping of cables observed at circuit breakers within distribution boards. Location: LT panel, Substation Room,Shed-1; SDB-ext, Ground floor; DB-2, Ground floor; DB-5, Ground floor; SDB-1, Level-3; DB-2, Level-2; SDB-3, Level-1; SDB-3(1),Level-1; SDB-EM, Ground floor. Photograph: Multi looping found of cables at circuit breakers. Remove multi looping of cables at circuit breakers within distribution boards. Alliance Standard Part 10 Section 10.3 Electrical Wiring and Cabling Do switchboards and/or distribution boards have clear identification markings? Distribution boards have no identification markings. Location: All Distribution boards. Photograph: No identification markings. Ensure clear and permanent identification marks are painted in all distribution boards, switchboards, sub main boards and switches. The Alliance for Bangladesh Worker Safety Page 10/19

11 06 Jul 2014 Alliance Standard Part 10 Section 10.7 BNBC Part 8 Section Do switchboards and/or distribution boards have capacity information labels? Distribution boards have no capacity information labels. Location: All Distribution boards. Photograph: No DB capacity information labels. Provide capacity information labels (Maximum current rating, no of circuit breakers etc.) for 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 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. The distribution boards have no capacity information labels, so "physical means to prevent the installation of more over current devices" is not considerable for this non-conformity at the moment. Location: All distribution boards. Photograph: No means to prevent the installation of more over current devices. Provide capacity information labels on distributions boards and ensure 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 11/19

12 06 Jul 2014 Are electrical wiring/cables properly identified? Electrical cables are not properly identified. Location: All distribution boards. Photograph: Electrical 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 substation room has adequate ventilation. Non-Compliance Level: 2 Though ceiling fans are installed in the room but no exhaust fans are installed to ensure proper ventilation of the substation room. Location: Substation Room,Shed-1. Photograph: Inadequate ventilation in substation room. Provide means of ventilation for the substation room. Consult a qualified electrical engineer to determine the required ventilation rates based on the installed equipment. Alliance Standard Part 10 Section Inspection of Substation Installations. Are all internal components of switchboards and/or distribution boards properly concealed (No missing circuit breaker or knockout covers)? Internal components of distribution boards are not properly concealed. Location: DB-6, Ground floor; SDB-2, Level-1. Photograph: Internal components are not concealed. Provide covers or blanks to conceal all live internal components of switchboards and/or distribution boards. The Alliance for Bangladesh Worker Safety Page 12/19

13 06 Jul 2014 Alliance Standard Part 10 Section Sub-Distribution Boards Are all switchboards and/or distribution boards properly grounded (earthed)? Distribution boards are not earthed. Location: DB-1-ext-1, Ground floor; DB-2, Ground floor. Photograph: No grounding. Provide grounding (earthing) for distribution boards. Alliance Standard Part 10 Section Circuit and System Earthing Each circuit is provided with a dedicated neutral. Each circuit is not provided with a dedicated neutral. Location: DB-3, Ground floor; SDB-3(2), Level-1; DB-2, Level-3. Photograph: No dedicated neutral. Provide dedicated neutral for each circuit. Alliance Standards Part 10 Section 10.3 Electrical Wiring and Cabling 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: DB-1-Ext-3, Ground floor; DB-5, Ground floor; DB-7, Ground floor; DB-8, Ground floor; SDB-EM, Ground floor; SDB-1, Level-3; SDB-3, Level-3. Photograph: No cable socket. The Alliance for Bangladesh Worker Safety Page 13/19

14 06 Jul 2014 Provide cable sockets for stranded conductors having a nominal crosssectional area 6mm2 or greater. Alliance Standards Part 10 Section Cable Ends Cable joints are through porcelain/pvc connectors with PIB tape wound around joint. Cable joints are not through porcelain, PVC connectors with PIB tape wound around joint. Location: DB-2, Ground floor; DB-7, Ground floor; SDB-2, Ground floor; SDB-3(1), Level-1; SDB-1, Level-3. Photograph: Improper cable joint 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 are not properly terminated. Location: SDB-4, Ground floor; SDB-EM, Ground floor. Photograph: Un-terminated wires found. Ensure all electrical cable properly terminated at its point of termination. Alliance Standards Part 10 Section Wiring of Sub-distribution Boards The Alliance for Bangladesh Worker Safety Page 14/19

15 06 Jul 2014 Required equipment and safety signage is posted within the room. Low Required equipment and safety signage is not posted within the room. Location: Substation Room, Shed-1. Photograph: No required equipment and safety signage posted in the room. 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 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. Location: All Stores. Photograph: No signage indicating the prohibition of light fixtures without protective covers. 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. The Alliance for Bangladesh Worker Safety Page 15/19

16 06 Jul 2014 Alliance Standards Part 10 Section Naked Lights Phase separators are provided between terminals on circuit breakers. Low Non-Compliance Level: 2 Phase separators are not provided between terminals on circuit breakers. Location: LT panel, Substation room, Ground floor; LT-Ext, Substation room, Ground floor; DB-1-EXt-3, Ground floor; DB-2, Ground floor; DB-3, Ground floor; DB-5, Ground floor; DB-8, Ground floor; DB-9,Ground floor; SDB-1, Ground floor; SDB-4, Ground floor; SDB-3, Ground floor; SDB-3(2), Level-1; SDB-3(1), Level-1; SDB-button, Level-1; SDB-1,Level-2; DB-1, Level-3; SDB- 1, Level-3; SDB-4, Level-3. 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 Are meters and other electrical devices (Ammeter, Voltmeter, PFI Auto Controller, etc) installed on the main electrical equipment operational? Low Meters and other electrical devices (Voltmeter) installed on the main electrical equipment are not operational. Location: LT Panel, Substation Room, Shed-1. Photograph: Voltmeter is not operational. Ensure meters and other electrical devices installed on the main electrical equipment are operational. Alliance Standard Inspection of the Installation Emergency Power System Is the generator room properly rated and physically separated from the remainder of the building? Generator room is not properly rated and physically separated from the The Alliance for Bangladesh Worker Safety Page 16/19

17 06 Jul 2014 remainder of the building. Location: Generator room, Shed-1, Ground floor. Photograph: Generator room is not rated and separated. Ensure the generator room properly rated and physically separated from the remainder of the building. Alliance Standards Part 10 Section Generator Room Are emergency power switchboards, distribution boards, and circuits properly identified? Emergency power switchboards, distribution boards, and circuits are not identified. Visual Assessment: No identification of emergency DBs, CKTs. All boxes and enclosures (including transfer switches, generators, and power panels) for emergency circuits shall be permanently marked so they will be readily identified as a component of an emergency circuit or system. The required marking can be by color code, the words emergency system, or any other method that identifies the box or enclosure as a component of the emergency system. NFPA 70 Chapter 7 Article Wiring, Emergency System Is the generator frame earthing (grounding) provided at two separate points? Generator frame earthing is not provided at two separate points. Location: Generator room, Shed-1. Photograph: Inadequate generator frame earthing. Provide two separate points earthing provided for generator. Alliance Standard Are inspection, maintenance, and testing procedures of the UPS being The Alliance for Bangladesh Worker Safety Page 17/19

18 06 Jul 2014 completed and documented? Low 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 lightning protection ground terminals are not bonded to the building or structure grounding. Worker Interviews: No bonding between the lightning protection ground terminals and structure grounding. Ensure the lightning protection ground terminals are bonded to the building or structure grounding. Alliance Standards Part 10 Section Lightning Protection The air termination network vertical and horizontal conductors are appropriately spaced. Factory personnel provided drawing that have not mentioned spacing between air termination network vertical and horizontal conductors. The Alliance for Bangladesh Worker Safety Page 18/19

19 06 Jul 2014 Document Review: There are 8 air termination network installed in the roof of the building. Consult with an expert engineer to have details design and drawing of lightning protection system and ensure the air termination network vertical and horizontal conductors are appropriately spaced. Alliance Standards Part 10 Section Lightning Protection The Alliance for Bangladesh Worker Safety Page 19/19