ELECTRICAL SAFETY INSPECTION REPORT SIKDER APPAREL HOSIERY LTD. Khadun (Dug No. 342/343), Tarabo, Rupgonj, Narayanganj, Bangladesh. Factory List: 1. Sikder Apparel Hosiery Ltd. Inspected by: Pema Wangdi Report Generated by: Pema Wangdi Inspected on July 03, 2014
SUMMARY The Sikder Apparel Hosiery Ltd. factory is established in its three storied (G+2) building, which has been initially approved for eleven stories. Allegedly, the building was constructed in 2005 and the factory started its production 2007. During the time of the inspection, the factory accommodated a total of about 921 workers, working on regular basis. 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. Sikder Apparel Hosiery Ltd. Page 2 of 16
FINDINGS AND RECOMMENDATION Finding No. E- 1 Category: TRANSFORMER Transformer conservator tank oil level not at required level. Conservator tank (on transformer) must be checked and required oil level must be maintained. Transformer conservator tank. Finding No. E- 2 Category: TRANSFORMER ROOM Cable trench filled with dust and spider s web. Establish a routine cleaning program to keep the cable trenches dust and vermin proof. Put metallic cover (checkered plate) on to the cable trench to prevent the accumulation of the dust and lint. Cables trench in the transformer room. Finding No. E- 3 Category: TRANSFORMER ROOM A barrier wall between transformer and panel is low. Transformer may be separated from panels by constructing barrier walls of required height. Electrical substation. Sikder Apparel Hosiery Ltd. Page 3 of 16
Finding No. E- 4 Category: TRANSFORMER ROOM The arching horn missing at transformer HT side. Arching horn should be installed at the HT bushing (may consult the servicing/supplier company). The HT bushing of the power transformer. Finding No. E- 5 Control device mounted on wall without enclosures. Protective devices should be encased in metal casing made of 20 SWG thickness metal sheets. MCCB in the electrical room. Finding No. E- 6 Category: SERVICE LINE Service cable between the cable trench and the distribution panel are unprotected. The cable should be supported on covered tray or ladder throughout its length up to the HT/LT panel base-plate. Service cable in the electrical room. Sikder Apparel Hosiery Ltd. Page 4 of 16
Finding No. E- 7 Category: TRANSFORMER ROOM Silica gel in transformer breather, discolored. Oil cup below transformer breather is not installed. Replace silica gel and must include in routine maintenance to check and maintain. Oil cup below transformer breather must be installed. Transformer breather Finding No. E- 8 Category: TRANSFORMER ROOM Excessive dust and/or lint deposit on the transformer. Transformer must be cleaned regularly and prepare a routine for proper maintenance. Before cleaning make sure that the system is properly disconnected from the main source. Clean the exterior of the transformer properly. Power transformer Finding No. E- 9 Category: EQUIPEMENT & MACHINE Large exhaust fans in production floors are directly controlled by the MCB. Large exhaust fans must be connected through control device such that it will not restart automatically when power is restored. Exhaust fan in the production floor Sikder Apparel Hosiery Ltd. Page 5 of 16
Finding No. E- 10 Category: CABLE & CABLE SUPPORTS Service cables from the electrical room to other building are partially supported in trays and/or raceways. Cables on trays / raceways / risers must be supported throughout its length. Cable accessories including junctions, Tee, drops and risers must be installed to support cables throughout length. Remediation Timeframe: 6 Months Service cables exiting from the electrical room. Finding No. E- 11 Category: CABLE & CABLE SUPPORTS Cables passing through wall and supported on cable ladder not protected and remaining gaps after passage of cables through wall not sealed. Provide metallic cover on the cable ladder to avoid physical damage of the cable insulation due to moving objects. Cables passing through permanent walls must be protected in covered cable tray/ steel pipe /PVC pipes and the remaining gaps after the passage of conduits must be sealed with fire resistance materials. Service cable running through wall (typical). Sikder Apparel Hosiery Ltd. Page 6 of 16
Finding No. E- 12 Cable running on the wall is not supported. Cable must be supported on cable ladder or riser. Provide covers made of noncombustible material preferably metal to protect the cables insulation from any physical damage.. Flexible conduit must not be used for long point wiring (except for special wirings). Service cables in the electrical room. Finding No. E- 13 Category: TRANSFORMER ROOM Multiple cables connected at a terminal of the transformer secondary. Remove all the multiple connections made at a transformer secondary and connect with bigger cables of required size to avoid multiple terminations. Power transformer. Finding No. E- 14 Cable trench is not covered. Cable trench must be covered by rigid material (checkered plate) and flammable things must be removed from the room. Change over switch in the electrical substation. Sikder Apparel Hosiery Ltd. Page 7 of 16
Finding No. E- 15 Open cable ducts used for cable support. Clean the duct & provide cover made of noncombustible material on the duct for preventing ingress of dust and debris in future. The cable duct in the production floor. Finding No. E- 16 The HT panel opened from the back. The detached back door is kept very close to the HT cable terminals inside the panel. The HT panel opened from the back must be closed. The detached door must be fitted to the panel taking proper shut down. HT panel opened from the back. Remediation Timeframe: Immediate Finding No. E- 17 Phase barrier/separators between different phases are not installed. Phase barriers between different phases supplied by the breaker manufacturer must be installed to avoid arc flashing. MCCB in the distribution panels. Remediation Timeframe: 1 month Sikder Apparel Hosiery Ltd. Page 8 of 16
Finding No. E- 18 Panel base plates removed to allow cable entry. 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. Distribution panels in the electrical room. Finding No. E- 19 Multiple cables are terminated into single point of bus-bar. Terminate each cable individually on the bus bar. Multiple cables shall not be terminated on same point of bus bar. Distribution panels in the production floors. Finding No. E- 20 Multiple wires installed in single lug/terminal. Terminate each cable proving individual lug according to the cable size. Multiple cables shall not be terminated on a single point of the bus-bar. Distribution panel in the production floor. Sikder Apparel Hosiery Ltd. Page 9 of 16
Finding No. E- 21 Wires connected directly 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 socket The distribution panel in the production floor. Finding No. E- 22 Openings in the panel side cover plate. Panel side cover plate must be sealed to prevent the ingression of lint/dust into the panel The distribution panel in the production floor Finding No. E- 23 Category: WIRING 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). Flexible PVC cable conduit. Sikder Apparel Hosiery Ltd. Page 10 of 16
Finding No. E- 24 Cable inside panel touching bare bus bar. Disconnect the panel from electrical system and rearrange all the wirings inside the panel. While rewiring ensure the cables do not touch to the bus bar organized inside duct if required. Distribution panel in the production floor. Finding No. E- 25 Wirings in boiler room are drawn in flexible PVC. Wirings drawn in flexible PVC conduit must be installed on supports to prevent conductors touching hot areas/components. Boiler room. Finding No. E- 26 Cables with flexible PVC conduit are directly laid on concrete floor. Cables must be laid into a covered cable-tray, installed on the floor to prevent any physical damages. Flexible conduit must not be used for long point wiring (except for special wirings). Inside the boiler room Sikder Apparel Hosiery Ltd. Page 11 of 16
Finding No. E- 27 Cables in flexible PVC conduit entering panels are not firmly fixed. Cables below and top of panel must be carried through rigid pipes/tray and supported properly (clamped with saddle, at regular interval of 600 mm).the conduit/tray shall run vertically or horizontally, shall never at angle. Distribution panel in the boiler room. Finding No. E- 28 Wires connecting to indicating lamps in panel are connected directly across the bus bar terminals. Indicating lamps connected directly to bus bar terminals must be connect through fuse or MCBs The distribution panel in the production floor. Finding No. E- 29 The distribution board installed close to the air pipe line. The distribution board door cannot be opened. The distribution board must be relocated and the door must open freely. Distribution panel in the dyeing section Sikder Apparel Hosiery Ltd. Page 12 of 16
Finding No. E- 30 The cables are not supported in tray throughout its length. The service cables must be supported in trays throughout its length. The unsupported cables between two trays must be supported in a rigid tray. Service cables in the dyeing section. Finding No. E- 31 Cables encased in flexible pipes passing through wall not protected and remaining gaps not sealed. Cables passing through permanent walls must be protected in covered cable tray/ steel pipe /PVC pipes and supported near the panel entry; the remaining gaps after the passage of conduits must be sealed with fire resistance materials. Cable passing through the wall. Finding No. E- 32 Power cables laid on concrete floor. Install cable tray with metallic cover to provide mechanical support to cables laid haphazardly on the floor. The cables must be protected and arranged properly in the cable tray. Cables in the electrical room. Sikder Apparel Hosiery Ltd. Page 13 of 16
Finding No. E- 33 Spacing around the MCCBs narrow and crowded inside panel. Keep at least 25mm clearance between the MCCBs for better heat dissipation and perform maintenance work. 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. Install PVC slotted wiring duct inside the panel to latch the cables. Distribution panel in the production floor Finding No. E- 34 Service cable from the production building to the workshop shed is not supported. Install a ladder or catenary wire for supporting the service cables. A workshop shed. Finding No. E- 35 Service cables encased in flexible pipe are supported against the water pipe line. The service cables must be laid along a dedicated cable trays/ladder. The cables must not be supported against the water pipe line. Cable laid along the water pipe line. Sikder Apparel Hosiery Ltd. Page 14 of 16
Finding No. E- 36 Cables with flexible PVC conduit are directly laid on concrete floor. Cables must be laid into a covered cable-tray, installed on the floor to prevent any physical damages. Flexible conduit must not be used for long point wiring (except for special wirings). Cables in the printing section. Finding No. E- 37 The service cables are terminated to a panel through the panel door opening. He cables must be terminated through the base plate using the cable glands. Distribution panel in the electrical room. Finding No. E- 38 Openings in the panel top cover plate. Make circular hole at the 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. Distribution panel in the electrical room. Sikder Apparel Hosiery Ltd. Page 15 of 16
Finding No. E- 39 Improper service cable joints within the panel. Service cables (existing cables) may be replaced or joint shall be provided with proper connector and PIB tape wound around into a junction box. Distribution panel in the electrical room. Finding No. E- 40 Rubber mat used inside the panel to separate the service cables. The rubber mat must be removed. The combustible materials must not be present inside the panel. Distribution panel in the electrical room. Finding No. E- 41 Category: BOILER & COMPRESSOR ROOM Compressor input cables laid on floor without protection. Use steel pipe/cable tray to ensure the mechanical protection of the cable laid on floor otherwise cable insulation may damage due to falling object or stepping of occupants onto it. Service cables in the compressor room. Sikder Apparel Hosiery Ltd. Page 16 of 16