INITIAL ELECTRICAL ASSESSMENT REPORTsfi.fairfactories.org/sfi_dev_files/1/Audit_Files/Bengal...

INITIAL ELECTRICAL ASSESSMENT REPORT(EAR)

Factory Name: Bengal Plastics Ltd. Unit-3

Address: Unit-3, Zerabo, Savar Savar Dhaka Bangladesh

Assessor: Emkay Enterprises LTD

Date: 28 Jun 2015

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The Alliance for Bangladesh Worker Safety /17

Introduction to the Report

The following report contains a site profile and summary of non-conformities identified during an onsite assessment commissioned by theAlliance for Bangladesh Worker Safety (Alliance) and conducted by a third-party Qualified Assessment Firm (QAF). The assessment wasconducted 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) forthe Bangladesh National Tripartite Plan of Action (NTPA). The goal of the Alliance process is to provide clear and practical technicalrequirements by which Bangladeshi Ready Made Garment (RMG) Factories producing for Alliance members may be consistently and fairlyevaluated for fire, structural, and electrical safety in a non-duplicative manner. Each assessment will prompt action plans that will be used byRMG factories to systematically and sustainably improve safety conditions for garment workers. Beyond tracking and reporting on actionsteps taken in a transparent manner, the Alliance organization and its members will seek to further support factory improvements throughtechnical assistance, training, implementation support for functional Worker Committees, and in some cases financial assistance and wagesupport 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 orcontinued safety against fire, electrical and/or structural integrity issues that may lead to injury or loss of life. The report is designed to providea non-exhaustive summary of risk issues, based on a limited sampling and duration of time onsite by the named QAF. Neither the QAF northe 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: www.bangladeshworkersafety.org.



Assessor: Emkay EnterprisesLTD

Date: 28 Jun 2015



GENERAL INFORMATION

General Information



Country: Bangladesh

Province: Dhaka

City: Savar

Zip Code:

Audit Duration: 01 Days

Re-Audit: Re-Audit After 0 Months

Draft Report Date : 28 June 2015

Final Report Date : To be filled out by the “Alliance QA” representative

Are all action items fromprevious assessmentcomplete? :

N/A

Buildings in Complex : There are 5 buildings. A. Main building: 2; B. Ancillary building: 3.

Is the building(s) ownedor rented by theFactory?:

Owned

Number of BuildingLevels (Stories) :

A. Main shed (Hanger shed): Single story prefabricated shed; B. Store shed (Warehouse shed): Single storyprefabricated shed.

Approximate BuildingArea (SF) :

Total: 66,220.00 SF, (Main shed: 41,580, Store shed: 24,640).

Date of BuildingConstruction :

A. Main shed: 2000-2002; B. Store shed: 2000-2002; C. Utility building: 2002; D. Dinning, child care & Medicalshed: 2005; E. Mosque: 2008.

Date of Last BuildingRenovation/Addition :

None

Ancillary Structures inComplex :

There are 3 ancillary buildings.

Approximate AncillaryStructures Area (SF) :

Total: 6,530.00 SF, (Utility building: 3,840; Dinning & Child care: 1,800; Mosque: 890)

Number of Occupants : Total occupants: 450 (Main shed: 200 @ 2 shifts; store shed: 20 @ 2 shifts; Utility building: 03 @ 2 shifts,




Date: 28 Jun 2015



Mosque: Nil; Dinning, childcare & medical: Capacity: 04 & 150 (During dinning).

Provide brief descriptionof the electrical systemfor each building.:

There are four generator (900 KVA each) for Powering the whole facility. Power is distributed through six MainDistribution Boards (MDB) and forty five Sub Distribution Board (SDB). Three PFI (Power FactorImprovement) panels are installed for improvement of the power quality.

Physical location ofSubstation? :

Sub Station located in separate shed.

What equipment/loadsdoes the UPS serve? :

Emergency lights, Exit signage.




Date: 28 Jun 2015



ASSESSMENT FINDINGS

Electrical System Information

Question: Are as-built electrical drawings indicating information such as panel and circuitlocations throughout the building(s) available for review?

Priority Level: High

Non-Compliance Level:

Description: SLD is not updated and reviewed by Alliance yet.

Source of Findings:

Suggested Plan ofAction:

Suggested DeadlineDate:

Standard: Alliance Standard Part 10 Section 10.3.7

Electrical System Maintenance

Question: Have workers that operate and maintain the electrical system receivedelectrical safety training? Is training documentation on site?


Non-Compliance Level: 3

Description: Document implies that, factory has developed a safety training program butdocuments are not proper (does not detail the agenda of the training).

Source of Findings: Document Review: Documents do not contain all necessary information.


Develop and implement an electrical safety program. Include key topics suchas lock-out/tag-out procedures, personal protective equipment requirements,etc. Keep records of completed training available on site.


07 Sep 2015

Standard: Reference NFPA 70e for example

Question: Are thermographic scans of electrical equipment completed at least everythree years?

Priority Level: Medium





Date: 28 Jun 2015



Description: No records of previous thermographic scan were found.

Source of Findings: Document Review: Document not available.


Complete thermographic scans at least on a three year cycle. Thermographicscans should be completed in accordance with the Standard for InfraredInspection of Electrical Systems & Rotating Equipment and NFPA70B or acomparable standard.


10 Aug 2015

Standard: Alliance Standards Part 10 Section 10.13.8 Electrical Inspections

Question: Is a periodical Insulation Resistance Measurement Program established andrecorded?



Description: Periodic Insulation Resistance Measurement Program has not beenestablished.



Develop an Insulation Resistance Measurement Program that ensuresdeterioration of insulation resistance will be identified quickly. Testing shouldbe in compliance with Inter National Electrical Testing Association (NETA). Alltransformers, switchgears e


24 Aug 2015

Standard: Alliance Standard Part 10 Section 10.13.4 Insulation Tests and 10.13.8Electrical Inspections

Electrical System Conditions

Question: All equipment is efficiently earthed and properly connected to the requirednumber of earth electrodes.



Description: Only one earth electrode is connected to the body of LT Panel (LT Switchgear-1) in Generator control room without providing an earthing bus bar.

Source of Findings: Photograph: One earthing connection connected to the body of LT Panel.


Provide earthing equipment at required locations and connect to requirednumber of electrodes. Refer to the BNBC for required number of electrodes. Incase of LT Switchgear-1 provide required earthing connection with requiredbus bar installed inside the




Date: 28 Jun 2015




07 Sep 2015

Standard: Alliance Standard Part 10 Section 10.13.7.1 Inspection of SubstationInstallations.

Question: Combustible materials are not stored within the substation room.



Description: Lights have been installed on wooden channel in generator control room.

Source of Findings: Photograph: Wooden channel in generator control room.


Remove all combustible materials within the substation room. The lights shallbe installed on either wall or non combustible material.


20 Jul 2015

Standard: Not Applicable

Question: Are all switchboards and/or distribution boards metal enclosed with a deadfront construction?



Description: Perforated back-cover has been installed for LT Switchgear-2 in Generatorcontrol room.

Source of Findings: Photograph: Back cover with hole in LT Switchgear-2.


Replace the back-cover with a solid metallic cover. The back-cover shall bemade of solid metallic sheet (minimum 18 SWG; as per BNBC).


10 Aug 2015

Standard: Alliance Standards Part 10 Section 10.7 Main Switch, Switchboards and MetalClad Switchgear

Question: No circuits are drawn for loads without the incorporation of a overcurrentprotection device (circuit breaker).



Description: Circuit is drawn without any protective device from bus bar of DB/Lighting-1.

Source of Findings: Photograph: Circuit breaker not installed in DB/Lighting-1.




Date: 28 Jun 2015




Provide circuit breaker for all connected load according to the respectiveservice cable. The rating of the circuit breaker shall not exceed the ratedcapacity of the cable.


24 Aug 2015

Standard: Alliance Standards Part 10 Section 10.9 Protection of Circuits

Question: Indications of overheating, overloading, or signs of burning were not observed.



Description: During thermographic scan, some hotspots were observed at multiplelocations. Refer to Thermographic Survey Report for detailed information.

Source of Findings: Visual Assessment: Inspected with thermal imager.


Suggested plan for specific issues have been incorporated in theThermographic Survey Report.


20 Jul 2015


Question: Is electrical wiring/cables sized according to capacity of circuit breakers (Nohigher rated circuit breakers with lower rated wiring)?



Description: Higher rated circuit breakers with lower rated cables were observed in somedistribution boards. For example, in DB/Lighting-01, MCB of 32 A wasprovided with cable of 1.5 sq mm that have the maximum current carryingcapacity of 18 A in free air.

Source of Findings: Photograph: Over rated CB in DB/Lighting-01.


Check all of the panels to find the over-rated circuit breakers (both MCCB andMCB), and then replace the circuit breakers with appropriate circuit breakersconsidering the respected cable size.


07 Sep 2015

Standard: Alliance Standard Part 10 Section 10.3.1 Electrical Connections.




Date: 28 Jun 2015



Question: No multi looping of wiring/cables observed at circuit breakers withinswitchboards and/or distribution boards.



Description: Multiple-termination into a terminal of circuit breaker was observed in panels ofthe factory. As an example, in MDB/CR (Crushing) multiple connections aretaken from single port of circuit breaker.

Source of Findings: Photograph: Multiple connections into MDB/CR (Crushing).


Remove the extra cable from the terminal of the MCB and connected from thebus bar through an appropriate circuit breaker.


07 Sep 2015

Standard: Alliance Standard Part 10 Section 10.3 Electrical Wiring and Cabling

Question: All metal in the building is connected to the building earthing/grounding systemsuch as metal rebar in concrete, metal frame of building, or metal water pipe.



Description: All metal components have not been connected to building earthing system.

Source of Findings: Visual Assessment: Visually inspected during audit.


Provide earthing connection to all exposed-conductive parts (metal) relatedto/in close proximity to electrical equipment/installation and utility service suchas metallic water/gas/steam pipes etc. such that all the metals remain at asubstantially same


07 Sep 2015

Standard: Alliance Standard Part 10 Section 10.10 Earthing

Question: The substation room is clean and free from dirt, lint, water, oil, and debris.



Description: Excessive dust was observed inside LT Panel in Sub Station and the cabletrench of generator control room was observed with sand.

Source of Findings: Photograph: Dust found in LT Panel of Sub Station.


Remove all dirt, debris, lint, water, oil, and improperly stored materials from thesubstation room.




Date: 28 Jun 2015




13 Jul 2015


Question: Do switchboards and/or distribution boards have capacity information labels?



Description: Only current capacity written on the panel door but other required informationis not provided.

Source of Findings: Photograph: Capacity information label not provided on MDB-A.


Provide a capacity information label which contains the current carryingcapacity and size of main cable, rated capacity of circuit breaker and the busbar (with dimension). Display panel schedule on panel door (inner side)printed on a sheet made of non


24 Aug 2015

Standard: Alliance Standard Part 10 Section 10.7 Main Switch, Switchboards And MetalClad Switchgear and 10.13.7 Inspection of the Installation

Question: Are electrical wiring/cables properly identified?



Description: No identification found on cables in panel and color code has also not beenmaintained.

Source of Findings: Photograph: Cables are not identified in DB/Lighting-02.


Provide identification/tagging mentioning the equipment/machines name (i.e.Sewing machine line-1 or Lighting line-2) and type of conductor (i.e. L1, L2,L3, N, PE) for every cable at its termination point or maintain the color-code atits termination poi


07 Sep 2015

Standard: Bangladesh Electricity Rules 1937 Rule 51 and 56

Question: The substation room has adequate ventilation.



Description: Sub Station room has no provision for ventilation system.




Date: 28 Jun 2015



Source of Findings: Visual Assessment: Inspected visually during audit.


Provide means of ventilation for the substation room. Consult a qualifiedelectrical engineer to determine the required ventilation rates based on theinstalled equipment.


24 Aug 2015


Question: Are all internal components of switchboards and/or distribution boards properlyconcealed (No missing circuit breaker or knockout covers)?



Description: Bottom plate of all panels in sub-station room and generator control room werenot installed to conceal live components of panel.

Source of Findings: Photograph: Base plate not provided in LT Panel in Sub Station room.


Make circular hole at the base plate of panels and provide cable glandaccording to the respective cable size for cable entry and exit so that thecables are not stressed on the sharp edges of the hole of panels. Providecovers (of noncombustible mater


10 Aug 2015

Standard: Alliance Standard Part 10 Section 10.3.9 Sub-Distribution Boards

Question: Are all switchboards and/or distribution boards properly grounded (earthed)?



Description: Grounding cables were found under sized in panels. As an example, inDB/Lighting-2, one 10 sq mm cable has been provided as earthing connectionwhere main phase cable is 50 sq mm.

Source of Findings: Photograph: Earthing cable size is not proper.


Provide earthing cable of this panel according to the size of the main servicecable (phase cable) i.e. at least half of the size of the phase cable and provideearthing connection at all required locations (panel, equipment etc.).


10 Aug 2015

Standard: Alliance Standard Part 10 Section 10.10.2 Circuit and System Earthing




Date: 28 Jun 2015



Question: Are switchboards and/or distribution boards free of dust and debris?



Description: Dust was found inside machine control box of machine D-01.

Source of Findings: Photograph: Dust found inside machine control box D-01.


Disconnect the panel from the electrical service and clean interior componentsof all dust and debris. Seal all openings within the enclosure to prevent dustand debris from entering.


10 Aug 2015

Standard: Alliance Standard Part 10 Section 10.3.9.1 Enclosures

Question: The substation room has adequate illumination levels.



Description: Only two CFL lights have been installed for generator control room which isnot adequate for routine inspection and maintenance work.

Source of Findings: Photograph: No sufficient illumination behind the panel of generator controlroom.


Provide additional light fixtures to increase illumination levels provided in theBNBC to ensure sufficient illumination around all the panel for routineinspection and maintenance.


24 Aug 2015


Question: Are there additional areas of non-compliance to report?



Description: Rusty connection was found in main MCCB terminal of DB/Lighting-02.

Source of Findings: Photograph: Photograph


Replace the nut-screw of the main MCCB with a new one to ensure soundelectrical connectivity.


24 Aug 2015




Date: 28 Jun 2015



Standard: Not Applicable

Question: Are electrical insulation mats provided in front of substation, switchboardsand/or distribution boards?

Priority Level: Low


Description: Pallet has been provided instead of electrical insulation mat. As an examplepallet has been used in front of DB/Lighting-01.

Source of Findings: Photograph: Insulation mat not proper.


Provide electrical graded rubber mats with the specifications of 650 V-protection and required area (accommodating at least two persons ordepending on the panels length).


10 Aug 2015

Standard: Alliance Standard Part 10 Section 10.13.7 Inspection of the Installation.

Question: Required equipment and safety signage is posted within the room.

Priority Level: Low


Description: Required safety signage is not posted on all panels in the generator.

Source of Findings: Photograph: Safety signage is not posted properly.


Indoor electrical installations that are accessible to unqualified persons shallbe made with metal-enclosed equipment. Switchgear, unit substations,transformers, pull boxes, connection boxes, and other similar associatedequipment shall be marked with a


10 Aug 2015

Standard: Alliance Standard Part 10 Section 10.3.7, Section 10.7.3, and 10.13.7, NFPA70 Chapter 1 Article 110.21, and Bangladesh Electricity Rules of 1937 Rule 46

Question: Phase separators are provided between terminals on circuit breakers.

Priority Level: Low


Description: MCCBs in MDB-A were not provided with phase separators.

Source of Findings: Photograph: MCCBs in MDB-A without phase separators.

Suggested Plan of Install phase separators between terminal connections. Verify phase




Date: 28 Jun 2015



Action: separators are installed at all remaining locations.


24 Aug 2015

Standard: Alliance Standard Part 10 Section 10.3.1 Electrical Connections

Emergency Power System

Question: Are cable trenches properly covered?



Description: Instead of using solid metal plate, grill type cover has been provided ontrenches of generator control room and generator room.

Source of Findings: Photograph: Grill type cover used in generator control room.


Use solid metal plate (checkered plate) on trenches of generator control roomand generator room to ensure the safety of occupant and resist deposition ofexcessive dust into the cable trenches.


10 Aug 2015

Standard: Alliance Standard Part 10 Section 10.13.7 Inspection of the Installation

Question: Are emergency power switchboards, distribution boards, and circuits properlyidentified?



Description: Components of the emergency power system do not have properidentification.

Source of Findings: Photograph: No identification for the IPS system located in workshop area.


All boxes and enclosures (including transfer switches, generators, and powerpanels) for emergency circuits shall be permanently marked so they will bereadily identified as a component of an emergency circuit or system. Therequired marking can be


10 Aug 2015

Standard: NFPA 70 Chapter 7 Article 700.10 Wiring, Emergency System




Date: 28 Jun 2015



Question: Is the generator frame earthing (grounding) provided at two separate points?



Description: One earthing connection was found for frame earthing of the generator-1,generator-2 and generator-3. And in generator-2, though two separateconnections are installed, proper termination method is not followed (lug notused).

Source of Findings: Photograph: Termination is not proper for earthing of the generator frame.


Install two distinct earth connections of minimum 35 sq mm for generatorframe earthing for generator-1, generator-2 and generator-3. And for allgenerators, terminate the connections providing proper socket according to thesize of the conductor.


24 Aug 2015

Standard: Alliance Standard 10.8.2.2

Question: Are inspection, maintenance, and testing procedures of the emergencygenerator being completed and documented?

Priority Level: Low


Description: Records regarding generator maintenance and testing of emergencygenerator were not found.



Establish a routine maintenance and testing program for the emergencygenerator. The program shall be based on all of the following: (1)Manufacturer's recommendations (2) Manufacturer's Instruction manuals (3)Requirements of NFPA 110 Chapter


07 Sep 2015

Standard: NFPA 110 Chapter 8

Question: Are inspection, maintenance, and testing procedures of the UPS beingcompleted and documented?

Priority Level: Low


Description: Documents regarding inspection and maintenance of the IPS were not found.

Source of Findings: Document Review: Documents not available.




Date: 28 Jun 2015




Establish an inspection testing, and maintenance program for theUninterruptable Power Supply (UPS) and associated components. Theprogram must based on the following: (1) Manufacturer's recommendations (2)Manufacturer's instruction manuals (3)


07 Sep 2015

Standard: Alliance Standard Part 13 Section 13.11 NFPA 111 Chapter 8 NFPA 70BChapter 28

Lightning Protection System

Question: Is a lightning protection system installed on the building?



Description: Lighting protection system has been installed. But, the design has not beendone according to the standard.



Have a qualified electrical engineer design a lightning protection systemaccording to the BNBC requirements. Have a licensed electrician install thedesigned system.


05 Oct 2015

Standard: Alliance Standards Part 10 Section 10.11 Lightning Protection. Calculate RiskIndex to determine if required.

Question: The air termination network vertical and horizontal conductors areappropriately spaced.



Description: Vertical and horizontal conductors are not appropriately spaced.





24 Aug 2015

Standard: Alliance Standards Part 10 Section 10.11 Lightning Protection

Question: The appropriate number of down conductors are installed based on thebuilding size.




Date: 28 Jun 2015





Description: Only four down conductors have been installed for the whole area of the shed.





24 Aug 2015


Question: The lightning protection ground terminals are bonded to the building orstructure grounding.



Description: The lighting protection system has not been bonded to the structure of theshed.



Have a qualified electrical engineer design a lightning protection systemkeeping the provision for bonding with the structure of shed according to theBNBC requirements. Have a licensed electrician install the designed system.


24 Aug 2015





Date: 28 Jun 2015



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