ELECTRICAL SAFETY INSPECTION REPORT - Fair …accord.fairfactories.org/.../1/Audit_Files/16957.pdf · · 2015-02-21ELECTRICAL SAFETY INSPECTION REPORT RIZVI FASHIONS LTD Kalma Bazar,

ELECTRICAL SAFETY INSPECTION REPORT

RIZVI FASHIONS LTD

Kalma Bazar, Savar, Dhaka, Bangladesh

Factory List:

1. Rizvi Fashions Ltd.

Inspected by: Hemlal Dahal

Report Generated by: Hemlal Dahal

Inspected on February 6th 2015

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Rizvi Fashions Ltd.

ELECTRICAL SAFETY INSPECTION REPORT

RIZVI FASHIONS LTD

1. INTRODUCTION

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 would be further dealt with as part of follow-up inspections.

2. LIMITATIONS

The information in this electrical safety inspection report was obtained during a visit to the facility

and during interviews with local factory management. It has not been possible to provide

independent verification for all the information and data collected, and, therefore, WEC cannot

accept general responsibility for omissions or errors arising from inaccuracies in this report from the

information obtained.

The findings and recommendations in this report are not intended to imply, guarantee, ensure or

warrant compliance with any government regulations. Additionally, the results do not imply in any

way that compliance with the findings or recommendations as stated in this report will eliminate all

risks or exposures not referred to in this report do not exist. Compliance with the findings and

recommendations stated in this report does not relieve the factory owner from obligation to comply

with specific project requirements, industry standards, or the provisions of any local government

regulations.

3. DEFINITION

3.1. Time Frame

The amount of time being allocated based on the remediation work volume of the electrical

issue considering the feasibility and ideal status of materials, capital and working condition.

Criticality and priority level of the issue is not taken into consideration. It is bound only for the

particular finding unless mentioned „typical‟, shall include the whole typical findings.

3.2. Priority Level

3.1.1. Electrical issues related to code violation and/or non-conformity with codes

possessing immediate fire hazard, direct threat to human safety, shall be

considered as P1 Level of priority. The execution of remediation works shall

commence immediately without compromising with any other issues and must

strictly complete within the allocated remediation time frame. It shall include only

the critical issues

3.1.2. Electrical issues related to code violation and/or non-conformity with codes,

protection of electrical switchgears and equipment, spatial arrangement and

location of switchgears and equipment, design and drawings, shall be considered

as P2 Level of priority. The execution of remediation work of P2 shall commence

along with or soon after the P1 level remediation work has commenced. It shall

include only the moderately-critical issues.

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Rizvi Fashions Ltd.

3.1.3. Electrical issues related to violation of code and/or non-conformity with codes,

workmanship of operation and maintenance and obsolete technology of electrical

system, shall be considered as P3 Level of priority. The execution of remediation

work of P3 shall commence along with or soon after the P2 level remediation work

has commenced. It shall include only the non-critical issues.

3.1.4. It doesn‟t take into consideration the remediation time frame and feasibility of

remediation. It doesn‟t take into consideration the capital, materials and working

environment.

4. GENERAL BUILDING INFORMATION

1. Factory Name: Rizvi Fashions Ltd.

2. Factory Address: Anwar Jang Road, 1 No. Kalma Bazar,

Savar, Dhaka-1341, Bangladesh

3. Accord ID: 12074

4. Inspection participants:

Shaikh Rezwan (Director)

Rizvi Fashions Ltd.

Mob: +880 1716480788

Email: [email protected]

Md. Anawar Hossain (Asst. Manager)

Rizvi Fashions Ltd.

Mob: +880 1717744918

E-mail: [email protected]

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Rizvi Fashions Ltd.

5. BUILDING DATA

A. General

The Rizvi Fashions Ltd. factory has been established with two 4-storied (G+3) buildings and

separate sheds for Boiler, Pump, Daycare/Doctor and Security at Savar. Reportedly, the

construction of buildings began in 2013 and the factory has been starting production since

2014. The production has been started in phased manner on 2nd

and 3rd

floors of the main

building. Main and Annex buildings are still in construction. Total number of workers employed

in the factory is 350 according to factory information.

The floor wise utilization of the buildings is as below:

Main Building

Ground floor: Office, Sample, Cutting, Knitting, Bonded Warehouse,

Finished Goods store.

1st floor: Sewing and Finishing Sections.

2nd floor: Under construction.

3rd floor: Under construction.

Annex Building

Ground floor: Substation, Generator and Compressor.

1st floor: Dining.

2nd floor: Under construction for Dining.

3rd floor: Under construction for Prayer.

Sheds: 1) Boiler, 2) Pump, 3) Childcare/Doctor, 4) Security/ RMS

B. Floor Layout Information

The floor area of main building is 3,633sq.m per floor and its height is 15.25m (tallest structure).

Site plan of the factory premises and floor plan of main building of Rizvi Fashions Ltd. are

presented below:

Figure 1: Site plan for Rizvi Fashions Ltd. factory

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Rizvi Fashions Ltd.

Figure 2: Ground Floor machine layout plan for Rizvi Fashions Ltd.

C. Electrical System

The primary power supply to the factory is delivered by REB through 11 kV overhead lines.

The 11kV power is tapped by HT cable protected by pole top DO fuse and delivered to 800kVA,

11/0.440kV floor mounted transformer through an 11kV VCB on the ground floor of the annex

building. The output of the transformer and generator is protected by a 2000A Air Circuit

Breakers connecting to the factory electrical system.

Figure 3: Electrical room of Rizvi Fashions Ltd. factory

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Rizvi Fashions Ltd.

As for stand-by operation, the factory has diesel generator of 400kVA. Besides, a 200kVA

diesel generator is available and dedicated to fire pump/hydrant system during times of mains

failure. Reportedly, the factory faces REB power interruption of approximately 1.5 hours per

day on an average. The single line diagram presented below shows the electrical system of the

factory.

Figure 4: Single line diagram of the electrical system

D. Electrical Installations

The factory has BBT system for power distribution to the production floors. The overhead light

fittings of production areas are generally supported directly on aluminium channels through

which the secondary lighting wiring is drawn. Wiring for fans in production floors and other

areas is drawn in concealed conduit though often PVC surface conduits are extended for other

loads. The wiring circuits are protected by MCCBs.

.

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Rizvi Fashions Ltd.

Figure 5: BBT and Aluminum channel wiring system for production floors

E. Operation and Maintenance

The power distribution system including the power transformer and generators are newly

established and the operation and maintenance is done by the factory‟s in-house electrical and

maintenance, and the factory has contract ADEX (manufacturer of transformer and electrical

panels) to deal with any major and emergency situations.

6. LIGHTNING PROTECTION RISK ASSESSMENT

There is no proper lightning protection system in the building. The calculation of the risk index for

lightning protection for this building is below.

Sl.no. Index category Index Figure

A Usage of Structure 6

B Type of construction 2

C Contents or consequential effects 5

D Degree of isolation 2

E Type of area and terrain 2

F Height of structure 5

G Lightning prevalence 21

Total index Figure 43

Recommendation:

The total risk index figure is more than 40, hence a lightning protection system is required. Select

an appropriate lightning protection system and install it at the highest point of the building structure.

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Rizvi Fashions Ltd.

7. FINDINGS AND RECOMMENDATIONS

Table below summarizes the major electrical safety issues identified during the inspection.

Recommendations have been provided to address each issue.

The 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 an approval.

FINDING NO: E- 1

CATEGORY: Lightning Protection & Earth

FINDING: Though “Total Risk Figure” is above 40, lightning Protection System (LPS) has been not installed yet.

RECOMMENDATION: Design and Install LPS for your factory; the factory must submit its LPS design to Accord before starting installation.

PRIORITY: P1

REMEDIATION TIMEFRAME: 16 WEEKS

FINDING NO: E- 2

CATEGORY: DESIGN, DRAWINGS & RECORDS

FINDING: Electric safety program is not initiated.

RECOMMENDATION:

Electrical safety training and awareness program for the electrical personnel and workers must be initiated and recorded.

PRIORITY: P2


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Rizvi Fashions Ltd.

FINDING NO: E- 3


FINDING: Insulation resistance test of electrical equipment is not performed.

RECOMMENDATION: Insulation resistance test of all power cables (up to Floor distribution board or SDB) must be performed in a periodic manner and recorded.

PRIORITY: P2


FINDING NO: E- 4


FINDING: Electrical Single Line Diagram (SLD) has inadequate information which has no effectiveness.

RECOMMENDATION: Prepare an accurate SLD with all necessary information, so any experienced person will then be able to understand the system.

PRIORITY: P2


FINDING NO: E- 5


FINDING: Thermographic scanning of the entire electrical system has not been performed.

RECOMMENDATION: Thermographic scanning of the entire electrical system must be performed twice in a year.

PRIORITY: P2


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Rizvi Fashions Ltd.

FINDING NO: E- 6

11kV Vacuum Circuit Breaker panel

CATEGORY: SERVICE LINE

FINDING: HT service cable dropping from pole is not protected near the base of the pole, above ground level.

RECOMMENDATION: Provide Steel pipe up to 2 meter from ground level to support and protect the HT cable from physical damage of the insulation.

PRIORITY: P2


FINDING NO: E- 7

Transformer inside the cubicle

CATEGORY: TRANSFORMER ROOM

FINDING: Transformer room congested.

RECOMMENDATION: Maintain safe working space (1.07 meter

preferably) surrounding the existing power

transformer.

PRIORITY: P1


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Rizvi Fashions Ltd.

FINDING NO: E- 8

Breather attached to the transformer


FINDING: Silica gel color is changed into white and oil cup is empty.

RECOMMENDATION: Silica gel in breather must be changed and oil cup must be filled with transformer oil as per the instruction of the manufacturer.

PRIORITY: P1

REMEDIATION TIMEFRAME: 1 WEEK

FINDING NO: E- 9

Cable trench inside the transformer room


FINDING: Cable Trench is not protected.

RECOMMENDATION: Provide covers on the trench made of noncombustible material preferably concrete slab to protect the cables‟ insulation from physical damage as well as prevent entering debris, dust and lint.

PRIORITY: P2


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Rizvi Fashions Ltd.

FINDING NO: E- 10

One of the DG sets of Rizvi Fashions

CATEGORY: GENERATOR ROOM

FINDING: Generator frame not connected to earth.

(Typical).

RECOMMENDATION: Two separate earthing (35 sq.mm) for generator

frame/body and one separate earthing (35

sq.mm) for neutral must be installed for

generator.

PRIORITY: P2


FINDING NO: E- 11

11kV Vacuum Circuit Breaker panel

CATEGORY: DISTRIBUTION & LT PANELS

FINDING: Inadequate insulation matting in front of high

voltage panels.

RECOMMENDATION: Provide high voltage graded insulation rubber

mats in front of high voltage electrical panels.

PRIORITY: P2


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Rizvi Fashions Ltd.

FINDING NO: E- 12

415V Switchgear panels

CATEGORY: DISTRIBUTION & LT PANELS

FINDING: Permanent naming/identification of switchgear

panel boards have not been done.

RECOMMENDATION: Permanent identification/naming of electrical

panels must be done.

Provide/hang circuit diagrams of panels/boards

in every panel.

PRIORITY: P2


FINDING NO: E- 13

Cables/conduits running along the building beam

CATEGORY: CABLE & CABLE SUPPORTS

FINDING: Cables/conduits drawn along the beam without

proper support.

RECOMMENDATION: Cable may be drawn on raceways/trays adequately supported to provide mechanical support and protection.

PRIORITY: P2


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Rizvi Fashions Ltd.

FINDING NO: E- 14

Hole on the floor slab

CATEGORY: CABLE & CABLE SUPPORTS

FINDING:

Hole on floor slab left unsealed after passing the

BBT.

RECOMMENDATION: Seal all penetrations using appropriate fire rated material and ensure no damage is caused during sealing work.

PRIORITY: P2


FINDING NO: E- 15

Distribution cables from BBT DB

CATEGORY: CABLE & CABLE SUPPORT

FINDING: Cables terminating at distribution boards are not protected (and not supported), near panel.

RECOMMENDATION: Install the cables on a tray made of noncombustible material preferably metal to support and protect the cables. Ensure glands are installed at the entry of the cables to seal the panel.

PRIORITY: P2


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Rizvi Fashions Ltd.

FINDING NO: E- 16

Cable/Conduit drawn from main building to Boiler shed

CATEGORY: CABLE & CABLE SUPPORT

FINDING: Cables drawn from one building to another are

not supported and not protected.

RECOMMENDATION:

Cables drawn from one building to another may

be drawn either on tray/ladder or catenary wire

and must be protected from physical damage

and weather. Ensure the cables are tightly

attached with the ladder and provide

weatherproof covers made of non-combustible

material preferably metallic sheet.

PRIORITY: P2


FINDING NO: E- 17

Highest point of the factory building

CATEGORY: LIGHTNING PROTECTION & EARTH

FINDING: Lightning arrestor is not installed

RECOMMENDATION: Lightning arrestor must be installed (according to BNBC Part 8, section 2.9.) with proper size air termination network, down conductors and earth termination.

PRIORITY: P2


ELECTRICAL SAFETY INSPECTION REPORT - Fair …accord.fairfactories.org/.../1/Audit_Files/16957.pdf · · 2015-02-21ELECTRICAL SAFETY INSPECTION REPORT RIZVI FASHIONS LTD Kalma Bazar,

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