INITIAL ELECTRICAL ASSESSMENT REPORTsfi.fairfactories.org/sfi_dev_files/1/Audit_Files/Silver Composite... · Introduction to the Report The following report contains a site profile

INITIAL ELECTRICAL ASSESSMENT REPORT(EAR)

Factory Name: Silver Composite Textile Mills

Address: B.K. Bari, Taltoli, Moniur, Mirzaur Bazar, GazipurGazipur Dhaka Bangladesh

Assessor: Emkay Enterprises LTD

Date: 27 Jun 2015

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The Alliance for Bangladesh Worker Safety Page 1/17

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.

FactoryName:

Silver Composite Textile Mills

Address: B.K. Bari, Taltoli, Moniur, Mirzaur Bazar, Gazipur Gazipur DhakaBangladesh

Assessor: Emkay EnterprisesLTD

Date: 27 Jun 2015



GENERAL INFORMATION

General Information

Factory Name: Silver Composite Textile Mills

Address: B.K. Bari, Taltoli, Moniur, Mirzaur Bazar, Gazipur Gazipur Dhaka Bangladesh

Country: Bangladesh

Province: Dhaka

City: Gazipur

Zip Code: 1749

Audit Duration: 1 Days

Re-Audit: Re-Audit After 0 Months

Draft Report Date : 06 July 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: 1; B. Ancillary building: 4.

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

Owned

Number of BuildingLevels (Stories) :

Main building: 6 stories (G.F + 5)

Approximate BuildingArea (SF) :

Total: 265,200 SF, (G.F: 44,200, 1st: 44,200, 2nd: 44,200, 3rd: 44,200, 4th: 44,200, 5th: 44,200)

Date of BuildingConstruction :

Main building: 2013-2014

Date of Last BuildingRenovation/Addition :

None

Ancillary Structures inComplex :

There are 04 ancillary buildings.

Approximate AncillaryStructures Area (SF) :

Total: 31,855 SF, (Ancillary-1: G.F: 3,335, 1st: 3,335, 2nd: 3,335, 3rd: 3,335, 4th: 3,335; Ancillary-2: 11,080;Ancillary-3: 3,000; Ancillary-4: 1,100)

Number of Occupants : Total occupants: 633; (Main building: G.F: 51, 1st: 440, 2nd: 122, 3rd: Not in use, 4th: Not in use, 5th:

FactoryName:




Date: 27 Jun 2015



5;Ancillary-1: G.F: 08, 1st: Family quarter, 2nd: Family quarter, 3rd: Staff quarter, 4th: security quarter;Ancillary- 2: 03; Ancillary-3: 02; Ancillary-4: 02).

Provide brief descriptionof the electrical systemfor each building.:

There are four generators (3pcs ;1364W each, 1pcs; 1200W each) for powering the whole facility. Power isdistributed through five MDB (Main Distribution Board), five DB (Distribution Board) and twenty two SDB (SubDistribution Board). The PFI (Power Factor Improvement) Panels are installed for the improvement of powerfactor.

Physical location ofSubstation? :

Substation (LT Switch gear) is located on Ground Floor of the building.

What equipment/loadsdoes the UPS serve? :

N/A

FactoryName:




Date: 27 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: 3

Description: As-built electrical drawings were available for review but several informationneed to be updated in the drawing. And Earthling layout is not available.

Source of Findings: Document Review: Documents is not available or proper.

Suggested Plan ofAction:

Have a qualified Electrical Engineer update the as-built single line diagramand earthling diagram detailing key components, and capacity of the electricalsystem.

Suggested DeadlineDate:

22 Sep 2015

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?



Description: Documents regarding electrical safety training program are not developed.

Source of Findings: Document Review: Documents are not available.


Develop and implement an electrical safety program. Include key topics suchas lock out tag out procedures, personal protective equipment requirements,etc. Reference NFPA 70e for example program requirements.


22 Sep 2015

Standard: Reference NFPA 70e for example

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

Priority Level: Medium


FactoryName:




Date: 27 Jun 2015



Description: Thermo graphic scans have not been performed previously.



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


22 Sep 2015

Standard: Alliance Standards Part 10 Section 10.13.8 Electrical Inspections

Question: Are periodic safety inspections of the electrical system components completedand documented?



Description: Periodical safety inspections of the electrical system components were notperformed before.



Establish a periodic inspection program to ensure the electrical systems arefree from damage, debris, dirt, lint, etc. Maintain records concerningInspections and follow up actions.


22 Sep 2015

Standard: Alliance Standard Part 10 Section 10.13 Inspection and Testing and Part 13Section 13.6 Housekeeping

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



Description: Periodic Insulation Resistance Measurement Program has not beenestablished.

Source of Findings: Document Review: Documents are not available


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 etc. shall be subject to an insulation resistancemeasurement test to ground after installation but before any wiring isconnected. Insulation tests shall be made between open contacts of circuitbreakers, switches etc. and between each phase and earth.

FactoryName:




Date: 27 Jun 2015




22 Sep 2015

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

Electrical System Conditions

Question: Are switchboards and/or distribution boards installed in compliant locations?



Description: Distribution boards are not installed at reachable height. For example, panelsof Die cutter section and fussing machine room is installed at more than 6 feetheight.

Source of Findings: Photograph: In Die cutter and fussing m/c room the SDB is at an unreachableheight


All distribution boards shall be installed a suitable height for ensuring easyoperation and maintenance of panels. Top end of the panel should be at 6 feetat maximum.


22 Sep 2015

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

Question: Do switchboards and/or distribution boards have a minimum clearance of 1 m(39 in) in front?



Description: Flammable materials were kept in close proximity of distribution board of stair-4.

Source of Findings: Photograph: Clearance was not proper in front of distribution board of stair-4


Remove the all flammable material kept near the panel. Keep the provision forminimum 1 meter clearance in front of the panels and distribution boards forease of access to operate.


25 Aug 2015

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

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


FactoryName:




Date: 27 Jun 2015




Description: During thermo graphic scan, some hotspots were observed at multiplelocations. Refer to Thermo graphic Survey Report for detailed information.

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


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


Standard: Alliance Standard Part 10 Section 10.3.5

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-Stair-02, MCCB of 140 A was providedwith cable of 10 sq. mm that have the maximum current carrying capacity of 50A in free air.

Source of Findings: Photograph: Over rated MCCB in DB-stair-02.


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 respective cable size.


22 Sep 2015

Standard: Alliance Standard Part 10 Section 10.3.1 Electrical Connections.

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 somepanels of the factory. As an example, in MDB of substation multipleconnections are taken from single port of circuit breaker.

Source of Findings: Photograph: Multiple connections into MCCB of MDB of substation.


Use a single bigger-size cable instead of using two or multiple cables into aterminal of the breaker.


22 Sep 2015

FactoryName:




Date: 27 Jun 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 earthling system.Provide earthling connection to all exposed-conductive parts (metal) relatedto/in close proximity to electrical equipment/installation and utility service suchas metallic w

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


Visual Assessment: Visually inspected during audit.


22 Sep 2015

Standard: Alliance Standard Part 10 Section 10.10 Earthing

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



Description: 1.Grounding cables are found with striped joint in SDB-D2/Canteen 2. Inseveral panels, PVC terminal was provided for earth connection which is notconnected to the frame of the panel. And door earthling of several panels werefound open. 3. Groundi

Source of Findings: Photograph: 1.striped earthling connection in SDB-D2/Canteen 2.PVCterminal was provided for earth connection in SDB-02/Office Maintenance. 3.Grounding cables were found under sized in DB-02/6th Floor


1. Provide earthling bus bar for proper distribution of earth connections. 2.Instead of PVC terminal use earthling bus bar which shall have soundelectrical connectivity with the frame of the panel. 3. Provide earthling cable ofthis panel according to the size of the main service cable (phase cable) i.e. atleast half of the size of the phase cable and provide earthling connection at allrequired location. (panel, equipment etc.)


25 Aug 2015

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

FactoryName:




Date: 27 Jun 2015



Question: Do switchboards and/or distribution boards have clear identification markings?



Description: Distribution boards have not been provided with clear identification markings.For example, each of the SDB, DB and MDB did not have clear identificationmarking.

Source of Findings: Photograph: No identification marking on the panel boards.


Provide permanent identification mentioning name of panels (i.e. SDB-1/1stFloor)on a durable material sheet posted on panels’ door.


25 Aug 2015

Standard: Alliance Standard Part 10 Section 10.7 BNBC Part 8 Section 2.11.5.4

Question: Are switchboards and/or distribution boards provided with physical means toprevent the installation of more over current devices than that number forwhich the panel board was designed, rated, and listed.



Description: Capacity information labels have not been found in order to determine howmany circuit breakers, the panels were designed for. For example, in SDB-03,1st floor, DIN rail channel is kept used for installing circuit breaker.

Source of Findings: Photograph: In SDB-03, 1st floor, space in DIN rail channel for installing circuitbreaker


Calculate and display the information of the capacity & panel-schedule of thedistribution boards and then provide a physical means to prevent theinstallation of additional circuit breakers.


22 Sep 2015

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

Question: Each circuit is provided with a dedicated neutral.



Description: Dedicated neutral is not provided with each circuit and neutral cables did nothave any identification. Therefore, it cannot be determined whether dedicatedneutral connections have been used. And no outgoing neutral cable was foundin some of the panels.

FactoryName:




Date: 27 Jun 2015



Source of Findings: Photograph: No outgoing neutral cables were found in DB-stair-01, groundFloor.


Provide dedicated neutral for every single phase circuit with identification usingan approved means. Joints are not allowed to provide neutral connection toanother load. Use a dedicated neutral cable (of same size as respective phasecable) from the neutral bus bar to the load without any joint throughout itslength.


08 Sep 2015

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

Question: Are electrical wiring/cables properly identified?



Description: Cables have not been provided with identification. Also, color code has notbeen maintained at MCB terminals in some panel boards. For example, cablesDB-stair-01, Ground Floor did not have identification.

Source of Findings: Photograph: Cables are not identified in DB-stair-01.


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 point (providing colored cable-sleeves) for identification ofconductor-type (i.e. Red/Yellow/blue for phase cable, Black for neutral cable,Green for earthling cable). Labeling-cable-tie/Marker-tie can be used for cableidentification.


22 Sep 2015

Standard: Bangladesh Electricity Rules 1937 Rule 51 and 56

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



Description: Base plate of the panel is not installed to conceal internal component of thepanel.

Source of Findings: Photograph: Base plate of the panel is kept open in SDB-Stair-5.


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 material) if any additional gap remains afterinstalling cable glands.

FactoryName:




Date: 27 Jun 2015




25 Aug 2015

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

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



Description: Distribution boards have not been provided with capacity information labels.

Source of Findings: Photograph: Capacity information label not provided on SDB-Stair-02.


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) printedon a sheet made of non combustible material.


25 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: Stranded conductors having a nominal cross-sectional area 6mm2 or greaterare provided with cable sockets. Conductors below 6 mm2 without cablesockets, all strands at the exposed ends are soldered together or are crimpedusing suitable sleeve or ferrules.



Description: Cables connected to MCCB of MDB without lugs were found in LT SwitchgearRoom.

Source of Findings: Photograph: Cables are connected in MDB of LT Switchgear without cablelugs.


Terminate cable with lugs of appropriate size, punch using proper lug puncher.Multiple cable connections shall be avoided into one terminal of the circuitbreaker.


08 Sep 2015

Standard: Alliance Standards Part 10 Section 10.3.8.3 Cable Ends

FactoryName:




Date: 27 Jun 2015



Question: Cable joints are through porcelain/PVC connectors with PIB tape woundaround joint.



Description: Cable joints were made without providing any connectors and only PVC tapewound around. For example, cable joints without connectors were observed inSDB-02/CAD Room of 2nd floor.

Source of Findings: Photograph: Cable joint in SDB-02/CAD Room of 2nd floor.


Use PVC connector with PIB tape wound around with a junction box with everycable joints.


22 Sep 2015

Standard: Alliance Standards Part 10 Section 10.3.8.4 Cable Joints

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



Description: Dust was found inside some electrical panels. For example, dust was found inMDB of LT switchgear room.

Source of Findings: Photograph: Dust found in MDB of LT switchgear room.


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.


25 Aug 2015

Standard: Alliance Standard Part 10 Section 10.3.9.1 Enclosures

Question: Electrical wiring and conduit is properly supported.



Description: Electrical wiring is kept on the floor of the pump room without providing anysuitable mechanical protection against the stepping of occupants.

Source of Findings: Photograph: Electrical wiring is kept on the floor of the pump room.


Use rigid steel pipes for the protection of the wiring on the floor of the pumproom and use industrial graded flexible pipes where necessary.

Suggested Deadline 11 Aug 2015

FactoryName:




Date: 27 Jun 2015



Date:

Standard: Alliance Standard Part 10 Section 10.3.2, 10.3.4.3, and 10.3.5

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

Priority Level: Low


Description: Door mat/Car-mat has been provided instead of electrical insulation mat. Asan example car-mat has been used in front of panels in LT switchgear room.

Source of Findings: Photograph: Insulation mat is not proper.


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


25 Aug 2015

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

Question: Are meters and other electrical devices (Ammeter, Voltmeter, PFI AutoController, etc) installed on the main electrical equipment operational?

Priority Level: Low


Description: The indicator lights of yellow and green phase were not glowing in MDB(sewing Section; electrical room) on 1st Floor.

Source of Findings: Photograph: Phase indicator lights are not working.


Repair the indicator lights of the distribution board or replace with a new one ifnecessary.


08 Sep 2015

Standard: Alliance Standard 10.13.7 Inspection of the Installation

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

Priority Level: Low


Description: MCCBs in MDB-01, 1st floor were not provided with proper phaseseparators(small-sized used).

Source of Findings: Photograph: MCCBs in MDB-01,1st floor without proper phase separators.

FactoryName:




Date: 27 Jun 2015




Install phase separators between terminal connections. Verify phaseSeparators are installed at all remaining locations.


08 Sep 2015

Standard: Alliance Standard Part 10 Section 10.3.1 Electrical Connections

Emergency Power System

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



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



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 by color code, the words “emergency system”, or anyother method that identifies the box or enclosure as a component of theemergency system.


25 Aug 2015

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

Question: Is an uninterruptable power supply (UPS) provided?



Description: Uninterrupted power supply (UPS) is not provided yet. But the installation is inprogress.



Provide uninterrupted power supply (UPS) for powering the life safety loads.


25 Aug 2015

Standard: Not Applicable

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


FactoryName:




Date: 27 Jun 2015




Description: Generator has been provided with only one frame earthling connection.



Install two distinct earth connections of minimum 35 sq. mm for generatorframe earthling.


08 Sep 2015

Standard: Alliance Standard 10.8.2.2

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.


20 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.





08 Sep 2015

FactoryName:




Date: 27 Jun 2015



Standard: Alliance Standards Part 10 Section 10.11 Lightning Protection

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



Description: Only four down conductors have been installed for whole area of the buildingwhich is not adequate for the building.





08 Sep 2015


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



Description: Lighting protection system has not been bonded to the structure of the shed.



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


08 Sep 2015


FactoryName:




Date: 27 Jun 2015

