initial electrical assessment...

INITIAL ELECTRICAL ASSESSMENT REPORT(EAR)

Factory Name: AKH APPARELS LIMITED

Address: 128 Hemayetpur Savar Savar Dhaka Bangladesh

Assessor: Bureau Veritas

Date: 02 Jul 2014

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The Alliance for Bangladesh Worker Safety /18

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.




Date: 02 Jul 2014



GENERAL INFORMATION

General Information



Country: Bangladesh

Province: Dhaka

City: Savar

Zip Code: 1340

Audit Duration: 01 Days

Re-Audit: Re-Audit After 0 Months

Draft Report Date : 07/06/2014

Final Report Date : 07/10/2014

Are all action items fromprevious assessmentcomplete? :

N/A

Buildings in Complex : There are three buildings in the factory premises out of which two are main production buildings and one isancillary building. The buildings are named as: 1) Five Story Main Production Building-02, 2) Four Story MainProduction Building-03, 3) Single Story Generator room with jute shed.

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

Owned

Number of BuildingLevels (Stories) :

1) Five Story Main Production Building-02, 2) Four Story Main Production Building-03, 3) Single StoryGenerator room with jute shed.

Approximate BuildingArea (SF) :

Total area of buildings in the factory premises: 150722 Sft.

Date of BuildingConstruction :

December-2007.

Date of Last BuildingRenovation/Addition :

5th Floor addition in Five story Main production Building-2 finished in 2011.

Ancillary Structures inComplex :

1) Single Story Generator room with jute shed.

Approximate AncillaryStructures Area (SF) :

1) Single Story Generator room with jute shed: 4722 Sft.




Date: 02 Jul 2014



Number of Occupants : Total number of occupants: 2150.

Provide brief descriptionof the electrical systemfor each building.:

Transformer (630KVA): 01 No, Power Source: Rural Electrification Board (REB), Generator (635KVA): 01 No,Solar System: 4.4 KW, Auto Transfer Switch: 01 No, Distribution Board: 03 Nos, Sub Distribution Board: 15Nos.

Physical location ofSubstation? :

Substation room is Located on ground floor in main production building.

What equipment/loadsdoes the UPS serve? :

No UPS for emergency load.




Date: 02 Jul 2014



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: 2

Description: Electrical diagram of main distribution circuit and floor levels circuitsconnecting electrical loads (machines, lights, cooling system etc.) are availableat site, but not "as-built".

Source of Findings: Document Review: Inappropriate electrical diagram.

Suggested Plan ofAction:

Have a qualified electrical engineer develop an as-built single line diagramdetailing key components and capacity of the electrical system.

Suggested DeadlineDate:

31 Aug 2014

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: Workers that operate and maintain the electrical system have not receivedelectrical safety training.

Source of Findings: Document Review: No electrical safety training., Worker Interviews: Noelectrical safety training.


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


31 Aug 2014

Standard: Reference NFPA 70e for example

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

Priority Level: Medium




Date: 02 Jul 2014




Description: No periodical Insulation Resistance Measurement Program is established andrecorded.

Source of Findings: Document Review: No periodical Insulation Resistance MeasurementProgram.


Develop an Insulation Resistance Measurement Program that ensuresdeterioration of insulation resistance will be identified quickly. Testing shouldbe in compliance with International 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.


31 Aug 2014

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

Question: Is the electrical switchgear and panel boards inspected on an annual basis toensure that the equipment is installed in accordance with the listed ratings?



Description: The electrical panel boards are not inspected on an annual basis to ensurethat the equipment is installed in accordance with the listed ratings.

Source of Findings: Document Review: No annual inspection record for electrical panel boards.


Inspect electrical switchgear and panel boards on an annual basis to ensurethat the equipment is in good working condition.


31 Aug 2014

Standard: Alliance Standards Part 10 Section 10.13.8 Electrical Inspections

Question: Have items identified in previous thermographic inspection reports beenaddressed?



Description: Items identified in previous thermographic inspection reports have not beenaddressed.

Source of Findings: Worker Interviews: No thermographic items have been addressed.


Complete action items identified from previous thermographic inspectionreport.




Date: 02 Jul 2014




17 Aug 2014

Standard: Not Applicable

Question: Transformers do not contain harmful substances such as PCBs.



Description: No evidence (certificate) is found that may confirm that transformer does notcontain any harmful substance.

Source of Findings: Document Review: There is no information about non-existence of the harmfulsubstances such as PCBs.


Consult with transformer manufacturing company to ensure that thetransformer do not contain any harmful substance.


31 Aug 2014

Standard: Not Applicable

Electrical System Conditions

Question: Underground service cables are laid in conformity with the requirements ofconcealed wiring.



Description: Underground service cable is laid with concrete casting which does not complywith the requirements of concealed wiring.

Source of Findings: Photograph: Underground service cables are laid in nonconformity.


Ensure underground cables for electrical service connection in the premisesare engaged in GI or PVC pipes and laid in earth trenches of sufficient depthas per BNBC 2.5.7.2.


31 Aug 2014

Standard: Alliance Standards Part 10 Section 10.3.10 Service Entry




Date: 02 Jul 2014



Question: The substation room has the required fire rating/protection and is physicallyseparated from the remainder of the building.



Description: The substation room has no required fire rating but physically separated bysliding glass (which is not fire rated) from the remainder of the building.Generator is also in substation room.

Source of Findings: Photograph: No fire rating for substation room.


Provide adequate fire protection for substation room and make it separatedfrom rest of the building.


31 Aug 2014

Standard: Alliance Standard Part 3 Section 3.4.2.1.4

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 in the building is not connected to the building earthing.

Source of Findings: Visual Assessment: Not all metal in the building is connected to the buildingearthing.


Connect all metal in the building to the building earthing/grounding systemsuch as metal rebar in concrete, metal frame of building, or metal water pipe


31 Aug 2014

Standard: Alliance Standard Part 10 Section 10.10 Earthing

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



Description: Electrical cables are not sized according to capacity of circuit breakers.Location: LT-Panel, Substation Room; Building-2, SDB -1, Ground Floor,Building-2; SDB -2, Ground Floor, Building-2; SDB-1, 2nd Floor, Building-2;SDB-1, 3rd Floor, Building-2; SDB-1, 4th Floor, Building-2; SDB-1, 5th Floor,Building-2; SDB-2, 2nd Floor, Building-2; SDB-3, 1st Floor, Building-2.

Source of Findings: Photograph: Higher rated circuit breakers with lower rated cables.




Date: 02 Jul 2014




Consult with a qualified Electrical Engineer and ensure electrical cables aresized according to capacity of circuit breakers.


14 Sep 2014

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: Multi looping of cables were observed at circuit breakers within distributionboard. Location: PFI, Substation Room, Building-2; SDB -1, Ground Floor,Building-2; SDB -2, Ground Floor, Building-2; SDB-1, 1st Floor, Building-2;SDB-2, 2nd Floor, Building-2; SDB-2, 3rd Floor, Building-2; SDB-2, 4th Floor,Building-2; SDB-2, 5th Floor, Building-2; SDB-Boiler -1, 2nd Floor (North site),Building-2; SDB-Fabric Store room.

Source of Findings: Photograph: Multi looping of cables at circuit breakers.


Remove multi looping of cables at circuit breakers within distribution boards.


31 Aug 2014

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

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



Description: Distribution boards are not provided with adequate clearance. Location: SDB-1, 4th Floor.

Source of Findings: Photograph: Not provided with adequate clearance.


Provide clearance of at least 1 m (39 in) in front of distribution boards.


03 Aug 2014

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




Date: 02 Jul 2014



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



Description: Indications of overheating were observed (high temperature of 78.7 degree C).Location: PFI, Ground Floor; Note: Detail thermography report is uploadedhere under General Information section , namely ' Thermography of AKHApparels Limited.'

Source of Findings: Photograph: Indications of overheating.


Find out cause of overheating and take proper action including replacing cableor equipment where necessary.


06 Jul 2014


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



Description: Distribution boards are not properly grounded. Location: All DistributionBoards.

Source of Findings: Photograph: No grounding at panel door.


Provide grounding (earthing) for Switchboards and distribution boards as perBNBC section 2.8.1.


31 Aug 2014

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

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



Description: Distribution boards have no clear identification markings. Location: Alldistribution boards.

Source of Findings: Photograph: No clear identification markings.


As per BNBC section 2.11.5.4 ensure clear and permanent identificationmarks are painted in all distribution boards, switchboards, sub main boardsand switches.

Suggested Deadline 03 Aug 2014




Date: 02 Jul 2014



Date:

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

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



Description: Distribution boards do not have capacity information labels. Location: Alldistribution boards.

Source of Findings: Photograph: No DB capacity information labels.


Provide capacity information labels (Maximum current rating, no of circuitbreakers etc.) for distribution boards.


17 Aug 2014

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

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: Distribution boards are not provided with physical means to prevent theinstallation of more over current devices than that number for which the panelboard was designed, rated, and listed. Location: All distribution boards.

Source of Findings: Photograph: No means to prevent the installation of more over currentdevices.


Ensure switchboards and 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 following NFPA 70section 408.54.


31 Aug 2014

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




Date: 02 Jul 2014



Question: Each circuit is provided with a dedicated neutral.



Description: Each circuit is not provided with a dedicated neutral. Location: All distributionboards.

Source of Findings: Photograph: No dedicated neutral.


Provide dedicated neutral for each circuit.


31 Aug 2014

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

Question: Are lighting and receptacle (socket) circuits segregated?



Description: Lighting and socket are not separated. Location: All switch boards and socketsadjacent to those are fed from same circuit breaker in the factory.

Source of Findings: Photograph: Lighting and socket are not separated.


Lighting and socket circuits must be separated at the noted locations. Have aqualified electrician separate the lighting and sockets into separate circuits.


31 Aug 2014

Standard: Alliance Standard Part 10 Section 10.3.7.2

Question: The substation room has adequate ventilation.



Description: The substation room does not have adequate ventilation. Generator is also insubstation room.

Source of Findings: Photograph: Inadequate ventilation in substation room.


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


17 Aug 2014




Date: 02 Jul 2014



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

Question: Are electrical wiring/cables properly identified?



Description: Electrical cables are not properly identified. Location: MCB BOX GeneratorRoom, Building-2; SDB -1, Ground Floor, Building-2; SDB-2, 1stFloor.Building-2; SDB-2, 2nd Floor, Building-2; SDB-2, 3rd Floor, Building-2;SDB-2, 4th Floor, Building-2; SDB-2, 5th Floor, Building-2; SDB-2, GroundFloor, Building-2; SDB-3, 1st Floor, Building-2; SDB-Boiler -1, 2nd Floor (Northsite), Building-2; SDB-Fabric Store Room, Building-2.

Source of Findings: Photograph: Electrical cables are not identified.


Ensure the means of identification is obtained by separate colorcoding,marking tape, tagging, or other approved means.


31 Aug 2014

Standard: Bangladesh Electricity Rules 1937 Rule 51 and 56

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



Description: Substation room is not clean. Generator is also in substation room.

Source of Findings: Photograph: Substation room is not clean.


Remove all dirt, debris, lint from the substation room


06 Jul 2014


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



Description: Internal components of distribution boards are not properly concealed.Location: SDB- Fabric store room; SDB-1, 3rd Floor; SDB-1, 5th Floor; SDB-1,P2 3rd Floor; SDB-2, 2nd Floor; SDB-2, 5th Floor; SDB-Boiler -1, 2nd Floor(North site).




Date: 02 Jul 2014



Source of Findings: Photograph: Internal components are not properly concealed.


Provide covers or blanks to conceal all live internal components of distributionboards.


03 Aug 2014

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

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



Description: Distribution boards are not clean. Location: MCB-Box-Generator Room,Building-2; SDB -2, Ground Floor, Building-2; SDB-2, 2nd Floor, Building-2;SDB-2, 4th Floor, Building-2; SDB-2, 5th Floor, Building-2; SDB-Fabric StoreRoom.

Source of Findings: Photograph: Dirt, debris are found in distribution boards.


Ensure distribution boards free of dirt and debris.


03 Aug 2014

Standard: Alliance Standard Part 10 Section 10.3.9.1 Enclosures

Question: Conduit expansion fittings are used for conduit runs that span a buildingexpansion joint.



Description: Conduit expansion fittings are not used for conduit runs that span a buildingexpansion joint.

Source of Findings: Photograph: Conduit run without conduit expansion fitting.


Use conduit expansion fittings for conduit runs that span a building expansionjoint.


17 Aug 2014

Standard: Alliance Standards Part 10 Section 10.3.8.5 Expansion Joints




Date: 02 Jul 2014



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: Cable sockets are not provided for stranded conductors. Location : SDB-2, 1stFloor; DB-1, 1st Floor, Building-3; PFI–Panel, Substation Room.

Source of Findings: Photograph: No cable socket.


Provide cable sockets for stranded conductors having a nominal cross-sectional area 6mm2 or greater.


17 Aug 2014

Standard: Alliance Standards Part 10 Section 10.3.8.3 Cable Ends

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



Description: Improper cable joints were found. Location : SDB -1, Ground Floor, Building-2;SDB-1, 2nd Floor , Building-2; SDB-1, 4th Floor, Building-2; SDB-1, 5th Floor,Building-2; SDB-3, 1st Floor, Building-2.

Source of Findings: Photograph: Improper cable joint


Ensure cable joints through porcelain/PVC connectors with PIB tape woundaround joint.


31 Aug 2014

Standard: Alliance Standards Part 10 Section 10.3.8.4 Cable Joints

Question: Are junction boxes and other electrical devices provided with covers?



Description: Junction boxes are not provided with adequate covers. Location: 4th floor

Source of Findings: Photograph: Inadequate electrical cover.


Provide adequate covers for junction boxes and other electrical devices.




Date: 02 Jul 2014




03 Aug 2014

Standard: Alliance Standard Part 10 Section 10.3.5 and 13.6.2

Question: Mechanical guards are provided for electrical equipment and wiring wherenecessary.



Description: No mechanical guards are provided for electrical wiring. Location: GeneratorRoom.

Source of Findings: Photograph: No mechanical guards.


Provide mechanical guards for electrical equipment where necessary.


03 Aug 2014

Standard: Alliance Standard Part 10 Section 10.3 Electrical Wiring and Cabling, 10.6.5Cables, and 10.7 Main Switch, Switchboards And Metal Clad Switchgear

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

Priority Level: Low


Description: Insufficient and non grated mats are provided in front of substation, distributionboards. Location: All distribution boards.

Source of Findings: Photograph: Although insulation mats are provide but those are insufficientand non grated.


Provide grated electrical insulation mats in front of distribution boards.


03 Aug 2014

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

Question: Signage indicating the prohibition of light fixtures without protective covers isinstalled at required locations.

Priority Level: Low


Description: No signage indicating the prohibition of light fixtures without protective coversis installed at required locations. Location: Store room/Ground floor.




Date: 02 Jul 2014



Source of Findings: Photograph: No signage indicating the prohibition of installation of withoutprotective covers light fixtures.


Light fixtures without protective covers (otherwise known as naked lights) shallnot be allowed in storage areas or in any area where the Inspector of theFactories Rules (1.6.3.7) Part 53 disallows these fixtures. Install signs postedin Bengali and English, indicating this prohibition at all entrances to theseareas.


03 Aug 2014

Standard: Alliance Standards Part 10 Section 10.15 Naked Lights

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

Priority Level: Low


Description: Ammeter, voltmeter, selector switches and indicator lamps are installed on themain electrical equipment but ammeters are not operational. Location: LT-Panel, Substation Room; DB-1, 1st Floor, Building-3.

Source of Findings: Photograph: Ammeters are not operational


Ensure meters and other electrical devices installed on the main electricalequipment are operational.


17 Aug 2014

Standard: Alliance Standard 10.13.7 Inspection of the Installation

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

Priority Level: Low


Description: Phase separators are not provided between terminals on circuit breakers.Location: LT Panel, Substation Room.

Source of Findings: Photograph: No phase separators.


Install phase separators between terminal connections at the noted


31 Aug 2014

Standard: Alliance Standard Part 10 Section 10.3.1 Electrical Connections

Emergency Power System




Date: 02 Jul 2014



Question: Are cable trenches properly covered?



Description: Cable trenches are not covered properly. Location: Generator room

Source of Findings: Photograph: Inadequate cable trench cover.


Provide adequate cover on cable trench.


03 Aug 2014

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

Lightning Protection System

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



Description: Lightning protection system is not installed on the building.

Source of Findings: Photograph: No lightning protection system.


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


28 Sep 2014

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




Date: 02 Jul 2014



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