INITIAL ELECTRICAL SAFETY ASSESSMENT - EXPANSION

INITIAL ELECTRICAL SAFETY ASSESSMENT - EXPANSION Factory Name: ACS TEXTILES (BANGLADESH) LTD. Tetlabo, Barpa Rupgonj, Narayangonj Rupgonj Dhaka Bangladesh 26 Sep 2018 The Alliance for Bangladesh Worker Safety Page 1/14

Factory Name: ACS TEXTILES (BANGLADESH) LTD. 26 Sep 2018 Introduction to the Report The following report contains a site profile and summary of non-conformities identified during an onsite assessment commissioned by the Alliance for Bangladesh Worker Safety (Alliance) and conducted by a third-party Qualified Assessment Firm (QAF). The assessment was conducted 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) for the Bangladesh National Tripartite Plan of Action (NTPA). The goal of the Alliance process is to provide clear and practical technical requirements by which Bangladeshi Ready Made Garment (RMG) Factories producing for Alliance members may be consistently and fairly evaluated for fire, structural, and electrical safety in a non-duplicative manner. Each assessment will prompt action plans that will be used by RMG factories to systematically and sustainably improve safety conditions for garment workers. Beyond tracking and reporting on action steps taken in a transparent manner, the Alliance organization and its members will seek to further support factory improvements through technical assistance, training, implementation support for functional Worker Committees, and in some cases financial assistance and wage support 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 or continued safety against fire, electrical and/or structural integrity issues that may lead to injury or loss of life. The report is designed to provide a non-exhaustive summary of risk issues, based on a limited sampling and duration of time onsite by the named QAF. Neither the QAF nor the 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. The Alliance for Bangladesh Worker Safety Page 2/14

26 Sep 2018 GENERAL INFORMATION General Information Factory Name: Country: Province: City: ACS TEXTILES (BANGLADESH) LTD. Bangladesh Dhaka Rupgonj Zip Code: 1464 Audit Duration: Re-Audit: 1 Days Re-Audit After 0 Months Draft Report Date : 02 October 2018 Final Report Date : 31 October 2018 Are all action items from previous assessment complete? : Buildings in Complex : No There are 30 buildings/sheds and 1 communication tower within this complex used by 2 factories either combinedly or separately with different FFC ID. Factories are named as: 1. ACS Textiles (Bangladesh ) Ltd. FFC ID-9329 and 2. ACS Towel Ltd. FFC ID-10868 Out of 30 buildings/sheds, 8 are production buildings/sheds and 22 are ancillary buildings/sheds. Production buildings/sheds are named as: 1) 2 storied pre-fabricated weaving shed unit-1. 2) 2 storied pre-fabricated warping shed. 3) 1 storied pre-fabricated processing shed. 4) 2 storied pre-fabricated weaving shed unit-2. 5) 3 storied (B+2) pre fabricated Towel shed (used by ACS Towel Ltd). 6) 3 storied RC weaving -4 building. 7) 3 storied RC digital printing shed. 8) 2 storied RC warping (sizing-3)- building. Ancillary buildings/sheds are named as: 1) 3 storied RC office building. 2) 3 storied RC Accessories building. 3) 2 storied RC utility building unit-1 4) 3 storied RC chemical godown building. 5) 3 storied RC staff quarter. 6) 1 storied pre fabricated grey and yearn shed (Demolition has been found in progress) 7) 2 storied RC utility building unit-2 8) 2 storied Medical center. Child care and pump room shed. 9) 3 storied RC new Security Barrack (audited by us). 10) Partially 3 leveled RC ETP complex (audited by us). 11) 1 storied RC security office attached with main gate (audited by us). 12) 1 storied RC security posts (6 Nos) (audited by us). 13) 1 storied RC smoking room (6 Nos) (audited by us). 14) 1 storied Empty drum store shed (audited by us). 15) 1 storied Wastage shed (audited by us). 16) 1 storied RC RMS room (audited by us). 17) 1 storied Carpentry workshop and Wastage room shed (audited by us). 18) 1 storied Salt store and ETP office shed (audited by us). 19) 1 storied Mechanical maintenance and oil heater shed (audited by us). 20) 1 storied Automobile workshop shed (audited by us). 21) 1 storied RC ATM Booth (audited by us). 22) 1 storied Parking shed (audited by us). Other Structure: 1) One 4 legged Self supported steel Communication Tower (audited by us). All production buildings/sheds and 8 ancillary buildings/sheds (SL No 1-8) out of 22 ancillary buildings/sheds were previously audited by another QAF. Demolition of one of the previously audited ancillary sheds named as prefabricated grey & yarn shed has been found in progress. Presently our audit scope is limited to 14 ancillary buildings/sheds (SL No 9-22) out of 22 ancillary buildings/sheds and one 4 legged Self supported steel Communication Tower. Out of 8 production buildings/sheds, 7 buildings/sheds are used by ACS Textiles (Bangladesh) Ltd and only one production shed is used by ACS Towel Ltd. 22 Ancillary buildings/sheds and communication tower are combinedly used by The Alliance for Bangladesh Worker Safety Page 3/14

26 Sep 2018 both factories. Names of 8 production buildings/sheds used by ACS Textiles (Bangladesh) Ltd are - 1) 2 storied pre-fabricated weaving shed unit-1. 2) 2 storied pre-fabricated warping shed. 3) 1 storied prefabricated processing shed. 4) 2 storied pre-fabricated weaving shed unit-2. 5) 3 storied RC weaving -4 building. 6) 3 storied RC digital printing shed. 7) 2 storied RC warping (sizing-3)- building. Names of production shed used by ACS Towel Ltd is: 1) 3 storied (B+2) pre fabricated Towel shed (used by ACS Towel Ltd). Names of Ancillary buildings/sheds excluding 1 storied pre-fabricated grey & yarn shed (which is in process of demolition) and communication tower combinedly used by both factories are given below: 1) 3 storied RC office building. 2) 3 storied RC Accessories building. 3) 2 storied RC utility building unit-1 4) 3 storied RC chemical godown building. 5) 3 storied RC staff quarter. 6) 2 storied RC utility building unit-2 7) 2 storied Medical center. Child care and pump room shed. 8) 3 storied RC new Security Barrack (audited by us). 9) 3 leveled RC ETP complex (audited by us). 10) 1 storied RC security office attached with main gate (audited by us). 11) 1 storied RC security posts (6 Nos) (audited by us). 12) 1 storied RC smoking room (6 Nos) (audited by us). 13) 1 storied Empty drum store shed (audited by us). 14) 1 storied Wastage shed (audited by us). 15) 1 storied RC RMS room (audited by us). 16) 1 storied Carpentry workshop and Wastage room shed (audited by us). 17) 1 storied Salt store and ETP office shed (audited by us). 18) 1 storied Mechanical maintenance and oil heater shed (audited by us). 19) 1 storied Automobile workshop shed (audited by us). 20) 1 storied RC ATM Booth (audited by us). 21) 1 storied Parking shed (audited by us). 22) One 4 legged Self supported steel Communication Tower (audited by us) Is the building(s) owned or rented by the Factory?: Number of Building Levels (Stories) : Approximate Building Area (SF) : Date of Building Construction : Date of Last Building Renovation/Addition : Ancillary Structures in Complex : Owned 1) 3 storied RC new Security Barrack: 3-story above grade. All floors are use as security barrack. 2) Partially 3 leveled RC ETP complex: Partially 3 story with underground tank. 3) 1 storied RC security office attached with main gate: 1-story above grade. 4) 1 storied RC security posts (6 Nos): 1-story above grade. 5) 1 storied RC smoking room (6 Nos): 1-story above grade. 6) 1 storied Empty drum store shed: 1-story above grade. 7) 1 storied Wastage shed: 1-story above grade. 8) 1 storied RC RMS room: 1-story above grade. 9) 1 storied Carpentry workshop and Wastage room shed: 1-story above grade. 10) 1 storied Salt store and ETP office shed: 1-story above grade. 11) 1 storied Mechanical maintenance and oil heater shed: 1-story above grade. 12) 1 storied Automobile workshop shed: 1-story above grade. 13) 1 storied RC ATM Booth: 1-story above grade. 14) 1 storied Parking shed: 1-story above grade. Other Structure: 1) One 4 legged Self supported steel Communication Tower: Height about 70 ft. 1) 3 storied RC new Security Barrack: Ground floor 5,573 sft, 1st floor 5,573 sft and 2nd floor 5,573 sft (Total 5,573 x3 floor = 16,719 sft). 2) Partially 3 leveled RC ETP complex: 3) 1 storied RC security office attached with main gate: about 463 sft. 4) 1 storied RC security posts (6 Nos): 56 sft x 6 nos = 336 sft. 5) 1 storied RC smoking room (6 Nos): 49 sft x 6 nos = 297 sft. 6) 1 storied Empty drum store shed: about 1,276 sft. 7) 1 storied Wastage shed: about 1,632 sft. 8) 1 storied RC RMS room: about 333 sft. 9) 1 storied Carpentry workshop and Wastage room shed: about 390 sft. 10) 1 storied Salt store and ETP office shed: about 210 sft. 11) 1 storied Mechanical maintenance and oil heater shed: about 1,190 sft. 12) 1 storied Automobile workshop shed: about 574 sft. 13) 1 storied RC ATM Booth: about 171 sft. 14) 1 storied Parking shed: about 1,800 sft. Other Structure: 1) One 4 legged Self supported steel Communication Tower: about 220 sft. 1) 3 storied RC new Security Barrack: 2015-2016. 2) Partially 3 leveled RC ETP complex: 2005-2007. 3) 1 storied RC security office attached with main gate: 2005-2007. 4) 1 storied RC security posts (6 Nos): 2005-2007. 5) 1 storied RC smoking room (6 Nos): 2018. 6) 1 storied Empty drum store shed: 2017. 7) 1 storied Wastage shed: 2017. 8) 1 storied RC RMS room: 2005. 9) 1 storied Carpentry workshop and Wastage room shed: 2005. 10) 1 storied Salt store and ETP office shed: 2006. 11) 1 storied Mechanical maintenance and oil heater shed: 2006. 12) 1 storied Automobile workshop shed: 2006. 13) 1 storied RC ATM Booth: 2014. 14) 1 storied Parking shed: 2015. Other Structure: 1) One 4 legged Self supported steel Communication Tower: 2013. 2018 Ancillary buildings/sheds are named as: 1) 3 storied RC office building. 2) 3 storied RC Accessories building. 3) 2 storied RC utility building unit-1 4) 3 storied RC chemical godown building. 5) 3 storied RC staff quarter. The Alliance for Bangladesh Worker Safety Page 4/14

26 Sep 2018 6) 1 storied pre fabricated grey and yearn shed (Demolition has been found in progress) 7) 2 storied RC utility building unit-2 8) 2 storied Medical center. Child care and pump room shed. 9) 3 storied RC new Security Barrack (audited by us). 10) Partially 3 leveled RC ETP complex (audited by us). 11) 1 storied RC security office attached with main gate (audited by us). 12) 1 storied RC security posts (6 Nos) (audited by us). 13) 1 storied RC smoking room (6 Nos) (audited by us). 14) 1 storied Empty drum store shed (audited by us). 15) 1 storied Wastage shed (audited by us). 16) 1 storied RC RMS room (audited by us). 17) 1 storied Carpentry workshop and Wastage room shed (audited by us). 18) 1 storied Salt store and ETP office shed (audited by us). 19) 1 storied Mechanical maintenance and oil heater shed (audited by us). 20) 1 storied Automobile workshop shed (audited by us). 21) 1 storied RC ATM Booth (audited by us). 22) 1 storied Parking shed (audited by us). Other Structure: 1) One 4 legged Self supported steel Communication Tower. Approximate Ancillary Structures Area (SF) : Number of Occupants : Provide brief description of the electrical system for each building.: Physical location of Substation? : What equipment/loads does the UPS serve? : 1) 3 storied RC new Security Barrack: Ground floor 5,573 sft, 1st floor 5,573 sft and 2nd floor 5,573 sft (Total 5,573 x3 floor = 16,719 sft). 2) Partially 3 leveled RC ETP complex: 3) 1 storied RC security office attached with main gate: about 463 sft. 4) 1 storied RC security posts (6 Nos): 56 sft x 6 nos = 336 sft. 5) 1 storied RC smoking room (6 Nos): 49 sft x 6 nos = 297 sft. 6) 1 storied Empty drum store shed: about 1,276 sft. 7) 1 storied Wastage shed: about 1,632 sft. 8) 1 storied RC RMS room: about 333 sft. 9) 1 storied Carpentry workshop and Wastage room shed: about 390 sft. 10) 1 storied Salt store and ETP office shed: about 210 sft. 11) 1 storied Mechanical maintenance and oil heater shed: about 1,190 sft. 12) 1 storied Automobile workshop shed: about 574 sft. 13) 1 storied RC ATM Booth: about 171 sft. 14) 1 storied Parking shed: about 1,800 sft. Other Structure: 1) One 4 legged Self supported steel Communication Tower: about 220 sft. In a total the numbers of occupants in the factory complex are 4,940 persons, ACS Textiles (Banglaesh) Ltd.- 4335, and ACS Towels Ltd. 605. Out of 4,940 persons, there is a capacity of 196 persons in the ancillary structures assessed and the per floor data are given as under: 1. 3- storied RC new Security Barrack: Capacity-Level 1: (32 sleeping + dining 26=) 58 persons, Level 2: 44 persons, and Level 3: 48 persons. 2. Partially, 3- leveled RC ETP complex: Level-1: 22 and Level-2: 4. 3. 1- storied RC security office attached to main gate: 5 persons, per shift is 5. 4. 1- storied RC security posts (6 Nos): 6 persons, one in one post per shift. 5. 1- storied RC smoking room (6 Nos): 18 persons, 3 in one room at a time. 6. 1- storied Empty drum storage shed: 02 persons. 7. 1- storied Wastage shed: 02 persons. 8. 1- storied RC RMS room:01 person. 9. 1- storied Carpentry workshop and Wastage room shed: 3 persons. 10. 1- storied Salt store and ETP office shed: 01 person. 11. 1- storied Mechanical maintenance and oil heater shed: 3 persons, per shift is 1. 12. 1- storied Automobile workshop, shed: 02 persons. 13. 1- storied RC ATM Booth: 3 persons in 3 shifts, per shift 1. 14. 1 storied Parking shed: 04 person. Other Structure: 1. One 4-legged Self supported steel Communication Tower: Nil. Service Line : REB. LT Panel : 04nos. MDB : Nil. FDB : Nil. DB : 01nos. SDB : 03nos. Transformer : 1X1500KVA, 1X1250KVA, 2X1000KVA. Generator : 10X900KW, 3X1064KW. UPS/IPS : Nil. COS/Interlocking : 02nos. PFI : 5X1000KVAR. BBT Riser : Nil. Lift : Nil. Fuel Tank Capacity : Nil. Transformer, LT Panel, Generator, COS, PFI already audited in previous assessment. Outside of production building. IPS/UPS not required for audited structures. Because life safety loads are used by built in battery. The Alliance for Bangladesh Worker Safety Page 5/14

26 Sep 2018 ASSESSMENT FINDINGS Expansion Details Are as-built drawings available for new electrical safety features of the building? High Non-Compliance Level: Reviewed as built drawing available on site. Document Review: Reviewed single line diagram available. Alliance Standard reference 8.20 Electrical System Maintenance Is the electrical switchgear and panel boards inspected on an annual basis to ensure that the equipment is installed in accordance with the listed ratings? Non-Compliance Level: 3 The electrical switchgear and panel boards is not inspected on an annual basis to ensure that the equipment is installed in accordance with the listed ratings. Document Review: No documentation provided. Establish a periodic inspection program to ensure the electrical systems are free from damage, debris, dirt, lint, and installed in accordance with their listed ratings. Maintain records concerning inspections and follow up actions. Alliance Standards Part 10 Section 10.13.8 Electrical Inspections The Alliance for Bangladesh Worker Safety Page 6/14

26 Sep 2018 Is a periodical Insulation Resistance Measurement Program established and recorded? Insulation Resistance Test Report was provided. But no pictorial evidence found. Document Review: No proper IR test program was recorded. Develop an Insulation Resistance Measurement Program that ensures deterioration of insulation resistance will be identified quickly. Testing should be in compliance with InterNational Electrical Testing Association (NETA). All transformers, switchgears etc. shall be subject to an insulation resistance measurement test to ground after installation but before any wiring is connected. Insulation tests shall be made between open contacts of circuit breakers, switches etc. and between each phase and earth. Alliance Standard Part 10 Section 10.13.4 Insulation Tests and 10.13.8 Electrical Inspections Electrical System Conditions Is a readily accessible single point of disconnect provided for each main electrical service feed? High Readily accessible single point of disconnect is not provided for each main electrical service feed. Location: SB/Security post. Photograph: No readily accessible single point of disconnect. Provide readily accessible single point of disconnect for each main electrical service feed. BNBC 2.7.5 Main Switch and Switchboards The Alliance for Bangladesh Worker Safety Page 7/14

26 Sep 2018 Are switchboards and/or distribution boards installed in compliant locations? High Distribution boards are not installed in compliant locations. Location: SB/Security post. Photograph: DB is not in a compliant locations. Relocate distribution boards to suitable locations for operation and maintenance. Alliance Standard Part 10 Section 10.7 Main Switch, Switchboards and Metal Clad Switchgear All metal in the building is connected to the building earthing/grounding system such as metal rebar in concrete, metal frame of building, or metal water pipe. High All metal in the building is not connected to the building earthing/grounding system. Location: ETP. Photograph: All metal has not proper grounding system. Survey the entire building to identify all locations of non-compliance. Connect all metal in the building to the building earthing system such as metal rebar in concrete, metal frame of building, or metal water pipe. Alliance Standard Part 10 Section 10.10 Earthing Do switchboards and/or distribution boards have capacity information labels? Non-Compliance Level: 3 Distribution boards have no proper capacity information labels. Location: All panel boards. Photograph: No proper capacity information labels in DBs. Provide capacity information labels (Maximum current rating, number of circuit breakers, rated capacity of circuit breaker, etc.) for Switchboards and/or distribution boards. Display panel schedule on panel door (inner side) printed on a sheet made of non-combustible material. The Alliance for Bangladesh Worker Safety Page 8/14

26 Sep 2018 Alliance Standard Part 10 Section 10.7 Main Switch, Switchboards And Metal Clad Switchgear and 10.13.7 Inspection of the Installation Are lighting and receptacle (socket) circuits segregated? Non-Compliance Level: 3 Lighting and receptacle (socket) are not circuits segregated. Location: Every floor of New security barrack Photograph: Lighting and receptacle (socket) has not been circuits segregated. Lighting and socket circuits must be separated at the noted locations. Have a qualified electrician separate the lighting and sockets into separate circuits. Alliance Standard Part 10 Section 10.3.7.2 Do switchboards and/or distribution boards have clear identification markings? Distribution boards have no clear identification markings. Location: SB/Security post. Photograph: No marking in SB/Security post. Provide clear and permanent identification marks on all distribution boards, switchboards, sub main boards and switches and post proper caution/danger signage in all electrical panel boards. Alliance Standard Part 10 Section 10.7 BNBC Part 8 Section 2.11.5.4 Are switchboards and/or distribution boards provided with physical means to prevent the installation of more over current devices than that number for which the panel board was designed, rated, and listed. Distribution boards are not provided with a physical means to prevent the The Alliance for Bangladesh Worker Safety Page 9/14

26 Sep 2018 installation of more over current devices than that number for which the panel board was designed, rated and listed. Location: SB/Security post. Photograph: No physical means for DBs. Verify the existing load does not exceed the panel rating. For switch boards and/or distribution boards, provide the physical means to prevent the installation of more over current devices than that number for which the panel board was designed, rated, and listed following NFPA 70 section 408.54. Alliance Standards Part 10 Section 10.7 Main Switch, Switchboards and Metal Clad Switchgear Electrical wiring and conduit is properly supported. Electrical wiring and conduit is not properly supported. Location: ETP. Photograph: No proper support for electrical wiring. Survey all wiring and conduit to identify all locations where it is not properly supported and protected from physical damage. Provide adequate supports for electrical wiring and conduit. Consult a qualified electrical engineer for required remediation work and selection of appropriate materials. 15 Nov 2018 Alliance Standard Part 10 Section 10.3.2, 10.3.4.3, and 10.3.5 Cable joints are through porcelain/pvc connectors with PIB tape wound around joint. Improper cable joints were found. Location: 1st floor of New security barrack. Photograph: Improper cable joints. Provide cable joints through porcelain/pvc connectors with PIB tape wound around joint before placing the cable in the box in accordance with Alliance Standard Section 10.3.8.4. Alliance Standards Part 10 Section 10.3.8.4 Cable Joints The Alliance for Bangladesh Worker Safety Page 10/14

26 Sep 2018 Lighting fixtures are supported from the structure and seismic bracing is installed as required. Lighting fixtures are not supported from the structure and seismic bracing is not installed as required. Location: ETP. Photograph: Lighting fixtures are not properly supported. Lighting fixtures need to be supported from the structure and seismic bracing will installed as required. Alliance Standards Part 10 Section 10.3.6 Lighting Fittings Electrical connections at equipment, fixtures, etc are properly secured. Electrical connections at equipment, fixtures, etc are properly secured. Location: ETP. Photograph: Socket is not properly fixed. Socket shall be fixed with structure properly. Alliance Standards Part 10 Section 10.3.1 Electrical Connections Are junction boxes and other electrical devices provided with covers? Junction boxes are not provided with covers. Location: 1st floor of New security barrack. Photograph: No cover for the Junction boxes. Provide adequate covers for junction boxes and other electrical devices according to Alliance Standard. The Alliance for Bangladesh Worker Safety Page 11/14

26 Sep 2018 Alliance Standard Part 10 Section 10.3.5 and 13.6.2 Mechanical guards are provided for electrical equipment and wiring where necessary. Mechanical guards are not provided for electrical equipment and wiring where necessary. Location: ETP. Photograph: No Mechanical guards. Survey all locations to identify missing mechanical guards. Provide mechanical guards for electrical equipment where necessary. 15 Nov 2018 Alliance Standard Part 10 Section 10.3 Electrical Wiring and Cabling, 10.6.5 Cables, and 10.7 Main Switch, Switchboards And Metal Clad Switchgear Signage indicating the prohibition of light fixtures without protective covers is installed at required locations. Low Non-Compliance Level: 3 Signage indicating the prohibition of light fixtures without protective covers is not installed at required locations. Location: Wastage shed. Photograph: Signage indicating the prohibition of light fixtures without protective covers is not installed at required locations. "Light fixtures without protective covers (otherwise known as naked lights) shall not be allowed in storage areas or in any area where the Inspector of the Factories Rules (1.6.3.7) Part 53 disallows these fixtures. Install signs posted in Bengali and English, indicating this prohibition at all entrances to these areas." Alliance Standards Part 10 Section 10.15 Naked Lights Lightning Protection System The Alliance for Bangladesh Worker Safety Page 12/14

26 Sep 2018 Is a lightning protection system installed on the building? High Non-Compliance Level: 2 Lightning Protection System is not installed. Location: Except New security barrack. Photograph: Absence of Lightning Protection System. Lightning Protection System should be installed following NFPA 780. 31 Dec 2018 Alliance Standards Part 10 Section 10.11 Lightning Protection. Calculate Risk Index to determine if required. The air termination network vertical and horizontal conductors are appropriately spaced. Non-Compliance Level: 2 Lightning Protection System is not installed. Location: Except New security barrack. Photograph: Absence of Lightning Protection System. Lightning Protection System should be installed following NFPA 780. Alliance Standards Part 10 Section 10.11 Lightning Protection The appropriate number of down conductors are installed based on the building size. Non-Compliance Level: 2 Lightning Protection System is not installed. Location: Except New security barrack. Photograph: Absence of Lightning Protection System. Lightning Protection System should be installed following NFPA 780. The Alliance for Bangladesh Worker Safety Page 13/14

26 Sep 2018 Alliance Standards Part 10 Section 10.11 Lightning Protection The lightning protection ground terminals are bonded to the building or structure grounding. Non-Compliance Level: 2 Lightning Protection System is not installed. Location: Except New security barrack. Photograph: Absence of Lightning Protection System. Lightning Protection System should be installed following NFPA 780. Alliance Standards Part 10 Section 10.11 Lightning Protection The Alliance for Bangladesh Worker Safety Page 14/14