cesc budge budge - vr 2012
TRANSCRIPT
R
Contents
Risk Inspection Report
Location Findings -
Fire, Natural Hazards & Machinery Risk
First Baseline Risk Evaluation
of
CESC Budge Budge Power Generating Station,
Budge Budge Trunk Road,Pujali Village,
Paragnas South
West Bengal -700 138
Person Contacted : Mr. Anupam Datta VP ( BBGS )
Visit by: V.Ramesh
Visit date: 21 st
February 2012
Prepared By
ICICI Lombard General Insurance Co. Ltd., Mumbai
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
2
Risk Report ,Budge Budge
Contents
Section I – Executive Summary
Key Site Activity
Specific information of the risk
Risk Exposure & Risk Summary
Section II –Risk Identification
Block details
Process Description
Risk Mitigation Measures
Fire Protection, Detection & Management procedures
Section III –Risk Improvement Measures
Risk Improvement & Loss prevention suggestions
Reference Information
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
3
Risk Report ,Budge Budge
Section I: Executive Summary
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
4
Risk Report ,Budge Budge
Key Site Activity
The company CESC was established in the year 1899 and was originally incorporated in the
UK. The company was then incorporated in India immediately after independence during
1947. The company was taken over by R.P. Goenka group during the year 1989.
The 3 x 250MW Budge Budge Generating Station is located on Budge budge trunk road under
Budgebudge police station in south 24 Parganas of West Bengal. The premises is bounded on
the east by Biraj laxmi Primary health Centre(Pujali), on the south by Rajarampur Village, on
the west by Achipur Village and on the north by river Hooghly.
The unit under study was a green field project and the construction activities were started in
the year 1992 and commercial production of the 1st
Unit was started during Oct 1997. The
commercial production of the 2nd
Unit was started in the year 1999 and the third unit was
commissioned in the year 2010. Presently all the units are operational.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
5
Risk Report ,Budge Budge
Specific Information of the Risk
Insured Budge Budge Power Generating Station, CESC Ltd
Operator Budge Budge Power Generating Station, CESC Ltd
Unit Thermal Power Station – 3x250 MW coal based thermal power plant
Class of risk Ordinary Hazard class (as per Fire Protection Manual)
Occupancy Electric Power Generation
Process Continuous
Certification
deatils and
special features
ISO : 9001-2008, OSHAS 18001 2007,Both revalidated
Plant
commissioning
year and
capacity
expansion
Unit I-1983
Unit II- 1986
Unit III-2010
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
6
Risk Report ,Budge Budge
Risk Location &
Address
Location of the plant
The Unit is located at Budge Budge 40 KMS away from Kolkatta on
Kolkatta-Budge Budge Trunk Road.
Public Fire
Tender
There is no fire brigade / tender available in the site and the nearest
municipal fire brigade is located at Budge Budge, which is at a distance
of around 7 kms away from the risk
Neighbouring The premises is bounded on the east by Biraj laxmi Primary health
Centre(Pujali), on the south by Rajarampur Village, on the west by
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
7
Risk Report ,Budge Budge
Exposure Achipur Village and on the north by river Hooghly
Loss
Information
Not available
General Locational Details
Sr.
No
Name and Address of Factory:- Budge Budge Power Generating
Station,CESC Ltd,
A. Nearest Railway Station and Tourist
Spots,if any.
Sealdah 7 Kms
B. Nearest National Highways and road
connections to various cities
with distances.
C. Nearest Airport(s) and Distance(s). Kolkatta 60 KMS
D. Nearest Port(s) and Distance(s). Kolkatta - 13 KM.
E. Nearest River(s), Dams, Hydroelectric
plants and their distance(s).
Hoogly River 800 M
F. Distance from Sea. More than 200 Kms from the risk
G. Mean Sea Level(MSL):- 105 M
H. Lowest and Highest Temperatures
through the year.
Summer:- 40– 44 °C
Winter:- 10 – 16 °C
I. Relative Humidity (RH). Highest:- 80- 90% in the morning
Lowest :- 25-35% in the afternoon
L
Average Annual Rainfall. 1750-1770 mm/yr.
M
History of floods / storms / earthquakes
at site during last 5 years:
No
N Nearest Public Fire Brigade, its distance
and brief summary of equipment
Budge Budge -7 Kms
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
8
Risk Report ,Budge Budge
therein:-
O
Nearest Police station including
manpower therein and its distance:-
Budge Budge -10 Kms
P Latitude/Longitude
220
28‟ 59 “N,88 0
10 „00 “E
Risk Exposure & Risk Summary
Peril Exposure Explanation
Fire High Fire is probable at the coal /Coal yard, belt conveyors,
coal screens, transformers, cable gallery, TG lube oil
tanks, switchgear units and LDO tank farm area. Hydrant
system installed.
Lightening
Moderate to
High
As per M.Re , the area is prone to Lightning. The strike
will be 4 -10 per KM2
.However adequate lightning
arrestors are provided to reduce the impact
VCE Low Hydrogen is used for cooling TG sets. Any leakage in
the cylinder storage could result in vapour cloud
explosion.Other fuel used is LDO , which is used as fuel
for boiler. The flash point of LDO comparatively on a
higher side, the chances of formation of flammable
vapour cloud in the facility are highly remote..
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
9
Risk Report ,Budge Budge
Vessel
Explosion/Implos
ion
Moderate Boilers are operating under atmospheric / normal
pressure. However required failsafe trips and other
safety parameters as laid down by inspectorate of boiler
is in place
Dust Explosion Moderate Dust explosion is probable in the coal handling area.
Chances of explosion of pulverized coal fired boilers
operating at high pressure cannot be ruled out. Earthing
and earth resistance maintained as per standards.
Earthquake
Moderate
This unit lies in Zone II as per TAC guidelines of
Earthquake zone and the risk is moderate to higher. As
per M.Re the zone falls under moderate category.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
10
Risk Report ,Budge Budge
Flood/
Inundation
High
Nearest river course Hoogly is at a distance of 800 M
from the risk and this unit is +6.00 m above sea level
and this region is prone to flood.However as per
information no loss reported due to flood.
Wind/ Cyclone
High
As per Munich-re natural hazard map the location comes
under Zone 2 and the wind speed expected is between
185-212 KMPH. Distance from the nearest
Seacoast/River is about 800 M, chances of damage by
cyclone are High
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
11
Risk Report ,Budge Budge
Hail storm
Low
The risk falls under Zone 2 as per M.Re,which is low in
exposure.
Tornado
Low
As per M.Re the risk falls under Zone1, which is very
low.
RSMD Low As per information no past incidents and that Employer
/employee ,Contractors and sub contractors relations
are good
Impact damage Moderate As per information no past incidents. Operation of crane
inside the power house is likely. This may occur during
repair or replacement of turbine/generator
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
12
Risk Report ,Budge Budge
parts/overhaul/maintenance.
Air craft /Vehicle
damage
Low The nearest airport is located at Dum Dum,Kolkatta
which is 60 KMS away from the risk. Hence risk of
Aircraft damage is low
Outside
Exposure
Low The premises is bounded on the east by Biraj laxmi
Primary health Centre(Pujali), on the south by
Rajarampur Village, on the west by Achipur Village and
on the north by river Hooghly
Theft and
burglary
Moderate Round the clock security have been deployed for the
unit. As such Chances of theft and burglary is moderate
Machinery
Breakdown
High TG/Generator/Boiler/Boiler feed pumps/DG
sets/Compressors/ID/FD Fans/CW Pumps/Motors are
installed. All these equipment are liable for machinery
breakdown.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
13
Risk Report ,Budge Budge
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
14
Risk Report ,Budge Budge
Section II: Risks Identification
Block layout details
Refer the Plot Plan – Annexure 1 –Not furnished
Process Description
BBGS is a 3x250 MW thermal power plant comprises of three units of 250 MW capacity each.
The boilers ( unit I & II) are designed and engineered by Babcock Engineering of UK and
supplied by ABB ABL. L & T of India erected these. The turbines and generators are supplied
by Roll Royce of UK and were erected by UB Engineering group of India. Mc Mallivar of UK
has provided the coal handling system.Third unit is supplied and erected by BHEL
The main plant area comprises of the railway siding for receiving coal, primary and secondary
crushers, boilers, powerhouse and other associated facilities including the offices. The coal
storage yard ash handling and disposal system are located in the adjoining facility across the
road. The coal is transported from the main plant to the storage area by conveyor.
The primary fuel for these units is bituminous coal supplied from coalmines. The coal
handling plant has been designed for 960 mth coal (- ) 300 mm size will generally be received
at site from mines. Coal will be unloaded in the yard either by wagon tipplers or in the tracks
hopper through bottom discharge wagons. The coal is crushed to (-) 20 mm by secondary
crushers. 2x 100% parallel chains of conveyors are provided to convey coal yard to boiler
bunkers.
LDO and HFO/ LSHS have been used as the fuel oil. LDO will be used during low load
operation of the boilers and for support & stabilization. Unloading, storage and transferring
facility to fuel oil system have been provided for the station.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
15
Risk Report ,Budge Budge
Heat for the power cycle of Units Nos. 1 & 2 of CESC, Budge Budge Generating Station is
derived from burning pulverized coal in a Natural circulation, balanced draft, two pass down–
shot fired, single reheat, single horizontal drum type boiler. Each unit has a single 250 MW
Parsons turbine generator, ABL boiler with a maximum continuous rating of 805 T/ hr.,
stream, and all auxiliary systems and equipment to make a complete generating unit.
Each boiler has been provided with two forced draft fans, three induced draft fans, two
primary air fans, one primary tubular air heater, two secondary tubular air heaters, six Ball
Race type pulverizes, six coal feeders, etc. Soot blowing is done. Light up is by EA ignition.
Main and reheat steam temperature is maintained from full load to 60 % load. The boiler is
capable of running without oil support for flame stabilization. 25 % BMCR requirement can be
achieved by burning HFO/ LSHS alone.
Feed water is taken from the de aerated feed water storage tank by motor driven feed water
pumps, and discharged through two stages of high pressure regenerative feed water heating
and flue gas economizer feed water heater into the boiler drum. Boiler water is in natural
circulation from the boiler drum through the furnace water walls back to the drum.
Separations of steam and water are accomplished in the drum and the steam is conveyed
through superheater sections of the boiler and intermediate two stages of desuperheating
stations. The steam cycle involved is a regenerative & reheating cycle with 3 cylinders of the
turbine HP (High Pressure), IP (Intermediate Pressure), LP (Low Pressure) cylinders.
Thereafter, the steam is expanded through the High-pressure cylinder of a tandem compound
turbine generator. After expanding through the high pressure turbine the steam is led back to
the reheater and reheat attempertor sections of the boiler, before being expanded through an
intermediate pressure turbine and low pressure turbine exhaust steam entering the
condenser. The condensate from condenser hotwell is again transported to the de aerator by
motor driven condensate extraction pumps through four stages of low-pressure regenerative
feed water heating system.
The turbine is capable of operation VWO normal pressure with all extractions in operation. It
utilizes electro-hydraulic controls. The start-up, shutdown and loading of turbine can be
achieved automatically. Turbine throttle pressure is 146 Kg/ Cm² (abs.) main steam
temperature is 537 ° C and reheat steam temperature is 535°C.
To facilitate cold start-up and quick reloading of the unit after temporary turbine outage, a 60
% capacity H.P. – L.P. turbine bypass system has been provided.
The turbine cycle includes two stages of feed water pumping (boiler feed pumps and
condensate extraction pumps), comprising seven stages of regenerative feed water heating
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
16
Risk Report ,Budge Budge
by turbine bled steam, viz., two high pressure regenerative feed water heating by turbine bled
steam, viz., two high pressure regenerative closed feed water heaters at the boiler feed
pumps discharge, four low pressure closed feed water heaters at the condensate extraction
pump discharge, and one direct contact heater (deaerator). All the feed water heaters are of
horizontal type. The two (2) lowest pressure heaters LPH – 1 & 2 are located in the neck of the
condenser and LPH – 1 is provided with an external drain cooler.
Each feed water heater drain is normally cascaded to the next lower pressure heater and the
lowest pressure heaters drains are cascaded to the condenser through condenser drains flash
box. Emergency drain of each feed water heater (except LPH – 4) is cascaded to the
condenser through condenser drains flash box. All heater drains are gravity type except LPH –
3 drains that is handled by a drain pump. Steam for regenerative feed water heating is
extracted from the turbine cycle at the exhaust from the high-pressure turbine (Cold reheat
steam), two intermediate stages of the intermediate pressure turbine, and one from the
exhaust of the intermediate pressure turbine, and three intermediate stages of the low-
pressure turbine.
Condensate is extracted from the condenser hot well pumped through the turbine gland
steam condenser, external drain cooler, four progressive stages of low pressure regenerative
feed water heating and sprayed into a direct contact deaerating heater. 2 x 100 % capacity
vertical condensate extraction pumps have been provided for this purpose.
Provision is kept for condensate bypassing of LP Heaters in two groups is the event of heater
flooding so that turbine is protected from water ingress, viz., LP Heaters – 2 & 1 and drain
cooler as one group, and LP Heaters – 3 & 4 as the other.
LP Heater – 2 drain is cascaded to LP Heaters – 1 via a flash box, while LP Heater – 1 drain is
cascaded to the condenser drains flash box via the drain cooler. LP Heater – 4 drain is
similarly cascaded to LP Heater – 3 while normal drain is pumped forward by a 1x 100% drain
pump via control valves to LP Heater- 3 main condensate outlet.
The turbine drives a 250 MW alternator with hydrogen cooled rotor and stator core, and DM
water-cooled stator windings at a speed of 3,000 rpm. The turbine shafts & generator rotor are
rigidly coupled together. The generator field is excited from a static system.
Deaeratad feed water from the deaertor feed water storage tank is pumped to the boiler flue
gas economizer by 2X 100% capacity boiler feed pumps through HP heater 6 & 7.Each boiler
feed pump consists of a booster pump and a main pump. Each HP heater can be by passed
individually from feed water side incase of heater flooding. HP Heater- 7 drain is cascaded to
HP Heater – 6, while HP Heater-6 is led to desecrator.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
17
Risk Report ,Budge Budge
Initial air extraction from the condenser and steady vacuum inside the condenser is achieved
by motor driven, water sealed air extraction pumps. During normal operation of the plant
vacuum is maintained by one of the pumps.
Each unit is provided with a reserve feed water tank (RFW tank). It holds a supply of
demineralised water from condensate storage tanks through condensate transfer pumps.
RFW tanks provide the means of filling the deaerator and condenser and maintain the
condensate level within the condenser. It also supplies water to the condenser air extraction
system and condensate extraction pump seals. In addition, the RFW tank receives the surplus
condensate when there is excess in the system.
Two nos. separate condensate storage tanks, interconnected to each other, are provided for
both the units. Condensate storage tanks receive demineralised water from DM plant.
Condensate storage tanks provide water supply for boiler filling, RFW tank makeup, deaerator
filling, cooling water head tank make up, condenser emergency make up, stator cooling make
up and chemical feed system for both the units through set of pumps.
The flow to LP turbine low-pressure exhaust has been connected to single shell, horizontal,
two passes, divided water box, surface condenser. The split design of cooling waterside of
the condenser enables one half to be isolated for inspection while the other half remains in
service. The water boxes are lined with coal tar epoxy to counteract the corrosive qualities of
the cooling water. In addition sacrificial magnesium anodes, provided in each water box, give
back up corrosion protection by means of electrolytic reaction between dissimilar metals.
The condenser for each unit is supplied with circulating water from the cooling tower basin by
2X 50 % CW pumps which pumps water through the condenser and discharge it back to the
CT basin thus forming a closed cycle cooling. The CW supply headers of units 1 & 2 are cross-
connected.
The plant equipment cooling water system meets the requirement of the auxiliary coolers,
other than the main condenser. The whole, system is subdivided into two – system. The
primary circuit uses DM water and is of closed loop type. This is employed to pick up the
heat load from various auxiliary coolers under TG & boiler packages and to reject the same
to a set plate heat exchanger. The open loop secondary circuit water and is employed to
pick up the heat load from above plate heat.
Requirement of cooling water to TG oil coolers are met thru Aux. cooling water header for all
units.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
18
Risk Report ,Budge Budge
The complete ash handling system is divided as bottom ash removal system and fly ash
Removal system. The fly Ash Removal system is continuous, whereas, bottom ash removal
system is intermittent and carried out once per shift.
Bottom Ash Removal system is a wet system. The bottom ash of each unit to crushed and
hydraulically conveyed in the form of slurry from bottom ash hopper to dewatering bins/ ash
tanks. Decanted water separated from the bins is further re circulated in the system. Trucks
remove collected bottom ash at the bins.
Fly ash collected in ESP & Air heater hoppers is removed in dry form by dense phase pneumatic
conveying system in tow stages. In the fist stage, fly ash collected in above hoppers is
pneumatically conveyed with compressed conveying air to Intermediate Surge Hoppers. In the
second stage, the dry fly ash is further conveyed with compressed conveying air to Intermediate
Surge Hoppers. In the second, the dry fly ash is further conveyed from Intermediate Surge
Hoppers to Fly Ash Silos by P-D pumps. Ash collected in fly Ash Silos is removed by trucks
through rotary un loader. Provision has been made to unload the ash from Intermediate Surge
Hoppers to trucks through unloading system in case of emergency.
Risk Mitigation Measures /Management Programs/Maintenance/Safety
The main hazard perceived is Fire/ explosion due to Boiler, Fire in lube oil system, Jet fire in
turbine or possible scenario.
Plant is operated by DCS
Entire plant is protected with fire hydrant system.
High velocity water spray system is fixed for generating, stationary transformers.
Smoke detectors fixed in control room, cable cellar, and office building
Safety Committee comprising top and middle management is in place.
LHS for unit III
Management Programs
Inspection procedures
Inspection is carried out for installations like Fuel storages, boilers, pressure vessels, lifting
tools and tackles by authorized agencies. Vibration monitoring, lubrication checks, online
monitoring is carried out.
Maintenance Procedures
Nalco has developed preventive maintenance program. The management emphasizes on
preventive maintenance procedure, which is based on continuous performance and health
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
19
Risk Report ,Budge Budge
monitoring of the machinery. The procedure includes monitoring of vibration, thickness, oil
analysis, dissolved oxygen analysis etc.
Maintenance Philosophy:
Preventive and predictive maintenance is being followed
Condition based monitoring is carried out
There are separate Electrical and Mechanical maintenance departments. Each
department is further broken into several specialized divisions, each responsible for
particular group of machinery.
Maintenance of various critical equipment like STG, boilers etc is carried out as per the
guidelines laid down by the suppliers.
The guidelines set by Central Electrical Authority are also strictly adhered to.
There is a centralized maintenance department in the company that looks into special
maintenance requirements of the various units which includes the unit under study.
Most of the critical equipments are on Annual Maintenance Contract. The technical
experts of original equipment suppliers are present during the overhaul of critical
equipments.
Safety Management
There is one Safety officer available (Mr.Chand Guchait ,Safety Engineer) at the site who
reports to the Manager – maintenance. There is no subordinate for the safety officer to assist
him and take over the charge during his absence. There is a safety Committee for the unit,
which is chaired by the Manager. Employees are trained in fire fighting and first aid
techniques. Fire drills are under taken to ensure good preparedness to meet any emergency.
Safety systems like work permit system are available in the facility.
Training:
Most of the plant personnel are covered.
Demonstrations carried out.
Mock drills carried out twice in a year.
Audits:
Internal safety audit is carried out once in a year.
External safety audits are also carried out once in a year.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
20
Risk Report ,Budge Budge
Manuals:
Disaster management plan
Safety Manual
Safety permits (hot & cold work, etc)
Safety policy is in place.
Safety Committee:
Meeting- carried out every month.
Activities:
Safety inspections carried out on daily basis.
Follow up actions initiated against inadequacies observed.
Fire Protection, Detection and Management Procedures
Fire & Safety Organization & Procedures
There is a Safety officer. A team comprising of supervisors and helpers report to him.
Regular wet and mock drills proposed.
Strict adherence of Hot and cold, excavation, work at height permits and confined
space is being followed
Fire Hydrant System & Hand Appliances; The plant is protected with hydrant system. Details
are as under
1. Hazard Category: -
(ordinary/low/high as per TAC
F.P.Manual)
Ordinary
2. Details of Fire Water Storage and
capacities.
7000 M3
3. a Hydrant Pump Details: (Electrical
driven Horizontal centrifugal end)
Pump room No :
i) No. Of pumps: -
ii) Make: -
iii) Capacity in m3/hr.: -
iv) Heads in mtrs: -
Motor
2 No
273 M3/hr
85 MWC.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
21
Risk Report ,Budge Budge
i) No. Of motors: -
ii) Make: -
iv) Capacity in KW/HP -
v) RPM
vi) Pressure
2
125 KW
2960
8.8 ksc
3. b Hydrant Pump Details: (Diesel
Driven)
i) No. Of pumps: -
ii) Make: -
iii) Capacity in m3/hr.: -
iv) Heads in mtrs: -
Engine
i) No. Of motors: -
ii) Make: -
iii) Capacity in BHP, -
iv) RPM
1
410
85 MWC
125 HP/167 KW
1485
4. Jockey Pump Details: -( Pump
House I )
i) No. Of pumps: -
ii) Make: -
iii) Capacity in m3/hr.: -
iv) Heads in mtrs: -
v ) Pressure
Motor
i) No. Of motors: -
ii) Make: -
iv) Capacity in KW/HP -
v) RPM
1
16.50
85 MWC
7.5 ksc
1
2900
5. Mulsifier Pump Details: (Electrical
driven Vertical )
Pump room No :
i) No. Of pumps: -
ii) Make: -
iii) Capacity in m3/hr.: -
iv) Heads in mtrs: -
1 No
273 M3/hr
85 MWC.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
22
Risk Report ,Budge Budge
Motor
i) No. Of motors: -
ii) Make: -
iv) Capacity in KW/HP -
v) RPM
vi) Pressure
1
125 KW
2960
8.8 ksc
6. Hydrant Pump Details: (Diesel
Driven)
i) No. Of pumps: -
ii) Make: -
iii) Capacity in m3/hr.: -
iv) Heads in mtrs: -
Engine
i) No. Of motors: -
ii) Make: -
iii) Capacity in Bhp -
iv) RPM
2
410
85 MWC
2
Cummins
125 KW
1485
7 Jockey Pump Details: -( Pump
House II )
i) No. Of pumps: -
ii) Make: -
iii) Capacity in m3/hr.: -
iv) Heads in mtrs: -
v ) Pressure
Motor
i) No. Of motors: -
ii) Make: -
iv) Capacity in KW/HP -
v) RPM
1
16.5
85 MWC
8.8 ksc
1
18.5 KW
2290
Details of hydrant:
Single Hydrant : 205
Riser Main : 95
Hand appliances : Varying types 650 Nos
Hose Box : 195
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
23
Risk Report ,Budge Budge
Water monitor : 20 Nos
Sprinkler Protection, Outside Equipment and Structures
Automatic Mulsifier System: Provided around Generator Transformer Nos , Unit Transformer
Station Transformers.
Water Monitor sprinklers: These are provided below the Conveyors of the Coal Handling
Plant and two nos. are installed at 0-0 level of Boiler Total No. is 20.
There is dedicated pumping arrangement for the Mulsifire system. The lubricating Oil tanks of
Outdoor transformers, coal belt conveyors are provided with mulsifiers,Water spray system
for CHP,LDO tanks.
Sprinkler protection, buildings and indoor equipment
Manually Operated Sprinklers: Provided for Main lube Oil Tanks and skids off. Turbine Nos. 1
& 2., Burner Front Floors of Boiler and Cable cellar for unit III.
Passive protection
Barrier walls provided between two transformers in the yard to avoid spread of fire
Cables entering unit control room, control and equipment rooms, Marshalling Rooms,
Mcc‟s in 13 M level from „0‟ M cable vaults have been coated with „Cable mastic‟ fire
preventive compound.
Fire barriers, supplied by Lloyd‟s insulation, have been used to seal the floor cut outs
below the panels, in all the location mentioned above.
Linear heat detector has been provided in all cable trays in around the periphery for
unit III only
Special Protection Systems
All Steam Turbine generators are protected with CO2 Battery type flooding systems
Smoke detectors and alarms are provided in the control room.
Manual call points are provided all over the complex.( 444 nos )
Fire monitoring is done in unit control rooms and repeater panels are provided at the
control room. In all 28 nos of panels provided
Infra red detectors around coal conveyor 18 nos provided
For Internal communication telephones, Walkie Talkie, PAS, hooters etc are available
Responsive indicators 44 nos installed
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
24
Risk Report ,Budge Budge
Public
Nearest fire brigade is available at a distance of 7 Km from the risk, at Budge Budge
Private Fire Department
Nil.
Emergency Organization & Procedures
Plant has Emergency plan . Mock drills in form of live demo are displayed every
month.
Mutual Aid
No.
Security / Alarms And Communication Modes
Security is on contract through local security services.
Internal communication is carried out by through intercom & Mobiles.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
25
Risk Report ,Budge Budge
Section III : Risks Improvement /Loss Preventions Suggestions
Risk Improvement Monitoring
A report of this type necessarily concentrates on the weak points and adverse conditions that
constitute a loss potential. The contents of the report, hence, should not be viewed as
implied criticism, but rather as support for management of the risks. Certain potential hazards
and conditions were evaluated during the plant round and were discussed with the fire/safety
department. The corrective actions are advised in order to eliminate or reduce the loss
potential. Completion of the following items will help to lower both the frequency and severity
of losses and minimize the possibility of costly business interruptions.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
26
Risk Report ,Budge Budge
Risk Management Controls & Programs
Management Program Rating Comments
Impairments to Protective
Systems
Fair Impairment procedures explained.
Smoking Regulations Above
average
Smoking is allowed in the designated
outside areas only. During the survey
evidence of uncontrolled smoking was
found
Maintenance Average Mainly in-house and also partly
outsourced to specialized companies
and likely to be controlled by computer
based predictive and preventive
maintenance program is planned based
on local regulations and vendors'
recommendations.
Employee Training Average Safety orientation training for all new
employees by the safety technician is
provided
Loss Prevention
Recommendations
Fair There is a corporate review process for
completing recommendations.
Pre-Emergency Planning Above
average
In place
Hazardous Materials
Evaluation
Above
average
Not much hazardous material in the
plant
Hot Work Above
average
There is a hot work permit available on
this site backed up with a written
procedure. The duration of the permit
should be limited to a single day (shift).
Loss Prevention
Inspections
Above
average
Mainly through in-house personnel
through visual inspections.
Surveillance Above
Average
CISF involved in security
Fire Protection Equipment
Inspection
Available Use effectively
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
27
Risk Report ,Budge Budge
Hazard Identification and
Evaluation
Above
average
Propose to have inspection team
Housekeeping Above
average
Need improvement
Risk Improvement Suggestions
Summary of Recommendations – 21 ST
February 2012
It is recognized that recommendations may require time and resources to complete. We
categorize recommendations in accordance with the following table
Priority▼Category► Software Hardware Condition Hardware Capital
High
(Would typically
pertain to a risk
element that has
been deemed to be
“Unacceptable”)
Procedure essential to
safety or loss prevention
absent or severely flawed,
or being applied in such a
manner that there is a real
and present hazard to plant
integrity.
For this we would expect
immediate action.
Present condition of
hardware constitutes a
real and present hazard to
plant integrity.
For this we would expect
immediate action.
Represents absence or
unacceptable nature of a
capital item that we
consider essential to the
safe operation of a facility.
For this we would expect
an immediate and binding
commitment to plan and
budget for implementation
at the first reasonably
practicable opportunity.
Moderate
(Would typically
pertain to a risk
element that has
been deemed to be
“Unsatisfactory”)
Procedure essential to
safety or loss prevention in
its present state is flawed,
but not to the extent that
the facilities are exposed to
unacceptable risk
We would expect a
commitment to study and
make such changes as are
necessary within a
reasonable time-frame
Present condition of
hardware gives cause for
concern, but not to the
extent that the installation
is in immediate danger.
We would expect to see
evidence that action had
been planned to be
carried out within a
reasonable time-frame.
Represents absence of a
capital item that we
consider highly desirable
for the safe operation of a
facility.
For this we would expect a
medium term plan to
upgrade the facilities, as
and when resources
permit.
Low
(would typically
pertain to a risk
element that has
been deemed to be
“adequate” or
better).
In an already adequate
procedure, these are
examples of best practice
that the assured might
follow.
No timetable specified.
Present condition of
hardware gives no cause
for concern, but could be
improved to achieve best
practice.
No timetable specified.
Represents an example of
best practice the assured
might choose to follow
during a revamp or
upgrade, when it would
not involve significant
additional cost.
No timetable specified.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
28
Risk Report ,Budge Budge
On Hydrant System
02.12.01 Display pressure vs. sequence of fire pumps start:
Category: Software Condition, Priority: Moderate
Consider displaying of pressure vs. sequence of fire pump start in the pump house.
02.12.02 Fire Pump and Hydrant Annual Flow Testing
Category: Software condition, Priority: Moderate
There are no facilities for the testing of pump flows, although tests have been done to
verify pump flows these are not in accordance with NFPA This recommendation
suggests that the current recirculation facilities be modified to include a flow test
gauge or a specialist company is called in once a year to verify pump flow
characteristics along with design hydrant flows.
02.12.03 Flow vs. Pressure performance test
Category: Software Condition, Priority: Moderate
Flow vs. Pressure performance test to be carried out once a year for all the hydrant
pumps
02.12.04 Display sequence of pumps details
Category : Software condition,Priority : Moderate
It is recommended to display the details of operation of fire pumps with its operating
parameters in the pump room.
02.12.05 Fire pumps kept in manual mode
Category: Software condition, Priority: Top
It is observed during our visit that the fire pumps were kept in running even though it is not
required, hence it is suggested that it should be used only for fire fighting
02.12.06 Tapping of hydrant lines by workers in the plant for cleaning
Category: Software condition, Priority: Top
During walk through in the plant, it was observed that in few places, water is being tapped by
workers from the hydrant line. This should be stopped immediately, as this may result in drop
in pressure.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
29
Risk Report ,Budge Budge
02.12.07 Dedicated power supply for hydrant pumps
Category: Hardware condition, Priority, Top
At present power supply for electric driven fire pump is drawn from common power source.
Apart from fire pumps other process pumps also installed. In the event of and breakdown in
power, the fire pumps cannot be used. Hence it is suggested to give dedicated power supply
for these fire pumps from main incomer or dedicated emergency power backup for the
pumps so that in the event of any breakdown in electric power, these pumps can still can be
operated without any problem. Reference can be drawn from fire protection manual for
segregation and dedicated power supply.
02.12.08 Hydrant main grid
Category: Hardware condition, Priority; Top
It was observed that in few places hydrant lines are not laid all-round the plants like SA and
PA plant as suggested in fire protection manual. Hence it is recommended to ensure
completion of grid all-round the process plant. However, if the grid is completed as suggested
in Fire protection manual, this point stands withdrawn.
02.12.09 Checking of pressure at remotest point of hydrant lines
Category : Software condition, Priority : Top
Considering the network, size, frictional loss and pressure, it is recommended to verify the
pressure at the remotest point after opening at least 2 or 3 hydrant points so that the pressure
at the remotest point is maintained at least 3.5 KSC.
02.12.10 Empty Hose boxes
Category : Software condition, Priority : Top
It is observed that in many places hose boxes seen empty without hose and gun.Ensure that
the boxes are fitted with hose reels with gun to use the same during fire fighting immediately
without waiting for its procurement.
02.12.11 Locking of Wet Risers
Category: Software Condition, Priority: Moderate
The plant is equipped with a number of wet risers serving a number of locations; each
riser is supplied with a local isolation valve. To ensure fire water is available at all
position, these valves are to be locked open with a leather strap or plastic chain.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
30
Risk Report ,Budge Budge
02.12.12 Provision of Foam monitor or DCP type Fire extinguishers of 68 KG
Category : Software condition,Priority : Top
It is a good feature that all the transformers are provided with High Velocity water Spray
System but management should consider putting all systems in automatic mode. The
management may consider providing a foam-monitor or DCP type fire extinguisher of 68 Kg
capacity nearby in order to fight fire involving the transformer oil.
02.12.13 Review inspection and testing program for diesel engine fire pumps.
Category: Software condition, Priority : Moderate
In order to ensure reliability of the engine pumps, it is suggested that the pump should be test
run for at least 30 minutes every month, or more frequently per the manufacturer‟s guideline
02.12.14 Supervise control valves for hydrant pipes Entire Plant Building
Category : Software condition, Priority : Top
Many isolation valves are installed on the hydrant pipe network. Because the hydrant pipe is
installed in a loop, accidental closure of one pipe may not stop water flow. However, if one or
more sections are closed for maintenance work and the valves are left closed, the hydrant
supplied from that section will not work. Most of the hydrant pipes are installed in elevated
positions, and immediate access may not be available.
It is suggested that all valves be confirmed to be fully open and that valves be supervised by
using cable ties. Whenever the valves are temporarily closed due to maintenance work this
should be recorded, and the valves returned to the open position and sealed with cable ties as
soon as the work is complete. All activity should be recorded
02.12.15 Fire System Inspection, Testing & Maintenance Standards
Category : Software condition, Priority ; Top
The plant has a fully manned fire station complete with fulltime fire personnel and part
of the function of this team is to carry out regular inspections, maintenance and
operation of the plants fire detection and protection systems
02.12.16 Fire Protection Training
Category: Software condition, Priority: Top
Plant is sufficiently bigger. Hazardous process/Materials are present in the plant.
Hence it is advised to give training for fire fighting to most of the employees apart
from creating awareness on hazard that are exposed in the plant.
At present many contractors still involved in construction. Hence contractors should
be provided with briefing on fire protection and awareness of safety inside the plant
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
31
Risk Report ,Budge Budge
including visitors.
02.12.17 Painting of HVWSS pipelines/hydrant lines
Category: Software condition, Priority: Top
It is observed that high velocity water spray system including deluge system the pipe
colour (Red) is totally faded, thereby could not differentiate easily with normal water
line. Hence it is recommended to paint entire fire hydrant line including spray system
with red colour.
02.12.18 Leakage of water through gland in Fire Hydrant pumps and Jockey pumps
Category: Software condition, Priority : Top
During inspection it was observed that the water was leaking continuously.This may
result in continuous loss of pressure and may not start automatically .Hence it is
recommended to arrest the leakage immediately to prevent leakage and loss of
pressure.
Coal conveyors /Mill:
02.12.19 Provision of Linear Heat sensing cables and Medium velocity water spray
system for coal conveyor system
Category: Hardware capital condition, Priority: Moderate
It is recommended to equip the Coal conveyors with linear heat detection cables by which
fire, at any point along the entire length of the conveyor, can be detected and medium
velocity water spray system. The water spray system should be interlocked with the linear
heat detection cables. In addition to this it is recommended that the belt conveyor and rollers
be earthed at various locations in order to prevent a spark generating from static charge.
02.12.20 Provision of Nitrogen inerting system
Category: Hardware capital condition, Priority: Moderate
Coal is susceptible for spontaneous combustion. Considering the size and the nature it is
recommended to install N2 inerting system for the coal bins to reduce the hazard resulting
from spontaneous combustion.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
32
Risk Report ,Budge Budge
Main power plant
02.12.21 Predictive Maintenance using IR Thermography imaging:
Category: Software Condition, Priority: Moderate
Where it is difficult to assess the health of the equipments
on visual inspection basis, a thermography imaging could
be an option. Infrared thermography is a vital tool to
inspect, control and optimize production processes and
installations. It is recommended that thermography
imaging may be used in determining the preventive
maintenance programs. Example: Hot spot detection in
electrical inspection of switchboards, panel‟s transformers, motors, and other electrical. Hot
spots /leak detection in Mechanical items - bearings, agitators, reactors, gearbox, boiler,
piping systems and other process vessel. The plant being new this can be checked during first
overhaul for turbo generators and for major transformers ,motors and control panels.
02.12.22 Use of ear plugs
Category ; Software condition, Priority Medium
Ensure usage of ear plug where the decibel level is high. It is observed that the
employees/labour working in those areas are not using ear plug. Strict adherence of wearing
ear plug should be followed. Usage of slogans should be displayed in Main power house and
DG house and other places where the decibel level is on the higher side.
02.12.23 Computerized Maintenance Management System:
Category: Software Condition, Priority: Moderate
For the size of the risk understudy, it is recommended to go for SAP or similar computerized
systems which would help in deep mining and better managing/ control of the maintenance
activities in a systematic means.
02.12.24 Smoke / Heat Detection System:
Category: Hardware Condition, Priority: Moderate
Consider installation of smoke / heat detection system for control rooms, including above
/below false ceiling, substations, MCC room, battery room, Warehouses, Admin block and
similar unmanned locations with the panel placed in the control room and a repeater panel in
the fire station for monitoring and quick responsive actions.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
33
Risk Report ,Budge Budge
02.12.25 Provision of automatic medium velocity water spray system for lube oil system
Category : Hardware condtion,Priority High
Lube oil system has huge oil reserve. This is used for turbine. Any fire resulting from lube oil
system may spread to turbine hall also. In order to minimize the fire spread consider
automatically actuated water spray system for lube oil tanks, oil consoles/piping net
work/pumps/ and bearing housing for the seal and lube oil connections of STG instead of
manually operated.
02.12.26 Provision of CO2 Flooding for turbo generators
Category: Hardware condition, Priority High
Turbo generators are run at high speed. Due to this and formation of electric current results in
increase in temperature. At times there is every possibility of fire emanating from generator.
In order to quench such fire it is suggested to provide automatic CO2 flooding system and the
CO2 manifolds /cylinders should be kept outside the main power house.
02.12.27 Installation of inergen clean system for main power house control room
Category : Hardware condition, Priority medium
Inergen Systems for control rooms: Considering the criticality of process and importance
process control rooms, if logistics permits management might consider installation of inergen
system, which is one of the latest inventions in fire protection systems (used in Refinery and
Petrochemical plants). Some write-up on this system given here (taken from website) -
Inergen is an environmentally green three dimensional fire suppression agent replacing Halon
1301. Critical facilities such as data processing rooms, telecommunications switching
facilities, process control rooms, and others, require a non-water based extinguishing agent
that:
Is electrically nonconductive
Is safe for use in human occupied facilities
Would not damage sensitive electronic equipment
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
34
Risk Report ,Budge Budge
Has zero ozone depletion, zero global warming, and zero atmospheric lifetime
Inergen is a blend of three naturally occurring gases--Nitrogen, Argon, and Carbon Dioxide. It
is stored in cylinders near the facility under protection. The strategy of fire extinguishments
employed by an Inergen system is like no other modern suppression system in use today. An
Inergen system lowers the oxygen content of the protected area to a point sufficient to sustain
human life, but insufficient to support combustion. It's that simple. Because it's not a chemical
agent, Inergen will not produce a heavy fog the way other extinguishing agents do, so escape
routes remain visible. The Inergen discharges through specially designed nozzles. To
minimize turbulence in the protected area Inergen nozzles are fitted with discharge deflectors.
02.12.28 Oil leakage Lube oil pump area
Category: Software condition, Priority High
It is observed that leakage of oil is seen near Lube oil system and boiler feed pump area.It is
recommended that the area should be cleaned immediately. Failing which it may result in
spread of fire in presence of hot spot nearby
02.12.29 Position of deluge valve for HVWSS
Category : Software condition, Priority Medium
At present the deluge valve for operation of HVWSS is positioned inside the fencing.It is
recommended to relocate outside the fencing area and that the valve should be protected
with brick wall
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
35
Risk Report ,Budge Budge
02.12.30 Temporary joints in basement
Category: Software condition, Priority : Top
It is observed in few places, temporary connection with wire joints seen in the basement.
Ensure these connections are made permanent to avoid any short circuit. It is observed in
cable gallery/cellar area also. Wiring was seen hanging in cellar area. This should be routed
through metallic conduit.
02.12.31 Running of power cables and instrumentation cables in same tray
Category : Software condition,Priority : Top
It was observed in few places near control room ,power cable and instrumentation cables are
run in the same tray.Considering the inference and flow of current the instrumentation cable
may not function effectively.Hence it is recommended to take these cables in a separate tray
rather than taking it together and distance atleast 30 cms between the tray is maintained for
effective performance of the instrumentation cables.
02.12.32 Coal dust powder deposits seen on the boiler ducts
Category : Software condition,Priority High
Coal/Coal powder deposits seen on the boiler ducts. Due to hot spot and presence of
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
36
Risk Report ,Budge Budge
spontaneous material there is every possibility of spread of fire from these
deposits.Ensure these powder deposits are cleaned periodically.
02.12.33 Vegetation in Switch yard,transformer and coal/coal yard/Open stock area
Category : Software condition,Priority High
In many places in the plant,dry vegetations are seen. Ensure that these vegetation are
cleaned periodically.
02.12.34 Protection for deluge valves and Proper fencing for Main generating/UAT and
Station transformers
Category : Software condition,Priority Medium
The deluge valve at present is not protected. It is recommended to raise concrete wall in
front of the valve to protect against explosion from oil fire arising from the transformer .Apart
from it should be ensured that proper fencing is provided all-round the main transformers to
avoid unauthorized entry of personnel .
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
37
Risk Report ,Budge Budge
02.12.35 Cable penetration- DG House
Category ; Hardware capital condition,Priority-High-
The cable penetrations are now kept open in few places. However ensure that this opening is
filled up with fire retardant cement mortar to prevent spreading of fire through the opening
02.12.36 Display of usage of PPE available but not being used
Category : Software condition, Priority : Top
Usage of PPE displayed in the plant,however plant personnel not obeying the
rules.Recommended to implement usage of PPE regularly and it should be monitored on daily
basis.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
38
Risk Report ,Budge Budge
02.12.37 : Unwanted material stored in the power house hall
Category : Software condition,Priority : Top
It was observed that in few places unwanted materials are stored in the power house .Ensure
that these unwanted wastes are removed immediately.
02.12.38 Fire Hydrant pipeline runs close to other lines, hindering for repair
Category ; Software condition, Priority : Moderate
It was observed that fire hydrant line runs very close to other lines resulting in difficulty for
repair or replacement of fire hydrant line and other utility line. Ensure that at least 30 cms gap
is maintained between the pipes.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
39
Risk Report ,Budge Budge
02.12.39Hand appliances no clear access
Category : Software condition,Priority : Top
It is observed from the photograph that access to Hand appliances is blocked due to presence
of various materials which should be removed for clear access for usage of hand appliances
during emergency.
02.12.40 No clear access for electrical control panel
Category : Software condition,Priority; Top
It is observed that materials/consumables were kept in such a way that access to electrical
control panel is blocked.It is adviced to remove all these materials so as to have clear access
to electrical control panel for access in case of emergency
02.12.41Loose wire,ordinary light seen near DG House
Category : Software condition,Priority : Top
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
40
Risk Report ,Budge Budge
Ordinary light and loose wiring seen near DG House. Ensure replacement of ordinary light
with industrial type and that the wirings are taken through metallic conduit wherever the
length of wire is in excess of 75 cms
02.12.42 Improvement of lightings and ventilation
Category : Software condition.Priority : Top
Lighting and ventilation in cable vault/gallery to be improved as the existing arrangement is
not sufficient
02.12.43 Smoke detectors cleaning
Category: Software condition, Priority: Top
The smoke/heat detectors installed near burner front appears to be totally blackened and it is
really doubtful whether the detector is in good working condition.Hence clean the detector
immediately and checks for its functioning.
02.12.44 Hydrant points close to electrical panel
Category: Software condition, Priority: Top
In few places hydrant points are located very close to electrical control panels/switches.
Ensure that these hydrant points are relocated in order to avoid short circuit resulting from
accidental leakage from hydrants into electrical control panel.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
41
Risk Report ,Budge Budge
Suggestions on Boiler
Have a competent service firm disassemble the low water cut-off and make-up water feeding
devices. All parts should be thoroughly cleaned and reconditioned as required, then tested
before the boiler is put into regular service. While in service the cut-off should be tested once
a week.
• Burner equipment should be cleaned and adjusted to give maximum efficiency. This can
save fuel costs.
• The boiler heating surfaces, firebox, ash pit, casing and ducts should be cleaned of all
deposits. Dirty internal surfaces not only waste fuel and additional costs , but also can lead to
the burning, bulging, cracking, corrosion and even explosion of the boiler.
• The safety/relief valve should be tested for freedom of operation. This is of primary
importance. The boiler must not be fired if the safety/relief valves are inoperative or otherwise
defective. These valves should be tested once a month while in service.
• If the boiler is of a type designed to permit cleaning of the water spaces, this should be
done, and, where necessary, a suitable chemical treatment should be used to minimize new
build-up of scale and to pre-vent corrosion.
• All pressure and temperature controls and gauges should be checked for satisfactory
operation and adjusted or replaced as necessary.
• The water level gauge glass must be cleaned to indicate the proper water level at all
times.Any leaking pipes or fittings located on the boiler or anywhere throughout the heating
system should be repaired or replaced to prevent a loss of water.
• All mechanical equipment, such as fans and pumps, should be checked for smooth
operation and proper lubrication.
• A suitable record of boiler operation should be established and maintained throughout the
year.
Suggestion for coal in open
Coal dumped at the coal yard is prone to spontaneous combustion; we suggest the following
precautionary measures -
Pile should be leveled by scraping and compacted by rolling. Distributing the coal
evenly avoids breakage and segregation of fine coal. The firm packing helps to shed
water
The sides of the pile should have a gentle slope as space limitations permit and
thoroughly compacted.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
42
Risk Report ,Budge Budge
Clear site of all vegetation such as grass weeds etc.
Provide drainage to prevent accumulation of water.
Majority of hotspots will be within 1-1.25meters of the surface and all stacks should be
inspected weekly for overheating. Overheating could be detected by following
Smell – low volatile chemicals coming off
Discoloration – White/yellowish powder deposits
Vapour being given off- inside temperature will be in the region of 1200C.
Provision for water spraying system should be made all along the coal storage
facility,as the system is already there it is necessary to check whether entire storage
area is covered or not.
General recommendations
1. Consider sealing of the cable entries, ducts, pipes etc trench to wall etc using fire
stop sealants /concrete from wall to wall, wall to floor and cable passage
between two sections are properly sealed to prevent spread of fire or
percolation of rain/ storm /fire fighting water
2. Consider doing Thermography of cable joints and cables using infrared gun and
cable temperature are measured once in a year & records maintained
3. For the earthing resistance checks, it is suggested to display earth pit numbers on
the pit and record the date, reading and next due date of inspection on the earth pit
it self. All these suggestions from d to g apply to refinery area also.
4. Provide fire door to isolate boiler and turbine hall, however the same is kept in
open. Consider installation of a heavy door closure system so that the door is
normally in closed conditions.
5. It is recommended to have flameproof lighting at the battery room and all switches to
be changed to industrial type
6. For easy accountability of FEA (Fire Extinguishers Appliances), it is recommended to
form a codification/numbering system for the FEA and display those tags adjacent to
the FEAs. Also it is advisable that all FEA are mounted on wall or stand and not on the
floor, to avoid any accidental damage. Also identify the area below by yellow and red
lines for quick identification/accessibility during emergency. At some locations the
extinguishers are not easily approachable. It is recommended to keep the approach to
these extinguishers unhindered.
7. An Emergency action plan directing the workers to take the necessary action in case of
emergency should be prepare and displayed throughout the plant. This will enable the
workers to follow the instruction properly in case of any Emergency
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
43
Risk Report ,Budge Budge
8. Position of the deluge valves are very close to the transformers, baffle wall could
be provided for safeguard and if logistics permits the DV can be placed outside the
fencing
9. Hydrant system should be in conformity with fire protection manual. Reference can be
made through TAC web site www.tac.org
10. Ensure that regular stability test conducted for building structure
11. Display as erected hydrant drawing at salient places
12. Regular DGA analysis be carried out for transformers
13. Rubbishes /wastes of all kinds were thrown in the empty drums.cable trays. It should
be avoided
14. Regular and periodical maintenance system to be in place as recommended by OEM
15. Ensure proper history card for each and every equipments
16. Procure adequate spares for critical equipments
17. The plant on completion will have 8 units of TG Sets.If finantial condition permits a
spare rotor for turbine may be kept as stand by in addition to OEM recommendation of
critical spares
18. Crane should be checked periodically for its efficiency and safe working
19. Provide hooter system while handling heavy materials by cranes to caution the
employees working in material handling area
20. Housekeeping should be improved in and around entire PLANT
21. It is recommended to have flameproof lighting at the battery room and all switches to
be changed to industrial type
22. For easy accountability of FEA (Fire Extinguishers Appliances), it is recommended to
form a codification/numbering system for the FEA and display those tags adjacent to
the FEAs. Also it is advisable that all FEA are mounted on wall or stand and not on the
floor, to avoid any accidental damage. Also identify the area below by yellow and red
lines for quick identification/accessibility during emergency. At some locations the
extinguishers are not easily approachable. It is recommended to keep the approach to
these extinguishers unhindered.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
44
Risk Report ,Budge Budge
23. An Emergency action plan directing the workers to take the necessary action in case of
emergency should be prepare and displayed throughout the plant. This will enable the
workers to follow the instruction properly in case of any Emergency
NFPA 850 “Recommended Practice for Fire Protection for Electric Generating Plants”
5-7.4.2* Turbine-Generator Bearings.
5-7.4.2.1* Turbine generator bearings should be protected with a closed-head sprinkler
utilizing directional nozzles. Automatic actuation is more reliable than manual
action. Fire protection systems for turbine-generator bearings should be
designed for a density of 0.25 gpm/ft2 (10.2 mm/min) over the protected area.
5-7.4.2.2 Accidental water discharge on bearing points and hot turbine parts should be
considered. If necessary, these areas may be permitted to be protected by
shields and encasing insulation with metal covers.
5-7.4.2.3 If a manually operated water system is installed, consideration should be given
to a supplemental automatic gaseous fire extinguishing system.
5-7.4.2.4 If turbine-generator bearings are protected with a manually operated sprinkler
system, the following should be provided:
(a) Manual activation should be from the control room or a readily
accessible location not exposing the operator to the fire condition. Staffing of
plant should be sufficient to promptly handle this function as well as other
responsibilities during an emergency of this nature.
(b) Documented procedures should be in place with authorized approval
given to operators to activate the system if necessary in a fire condition.
(c) Periodic training should be given to operators regarding the need for
prompt operation of the system.
Following Codes to be followed in Fire Protection:
IS 2189 - Selection, Installation and Maintenance of Automatic Fire Detection and
Alarm System –
IS 2190 - Selection, Installation and Maintenance of First-aid Fire Extinguishers – Code
of Practice IS 3844 - Code of practice for installation and maintenance of internal fire
hydrants and hose reels on premises
IS 6382 - Code of Practice for Design and Installation of Fixed Carbon Dioxide Fire
Extinguishing System
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
45
Risk Report ,Budge Budge
Tariff Advisory Committee‟s Fire Protection Manual and Water Sprinkler System
Specifications
NFPA 12 – Carbon Dioxide Fire Extinguishing Systems
NFPA 1600 – Disaster Management
NFPA 921 – Fire & Explosion Investigation
Following Codes to be followed under Occupational Health and Safety:
IS 14489 – Code of Practice for Occupational Safety & Health Audit
NFPA – 101 Life Safety Code
Electrical Risk: IS 5572 – Hazardous Area Classification / Selection of Electrical
Equipment for Hazardous Areas
IS 2309/ NFPA 780/ BS 6651- Lighting Protection
NFPA 70 B – Recommended Practice for Electrical Equipment Maintenance
NFPA 70 E – Standard for Electrical Safety in Employee Work Places.
Risk Improvement Implementation
The risk engineer has attempted in identifying the hazards and bringing out loss prevention
best advices to mitigate them. The final conference was done with the plant management
team during which the risk improvement areas were discussed and the same has been
enumerated in this report.
A report of this type necessarily concentrates on the weak points and adverse conditions that
constitute a loss potential. The contents of the report, hence, should not be viewed as
implied criticism, but rather as support for the management. The corrective actions are
advised in order to eliminate or reduce the loss potential
In respect to the advice given in this report we would be glad to review your comments,
alternatives and action proposals or to provide further information if required. Implementation
of risk improvement suggestions will help to lower both the frequency and severity of losses
and minimize the possibility of costly business interruptions.
We would like to thank all those who contributed to this report, by helping during the survey,
providing information and co-operating in a very kind and open way. We certainly have
appreciated it and also the very kind hospitality throughout the visit.
This report is provided to you for informational purposes only to reduce the possibility of loss to property by bringing to your attention certain potential hazards or
conditions. You must make the decision whether to take any action. ICICI Lombard undertakes no duty to any party by providing this report or performing the activities on
which it is based.
Date of Inspection: 21 February 2012
46
Risk Report ,Budge Budge
Reference Information
Location Findings:
CESC,Budge Budge Generating Station
Fire, Natural Hazards Machinery
First Baseline Risk Evaluation
Visit by: V.Ramesh
Visit date: 21 st
February 2012