RPCL

Chapter 4
Health, Safety, Hazards and Risks in the Industry

4.1 Types of Hazards

There are three main types of hazards will be explored.
1. Electrical Hazards.
2. Mechanical Hazards.
3. Chemical Hazards.

1. Electrical Hazards

At the RPCL 150 MW Power Plant, electrical systems operate at medium to high voltages, often in the range of
11 kV to 132 kV or more. These systems include generators, transformers, circuit breakers, switchgear, and
control panels all of which carry the risk of serious injury if not properly managed.

Common electrical hazards at the plant include:

● Electric Shock – Occurs when a person comes into direct contact with a live electrical component or
wire.

● Arc Flash – A sudden release of electrical energy through the air due to a fault, which can result in
intense heat, light, and pressure.

● Short Circuits – When unintended connections allow current to flow through an unsafe path , possibly
leading to fire or system failure.

● Equipment Failure – Old or poorly maintained electrical systems can fail, causing sparks, explosions,
or shutdowns.

Figure: Arc Flash and Electric Shock

Related Example:

During our visit, the safety officer shared a real incident from a few years ago:

An operator was performing a routine inspection near a 33 kV switchgear panel. Due to an

unnoticed loose connection and high humidity inside the room, an arc flash occurred when the
panel door was opened. The sudden discharge caused severe burns on the operator's arms, and part
of the panel was damaged by the heat. Fortunately, the operator was wearing basic PPE, which
prevented life-threatening injuries. After the incident, additional safety barriers, insulation
improvements, and infrared thermographic inspections were implemented to avoid recurrence.

2. Mechanical Hazards:
The RPCL 150 MW Power Plant uses numerous heavy rotating and moving machines such as turbines, pumps,
compressors, motors, cooling fans, and valve actuators. These machines are essential to power generation but
pose significant mechanical hazards if not properly handled or maintained.
 Figure: Mechanical Hazards

Common mechanical hazards at the plant include:

● Entanglement – Occurs when loose clothing, gloves, or body parts get caught in rotating equipment.

● Crushing Injuries – Can happen when working near moving pistons, valves, or heavy machinery.

● Shearing/Cutting Hazards – Exposed blades or moving parts can cause severe lacerations or
amputations.

● Impact Injuries – Tools or parts may fall or be ejected at high speed during mechanical failure.

Chemical Hazards:
The RPCL 150 MW Power Plant utilises various chemicals for its day-to-day operations, especially in areas like
fuel handling, water treatment, lubrication, and cleaning. While these substances are essential for the plant's
functionality, they also pose significant chemical hazards if not stored, handled, or disposed of properly.

Common chemical hazards at the plant include:

● Toxic Exposure – Chemicals like acids, alkalis, or ammonia used in water treatment can be harmful if
inhaled or absorbed through the skin.

● Corrosive Burns – Strong acids and bases can cause severe skin or eye injuries on direct contact.

● Flammable Vapours – Fuels like diesel or lubricants can release vapors that pose fire or explosion
risks.

● Respiratory Issues – Inhalation of fumes from cleaning agents or fuel additives can lead to lung
irritation or long-term health issues.

● Environmental Hazards – Improper disposal of chemical waste can contaminate water or soil,
affecting the surrounding environment.

Figure : Chemical hazards

4.2 Safety Measures and Protocols Followed

At the RPCL 150 MW Power Plant, ensuring the health and safety of all personnel is a top priority. The plant
follows strict safety protocols in line with national and international standards to minimize risks in high-hazard
environments such as power generation. Two key areas we observed during our visit were the use of personal
protective equipment (PPE) and the implementation of emergency plans and drills.

Personal Protective Equipment (PPE):

All employees and visitors at RPCL are required to wear appropriate PPE depending on their work area and
role. The following PPE are commonly used at the plant:

● Safety Helmets—Protect against head injuries from falling objects or accidental contact in mechanical
zones.

● Insulated Safety Gloves—Used by electrical maintenance workers to protect against electric shock.
● Safety Goggles/Face Shields—Protect eyes from chemical splashes, dust, or sparks.
● Ear Protection (Earplugs/Earmuffs)—Required in high-noise areas, especially near turbines and
generators.
● Flame-Resistant Clothing—Worn by workers near boilers, turbines, and other high-temperature zones
to prevent burn injuries.
● Chemical-Resistant Aprons and Gloves—Used in water treatment and chemical handling sections.
● Steel-Toed Boots—Protect feet from heavy objects, sharp debris, and electrical hazards.
● High-Visibility Jackets—Help improve visibility in outdoor or dimly lit areas, especially for night
shifts or during outages.

Figure: Personal Protective Equipment (PPE)

Emergency Plans and Drills

RPCL 150 MW Power Plant maintains strong emergency preparedness to handle incidents like fires, gas leaks,
electrical faults, and chemical spills. The plant is equipped with emergency shutdown systems, fire detectors,
extinguishers (CO₂, foam, dry powder), and clearly marked evacuation routes with assembly points.

First aid kits are available throughout the facility, and some staff are trained in CPR and basic medical response.
Regular emergency drills, such as fire and evacuation exercises, are conducted to ensure all employees can
respond quickly and effectively. During our visit, we observed a fire drill where workers safely evacuated the
turbine hall and assembled at the designated point within minutes.
 Figure : Fire fighting Room

4.3 Training and Preparedness

At RPCL 150 MW Power Plant, staff are regularly trained to identify, manage, and mitigate workplace risks.
New employees undergo a 6 month of training with safety orientation before starting work, which includes
training on PPE use, emergency procedures, and hazard identification.

Regular refresher courses and on-site drills are conducted to keep all staff updated on the latest safety protocols.
Specialised training is also provided for handling high-voltage equipment, hazardous chemicals, and emergency
shutdown procedures. Safety posters and signs throughout the plant reinforce key instructions.

This continuous training ensures that all workers remain alert, prepared, and capable of responding effectively
to any potential risks.

4.4 Incident Reporting System

RPCL follows a structured incident reporting system to ensure all accidents, near misses, and safety violations
are properly documented and addressed. If any incident occurs, employees are required to immediately report it
to their supervisor and plant engineer.

A detailed accident log is maintained, which includes the time, location, cause, and people involved. After
logging, a root cause analysis is carried out to identify what went wrong and how it can be prevented in the
future. Based on this analysis, the management updates safety protocols and provides corrective training if
necessary.

This system promotes a transparent safety culture and helps reduce the chances of repeated accidents by
learning from every incident.

Chapter 5
Conclusion and Lifelong Learning

5.1 Summary of Learning

The industrial training program at RPCL 150 MW Power Plant, Gazipur, provided us with a practical and in-
depth understanding of power plant operations and real-world engineering challenges. Throughout the training
period, we had the opportunity to observe the complete process of electricity generation — from fuel supply and
combustion to turbine operation, power transmission, and load balancing.We witnessed how theoretical subjects
like power systems, electrical machines, and control systems are implemented in actual industrial settings. The
training sessions included exposure to different departments such as control room operations, mechanical
maintenance, and electrical protection systems. Moreover, we gained knowledge about safety measures, hazard
mitigation, emergency handling procedures, and the use of modern monitoring tools like SCADA. This
experience significantly enriched our technical skills and introduced us to industry-level professionalism and
discipline.

5.2 Long-Term Impact on Academic Knowledge

The impact of this training goes beyond temporary exposure; it has created a strong foundation for our future
academic and research activities. Concepts that were once confined to textbooks and lectures became much
more understandable and memorable through direct observation and practical demonstration.

For instance, seeing the function of a generator’s excitation system, the operation of high-voltage circuit
breakers, or the role of synchronisation in load sharing gave us a clearer picture of their importance in
maintaining grid stability. These insights will not only improve our grasp of core engineering subjects but also
enhance our performance in project work, labs, and final-year thesis research.

Furthermore, the training sparked curiosity about advanced topics such as power plant automation, energy
efficiency, renewable integration, and predictive maintenance. This will support long-term learning and
possibly inspire postgraduate studies or specialised research in energy systems, smart grids, or electrical
protection.

5.3 Real-World Relevance

This industrial training significantly deepened our understanding of how engineering principles are applied in
real-world scenarios. It provided us with valuable insight into the operational environment of a thermal power
plant and the roles engineers play in ensuring efficient, safe, and uninterrupted power delivery.

We learned about the importance of time management, precision in execution, teamwork among various
departments, and the critical nature of documentation and reporting. Observing how engineers and technicians
tackle technical issues, follow standard operating procedures, and adhere to safety protocols gave us a realistic
idea of the professional standards expected in the power sector.

Additionally, the visit exposed us to the challenges of maintaining a power plant under fluctuating demand, fuel
variation, and unexpected faults. This perspective gave us a deeper appreciation for power system reliability,
preventive maintenance practices, and system redundancy planning — topics often discussed theoretically in
academic contexts.

5.4 Lifelong Learning Perspective

One of the most valuable takeaways from the training was the realization that engineering is a continuously
evolving field. The professionals we interacted with emphasized the need for continuous learning, staying up-
to-date with emerging technologies, and developing both technical and soft skills to stay relevant in the
industry.

This experience has motivated us to take charge of our own learning journey. Whether it's through online
platforms, certifications in areas like PLC, SCADA, or industrial safety, or staying informed about sustainable
energy trends, we now understand the importance of lifelong learning in achieving personal growth and
professional excellence.

The training also encouraged us to adopt a mindset of self-reflection and improvement. We saw how
experienced engineers continued to engage in training, attend seminars, and adapt to new systems. Their
commitment to professional development inspired us to follow a similar path, recognizing that success in
engineering is not just about academic results, but about continuous adaptability and innovation.

5.5 Conclusions
In conclusion, the industrial training at RPCL 150 MW Power Plant was an immensely beneficial and eye-
opening experience. It served as a crucial bridge between academic theory and practical implementation. We
not only enhanced our technical knowledge and industrial awareness but also developed a more mature
understanding of safety, teamwork, and ethical responsibility in engineering practice.

This training gave us the confidence to work in industrial environments and the motivation to pursue further
knowledge. It prepared us for future internships, final-year projects, and eventual employment in the power and
energy sector. Most importantly, it instilled in us the importance of being proactive learners and responsible
engineers who contribute positively to society and the profession.

Desco
Chapter 4
Health, Safety, Hazards and Risks in the Industry

4.1 Types of Hazards

As a power distribution company, DESCO operates and maintains high- and medium-voltage electrical
infrastructure such as distribution substations, transformers, poles, underground cables, and smart metering
systems. Due to the nature of its work, the company faces several types of hazards in the field and operational
environments.

1. Electrical Hazards
DESCO’s operations involve working with medium-voltage distribution systems (typically 11 kV, 33 kV),
which include substations, distribution transformers, underground cables, and overhead lines. These systems
pose serious risks if safety protocols are not strictly followed.

Common electrical hazards at DESCO include:

● Electric Shock – Occurs when personnel come into direct contact with live wires or energized
equipment during fault detection, maintenance, or installation.

● Arc Flash – A dangerous release of electrical energy that can occur during switching operations or due
to insulation failure. It produces intense heat and light that can cause severe burns or blindness.

● Short Circuits – Caused by damaged insulation or poor connections, which can lead to sudden faults,
fires, or explosions.

● Equipment Failure – Ageing infrastructure or improper maintenance can lead to failure of breakers,
cables, or switchgear, increasing the risk of injury or fire.

Figure: Electrical Hazard Sign

2. Mechanical Hazards
While DESCO does not operate heavy machinery like a power plant, field teams work with tools such as cable
cutters, crimping machines, pole climbing gear, and portable generators. Improper handling of these tools can
result in injuries.

Common mechanical hazards include:

● Entanglement – Clothing or body parts caught in portable cable-pulling machines or winches.

● Impact Injuries – Tools or hardware falling during pole or panel work.
● Cuts and Lacerations – Caused by sharp conductors, splicing tools, or metal enclosures.
● Muscle Strain – Due to lifting heavy cables, climbing poles, or awkward working positions in confined
spaces.

3. Chemical Hazards
DESCO deals with a few chemicals during operations, primarily:

● Transformer Oil – Used in distribution transformers. Leakage or spillage can lead to skin burns,
inhalation of fumes, or slip hazards.

● Battery Acid – Found in backup power systems and substations. Can cause corrosive burns or
environmental damage if not handled properly.

● Cleaning Agents – Used in switchgear rooms or substations, may cause respiratory irritation if not
ventilated.

Common chemical hazards include:

 ● Toxic Exposure – From inhalation of fumes during battery maintenance
● Corrosive Burns – Due to accidental contact with acid or oil.
● Environmental Contamination – Improper disposal of oil or acid can lead to soil or water pollution.

Figure: chemical hazard

4.2 Safety Measures and Protocols Followed

Personal Protective Equipment (PPE)

DESCO ensures that all field technicians and engineers are equipped with the required PPE according to their
job roles. Regular audits are conducted to ensure proper use.

Common PPE at DESCO includes:

Insulated Gloves and Boots – For live-line work and underground cable handling.
Safety Helmets – To protect against falling objects, especially when working at height.
Safety Goggles and Face Shields – During transformer oil handling or cutting operations.
Flame-Resistant Clothing – Used for live electrical operations.
Fall Protection Gear (Harnesses) – For pole and rooftop work.
High-Visibility Vests – Especially during roadside work to ensure visibility.
Steel-Toed Boots – To prevent foot injuries from falling tools or hardware.

Emergency Plans and Drills

DESCO maintains strict emergency response protocols to minimize damage and ensure worker safety in case of
an incident.

● Emergency Shutdown Procedures – For de-energising faulty lines or equipment.

● Fire Safety – Fire extinguishers (CO₂ and dry powder) are installed in substations and service centers.

● Evacuation Plans – Clearly marked in control rooms and office buildings.

● First Aid Stations – Located in every zone office, with trained staff on duty.

● Emergency Drills – Conducted periodically, such as fire simulations or electrical accident responses,
to prepare workers for real incidents.

Figure: First Aid box ,Desco

4.3 Training and Preparedness
DESCO places strong emphasis on safety training and continuous learning to reduce operational risks.

● New Employee Orientation – Covers electrical safety, PPE usage, LOTO procedure, and emergency
protocols.

● Regular Refresher Training – Includes live-line maintenance safety, CPR, fire handling, and safe
ladder/pole climbing.

● Toolbox Talks – Conducted daily before starting field work, to discuss task-specific hazards and
precautions.

● Mock Drills – Held periodically for emergency evacuation, electrical rescue, and transformer failure
scenarios.

● Safety Posters and Digital Alerts – Displayed in control rooms and sent via internal messaging to
reinforce awareness.

This ongoing training ensures that DESCO employees are equipped to handle both routine and emergency tasks
safely and professionally.

4.4 Incident Reporting System

DESCO follows a transparent and structured incident reporting mechanism to improve accountability and
prevent repeat occurrences.

● Immediate Reporting – Employees must notify supervisors of any accidents, injuries, or near misses.

● Accident Logbook – Maintains detailed records of each incident, including cause, location, people
involved, and equipment status.

● Root Cause Analysis – Carried out by the safety department to identify contributing factors and
recommend corrective actions.

● Corrective Measures – May include additional training, PPE upgrades, or procedural changes.

● Feedback Loop – Findings from incidents are shared across teams to create awareness and improve
practices.

5.1 Summary of Learning

The industrial training program at DESCO (Dhaka Electric Supply Company Limited) provided us with an in-
depth understanding of the technical and operational aspects of power distribution systems. As a distribution
utility, DESCO is responsible for delivering electricity from the grid to end users, and this visit allowed us to
observe its functions from multiple perspectives.

We learned about grid operation and protection, including how distribution feeders are controlled, monitored,
and protected through devices like relays, reclosers, and circuit breakers. In the system operation unit, we
observed the SCADA (Supervisory Control and Data Acquisition) system used for real-time monitoring of the
network.

In the substation maintenance section, we witnessed periodic inspection, oil testing in transformers, earthing
system checks, and thermographic scanning used to identify hotspot issues. We also saw how fault isolation and
backfeeding techniques are used to restore power efficiently during an outage.

Additionally, the commercial operations department gave us insight into the billing system, smart meter data
management, load analysis, and customer complaint handling. This helped us understand the financial and
customer service responsibilities tied to technical performance.

Overall, the training enriched our knowledge in both the technical and managerial aspects of power distribution
and helped us appreciate the coordinated efforts involved in maintaining system reliability and customer
satisfaction.
5.2 Long-Term Impact on Academic Knowledge
The training had a profound impact on our academic perspective. The theoretical concepts we learned in power
systems, electrical machines, and protection systems became much clearer through real-time observation.

Understanding how protective relays work in the field, how load is balanced across feeders, and how
substations are maintained reinforced core engineering principles. Observing practical use of load break
switches, CT/PT transformers, and GIS mapping improved our retention of related coursework.

We also became familiar with energy audit techniques, power loss minimization strategies, and feeder-wise
demand analysis — all of which are highly relevant for research and future final-year projects. The exposure to
smart grid integration and data-driven decision-making sparked our interest in areas such as distribution
automation, demand forecasting, and advanced metering infrastructure (AMI), all of which have strong
academic and research potential.

5.3 Real-World Relevance

Our visit to DESCO revealed how theoretical knowledge is applied to real-world power distribution challenges.
We saw how engineers handle system protection, manage network reconfiguration during faults, and ensure
stable voltage levels across substations.

In system operation, we observed how SCADA systems are used to remotely monitor feeder loads, voltage
drops, and outage durations, enabling quick response. In the field, we saw how linemen conduct live
maintenance, identify fault zones, and apply personal and system-level protective measures to avoid accidents.

In the commercial section, we learned how energy metering, revenue collection, and complaint redressal are
tied directly to technical performance and customer reliability. This highlighted how engineering decisions must
align with economic and service-level objectives.

The visit showed us how crucial coordination is between control room engineers, field technicians, and
commercial teams. It also gave us an appreciation of the importance of time-bound response, efficient
documentation, and digital integration in managing modern distribution systems.

5.4 Lifelong Learning Perspective

The training underscored that electrical engineering, especially in power systems, is a dynamic field that
constantly evolves with technology and policy changes. Engineers at DESCO emphasized the need to
continually upgrade technical knowledge, especially in areas like smart grid infrastructure, energy management
systems (EMS), and distribution automation.

Witnessing professionals working with real-time monitoring tools, remote-controlled breakers, and advanced
fault analysis software inspired us to pursue lifelong learning through certifications, technical workshops, and
online training in SCADA, PLC, and GIS technologies.

This experience also highlighted the value of soft skills such as communication, teamwork, and critical thinking
all of which are vital for effective engineering practice. We now understand that to be successful professionals,
we must be adaptable, open to learning, and proactive in following industry trends and technological
advancements.

5.5 Conclusions
In conclusion, the industrial training at DESCO was a transformative learning experience. It provided hands-on
exposure to the technical, operational, and commercial sides of the power distribution sector. It not only helped
us apply theoretical knowledge in a practical setting but also gave us a deeper understanding of the role of
engineers in ensuring efficient, safe, and reliable electricity delivery.

We developed a better understanding of grid protection, system reliability, substation health, and consumer
services, which will aid us in our academic, research, and career development. The training also strengthened
our safety awareness, teamwork skills, and ethical perspective.

This experience has equipped us with both the knowledge and the motivation to contribute to the power and
energy sector as capable, responsible, and forward-thinking engineers.
Complex Engineering Problem : Desco

Complex Engineering Problem

Problem: Accidental Backfeeding During Fault Isolation in Ring Main Systems

In DESCO’s urban power distribution network, Ring Main Units (RMUs) and interconnected feeders are widely
used to ensure redundancy and improve supply reliability. During fault conditions, alternate power paths are
activated to maintain supply to critical zone s. However, this creates a potential for accidental backfeeding
if isolation is not executed properly.

Backfeeding occurs when a supposedly de-energized line receives unintended voltage from another live source
through a ring connection. If field staff begin maintenance on such a feeder without full isolation, it can lead
to:

● Electric shock or electrocution

● Arc flash injuries

● System instability or equipment failure
● Legal and ethical violations of safety protocols

Problem Evaluation (Based on Standard Engineering Complexity Criteria)

Criteria Assessment

1.Ability/Knowledge Required Requires multi-disciplinary knowledge in power system protection,

to Resolve the Problem SCADA operation, safety standards, and field operation protocols.
Understanding of live-line safety, switchgear behavior, and
coordination logic is essential.

2. Range of conflicting Tension exists between the need for continuous power supply and
required absolute safety. Field teams seek minimal outages for consumers,
while safety regulations require full de-energization. Operations and
safety departments may have differing priorities.

3. Depth of Analysis Required Requires feeder topology mapping, fault current path analysis, real-
time SCADA data correlation, and risk simulation. Must evaluate
multiple isolation points and path dependencies.

4. Extent of Applicable Codes Must comply with: BNBC Electrical Safety Guidelines
ILO & ISO 45001 (Occupational Health and Safety)

Proposed Engineering Solution: Integrated Feeder Isolation Verification & Safety Authorization System

1. SCADA-Based Double Confirmation Mechanism

● Require dual-operator confirmation (control room + field supervisor) via SCADA before maintenance
starts.
 ● Integrate real-time verification of switch status using feeder current and voltage monitoring.

● No work order to be issued until system confirms feeder is de-energized at all possible feed points.

2. Live Feeder Status Display in the Field

● Install LED-based “LIVE/ISOLATED” indicator panels at critical field locations and substations.

● Indicators to be fed from SCADA’s real-time status to visually confirm safe status before physical work.

3. Personal Digital Lockout-Tagout (e-LOTO) Authorization

● Field technicians scan an RFID badge to register their presence at the worksite.

● The system verifies feeder de-energization before allowing equipment access.

● Creates an audit trail of who is authorized and when isolation was confirmed.

4. Backfeed Path Simulation Module in SCADA

● Implement a logic engine in SCADA that simulates alternate power paths during switching.

● If any path provides unintended energization, the system prevents isolation command execution.

5. Specialized Training for Rare Events

● Conduct scenario-based training for accidental backfeeding events.

● Include visual simulations, protective equipment failure cases, and SCADA override training.

● Reinforce checklists and field coordination protocols between control room and maintenance teams.

6. Digital Incident Logging and Accountability

● If an incident occurs, the system logs switch states, time stamps, and personnel ID.

● Provides a digital record for root cause analysis, stakeholder review, and corrective action.

Expected Outcomes

● Zero tolerance for live maintenance errors

● Enhanced coordination between field teams and control room

● Reduced risk of electrocution and system failure

● Traceable accountability and digital logs

● Compliance with national and international electrical safety codes