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    Case Study - Boiler Explosion

    Uploaded by

    Satish Chavan
    This document summarizes a case study submitted by Satish Chavhan on the boiler explosion that occurred at the Feroze Gandhi Unchahar Thermal Power Plant. It provides details on the installed capacity of the plant and commissioning dates of its 6 units. It then lists mistakes made leading up to the accident, such as bypassing the master fuel trip, excessive number of workers in the boiler area, and irregular maintenance practices. The consequences section notes that 46 people died and over 100 were injured in the explosion. The plant's 6th unit boiler license was subsequently cancelled due to irregularities found during the investigation.

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    Case Study - Boiler Explosion

    Uploaded by

    Satish Chavan
    195 views18 pages
    This document summarizes a case study submitted by Satish Chavhan on the boiler explosion that occurred at the Feroze Gandhi Unchahar Thermal Power Plant. It provides details on the installed capacity of the plant and commissioning dates of its 6 units. It then lists mistakes made leading up to the accident, such as bypassing the master fuel trip, excessive number of workers in the boiler area, and irregular maintenance practices. The consequences section notes that 46 people died and over 100 were injured in the explosion. The plant's 6th unit boiler license was subsequently cancelled due to irregularities found during the investigation.

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    This document summarizes a case study submitted by Satish Chavhan on the boiler explosion that occurred at the Feroze Gandhi Unchahar Thermal Power Plant. It provides details on the installed capacity of the plant and commissioning dates of its 6 units. It then lists mistakes made leading up to the accident, such as bypassing the master fuel trip, excessive number of workers in the boiler area, and irregular maintenance practices. The consequences section notes that 46 people died and over 100 were injured in the explosion. The plant's 6th unit boiler license was subsequently cancelled due to irregularities found during the investigation.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    195 views18 pages

    Case Study - Boiler Explosion

    Uploaded by

    Satish Chavan
    This document summarizes a case study submitted by Satish Chavhan on the boiler explosion that occurred at the Feroze Gandhi Unchahar Thermal Power Plant. It provides details on the installed capacity of the plant and commissioning dates of its 6 units. It then lists mistakes made leading up to the accident, such as bypassing the master fuel trip, excessive number of workers in the boiler area, and irregular maintenance practices. The consequences section notes that 46 people died and over 100 were injured in the explosion. The plant's 6th unit boiler license was subsequently cancelled due to irregularities found during the investigation.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 18

    Case Study

    on
    NTPC, Unchahar Boiler Explosion
    By
    Satish Chavhan

    Submitted to
    Prof. Pavan Totla

    National Institute of Construction Management &


    Research, Pune
    PGP PEM(2018-20)
    Feroze Gandhi Unchahar Thermal Power Plant

    • Installed capacity- 1,550 MW.


    • Units Commissioned
    Unit I : 210 MW Nov 1988
    Unit II : 210 MW Mar 1989
    Unit III : 210 MW Jan 1999
    Unit IV : 210 MW Oct 1999
    Unit V : 210 MW Sep 2006
    Unit VI : 500 MW Mar 2017(COD-September 30, 2017)
    MSP

    SEPARATOR

    ROOF TUBE
    I/L Header

    SEPARATOR
    FRH
    DRAIN TANK SH DIV FSH
    Panel

    LP-BP
    LTSH
    LTRH

    HP-BP
    ECO
    VERTICAL WATER WALL

    G LTRH I/L Header


    ECO I/L Header
    LPT LPT IPT HPT

    CRP

    CONDENSER
    BRCP

    A B C
    CEP
    DEAERATOR
    GSC
    A B
    BFBP

    A B
    MD-BFP
    TD-BFP

    l
    WW LOWER Header HP BFWP
    FUEL FEEDING
    MASTER FUEL TRIP(MFT)
    If any of the predetermined master fuel trip condition occurs a master fuel
    trip is initiated. The first out cause of trip indication is displayed and
    alarmed. Conditions of a master fuel trip are:
    • All FD Fans off
    • All ID Fans off
    • Boiler air flow low for 3 secs
    • Loss of all fuel
    • Loss of all flame
    • Furnace pressure very high/Low
    • Drum level very high/low
    • Critical Flameout
    • Delayed light-up
    • Re-heater protection operated
    On 1st November 2017 plant was running at 500MW
    Ash evacuation from bottom ash hopper stopped
    • Ash level increased in furnace more than 25m

    • NTPC has started cutting their load to 200MW


    from 500MW
    • More then 30 workers started
    Poking in 8 manholes (4 Hoppers)
    • At the same time Higher
    official bypassed MFT
    Water
    Wall
    Leakage

    Due to the heavy steam leakage pressure


    Started increasing.
    • Due to sudden opening at corner no-2
    flue gases and steam came out
    • Unburnt coal flew to second pass and
    started burning near economiser
    MISTAKES
     Instead of taking shut down, operation department continued
    to run the unit with reduced load.
     Consent from higher officials for Master Fuel Trip
    (MFT)Bypass
     6th Unit was continuously running more than 1000Hr, which
    was against CEA guidelines)
     Boiler erection was completed in 30 month of record break
    time.
     During running condition max 6 people required in boiler
    area. (Chairman, All India Power Engineers Federation). But
    more than 300 people were working at the time of accident.
     Ash level indicator was not installed in bottom ash hopper.
    Continued…
     Double poking should be done after taking boiler shut
    down.
     Workers working in boiler area did not have safety mask.
     There was no early warning alarm in boiler area.
     COD was done without cleaning scrap, insulation work
    and painting, and same has been carried out in running
    unit.
     The fire hydrant line and the detection system failed to
    respond.
     Irregular soot blowing.
     Use of low grade coal.
    COMMITTEE REPORT
    CONSEQUENCES
     46 People died, more than 100 people injured, many contract workers are still missing.
     6th Unit boiler licence has been cancelled on 14th Nov 2017 due to irregularities in plant
    Report by Delhi Solidarity Group
    Questions on MOP and NTPC Management
    Thank You

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