CASE STUDY OF MAJOR FIRE INCIDENT THAT TOOK PLACE AT
CISF UNIT PPCL BAWANA NEW DELHI ON 24.03.2015
OBJECTIVE:
To analyze the cause, shortcoming, consequence and remedial measures
to prevent reoccurrence of such incidents.
ABSTRACT:
An explosion took place and followed by huge flames in gas turbine
generator transformer #3 of module-II. Message received at fire control room given
by HC/GD V.S. Bartwal who was on duty at DG set (near GT.03). Fire wing
personnel took 01.30 hours hectic and laborious work in dousing the major fire
without causing any causality either to CISF personnel, employees or any other
agencies. Loss of property due to fire in amount is Rs. 8,80,18310/- (Eight Crore
Eighty Lakh Eighteen Thousand Three hundred Ten Rupees only)
INTRODUCTION:
Pragati Power Corporation Limited PPCL Bawana is located in the
North West District of New Delhi. Pragati Power Corporation Limited is Public
Sector Enterprise under the Ministry of Power, Government of NCT, and Delhi
which generates power exclusively for the Delhi State. The site is located at Sector-
V, State Industrial Development Corporation Industrial Area, Bawana, in Delhi,
adjacent to the 400 K.V Sub- Station of Delhi Transco Ltd. The site is well
connected through ring road to all the national highways passing through Delhi.
The Plant is situated at about 40 kms from New Delhi Railway Station and 70 kms.
from IGI Airport New Delhi. This site is very vulnerable as security point of view
and also sensitive as it is near 400 KV Sub-Station of Delhi Transco Ltd. The
projects area is about 97 Acres and total generation capacity will be 1500 MW. i.e.
250 MW X 4UNITS= 1000 MWs gas based Plant and 250 MWs X 2 UNIT=500
MWs i.e. steam Generation Plant. The total expenditure for the project is estimated
to be Rs. 5000 Crores.
BRIEF NOTE ON FIRE SUBMITTED BY GENERAL MANAGER (PROJECT)
GT#3 along with STG #2 was running on 220 MW and 108 MW
respectively. Today i.e. 24.3.15 at about 04.47 hrs .the machine tripped on
transformer differential and overall differential protection and simultaneously an
explosion was also heard by the control room staff. Operation staff on duty
immediately rushed to the site and found that the Generator Transformer had
exploded and was in flames. By that time CISF fire wing had also came into action
and both the fire tenders and additional fire hydrant hoses were pressed into action
to douse the flames. AFF foam was also used to blanket the flames and by 06.00 hrs
the fire was brought under control.
From the preliminary examination and visual inspection, prima facie it is case of
total damage to the transformer along with part of the bus duct, surge arresters, over
hanging strings, bushings and the part of the piping of the emulsifier system got
bent because of the intense heat.
The brief history of the Transformer is as under:
Date of first charging : 19.06.2012
Date of base load : 27.06.2012
Date of commercial Operation : 28.10.2013
The gas turbine no.3 was in continuous operation since 24.01.2015 and has
clocked almost 178605 fired hours. This transformer is covered under IAR policy
taken for the entire plant under M/S Oriental insurance company.
INCIDENT DESCRIPTION:
on 24.03.2015 at about 04:45 Hrs a major fire occurred/ broke out in the
Transformer of Gas Turbine-III of the PPCL-III Bawana plant. Immediately the
massage was passed to fire control room by the on duty CISF personnel (HC/GD
V . S. Bartwal) and the Ist Turn Out along with fire crew headed by SI/Fire Deva
Ram and Second Turn Out along- with crew headed by ASI/Fire Amar chand
reached at the spot and started extinguishing the fire. The message was also
passed to Dy. Commandant & Asstt. Commandant , who directed Insp/Fire and
Insp/Plant to mobilize the manpower so that the fire is controlled and extinguished.
Accordingly, off duty personnel were mobilized and Asstt. Commandant/Fire,
Inspector/Plant and Inspector/Fire along with the mobilized group consisting of
SOs-19 & Ors- 64 reached at the spot at about 04:52 hours. Asstt.
Commandant/Fire took control of the Fire Fighting Operation and the mobilized
personnel assisted the fire crew in the fire fighting process. In the mean time Dy.
Commandant reached at the spot at about 05:25 hours took charge of the Fire
Fighting operation. Being major fire the message was also passed to Delhi fire
Service, Sector-IV, Bawana and their fire fighting crew along with two tenders
reached at the spot at about 05:28 hours and helped in controlling/extinguishing the
fire. The message was also passed Director/Technical, GM, AGM and other
management officials and they also reached at the spot and shared their
advice/suggestion with undersigned in a better way to control/extinguish the fire.
Local Delhi police was also informed and accordingly police personnel also arrived
at the spot and remained at the spot till the fire controlled. MD IPGCL/PPCL also
visited the spot and issued necessary instructions to management officials. . In the
fire fighting operation 2200 litre AFFF (FOAM) , 96 Nos. Delivery Hoses were
instantly used, and because of that major flame and surrounding fire was controlled
in about One and Half hours and total control over fire in 04 hours. The surrounding
vital installations like DG Set, Auxiliary Transformer, Generating Transformer,
hydrogen room etc. (estimated property of worth Rs.70 Crores) were also saved by
that instant action. Since, the fog/smoke is coming out due to smoldering of
insulating material and cooling process is continuing, so that the transformer’s
temperature does not arise. No injury/casualty reported during the fire incident. The
undersigned held a meeting with the GM on the issue and he told that because of
the fire about 10 to 12 crores loss might have occurred to the plant. Earlier major
fire incident report sent to higher formation vide letter no 83 dated 25/03/2015 in
that report preliminary loss told by senior management official approx. 25 to 30
crores. The Total Loss is the actual cost of the equipments and appliances which is
8,80,18,310 Rupees (Eight Crore Eighty Lakh Eighteen Thousand Three hundred
Ten Rupees only). The same equipment is replaced by the BHEL because the items
are under warranty/Guarantee.
CHRONOLOGY OF THE FIRE INCIDENT:
1. Fixed fire detection or fire protection system(sprinkler system) provided to the
Generator Transformer had not started automatically at the time of outbreak of
fire because of explosion took place so that sprinkler system ruptured
2. It is suspected that the internal fault of Generator Transformer leads to blast and
followed by fire with huge flames developed into a major fire and engulfed in
surrounding area of Generator Transformer.
INJURY/CAUSALITY TO PERSON:
No injury/causality reported due to fire.
SEQUENCE OF FIRE FIGHTING:
1. On 24.03.2015 at around 04.45 Head Constable/GD V.S. Bartwal who was
present at D.G. Set informed at fire control room over Walkie-Talkie that fire
broke out at Generating Transformer of Gas Turbine-iii
2. At about 04.45/20 Fire tender along with crew headed by S.I./Fire Devaram
rushed to fire spot and reached 04.47hrs .Second Turn out along with crew
headed by A.S.I./Fire Amar chand also reached at spot on same time because
of message heard over Walkie-Talkie by second Turn out which was parked as
a stand by inside the plant between Module-1 and Module-2.
3. At fire spot crew observed huge flame coming from generator transformer and
in surrounding area of GT-03.
4. Assured cut of line electric supply from plant control room through mobile
shift I/C instructed crew personnel to start fire fighting with both fire tender
and to connect the fire tender with nearest landing valve. Crew immediately
started fire fighting operation with foam.
5. At about 04.52hrs Asstt. Comdt. / Fire and inspector/fire reached at fire spot
and after few minutes extra man power (off duty personnel) from unit line and
residence also reached at fire spot.
6. Extra delivery hose and foam transported at fire spot from store of fire
station .In the meantime two fire tender of Delhi fire service also reached at
spot
7. At about 05.25 Dy. Comdt. Also reached at Fire spot. Fire personnel took
01.30 hrs. Hectic and laborious work to control huge flames of transformer and
surrounding area flame controlled at about 06.15 hrs .
8. Fire personnel took another 04 hrs to extinguish the fire after control the huge
flames .The sincere and dedicated action of fire personnel continuously for
about 04 hrs enable to control the major fire at around 08.45 fire extinguisher
and cooling process going on by fire wing personnel. At around 07.30 hrs
management officials reached at spot and appreciated the fire fighting work.
9. Cooling process with water completed on dated 27.03.15 at about 16.00 hrs.
Cooling process took about 80 hrs .
PREVENTIVE MEASURES:
a) Electrical cables, Electrical equipments and circuit breakers etc should be
periodically checked /tested by the competent person.
b) Standardize and qualitative electric material should be used.
c) Good housekeeping should be maintained to avoid spread of fire.
d) Fixed fire detection and protection system should be reliable and checked at
regularly.
e) Internal safety device of transformer completely failed at one stage transformer
should automatically trip before explosion it should be checked.
CONCLUSION:
The fire incident might be taken place due to failure of the internal safety
device of transformer. At certain temp. it should be auto trip but auto system failed
and also no any type of warning indicated at plant control room and the transformer
sudden exploded. It could have been averted if the safety device timely checked by
the responsible personnel. Even after this the fire crew assisted by security
personnel were pressed into action, with due care of their safety and security of the
life engaged in fire fighting continuously for a period of 04 hours and controlled
the MAJOR FIRE.
DEPUTY COMMANDANT
CISF UNIT PPCL BAWANA
INCIDENT DESCRIPTION:
on 24.03.2015 at about 04:45 Hrs a major fire occurred/ broke out in the
Transformer of Gas Turbine-III of the PPCL-III Bawana plant. Immediately the
massage was passed to fire control room by the on duty CISF personnel (HC/GD
V . S. Bartwal) and the Ist Turn Out alolng with fire crew headed by SI/Fire Deva
Ram and Second Turn Out along- with crew headed by ASI/Fire Amar chand
reached at the spot and started extinguishing the fire. The message was also
passed to Dy.Commandant & Asstt. Commandant , who directed Insp/Fire and
Insp/Plant to mobilise the manpower so that the fire is controlled and extinguished.
Accordingly, off duty personnel were mobilised and Asstt. Commandant/Fire,
Inspector/Plant and Inspector/Fire along with the mobilised group consisting of
SOs-19 & Ors- 64 reached at the spot at about 04:52 hours. Asstt.
Commandant/Fire took control of the Fire Fighting Operation and the mobilised
personnel assisted the fire crew in the fire fighting process. In the mean time
Dy.Commandant reached at the spot at about 05:25 hours took charge of the Fire
Fighting operation. Being major fire the message was also passed to Delhi fire
Service, Sector-IV, Bawana and their fire fighting crew along with two tenders
reached at the spot at about 05:28 hours and helped in controlling/extinguishing the
fire. The message was also passed Director/Technical, GM, AGM and other
management officials and they also reached at the spot and shared their
advice/suggestion with undersigned in a better way to control/extinguish the fire.
Local Delhi police was also informed and accordingly police personnel also arrived
at the spot and remained at the spot till the fire controlled. MD IPGCL/PPCL also
visited the spot and issued necessary instructions to management officials. . In the
fire fighting operation 2200 litre AFFF (FOAM) , 96 Nos. Delivery Hoses were
instantly used, and because of that Major flame and surrounding fire was controlled
in about One and Half hours and totol control over fire in 04 hours. The
surrounding vital installations like DG Set, Auxiliary Transformer, Generating
Transformer, hydrogen room etc. (estimated property of worth Rs.70 Crores) were
also saved by that instant action. Since, the fog/smoke is coming out due to
smouldering of insulating material and cooling process is continuing, so that the
transformer’s temperature does not arise. No injury/casualty reported during the fire
incident. The undersigned held a meeting with the GM on the issue and he told that
because of the fire about 10 to 12 crores loss might have occurred to the plant.
Earlier major fire incident report sent to higher formation vide letter no 83 dated
25/03/2015 in that report preliminary loss told by senior management official
approx. 25 to 30 crores but after fire incident senior management official visited
BHEL BHOPAL for cost assessment of GT to reveal the cost for insurance claim
purpose on return now cost assessed 10 to 12 crores. He also told that a committee
of experts will be constituted to ascertain the causes of fire and actual loss.
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