TYSER RISK MANAGEMENT
(Bangladesh) LIMITED
RISK ENGINEERING REPORT
NORTH WEST POWER GENERATION COMPANY LIMITED
225 MW Combined Cycle Power Plant Unit – II
Sirajganj
Bangladesh
June 2020
Prepared For
Tysers, UK
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TYSER RISK MANAGEMENT (Bangladesh) LIMITED
By appointment and instruction of Tysers, UK, a Risk Engineering Survey of 225 MW Combined Cycle
Power Plant Unit – II, North West Power Generation Company Limited located at Sirajganj, Bangladesh
was carried out on 16th June 2020 by Tyser Risk Management (Bangladesh) Limited. Enclosed please
find the report.
This is a Confidential Report, and as such, all parties in receipt of this report are requested to maintain
confidentiality of its contents. It has been prepared for the Reinsurers for the specific purpose (outlined
in the instruction referred to above) and should not be shown to, nor relied on by, any other party or
for any other purpose. Tyser Risk Management (Bangladesh) Limited accepts no liability nor does it
assume control over the original or subsequent copies.
Reliance on Information Provided / Acceptance in Good Faith__________________________
This report has been prepared primarily from the information provided to the inspection team by the
concerning authorities at site, and from whatever was apparent to the inspection team during physical
inspection of the sites.
Limit of Service__________________________________________________________________
All and any recommendation, advice, comment, or suggestion, whether verbally or formally presented
in this report is based on information provided by the concerning authorities at site, from physical
inspection of the site, and our experience and exposure to the hazard and credible risks associated with
the process for which logical and economical resolutions can be incorporated within the system
(process, design, instrument, and environment).
It is explicitly understood by Tysers, North West Power Generation Power Company Ltd., its
Reinsurers, associates, and all others that it is unrealistic and impossible to ascertain each and every
hazard or risk present at any particular site or process. As such, Tyser Risk Management (Bangladesh)
Limited does not certify that all credible or incredible risks have been assumed, considered, or
incorporated in the report. Natural disasters (except Flood, Cyclone, and Earthquake) or “Acts of God”,
or unforeseen “Acts of War”, and other extreme circumstances beyond human or economic control
may not have been considered or expressed in the report.
Any recommendation, advice, comment, or suggestion regarding any process, design, instrument, or
environment shall be construed as a singular recommendation, advice, comment or suggestion for all
processes, designs, instruments, and environments similar in nature and design present within the same
compound or site. The physical inspection of the property and the recommendations herewith are purely
advisory and are for the purpose of assisting the client to manage the risks that could or may affect its
interests. Neither Tyser Risk Management (Bangladesh) Limited nor its employees, or associates, make
any warranty, whether express or implied, concerning the content of the report submitted.
Enclosed please find the Risk Engineering Report.
For and on behalf of
Tyser Risk Management (Bangladesh) Limited
Riasat Farabi
Manager, Technical
riasatfarabi@trmbl.com
HOUSE 80 (A-2) ROAD 07 BLOCK H BANANI DHAKA 1213 BANGLADESH
PHONE: + (8802) 985 4291 FAX: +(8802) 985 1186, A CONCERN OF TYSERS, UK
EMAIL: INFO@TRMBL.COM WEB: WWW.TRMBL.COM
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ESTABLISHED IN 1820
TYSER RISK MANAGEMENT (Bangladesh) LIMITED
Preface
Tyser Risk Management (Bangladesh) Limited has been appointed by Tyser, UK for conducting a Risk
Engineering Survey of 225 MW MW Combined Cycle Power Plant Unit – II, North West Power Generation
Company Limited (NWPGCL Unit – II) at Sirajganj, Bangladesh. The initial risk engineering survey was
th
carried out previously by Tyser Risk Management (Bangladesh) Limited at 11 June 2018. This year, on 16th
June 2020, Tyser Risk Management has done a follow-up Risk Engineering Survey of the facilities.
It should be noted that the findings and recommendations of the study are based on physical survey of
the site and the data provided by the plant authorities. Some of the information have also been used from
the previous Risk Engineering Report.
Tyser Risk Management has exercised all reasonable skill, care and diligence in carrying out the
study.
This report is not deemed to be any undertaking, warranty or certificate.
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TYSER RISK MANAGEMENT (Bangladesh) LIMITED
Recommendations for Risk Improvement
Risk Improvement Recommendations
The recommendations / suggestions for risk improvement presented here makes no claim for
completeness or exhaustiveness. The recommendations presented here for minimizing potential
losses that are based on brief general observations and discussions at the site. These are not the
result of detailed engineering studies. The Insured remains fully responsible for compliance with
all applicable laws and regulations.
The recommendations are categorized in below given criteria:
: Highest, for urgent consideration
: Orange: Serious
: Yellow: Relatively Important
: Green: For prudent risk engineering practice
: Blue: Complied per records
Review of New Recommendations
No
Recommendation from 2018
2020-01
Acid Container need to be removed from battery bank room
2020-02
A Permanent Scrap Shed Need to be Built
2020-03
Automatic Fire Detection & Protection System, CCTV, Containment
Bund need to be implemented in Chemical Storage of NWPGCL Unit II
2020-04
Automatic Fire Detection & Protection System, Aisle Marking need to
be implemented in Storages of NWPGCL Unit II
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TYSER RISK MANAGEMENT (Bangladesh) LIMITED
Serial
No.
2020-01
Recommendation
Acid Container need to be removed from battery bank room:
At the time of inspection, it was found that some of the acid containers are
kept aside in the battery room. As all these batteries produces hydrogen all the
time and hydrogen is a highly explosive gas so it is mandatory not to keep any
chemical related substance in the room.
So, it is recommend that those should be removed from battery bank room &
place it in the chemical store.
2020-02
A Permanent Scrap Shed Need to be Built:
During site survey, it was noticed there was a temporary place for keeping
corrosion inhibitor bottles which has kept at open space. As the plant will
continue its operation, more scraps will be formed and for that the plant should
build a proper designated scrapyard to dispose those in proper and safe
manner.
So, it is recommended that they should build a permanent scrap shed soon.
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TYSER RISK MANAGEMENT (Bangladesh) LIMITED
2020-03
Automatic Fire Detection & Protection System, CCTV, Containment
Bund need to be implemented in Chemical Storage of NWPGCL Unit II
During inspection, it has been observed that a new chemical storage has been
built for NWPGCL Unit II. At this chemical store, huge quantity of important
chemicals have been stored without keeping proper safety measures. It is
strongly recommended to install automatic fire detection and protection system
as per NFPA guideline at chemical storages along with CCTV and most
important to keep these chemicals within separated Containment Bund.
2020-04
Automatic Fire Detection & Protection System, Aisle Marking need to
be implemented in Storages of NWPGCL Unit II
At the time of inspection, it has been observed that in storage, there are huge
quantity of electrical and mechanical materials has been stored without keeping
proper safety measures. It is strongly recommended to install automatic fire
detection and protection system as per NFPA guideline at storages along with
CCTV and aisle marking.
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TYSER RISK MANAGEMENT (Bangladesh) LIMITED
Review of Previous Recommendations
SL. NO.
Recommendation from 2018
Status
2018-01
Electrical Earthing Continuity Test timing should be changed
Complied
2018-02
Pipe line color codes should be maintained throughout plant
In Progress
2018-03
Fire pump maintenance need to done as per NFPA 25 guidelines
In Progress
2018-04
Safety Audit by third party should be carried out
2018-05
In Progress
2018-06
Overall housekeeping needs improvement.
All the exit signs should be operational.
2018-07
Plant condition monitoring needs expansion
In Progress
2018-08
Battery room exhaust fan need to be operational 24/7.
Complied
2018-09
Plant Procedure
Complied
2018-10
Detector maintenance procedure need to improve
Complied
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Complied
Complied
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TYSER RISK MANAGEMENT (Bangladesh) LIMITED
Serial
No.
Recommendation
Status on June 2020
201801
Electrical Earthing Continuity Test timing should be
changed:
It was noted that the electrical earthing continuity tests are
scheduled once for the winter season in Bangladesh, i.e.
December/January. It is recommended that, either two tests
are carried out each year, or if one test is to be carried out
then it must be within the hottest and wettest months of the
year (typically June/July in Bangladesh).
Complied:
NWPGCL Unit II had
already changed schedule
for
their
electrical
Earthing Continuity Test
on hottest season. Latest
report has been attached
with the report.
201802
Pipe line color codes should be maintained
throughout plant:
During inspection it was observed that appropriate color
codes had not been maintained for the pipelines. It is
recommended the plant confirms to an international
standard, such as the ANSI A13.1 for pipeline color coding.
201803
Fire pump maintenance need to be done as per NFPA
25 guidelines:
At the time of inspection it was informed by the plant
personnel that all the fire pumps are being inspected and
maintained regularly, however not as per any particular
maintenance standard.
It is recommended that the inspection and testing is carried
out as per NFPA – 25 (Edition 2011, Chapter – 8, or latest)
guidelines. Annual flow test and churn test for various FW
pumps should be conducted. Corrective steps should be
taken for those pumps showing more than 10% drop in
design performance. Fire pumps are safety critical
equipment. It is accepted practice throughout the industry to
periodically recheck fire pump operating curves by carrying
out a detailed pump head vs' design capacity check (3 points:
zero flow, design rated flow, 150% of the design rated flow.
once per year). In this respect, NFPA 25 (section 5-3.3.1)
provides an accepted fire protection guideline. The resulting
flow pressure (capacity-head) curve should be compared to
the vendor supplied pump performance curve in order to
facilitate detection of deterioration in impeller or driver
performance that could reduce firewater supply
effectiveness under emergency conditions.
In Progress:
NWPGCL Unit II has
already prepared a color
coding board, which they
will be implemented
throughout the pant.
Already 80% work has
been done. Some of the
tanks remained.
Hopefully they completed
it by end of this year.
In Progress:
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NWPGCL Unit II already
started working on it. At
present procurement of
the flow meter is
hindered because of
recent outbreak of Covid19.
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TYSER RISK MANAGEMENT (Bangladesh) LIMITED
201804
Safety Audit by third party should be carried out:
201805
Overall housekeeping needs improvement:
Audit is an essential part of any safety management system.
Although, internal audit is carried out in scheduled interval, a
third party external audit is required to ensure the quality of
internal audits. In addition, detail audit to ensure the safety
management system is working properly is required by
external third party auditors. Therefore, it is recommended
that NWPGCL arranges safety audit by third party at least
once every three year interval.
While the overall housekeeping condition of NWPGCL –
Sirajganj Unit - II is satisfactory (Still lots of construction is
going on for unit 3 & 4), there is however room for
improvement. Several waste items from plant installation and
commissioning still remains within the plant area. These
should be removed as soon as possible, and definitely prior
to onset of the next cyclone season (March-April).
The housekeeping philosophy the plant should observe is –
Complied:
It was informed by the plant
personnel that lenders of
the project have a strong
monitoring on EHS aspect.
AECOM India, MIGA
performed EHS audit at
regular interval. Besides
local consultant /auditors
(EQMS) also performed
routine audit and related
reported has been attached
with this report.
In progress:
During the site visit lots of
improvement seen
regarding housekeeping in
NWPGCL Unit II. But still
there are lot of scope for
improvement. As some of
the scrap found outside in
appropriate places.
“A designated place for everything, and everything in its
designated place”
201806
All the exit signs should be operational:
Complied:
During inspection all the
The number of Exit Signs in the plant was adequate. At the exit signs seemed to be
time of inspection most of the exit signs were not in operational.
operation. The plant management informed that as these Exit
signs are under maintenance, that’s why these signs are not
working. It is highly recommended to make sure that all these
Exit Signs are working and they are operational 24/7.
201807
Plant Conditioning Monitoring Needs
expansion :
The Plant Condition Monitoring system is partially in place
e.g. periodic lube oil testing of HFO engines, but other testing
e.g. thermography for plant equipment and electric
switchgear, MCC etc.), transformers commissioning test
record was not readily available which should form a baseline
data for the periodic inspection and testing of the transformer
and its oil.
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In Progress:
HSD oil sample test, DGA,
Furan test has already done
by NWPGCL Unit II.
Other test procedures are
to be done within August
2020.
TYSER RISK MANAGEMENT (Bangladesh) LIMITED
A complete Condition Monitoring Plan should be developed
at the earliest and a base line data recorded. A trend analysis
of all tests results and data recorded be undertaken as this
would greatly help in predicting the condition and will enable
the insured to take preventive measures before occurrence of
a breakdown.
Following equipment and data monitoring should be
covered:
Vibration Measurement and Analysis (Rotary &
Reciprocating Equipment)
Oil Condition and Wear Debris Analysis (Rotary &
Reciprocating Equipment)
Transformer and Transformer oil tests (DGA and
Furan test).
Thermography (covering steam & exhaust gas piping
and switchgear system)
Corrosion Monitoring (CP, NDT, thickness testing)
Performance trending of major equipment (Design
vs. Actual output)
201808
Battery room exhaust fan need to be
operational 24/7:
Complied
During inspection battery
bank exhaust fan found in
At the time of inspection it was found that the exhaust fan in operational.
the battery room is not working. As all these batteries
produces hydrogen all the time and hydrogen is a highly
explosive gas so it is mandatory to run the exhaust fan 24/7.
It will make sure that all the hydrogen will be removed from
that room and hydrogen will go to atmosphere.
201809
Plant Procedure:
The plant operating & HSE procedures should be developed
in a manner that these become specific to a NWPGCL plant.
A list of procedures be first developed and then a monthly
schedule of progress be prepared targeting for completion of
procedures by end 2019.
The following procedures should also be developed and
implemented:
1.Emergency Response Procedure
A comprehensive procedure should be developed after
conducting a detailed Impact Assessment (IA), under various
possible scenarios, targeting for availability and
implementation by early 2020.
2.Fire System Impairment Procedure
During the operating period there will be occasions when
isolation of the Fire detection or suppression system for an
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Complied:
NWPGCL Unit II has
already prepared
Emergency Response
Procedure, Fire System
Impairment Procedure, Oil
Spill handling procedure,
.MOC Procedure.
TYSER RISK MANAGEMENT (Bangladesh) LIMITED
area is required, for routine maintenance or rectification
work. Only authorized personnel should be assigned the task
of controlling the fire system impairment and the work
should be managed in such a way so as to be completed in
shortest possible time. The procedure should cover different
areas and equipment type, clearly listing alternate
arrangements to be made for fire surveillance / extinguishing.
A format should be part of the procedure giving details of the
fire system impairment, actions required and approvals, it
should be signed-off subsequent to normalisation of the
system.
3.Oil Spill handling procedure
In view of large quantity of fuel oil being handled and stored
at NWPGCL, a specific procedure titled “Oil Spill handling
Procedure” should be developed. Depending upon the
scenario, the procedure may be classified into three Tiers as
shown below:
Tier-1---A small spill.
Tier-2---A medium spill, such as from storage tank leakage
incidents or bursting of a pipeline in / around tank farm or
during fuel unloading from sea tanker.
Tier-3--A large spill, bursting of bulk tank or day tank or any
other accident, where substantial outside resources will be
required
The procedure should include equipment and material
required for handling Tier-1 and 2 level incidents and training
of staff.
In order to avoid accidental spillage, it is prudent that
unloading instructions be displayed in Bangla language at the
un-loading bay for clear understanding of all involved.
4.ESD Trip Bypass Procedure
It is to be realized that situations may arise where the ESD
/Trip system has to be overridden or bypassed mainly due to
faulty instruments; however it is imperative that the
overridden ESD or Trip system is normalized in shortest
possible time. In the interim period specific instructions
should be available for monitoring of the relevant areas and
actions to be taken to address a resultant emergency situation
to avoid a mishap.
5.MOC Procedure
NWPGCL should develop a comprehensive MOC procedure
for the Plant carrying full details of the Changes in plant
design, control system settings, documents and operating
procedures. Requirement of PHA techniques i.e. Hazard
Identification (HAZID), Hazard Analysis (HAZAN), Hazard
and Operability Studies (HAZOP). The procedure should
depict BRPL plant manager and higher management’s formal
approval based on the nature of the change for any changes
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Oil Spill pipe line
For ESD Trip Bypass
procedure the plant
personnel informed
through e-mail:
“We do not bypass ESD
system. So it was a
question from your side
if any fault in
any instrument happens,
how to mitigate the
issue. I cannot share full
details. But in brief, let’s
assume one core turbine
bearing temp
thermocouple, which
uses 3 different channels.
If one channel gets
faulty/deviates from
the values from others, it
gives an alarm. If more
than one channel gets
faulty, it goes to Trip
automatically. Second,
We have different access
modes to the logic
architecture of
application server. Any
change in logic diagrams
for overriding need to be
performed by OEM
people (Either from
Remote monitoring or
from site). We do not
have access for
overriding ESD. (like
TYSER RISK MANAGEMENT (Bangladesh) LIMITED
to important operating parameters and any change plant converting 2-out-of-3 to
design aspects. A complete record in an easily accessible 1-out-of-3).”
format should be available at the plant.
2018- Detector Maintenance procedure need to
improve:
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At the time of inspection it has been observed that smoke
and heat detector check-up and maintenance schedule is in
place. These detectors has been checked yearly and found
satisfactory. The plant personnel use jute smoke to find out
whether these smoke detectors are working or not. To find
out whether the heat detectors are in working condition the
personnel use heat gun to generate heat.
•
Smoke detectors need to be checked by sample gas
(Aerosol type) found in fire-fighting accessories shop, also
the response time need to be noted.
•
Smoke detector batteries (if there is any) need to
replace after every 6 months.
•
Any smoke/ heat detector need to be replaced after
every 10 years of use.
•
Heat detector’s response time need to be noted as
well as the set point should be noted.
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Complied
Smoke detection system
has been checked through
Aerosol type gas and heat
detection has been
inspected through heat
gun.