Risk Inspection Report

On
Shirpur Power Pvt. Ltd.

Visited By: Rama Chandra Barik

Visited Date: 19th Oct 2021

Prepared By

Universal Sompo General Insurance Co. Ltd.

103, First Floor, Ackruti Star, MIDC Central Road,
Andheri (East), Mumbai-400093
Risk Inspection Report on Shirpur Power Pvt. Ltd.

Report prepared by
Mr. Rama Chandra Barik
Risk Engineer, HO - MUMBAI
Universal Sompo General Insurance Co. Ltd.

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Risk Inspection Report on Shirpur Power Pvt. Ltd.

CONTENTS
Acknowledgement

Disclaimer

▪ EXECUTIVE SUMMARY
• Purpose of survey

▪ RISK SUMMARY
• About the insured

1. Plant profile
2. Exposure
3. Construction & plant layout
4. Flammable liquids/gas
5. Fire protection equipment
6. Public fire department
7. Security system
8. Fire management
9. Utilities
10. History of Loss

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Risk Inspection Report on Shirpur Power Pvt. Ltd.

ACKNOWLEDGEMENT

We sincerely thank the Management of Shirpur Power Pvt. Ltd. for the courtesy and cooperation
extended to Rama Chandra Barik from Risk Inspection team during the visit, inspection and
subsequent discussions at site at on 19th Oct 2021.
We are enthused by the response of your executives and the keen interest they have shown in various
aspects of insurance and loss prevention pertaining to the plant. Without their cooperation, it would
have been difficult to prepare this report.
The main purposes of this risk inspection is to collect and update the risk information on underwriting
purpose and to provide recommendations for improvement which is considered to be necessary in view
of disaster prevention. This report is made based on the findings of site tour and material furnished by
your management. We hope our association will be mutually beneficial for both the organizations in
understanding the needs and finding out the solutions. For any further clarification, please do not
hesitate to contact us.

…Team USGICL

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Risk Inspection Report on Shirpur Power Pvt. Ltd.

DISCLAIMER

1. Liability arising from use of the report and validity of the report
• The report contained herein is made with an intention to provide a user with reference information
in his decision making and any liability arising from use of the report shall revert to the user.
• Use of any part extracted from the report may compromise the validity of the report.
• The report is made based on the conditions at the date of survey, hence its validity will be lost if any
change occurs in the conditions pertaining to the information contained in the report.
2. Comprehensiveness
• The report contains a mere summary and does not contain every possible hazardous event or risk
factor.
• Information contained in the report may require re-examination, if new facts are discovered after
further investigation.
3. Authenticity
• The report contained herein is made based on the information made available to us from the material
produced by your company and /or authorised personnel of your company, interviews with persons
in charge of facility management, site investigation of the properties, as well as the information
obtained from the public organisations.
• It is understood that when risk evaluations are made using any quantitative evaluation model in the
report, result of such risk evaluation contains a certain margin of error based of uncertainty of the
model.
• The report can be influenced by the preconditions specified in (1) and (2) above. It does not
warranty any information contain in the report, regardless of being specified or implied, including
the matters concerning existence or non-existence of hazardous conditions.
4. Exemption
Universal Sompo General Insurance Company Limited offers advice to its clients. Therefore,
USGICL, its representatives and employees thereof, shall not be held liable for any damages arising
out of any advice, either oral or written, or any recommendations contained in the report.

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Risk Inspection Report on Shirpur Power Pvt. Ltd.

1. Executive Summary

[Purpose of survey]

A risk survey of Shirpur Power Pvt. Limited was carried out to obtain and update underwriting
information, as well as, to offer recommendations for areas of possible risk improvement to the plant in
terms of fire and other perils for the subject plant from the below 6 viewpoints.
This property risk survey report has been prepared in order to provide an impression of the overall safety
level of the plant and loss prevention recommendations.

Exposure Conditions of the surroundings, natural calamities and sporadic hazards.

Construction Structure of buildings, open space, conditions of fire cut‐off.
Occupancy Working procedure, conditions of risks and combustibles in safekeeping,
repair and maintenance, safety design and safety appliances.
Protection Fire Fighting equipment, fire hydrant system, fire brigade of the plant, public
fire station, safekeeping, smoke & heat detection system, sprinkle system-
adequacy, maintenance and functional aspects, existence fire emergency plan
& fire safety training.
Management Cleaning up and neatening, 5S, control of smoking, organization and
countermeasures, supervision.
Natural Hazards Wind, Lighting, Flood, Snow, and Earthquake.

Methodology

The risk inspection methodology followed is depicted below

Pre site visit Discussion with Presentation of

Data Request employees & Salient
Site visit examination of Findings and
Opening
Meeting records Submission of
Report

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Risk Inspection Report on Shirpur Power Pvt. Ltd.

RISK SUMMARY
[About the Insured]

Insured Name: Shirpur Power Pvt. Limited

Address: Plot No 1,Phase 1,Nardhana MIDC-Waghode, Taluka Sindkheda Dhule Betawad S.O Dhule
Maharashtra Pin - 425403
Contact persons: Mr. Dinesh Nagarkar (Consultant)

Mr. Bharat Hare (SPPL Employee)

Mr. P.F. Powar (Security In-charge)

Mr. Pravin Sonawane (SPPL Employee)

Occupancy: Thermal Power plant (silent unit)

Shirpur Power Private Limited (in Liquidation) incorporated on August 22, 2005 is registered at Registrar of
Companies, Ahmedabad. SPPL is a green field thermal power plant of 300 MW (2 X 150 MW) capacity of thermal
power at Nardana, District Dhule, State Maharashtra based on the blended coal from India and Indonesia. The
Company is a 100% subsidiary of Zep Infratech Ltd. (formerly known as Zeppelin Mobile Systems India Ltd.).
Shirpur Power Pvt. Ltd. is a coal based thermal power plant; project cost was 2485 Cr. INR. It has two production
units, each of capacity 150 MW,
Unit 1 of 2X150 MW – commercial operation date achieved on October 1, 2017.
Unit 2 of 2X150 MW – 98% ready for trial run
The plant comprises a Coal handling unit, Boiler – Turbine - Generator system, Ash Handling unit, Feed and
Circulation water systems, Transmission system and other ancillary systems like water Treatment Plant, Coal
weighing systems, Diesel generators etc.
Presently the plant is in stopped condition (in liquidation). Few staff and workers have been appointed for daily
routine works to maintain the shut thermal power plant.
Power supply to the plant is cut off since June 2018. The power requirement for all the routine works and lighting is
fulfilled by operating in house DG.

1. Plant profile

1) Date of start of operation in this plant building: Aug-2017

2) Scale of plant:
Plot area: 200 Acre

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Building area: 100690 square meters, rest is greenery
3) Workforce:
Presently, around 30 persons (including security) are appointed in the site to maintain the plant.
4) Working hours:
Staffs and operators come in daytime to complete their schedule job. Security people stay for 24
hours in the premise.
Security guards do follow 3 shifts in one day. In each shift at least 5 security guards stay at the
premise.
5) Main products and output
The thermal power plant capacity is 300 MW. It has two units each of capacity 150 MW.
6) Production Process
In the plant, coal handling plant, fly ash handling plant, DM water plant, ETP are common for both the
units. Few silent features are bulleted below.

• Unit-1 & 2 is DCS operated fully automated plant. The plant has the facility to be monitored and
operated from a centralized DCS control room.
• Electrostatic Precipitators were installed to control the emissions from the boilers.
• Tall stack of height 150m was installed for effective dispersion of the pollutants into the atmosphere
• Online stack monitoring systems were installed on the flue gas lines as per the CPCB guidelines
• Dust suppression systems were installed at the railway wagon coal unloading stations
• Water sprinklers were provided at the coal stacker reclaimer area for controlling the dust emissions
• Dust suppression systems were installed on all coal bunkers
• Dry fly ash handling systems and storage silos were provided for achieving fly ash utilization during
the operational phase of the plant
• Adequately designed wastewater collection, treatment and reuse facilities are installed in the plant.
• Three number of storm water recharge pits were constructed at the site.

Presently, the following activities are being done in the premise.

1. Bearing of turbines
2. Pressurizing of boilers to avoid tube corrosion

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2. Exposure

1) Adjacent properties and distances

Direction Adjacent properties

North Wonder cement (after western railway line)
East Open farming Land
South Open farming Land
West Ultratech cement factory (Under construction)

2) Topography and weather

• Latitude & Longitude: 21.15794 (N), 74.85461 (E)

• Altitude: 614 feet from sea level

• Nearest river: Tapi river is at 16 km from the site.
History of Flooding: There is no record of flood due to river.

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• Sea: Arabian Sea at more than 300 km
History of Loss by high tide: No
• There was no inland flooding in the past. (Inland flooding refers to flooding caused by inadequate
drainage capacity of the premises.)
• Lightning: The number of days with lightning is lower than the national average.
• Seismic zone: Zone III: Moderate Damage Risk Zone (MSK VII) as per Vulnerability map of
India, 2019.
• Storm: Moderate Damage Risk Zone (Vb=39 m/s), as per Vulnerability map of India, 2019
• Landslide: Unlikely as per Vulnerability map of India, 2019
• Due to lack of maintenance, the plant is full of plants and grasses all over the area. Bush fire
chances is very high.
• The coal storage area has a bulk storage of approx. 600 MT of coal in open yard.

3. Construction & plant layout

1) Status of main building

• The occupancy is a multiple block occupancy of Class 1 as per IIB. The plant lay out was received
from the client.
• Major blocks mentioned below are at safe distance from each other.
• The plinth height of all buildings is >3 feet from the surrounding ground level.
• The whole compound is surrounded by 12 feet height concrete wall with 3 feet height concertina
wires.
• Road condition towards the plant is good, but inside the plant is very poor.
• There are 2 number of main gates for entrance/exit the compound. Presently both are in shut and
locked condition, guarded by security. One temporary gate arrangement has been done for human as
well as vehicle entry, guarded by security.
Name of the building Structure No of floors Building height
BTG (Boiler Turbine Steel structure 9 54 m
Generator) unit 1& 2
WTP Steel structure G 5m
ETP Steel structure G 5m
CHP (Coal Handling Plant) Open steel structure - 20m

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• There is a pump house at Tapi riverbank at 16 km from the plant. The security guards stay there for
24 hours.
• Separate installation for fire water storing and pump house, with alternative power source.

4. Flammable liquids / Gas

Flammable Liquid/gas Use Average stock maintained at

site
HSD Stored in barrels and drums, used 200 liters
in DG.
Petrol Stored in a store nearer to office, 25 liters
used for portable generator for
office

5. Fire protection equipment

1) Fire alarm / Gas detector

• Automatic fire alarm installed in the premise. Almost all area is covered.
• Smoke detectors are installed in the plant control room, MCC room & PLC rooms.
• As there is no power inside the plant, none is in functioning condition.
2) Fire-extinguishers

• All the fire extinguishers refilling is due since 2018.

3) Fire hydrant system

• Outdoor fire hydrant with posts and hose reel stations are installed in the premise covering all the
buildings.
• Fire pump house is a separate building with overground water reserve.
• Presently, there is no power for fire pumps. The reserve tank is also in empty condition.
• But there is a provision of operating fire pumps with the help of DG.

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• The pumps detail is as below.
Pumps Main pump Jockey pump Diesel pump
Make FLOWMORE FLOWMORE FLOWMORE
Quantity 2 2 2
Flow rate in m3/hour 273 25 273
Head in m 88 90 88
Power 110 kW 22 kW 154 hp

• There is emergency power supply from DG to the fire hydrant pumping system.

4) Sprinkler system
• Water sprinkler system is installed in the premise for LDO storage area, all transformers.

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5) One fire tender carrying 6000 liters water, 1000 liters foam, CO2, 2*DCP*50 liters is deployed. The fire
man cum tender driver stays nearby the plant and is responsible for 24 hours.

6. Public Fire department

Name of fire station Sind Kheda Public fire brigade

Distance 20 km
Arrival time during emergency 30 minutes
No of fire pumper trucks 1 (water)

• No other detail was received.

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7. Security System

• 5 security guards always stay at the premise shift wise.

• They do guard and patrol the premise all the time.
• Entry pass is followed strictly.
• All security guards are trained for firefighting.

• Fire Management
8.

• Smoking is fully restricted.

9. Utilities

• 2 no of compressors
• 2 no of cooling towers
• 2 no of coal fired boilers
• 1* 750 kVA is in stop condition. 1*25 kVA is used for lighting and for current schedule works.

10. History of Loss

As per the information received from the client, there was no reported fire incident or loss history since last 3
years.

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THANK YOU

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