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Chapter 1: Preamble and Genesis
COAL STORAGE YARD
POWER TRANSMISSION
AIR
TURBINE
BOILER
GENERATOR
TOWER
DRAUGHT
FEED WATER
PROCESSING PLANT
PUMP
__
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------------------·-------------- -
Figure 1. Diagramatic flow chart of power generation in coal-fired
thermal power plants
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ANNEXURE 3
REPORT OF THE VISIT BY NIOH SCIENTISTS
(23-26 FEBRUARY 2009)
RIHAND SUPER THERMAL POWER PROJECT, Rihand, UP
(NATIONAL THERMAL POWER CORPORATION)
NATIONAL INSTITUTE OF OCCUPATIONAL HEALTH
(INDIAN COUNCIL OF MEDICAL RESEARCH)
AHMEDABAD 380 016
1
BACKGROUND
A Writ Petition (Civil) No. 79 was listed before a Bench Presided over by Hon’ble
Chief Justice of India on 16.1.2008 has sought directions from Court for nine (9)
points as raised (as per letter of Sri A Sharan, Additional Solicitor General, Govt.
of India dated 17th January 2008 addressed to Shri A Razdan, Secretary, Ministry
of Power, Govt. of India) in the Writ regarding the persons working in Coal Fired
Power Plants. It was further stated out of nine (9) points seven (7) points are part
of various statutes of different Acts promulgated by Govt. of India from time to
time. The following two points needs consideration and entrusted to National
Institute of Occupational Health, Ahmedabad, for conducting survey / study for
effective implementation of health and safety norms:1.
Safe methods be followed for the handling, collection and disposal of
hazardous wastes to be recommended by NIOH.
2.
Appointment of a Committee of experts by NIOH including therein
Trade Union representatives and Health and Safety NGO’s to look into
the issue of Health and Safety of workers and make recommendations
In a meeting with officers of Ministry of Power, Govt. of India and Central
Electricity Authority (CEA) on 13.7.2008 it has been decided to entrust NIOH with
the responsibility of conducting study / survey on the effective implementation of
the Health and Safety norms in particular, with the following terms of reference
(as per DO, letter of Sri Razdan to Sri Naresh Dayal, Secretary, Ministry of
Health & Family Welfare, dated 15. 7. 2008):
1.
Safety norms as provided in the various statutes/rules/Regulations;
2.
Whether these are being implemented effectively: and
2
3.
If not, remedial measures needed for effective implementation
specifying in particular, the authority responsible/to be made
responsible for effective implementation of the provisions of the
Statutes/Rules/Regulations.
VISIT OF NIOH TEAM
It has been decided by CEA that initially two units may be considered and the
units have also been identified. One of the units is Rihand Super Thermal Power
Project, at Rihand UP, and other unit of a Gujarat Electricity Board (GEB). There
was no response from GEB. On the basis of the response from Rihand power
station, a NIOH team of five scientists visited the unit from 23rd to 26th February
2009, for an on-spot visit of the plant units, its different activities as well as
interaction amongst the working population including the management officials at
several levels. The scientists are:
1.
Dr P K Gangopadhyay, Scientist F and Officer – in- Charge,
Regional Occupational Health Centre (Eastern), Kolkata.
2.
Dr A K Mukherjee, Scientist E, Regional Occupational Health
Centre (Eastern), Kolkata.
3.
Dr (Mrs) Anjali Nag, Scientist E, National Institute of Occupational
Health, Ahmedabad,
4.
Dr Asim Saha, Scientist C, National Institute of Occupational
Health, Ahmedabad,
5.
Dr S Raghavan, Scientist B, National Institute of Occupational
Health, Ahmedabad,
3
Rihand Thermal Power Station
Rihand Super Thermal Power Project/Station is one of the large power
generating units of National Thermal Power Corporation, a Govt. of India
enterprise situated at the south-eastern tip of Uttar Pradesh (bordering Madhya
Pradesh and Bihar). The area is also consisting of other power projects namely
Singrauli Thermal (2000MW), Vindhyachal Thermal (3260 MW), Anpara Thermal
(1600 MW), Obra Thermal (1550 MW), Rihand Hydel (300 MW), Obra Hydel
(100 MW) and Renusagar Power Co (732.5 MW). Other industries located in the
area are Hindalco (Aluminium factory), Kanoria Chemicals and High Tech
Carbon, as well as coal mines. The region is locally known as Dakshinanchal.
The Rihand Super Thermal Power Project is located at Rihand Nagar, Bijpur,
Sonebhadra District in Uttar Pradesh province of India. Unit I and II of first stage
commissioned 1988 and 1989 respectively. These units started production of
electricity on commercial basis in January 1990 and January 1991 with installed
capacity of 500 MW each. Stage II with unit III and unit IV of 500 MW each were
commissioned and commercialised on August 2005 and May 2006. The chimney
heights were 224.5 and 275 meters for stage I and stage II respectively. The
sources of coal and water for the functioning of the units were Amlori Mines and
Rihand Reservoir of Govind Ballabh Pant Sagar respectively. The generated
electricity distributed to different states like UP, Haryana, Punjab, Jammu &
Kashmir, Himachal Pradesh and Chandigarh. In stage III further 1000 MW (500
MW each of two) is also coming up. The station has already registered more than
100% PLF (Plant Load Factor).
Initially the visiting NIOH team had a meeting with the General Manager
and all the departmental heads. A detailed discussion took place explaining the
aims and objectives of the visit. They have been asked to co-operate with the
team. The management also urged to take the team to all the sites inside the
4
plant as well as the surrounding community areas, and explain different
activities/operations. The team visited the various sites and collected a few
samples of dusts and ambient gases. Noise levels were measured in some of the
processes. The team paid special attention to waste disposal, liquid waste
treatment plant, fly ash disposal/ash pond and ash brick production units. The
team also visited the hospital and the surrounding community. Welfare activities
taken up by the management of the plant for the employees of the plant and
surrounding community have also been taken into consideration, including the
regular training activities.
The organisation has also submitted some of the information / records as
asked for to the team members. The records are regarding injury / accident,
environmental
occupational
impact
disease
assessment,
statistics,
environmental/epidemiological
pre-employment
and
periodic
studies,
medical
examination, onsite & off site emergency preparedness (mock drill), emission
quality, community monitoring data, fly ash characterization and its impact on soil
fertility and crop yield, safety reports and list of workers.
Some important information are:
A.
The details of the main raw materials used year-wise and the quantity of
power generated are as follows:
Description
Unit
2003-04
2004-05
2005-06
2006-07
2007-08
2008-09
Coal
Consumption
Oil
Consumption
Power
Generation
PLF
MT
4765802
4747997
6186960
10246908
10690492
9612866
MT
1798
1364
2441
2730
1686
2600
MUs
7956.263
7988.110
9805.008
16100.321
16763.283
14947.649
%
90.58
91.19
85.20
91.90
95.42
96.41
5
B.
Fatal accidents at Rihand Super Thermal Power Project from 2002-2009:
There were ten (10) fatal accidents took place in this power plant. All the
workers were contractual labourer – mainly engaged by NBCC (5) or
BHEL (4). In all the cases enquiry committee constituted and
compensation paid in each case (Rs 1,71,000/- to Rs 3,24,642/-).
C.
Annual Health Check-up of Employees (Occupational Health Hazards)
from 2003-04 to 2007-08.
The submitted report indicated that there was not a single case of a) Coal
Worker’s pneumoconiosis; b) Silicosis; c) Lead poisoning and d)
Dermatitis. However, so-called noise induced hearing loss was reported in
case of some workers.
Chronic Respiratory Illness of the nearby
population has also been reported.
D.
Safety Training and Awareness Programmes
The organisation undertakes safety training and awareness programmes
regularly for NTPC Employees, contractual workers and community. This
also includes first aid training, fire fighting training, disaster management
and emergency preparedness, competition, health check-up, etc.
E.
Risk Assessment Study
The study suggested areas of fire hazard and explosion hazards; areas
susceptible to release of chemicals and gases; hazardous locations of
possible bursting of pipelines; areas susceptible to flood; hazards
associated with machinery/plants, storage godown, etc
6
1
Figure 1. In-side view of some sections and operations at Rihand power plant
Processes involved in power generation
The processes involved in generation of power are complex. Initially, the coal
from Amlori mines in wagons are received at the Merry Go Round (MGR)
department and transported to the raw coal bunkers at the wagon hooper area of
coal handling plant (CHP). This is a captive railway of Rihand STPP. The coal is
unloaded to the paddle feeder to scoop the coal to conveyer belt and transported
to crusher and to the Bowl mills. The coal is pulverised in Bowl mills. The finely
crushed coal (< 88 μm) is taken to the furnace through coal pipes with the help of
cold and hot air mixture from PA fan. Water from the boiler feed pump passes
through economiser and reaches to the boiler drum → to the water wall tubes in
the furnace to convert into steam. The steam generated is separated from the
water and is super heated to 540 °C by super heater located inside the furnace
and finally it is fed to turbine. The flue gases from the furnace are extracted by
induced draft (ID) fans, → cooled by passing through pent house and air preheaters and ultimately sent to electrostatic precipitators (ESP) to collect / settle
the ash particles to minimise the stack emission of fly ash. The fly ash is mixed
with water to form slurry and is pumped / carried to ash pond via liquid waste
treatment plant. All other liquid wastes, water from cooling tower, water from ash
handling, water mixed with oil and grease from different plant areas are also
carried to liquid waste treatment plant to separate oils and ash from the water
through ash water re-circulation system (AWRS) and ash dust pump house
(ADPH). The separated ash is also pumped to the ash pond. The oils are
recovered for re-use. The water is treated with alum, lime bleaching in the water
treatment plant for re-circulation of water. In the water treatment plant liquid
ammonia is used for final adjustment of water PH before re-use. The plant is
having a closed circuit wet cooling system to condense the steam. Dry fly ash is
collected from ESP and also from the bottom of the boiler in bags and is utilized
in brick manufacturing in RSTPP. The fly ash produced in the plant is also used
either in construction work, in agriculture purposes and or as land fills etc.
8
The steam is conveyed to the turbine by two high-pressure steel pipes
fitted with stop valve and control valves. The steam enters the turbine through
the control valve and rotates the blades and transforms the heat energy into
mechanical energy. The steam is re-cycled to rotate the turbine blades in series
of stages. The turbine shaft rotates at 3000 revolutions per minute. To conserve
water, hot water is circulated through cooling towers to cool and re-use. The
electricity is produced in the generator and is fed through the terminal
connections. All the operations monitored and executed through a group of a
engineers that manned the control room operations. Engineers monitor the
output of electricity, supervise and control the operations. The major plant
sections / operations of Rihand-STPP are:
a) Coal handling plant
b) Main plant (Boiler, Turbo Generator)
c) Water treatment plant
d) Fuel handling plant
e) Pump house
f) Stores
g) Liquid waste treatment plant (LWTP)
h) Electrostatic precipitator (ESP)
Large quantity of water is generally used for condensing and cooling
processes in the plant. The used water with elevated temperature and
contaminated with chemicals are again discharged usually into the receiving
surface water. This may deteriorate the quality of water and affect the aquatic
9
lives and human health due to higher water temperature. In Rihand-STPP it was
found that the there is liquid waste treatment plant (LWTP), which separate
contaminants, and the water is re-circulated. A number of natural water
catchments were found to be made by the Rihand- STPP in the surrounding
villages to facilitate fresh water facility as well as preserve water habitats,
agriculture and growth of greenery.
10
1
Figure 2. In-side view of some sections and operations at Rihand power plant
The team noticed some drawback and lacunae in different operations and the
shop floors. In brief,
1.
Merry Go Round (MGR) and Captive Railway Network & Workshop
→
The network system from mines up to MGR not considered here.
From MGR up to Coal Handling Plant
→The
diesel locomotive
maintenance area needs proper training of contractual labourers for
handling oils, greases, etc. A better supervision with personalized
touch is desirable for its up keepings.
2.
Coal Handling Plant
→ The different operations involved in this area
appears to be dusty and noisy. There are scopes for improvements.
3.
Coal mills, Boiler Area→ Dust, heat, noise have impacts;
4.
Electrostatic Precipitators → Dust appears to be problem.
5.
Turbine Area, Control Rooms → Noise & Heat requires minimization
below permissible limit
6.
Water treatment plant, Fuel handling plant, Liquid waste treatment
plant (LWTP), Pump House, Stores → Scopes of improvement.
7.
Chemical Storage tanks, Flue gases and Fly ash
improvement desired.
12
→
Further
Air emissions
Generally, primary emission in the air of any thermal power plant includes the
combustion product of fossil fuels or bio-mass i.e, SO2, NOx, respirable dust (PM
or fly ash), CO, CO2. Besides, other pollutants like, heavy metals, HF, volatile
organic compounds (VOCs), etc. The dust in the plant is produced due to
handling of solid fuel (coal), additives, solid wastes (e.g. fly ash). The silica
content of the dust is very important. It was observed that the coal used contains
about 27% ash. The fly ash produced from the plant contains about 60% SiO2.
Stack emissions of SO2, NOx, CO, respirable particulate matter (RPM) or
opacity (dust) of the 500 MW capacity each of units 3 & 4 of Rihand-STPP
recorded were found to be 20.25 ppm, 21.06 ppm, 5.31 ppm and 43.02 mg/Nm3
& 14.80 ppm, 9.40 ppm, 28.80 ppm, and 52.26 mg/Nm3, respectively during the
visit.
Occupational exposures
In the thermal power plant, dust is a major occupational hazard as large quantity
of coal is used and a huge amount of fly ash is generated. Noise is a recognized
hazard, due to operations of turbine generators, auxiliaries, boilers, crushers,
pulverizers, pumps, motors, compressors, diesel engines, vibrators, etc. It was
observed that the turbine floor is very noisy. The CHP consisting of paddle
feeder, crusher, pulverizer, reclaimer, conveyer are also noisy processes. In the
plant areas the operators, supervisors and executive engineers work in a
centralized segregated control room. However, cleaning personnel and
maintenance workers are generally exposed maximally to noise hazards. The
surrounding areas of high noise machinery were identified as noise prone areas
of the plant and the workers movements are restricted. The turbine and boiler
13
areas were found to be the heated zone in the plant, besides furnace operations.
The thermal insulations used in the hot ductings carrying steam were of glass
wool. Gaseous pollutants are mainly SO2, NOx, VOCs.
Environmental pollution
The ambient air around any thermal power plant may be polluted by the stack
emissions from the plant. The combustion products of the solid fuel comprising of
SO2, NOx, HF and the green house gases (GHGs) along with particulate matter
in the form of fly ash are discharged continuously. The ambient air expected to
be polluted by these pollutants. Besides, the heavy metals (Pb, Cr, Hg, As, etc.)
present as impurities in coal may also be present in the air in higher levels. The
acidic nature of the fly ash may lead to acid rain in the surrounding localities. The
air quality around any thermal power plant is deteriorated and populations of the
surrounding localities are usually affected. The children are specially victim of
various respiratory ailments. Besides, agriculture and yield of the fruit plants may
also be affected. Hence, regular monitoring of the air and water qualities
around the thermal power plant is very much essential. The company has
started monitoring the ambient air quality continuously of its township and
surrounding locality, since January 2009. The samplers are located in Avantica,
Vasantica, Sirsoti and Punarwas. They are in south-east or south-west direction
of the main plant. The parameters measured are total suspended particulate
matter (TSPM), respirable particulate matter (RPM), SO2 and NOx. The available
report showed that the SO2 and RPM levels in the air are higher than the 24hourly recommended permissible limits for industrial areas on some occasions as
noted during the visit from the existing available records. The meteorological
parameters are also recorded in each of the monitoring stations.
14
Workplace monitoring
During the period of the visit, the NIOH team carried out an environmental
monitoring within the plant processes by using the both real time direct reading
equipment and integrated samplers. The respirable dust (PM10) at different plant
operations was undertaken by using a direct reading instrument (EPM – 5000),
Enviromental Devices Corporation, USA and low volume integrated sampler Air
Check, SKC, USA. Some results are presented in Table 1, indicating that the
crusher area is dusty and the workers engaged within the plant may be exposed
to high level of coal dust.
Monitoring of combustion gases like SO2, H2S along with oxygen and hydrocarbons (LEL-Lowest Explodable Limits, expressed as methane) were monitored using
Gas Alert Micro 5 gas monitor manufactured by BW Technologies, Canada.
The
instrument is capable to analyse the toxic gas concentration in parts per million (ppm).
None of these gases were found to be detectable in analytical range of the equipment.
The workers mostly confined in the control rooms of each of the plant operations
and hence workplace exposure is mostly within permissible limits except for the
cleaning and maintenance workers who work in the shop floors.
Table 1. Respirable particulate matter (PM10) levels recorded at different plant
locations during the period 23 – 26, February, 2009
Sl.
No.
Plant operation area
1
2
3
4
5
6
7
8
Turbo Generator
Boiler-3, Firing Floor-Corner 1, AB Elevation
Track Hooper-Coal Handling Plant
Crusher-II at ~15 feet distance
Crusher-II at ~ 8 feet distance
ESP-4 on the wayside but inside ESP area
ESP-4 in the middle of ESP
Control Sample (Outside power plant)
15
Respirable
dust (PM10)
Concentration
(mg/m3 )
0.030
0.073
0.083
1.466
2.336
0.189
0.319
0.085
Noise monitoring
The noise levels at different locations in the plant areas were recorded by a
precision Sound level meter (model, 2230 B&K, Denmark). The noise levels,
Leq05 values maximum and minimum were recorded near the noisy machines
(identified as noise prone area) in the plant, in working locations of workers and
also out side of some operating areas. The results of the noise monitoring are
shown in Table 2. The octave band analysis of the sound pressure levels of
different plant operations are presented in Table 3.
Table 2. Walk through noise level recording at different plant areas.
Leq 5
Monitoring Locations
Coal unloading plant out side
Coal handling plant (CHP) inside near Conveyer
motor.
CHP control room, Inside with AC
CHP control room, Out side the room
Out side the CHP control room building - In front
of the Crusher House – 2
Near Boiler at firing floor (AB – Elevation)
Turbo Generator (TG) – 3 (Beside Turbine driven
boiler feed pump (TDBFP), RHS)
TG – 4 (High Pressure Turbine, LHS)
Away from TDBFP
TG – 4 (TDBFP end) RHS
TG (Central control room)
Electrostatic Precipitator (ESP), beside ID Fan 3B
16
Min
dB(A)
Max
dB(A)
66.1
83.4
78.4
93.0
50.9
77.2
83.4
90.4
93.2
95.2
86.4
92.8
87.7
61.4
71.6
90.8
65.5
82.5
SPL
dB(A)
56.4
61.5
80.5
75.2
As observed, Turbo generator (TG) floor is the high noise prone area.
Though operators, supervisors and executive engineers are mostly confined in
the control room, the cleaning and maintenance workers work in the turbine floor
and are exposed to high noise levels to the tune of 86 to 95 dB(A). The area is
also found to be heated zone along with the adjacent boiler area. The octave
band analysis of the sound pressure levels (SPL) at different operations showed
that the noise levels are highest at the central frequencies 1 and 2 kHz. At the
Turbo Generator (TG) – 3, beside TDBFP, the noise level at the central
frequency of 2kHz is above 90 dB(A). Noise levels in the control rooms of CHP
and TG were observed to be much lower than the respective shop floors. About
five workers always work in the control rooms of CHP and TG with AC. The AB
elevation (Boiler – 3) at firing floor also showed maximum Leq5 of 93.2 dB(A).
The area around ESP unit having noise levels between 71.6 to 82.5 dB(A) at
measuring point 30–40 feet away from the ID fan.
17
Table 3. Octave band frequency analysis of the sound pressure level (SPL) at
different plant locations.
Monitoring
Locations
Coal unloading
plant out side
(JH-3)
Coal
handling
plant
(CHP)
inside,
(near
Conveyer
motor.
CHP
control
room
Near Boiler at
firing floor (AB –
Elevation)
Turbo
Generator (TG)
– 3 (Beside
Turbine driven
boiler
feed
pump (TDBFP),
RHS)
TG – 4 (High
Pressure
Turbine, LHS)
Away
from
TDBFP
TG – 4 (TDBFP
end) RHS
TG (Central
control room)
Electrostatic
Precipitator
(ESP), beside
Induced draft
(ID Fan ) 3B
Octave band analysis (frequencies in Hz ), SPL in dB(A)
31.5 63.0 125 250 500 1k
2k
4k
8k
16k
64.2 64.6
64.8
65.2
64.8
64.9
65.7
66.5
67.4
44.3
57.0
61.4
70.8
74.5
78.4 76.1 77.0
65.0
40.8
16.8
29.6
46.7
47.4
63.6 45.7
53.6
37.8
38.5
29.2
43.1
52.5
61.0
66.4
77.2 82.1
80.0
74.4
61.7
44.7
55.1
63.8
71.7
77.4 79.7 86.4
90.5
48.2
58.8
67.8
70.3
77.2 81.4
83.9 85.4
83.3
51.0
61.2
70.1
75.3
77.7
81.8
86.1
85.7
71.0 57.2
29.6
42.8
51.6
52.6
52.8
56.2 57.9
54.0
32.7 25.1
44.8
53.8
59.3
63.7
68.5
71.1
59.7 45.5
18
65.1
66.8
87.8
72.1 51.2
53.7
46.0
The geographic locations of other power plants and industries are
illustrated below.
19
Salient observations
•
The brief visit of the NIOH team of scientists brings out first hand information.
Rihand power plant has taken different measures in keeping the plant area as
clean as possible and near-zero discharge of liquid waste so as to prevent
any deterioration of the health of the workers in particular, and people in the
community environment, in general. Corporate social responsibility has also
been taken care off. The company has taken endeavour for community
upliftment. Solar power supply and storage of rainwater has also been tried.
The measures taken for involving the surrounding community and their
improvement is praiseworthy. However, there are lots to be done for the
community.
•
Rihand power station maintains a 50-bedded hospital for its employees and
dependents. Regular health check-ups are organised along with daily
preventive and curative services as provided for. The hospital also looks after
the CISF, their dependants and schools. Also, health care facilities have been
offered to the surrounding community on token payment basis.
•
Occupational health has been looked after by an Occupational health
physician (certificate course), maintaining a very small set-up. This facility
needs to be augmented with more manpower and other required facilities.
Innovative approach may be required in implementing core Occupational
Health and Safety (OHS) elements in different operations of the coal fired
thermal plant.
•
In the plant area there are places/locations/operations where environmental
conditions need improvement. Hazards of dust and noise need to be
mitigated. Though zero discharge of effluents has been attempted, there was
some degree of success. Sewage treatment and fly ash use require careful
20
planning. Accordingly, the occupational health services need to be
strengthened, for which there is a requirement of a full-fledged occupational
health unit. The OHS unit requires qualified professional for monitoring of
potential risks of health and safety at workplaces. Documentation and records
management are essential requisite, which need to be improved and
strengthened.
•
Observations suggest that the management of the power plant should
develop
a
viable
workplace
standard.
Suitable
implementation
of
organization-specific workplace standard might be beneficial in mitigating
workplace hazards, increasing work efficiency, and substantially improving
health and well-being of the people involved.
•
Human-machine-environment-organization
relationships
are
crucial
to
influence the socio-technical systems components. In other words, manmachine system incompatibilities should be clearly understood – an example
is the functions of the control room of the plant. Display-control compatibility
and the operator’s cognitive performance have direct linkage to the
effectiveness of the control room functions.
•
There are requirements for broad based study covering total environmental
assessment of all operations including the surrounding community to
ascertain the magnitude of the problem. Total coverage of the workers and
sub sample of the community is essential for a comprehensive health risk
assessment.
•
The NIOH recommends an in-depth study on occupational health
assessment, covering various plant operations and also monitoring the
population in the surrounding community environment.
21