Professional Documents
Culture Documents
ACCIDENT OF #2 CHIMNEY
COLLAPSE BALCO 4×300MW CPP
PROJECT
Investigation Team of
Contents
Chapter-1 General....................................................................................................4
1. General Status of Chimney Construction ............................................................4
2. Accident Description ...........................................................................................6
3. Eyewitness Statement ..........................................................................................6
4. Emergency Treatment After The Accident ..........................................................6
5. Expert Consulting................................................................................................6
6. Documents & Data ..............................................................................................7
Chapter-2 Chimney Design......................................................................................7
1. Soil Investigation for Chimney ...........................................................................7
2. Chimney Design ..................................................................................................7
3. Chimney Design Recheck ...................................................................................8
Chapter-3 Material for Chimney Construction.....................................................9
1. Construction Water ..............................................................................................9
2. Coarse Sand & Stone Aggregate .........................................................................9
3. Cement.................................................................................................................9
4. Reinforcement .....................................................................................................9
5. Concrete...............................................................................................................9
6. Conclusion...........................................................................................................9
Chapter-4 Construction Facilities and Equipments............................................10
1. Batching Plant ...................................................................................................10
2. Slip Form System ..............................................................................................10
3. Temporary Lightning Protection .......................................................................10
Chapter-5 Construction Management.................................................................. 11
1. Experience of GDCL......................................................................................... 11
2. Construction Management................................................................................. 11
3. Construction Management System....................................................................12
4. Conclusion.........................................................................................................12
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Analysis Report On The Accident Of #2 Chimney Collapse
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Analysis Report On The Accident Of #2 Chimney Collapse
Indian Bharat Aluminium Company Ltd awarded the EPC contract for its 4x300MW
Captive Power Plant Project to Shandong Electric Power Construction Corp. For this
project, every two units share one 275m double piped flue can chimney. As approved
by the contract owner, the chimney work EPC contract was awarded to GDCL.
BALCO appointed DCPL to be their engineering and construction supervision
company. Site representative for project financing is BV. Till the accident, the RCC
work for #1 chimney shell is completed. Flue can erection was preparing. RCC work
for #2 chimney had reached 247.5m.
Chapter-1 General
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Analysis Report On The Accident Of #2 Chimney Collapse
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Analysis Report On The Accident Of #2 Chimney Collapse
2. Accident Description
On September 23rd 2009 after 3 o’clock p.m. local time, the weather at site area
suddenly changed, the wind blew strongly accompanied with thundering and
lightning, and then it started to rain heavily. A moment later about 4 o’clock p.m.,
the chimney (#2 chimney) in construction which has already reached the height
of 274.5 meter collapsed during severe rainstorm and thundering.
3. Eyewitness Statement
Our personnel reported the accident to the owner immediately after the accident
happened. We tried to organize our subcontractors to rescue, but it had to be
cancelled due to the attack launched by a few of labors at site. Local police and
government officials hurried to the scene for rescue, sealed off the accident
scene and took some special measures to protect Chinese staff. Then our H.O
started the emergency plan at once, an accident treatment group was organized
and deployed the concerned personnel to site emergently. At the same time, an
accident analysis group was organized by our company, regarding the cause of
the accident we consulted and discussed with well-known expert of China
specializing in engineering, civil, mechanics and weather for several times.
After the accident, the government took charge of organizing the rescue job, the
accident treatment group from our side contacted with all concerned parties
actively, follow up the condition of the accident and rescue progress on daily
basis, try our best to collect all the true and valid information from various
resources to develop the accident investigation job.
5. Expert Consulting
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Analysis Report On The Accident Of #2 Chimney Collapse
According to the information which has been collected by us, we have analyzed
various reasons and factors that may cause the chimney collapse and screened
all the information that collect from various aspects. The reference information
are as following:
2. Chimney Design
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Analysis Report On The Accident Of #2 Chimney Collapse
After the chimney accident, the chimney contractor GDCL contacted IIT (Delhi)
to recheck the chimney design. Expert S.N. Sinha from IIT (Delhi) said in his
report on October 23, 2009 that design of the chimney is safe and adequate.
[enclosed Annex III of GDCL Technical Committee Report- Consultancy Report
on Cause of Collapse of Chimney No.2].
Relevant experts from SDEPCI and Special Committee for Civil Construction
for Electrical of Engineering Institute of China rechecked the chimney design
according to relevant Chinese Standard. They also compared the chimney design
with Chinese Standard.
Although there are some differences between Chinese and Indian Design on
chimney concrete strength grade, shell thickness & dimension and reinforcing,
full duct hole and strengthen measure for holes erection and slipping form
technology, the result of inspection indicated that chimney design is adequate
under normal design loading work condition.
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Analysis Report On The Accident Of #2 Chimney Collapse
1. Construction Water
Sand coarse and stone aggregate were purchased locally in India. Certificate of
Origin is available. They did sample test for every batch of material. BV and our
engineer supervised the process. The tests were qualified.
3. Cement
In chimney shell construction, GDCL only used #43 OPC cement. #43 cement
was purchased from Ultra Tech and Ambuja Company by GDCL. They did
sample test for every batch of material. BV and our engineer supervised the
process. The tests were qualified.
4. Reinforcement
After the accident, we did sample recheck on site reinforcement. We totally took
6 sets of 12mm and 16mm diameter reinforcement (3 were used and 3 were not).
All are qualified [enclosed Mechanic Performance Test Report for
Reinforcement used in Chimney shell].
5. Concrete
As per code, GDCL did cubic block every time before they did concreting, and
then they did 7-day and 28-day strength test. BV and our engineer supervised
the process. The tests were qualified.
6. Conclusion
After check the material quality certificate for chimney construction, site
material sample test report and other materials, we confirmed that the material is
satisfied the design and code requirements.
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Analysis Report On The Accident Of #2 Chimney Collapse
1. Batching Plant
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Analysis Report On The Accident Of #2 Chimney Collapse
1. Experience of GDCL
2. Construction Management
Shell Construction:
Our engineers reviewed and examined the shell slip form construction scheme
submitted by GDCL and submitted to DCPL and BALCO for review and
approval. In the process of shell construction, our engineers together with DCPL
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Analysis Report On The Accident Of #2 Chimney Collapse
& BALCO engineers implemented one nos. acceptance every two days for the
rebar, radius, verticality and appearance quality of the shell. There was no
abnormality occurred during construction and the whole construction process
was under controllable & controlled conditions.
250
200
150
100
50
0
09-2-9
09-2-16
09-2-23
09-3-2
09-3-9
09-3-16
09-3-23
09-3-30
09-4-6
09-4-13
09-4-20
09-4-27
09-5-4
09-5-11
09-5-18
09-5-25
09-6-1
09-6-8
09-6-15
09-6-22
09-6-29
09-7-6
09-7-13
09-7-20
09-7-27
09-8-3
09-8-10
09-8-17
09-8-24
09-8-31
09-9-7
09-9-14
09-9-21
4. Conclusion
To sum up, in the various construction stages for pile foundation, foundation and
the shell of the chimney, the management of SEPCO, DCPL and BALCO was
all in good condition, there were no unusual conditions in the process of the
construction and the construction quality was under controlled conditions all the
time.
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Analysis Report On The Accident Of #2 Chimney Collapse
Our personnel did a serial of check and survey on the form of chimney at site after the
collapse, including chimney foundation and pile check, sample test for RCC debris of
the chimney and reinforcement and distribution status of the chimney debris.
After the accident happened, the government’s investigation team sent persons
to dig out the whole foundation and to clear & clean the surface; besides, dig out
the three piles in the bottom at the southern side of the foundation, and our
engineers & experts executed inspection and observation at site for many times
and observed: the pile body was in good condition and there’s no fracture; no
crack on the surface of the foundation, no uneven subsidence and no deviation
for the foundation.(see pile foundation pix 1-3)
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Analysis Report On The Accident Of #2 Chimney Collapse
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Analysis Report On The Accident Of #2 Chimney Collapse
After the accident occurred, we implemented sampling reinspection for the site
rebar and got totally six groups (three groups have never been used and three
groups have been used) of 12mm and 16mm diameter rebar, and the testing
results were all qualified. [Testing reports for shell rebar dynamics performance]
我方委托当地有资质的实验室(加尔各答)进行混凝土钻芯取样试验。根
据试验结果,所有取样合格。
According to witnessed testimony, when the accident occurred that day, there
was furious storm with strong thunder and lightning at construction site: “at that
time “fierce wind” at site, difficult for persons to advance and even the office
doors could not be closed”, “the wind was too strong, although #2 turbine hall
roof had already been enclosed there’s no place to shelter from wind & rain”,
“fierce wind, lightning flashes and thunder rumbles and rainstorm pouring”,
“accompanied strong lightning from the sky to the ground and the situation was
quite shocking”, “the strong wind made the windows sound heavily and I had
never experienced so strong wind”.
Generally speaking, wind velocity of gust is 50% or even stronger than average
wind velocity. The stronger the average wind velocity is, the rougher the ground
surface is, and the wind velocity of gust is more percentage than average wind
velocity.
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Analysis Report On The Accident Of #2 Chimney Collapse
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Analysis Report On The Accident Of #2 Chimney Collapse
Through review and examination for the lightning record, we thought: the
lightning report provided by IPLN Company showed that there were nine times
of thunder strokes within 6km around #2 chimney when the accident occurred,
and the occurring time of the lightning record conformed to the collapse time of
chimney; although there was slight difference between the coordinate of
measured thunder stroke and the coordinate of #2 chimney (22°23′50″ north
latitude and 82°44′23″ east longitude), in view of the working principle and
inherent error of lightning locator, it could be confirmed that chimney collapsed
accident conformed to thunder stroke record information.
¾ Witness Statement
B.C.Chatterjee (GDCL site staff) reported that before the collapse they saw a
lightning entered the hollow of the top of chimney. [20091027 GDCL Technical
Committee Report Annex 1 - Eyewitness Report on Chimney Mishap at Korba].
3. Man-made Factors
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Analysis Report On The Accident Of #2 Chimney Collapse
From 3rd Nov.2009 to 14th Nov.2009, several field surveys for the cleared chimney
site have been conducted by our investigation team, and detail surveys and
investigations have been done for the cleared chimney foundation, the remaining
concrete at the bottom of chimney shell, shell reinforcement, the broken concrete
scattering distribution when the chimney collapsed and the distribution of surrounding
buildings/ structures. Details are as follows:
烟囱北侧
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Analysis Report On The Accident Of #2 Chimney Collapse
Photo-6 Bird’s View of working platform for Water Wall of boiler (North to chimney area)
North to Chimney
Photo-7 Bird’s View of working platform for water wall and ESP hopper (N by E area of Chimney)
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Analysis Report On The Accident Of #2 Chimney Collapse
Chimney foundation surface is cleaned. There are several deep pits with water in
them at outer side of foundation which were used for checking the quality of
pouring pile under the foundation. Showed in Photo-8 and Photo-2 ~ Photo-4.
From the foundation surface, we did not find any apparent cracks or damages,
except for some scratches by excavator. Foundation concrete quality is good as
seen at site. See Photo-9 and Photo-10.
South of
Chimney
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Photo-9 Integrality status at the top of chimney foundation
After the collapse of the chimney, the broken concretes are mainly dropped at
chimney north by east - each platforms of ESP, hopper and working platform for
water wall area which is at north by east side of chimney. The sizes of broken
concretes are not the same: the ones which are at #3 ESP area are bigger, the
ones which are at working platform for water wall are smaller, and some are
even like powder; the down sides of two hoppers of #3 ESP from south are
blocked by big broken concretes; although the 4 hoppers from north are not
blocked, there are many small concrete pieces on the ground under the hoppers;
besides, many stairs and steel grids at each platform of #3 ESP were broken by
concrete pieces. See Photo-11 ~ Photo-20.
Analysis Report On The Accident Of #2 Chimney Collapse
Photo-11 blocking status A of broken concrete (the west hopper on south side of #3 ESP)
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Analysis Report On The Accident Of #2 Chimney Collapse
Photo-12 blocking status B of broken concrete (the lower part of east hopper on south side of #3 ESP)
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Analysis Report On The Accident Of #2 Chimney Collapse
Photo-13 scattering status A of broken concrete (EL 9.1m platform of #3 ESP area )
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Analysis Report On The Accident Of #2 Chimney Collapse
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Analysis Report On The Accident Of #2 Chimney Collapse
5.3kg
12.8kg
34.5m away from the
center of the chimney
slid form
component
12.3kg
35m away from the
center of the chimney
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Analysis Report On The Accident Of #2 Chimney Collapse
20.9kg
36.4m away from the
center of the chimney
5.9kg
24.9kg
37.5m away from the
center of the chimney
4.2kg
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Analysis Report On The Accident Of #2 Chimney Collapse
Concrete pieces at working platform for water wall of boiler at north side of
chimney are very dense. The pieces are very small, and they are mainly like
powders. See Photo-21 ~ Photo-26; There are a bit of concrete pieces at boiler
operation platform area which is far from chimney. See Photo-27.
Photo-21 scattering status A of broken concrete on the water wall of boiler (at north side of chimney)
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Analysis Report On The Accident Of #2 Chimney Collapse
Photo-22 scattering status B of broken concrete on the water wall of boiler (at north side of chimney)
Photo-23 scattering status C of broken concrete on the water wall of boiler (at north side of chimney)
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Photo-24 scattering status D of broken concrete on the water wall of boiler (at north side of chimney)
Photo-25 scattering status E of broken concrete on the water wall of boiler (at north side of chimney)
Photo-26 scattering status F of broken concrete on the water wall of boiler (at north side of chimney)
Photo-27 scattering status of broken concrete on the operation level of boiler(at north side of chimney)
Analysis Report On The Accident Of #2 Chimney Collapse
Photo-33 shows that after the collapse, there was a new pile of earth at the north
side of the chimney. According to the relevant position between this new pile of
earth and buildings around chimney in the picture, we can conclude that the new
pile of earth is backfilling earth of chimney foundation raised by the falling of
the root of chimney shell. The new pile was pushed 5 meters to north side of the
chimney shell.
From the photos taken after the accident, there are laminated concreted shells at
the bottom of chimney which fell down to the south side. It is presumed that the
circled shell was damaged by extrusion, while the inner sides were covered each
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Analysis Report On The Accident Of #2 Chimney Collapse
Photo-29 Overlap condition A of the bottom section of chimney shell after collapse
Photo-30 Overlap condition B of the bottom section of chimney shell after collapse
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Analysis Report On The Accident Of #2 Chimney Collapse
Broken concrete and pulverized concrete piled up at the root of chimney shell, it
was analyzed that the same may be caused by the piling of the concrete pieces
which was resulted by the inside recessing damage of the middle part and root
part of chimney shell. The details are as indicated in Photo-30 & Photo-31.
It is presumed according to photos taken on site, all wrecks of slip form system
and operation platforms fell at the south side of the chimney, and they fell down
first. Some of the slip form system and operation platform fell down at 20m to
30m of south-east side of the chimney.
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Analysis Report On The Accident Of #2 Chimney Collapse
EL 223m (2009.09.08)
EL 186m
EL 146m
EL 106m
EL 66m
EL 26m
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Chapter-9 Fracture Morphology Analysis of Chimney Collapse
We analyzed and speculated through survey data from the chimney collapse at
site and various existing photos & data after chimney collapsed and witnessed
testimony, and there were the following morphologies for chimney collapse
breaking:
¾ The chimney shell suffered from thunder stroke in the strong wind in a
sudden way, and the chimney shell also bore many strong effects of
complex impacts, consequently the part at the tens meters of the top of
concrete shell broke off with destructiveness towards southern side; the
Analysis Report On The Accident Of #2 Chimney Collapse
slip form platform fell on the ground in the southern side of the chimney
and the concrete debris of shell cracking scattered in #3 ESP in the
direction of north by east.
¾ Under the joint impacts of chimney top section’s breaking fracture pull,
pressure, torsion and strong wind, the concrete shell in the middle section
suffered from partial destabilization, inside concave and inflexion, and
broken concrete fell and filled inside the shell in the chimney bottom.
¾ chimney bottom section suffered from the joint effects of pull, pressure
and torsion from the middle section’s, and the concrete shell in the bottom
flue opening and holes remaining position of the opening was pressed and
damaged, then collapsed towards south by east with the collapsed debris
remained about 75m.
Photo-34 fresh earth deposits after concrete shell collapsed (in the chimney northern side)
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Analysis Report On The Accident Of #2 Chimney Collapse
In conclusion of the above analysis, #2 chimney designs for BALCO project satisfied
the related standard and requirements, construction facilities and materials satisfied
the requirements of designs and specifications, construction technology was
reasonable and construction management was in order.
To sum up the site weather conditions, debris distribution after chimney collapse,
concrete debris distribution conditions and witnessed testimony that day, and after our
analysis of all aspects we think that, under the complex impacts of strong thunder and
lightning and strong wind, some section of #2 chimney shell upper portion or top of
chimney firstly suffered from damage, causing top section damaged fracture, and the
bottom shell suffered integrated effects of torsion, pull, pressure and impact and
continuously collapsed and damaged.
We shall try all our efforts to obtain updated information and execute analysis
continuously. If there’s further result, we will complement the investigation
report in a timely manner.
Chapter-11 Appendices
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Analysis Report On The Accident Of #2 Chimney Collapse
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Various physical phenomenon and damage due to thunder stroke discharging are as
follows:
Electricity Effects:
When thunder stroke discharging, there can be produced ten thousand volts impulse
voltage;
Heat Effects:
when several dozens to several thousands Amps of strong thunder and lightning
current passed conductor, it can be changed to a lot of thermal energy in extremely
short time. Taking medium thunder as example: instant power P of thunder main
discharging is extremely large, take I=50kA, arc road drop E=”6kV”/m, thundercloud
is calculated by 1000m height, main discharging power
P=”UI”=50x6x1000=300,000MW, it is even higher than any power plant’s power all
over the world at present. This shows that thunder discharging instant power is
extremely high, i.e. the destructive power is extremely high.
Mechanical Effects:
due to thunder’s heat effects, the air in the thunder passageway expanded when heated,
and meanwhile make water content and other matter resolve into gas and spread
around by supersonic velocity, therefore, there’s strong mechanical pressure inside the
objects stroke by lightning, causing the stroked objects suffering from severe damage
or causing explosion.
Other Effects:
There are such effects as electromagnetic induction and thunder incoming wave, etc.
of other effects for thunder.
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