Skip navigation 
Previous Page
29
ENERGY INTERNATIONAL
June/July 2012 www.esb.ie/em
Safety Performance and Award Recognition
Generation Operations
MARINA GENERATING Station recently marked 10 years without a staff or contractor lost-time injury (LTI). Recognition must be given to staff, contractors, line management and other stakeholders who have worked on projects in the station over the years, as their commitment and continued dedication to Health & Safety made this milestone achievable.
After a sustained outage of more than 1,500 days, including the refurbishment works, Turlough Hill has reached synchronisation in their project without incurring an LTI. Once again, this is a significant achievement as there were more than 400,000 contractor and staff person-hours worked, with a peak contractor number of 120 during the project.
Rousch in Pakistan is two-thirds of the way through a 60-day outage. There is a significant scope of work being undertaken with the peak number of persons on site in excess of 700. To date, the overhaul is running to schedule with no significant incidents or LTIs recorded.
Erne Stations has completed approximately 670 days of its scheduled outage to date without an LTI. This is a considerable accomplishment as there have been over 150,000 contractor and staff person-hours worked, with a peak contractor number of 50 during the project.
Across all of ESB Generation, a significant milestone has been reached, as it is now more than a year since we last recorded a contractor LTI. These milestones have been reached through a concerted effort from staff and contractors to ensure that safety awareness and standards are at the forefront of everyone’s mind. This is a considerable improvement on previous years. It demonstrates that it is possible to achieve our goal of no staff member or contractor suffering an injury on our sites.
As identified in Safety Update Notice (SUN) 8, the purpose of the new Energy International Health & Safety Excellence Awards is to recognise achievements and other safety initiatives which have been implemented throughout our business. The above mentioned milestones will be given consideration for these awards, as they fit into the necessary criteria.
Even though this is a significant achievement, we must keep our eyes focused on the task ahead. The goal remains: zero injuries.
Implementing new safety rules at Moneypoint
Back-to-back overhauls at Aghada
Generation Operations
AGHADA UNDERTOOK AN ambitious project this year in scheduling two back-to-back combustion turbine (CT) generator overhauls, CT12 followed by CT14. Both units required major inspections of the generator and a cover lift of the CT compressor to inspect the blading. A dedicated project team, with Jim Murphy as Project Manager, was set up at an early stage in the project to ensure all elements of the planning phase were carried out in great detail.
Included in the generator workscope is the removal and non-destructive testing of both rotor end winding retaining rings. Retaining ring removal also facilitates replacement of the winding ‘omega’ connection. This ‘omega’ connection experiences a flexing/stress cycle each time the CT runs to speed. The ‘omega’ connections of CT12 and CT14 had both reached manufacturer’s life recommendation (1,500 starts) with resultant risk of opencircuiting in service with consequent non-availability of the unit while forced outage repairs are completed.
The contract for the major inspection was awarded to Quartzelec (UK) following a competitive tendering process. The work involves the removal and transport of both rotors to their works in Rugby for inspection and repairs. Although it is possible to complete the rotor works at site, it was deemed prudent to complete them at the repair workshop to ensure a rapid response to any ‘as found’ and winding spares requirements. The turnkey contract with Quartzelec also includes overhaul of the generator seal oil system and other generator auxiliary plant. A pre- and post-generator works performance test will be completed to ensure contract requirements are fulfilled.
The CT12 overhaul commenced on 20th February and the unit has been returned to service having successfully completed its performance test. CT14 rotor is currently at Quartzelec’s works in Rugby and was due back at site on 13th May with a target return to service date of 19th May.
The CT compressor inspection on both units revealed stator vane ‘tip rock’ issues which were addressed by shimming the stator vanes in their carriers. A GE erector was employed on site to oversee the compressor inspection, with works being completed by a combined ESB-contractor team.
This project has been exemplary from a number of perspectives and is a credit to the Project Team and all station staff. Prior to the commencement of the outages, the Project Manager convened a contractor safety conference with all the main and sub-contractors. The Station Manager, Paul Smith, opened the conference and reinforced the requirement for the highest standards of safety to be delivered throughout the durations of the outages. An expectation of good near-miss incidents and accident reporting was established from the outset with an incentive scheme to encourage staff and contractors to report all learnings. This has worked well and to date there has been no accidents on the project.
Also of note is the contractor laydown area which was well planned and organised, and the appointment of a Quality Manager to enhance the management of quality on the outages. The Quality Manager is supported by a third party quality assurance resource at the Quartzelec works, together with local support from Oistin McGrath of ESBI. These factors have had very positive effects on the works outcome, and the continued commitment, dedication and efforts of all staff will provide the necessary support to successfully complete the remaining outage works.
