NHA s Operational Excellence (OpEx) Program. Program Information & Safety Reports Summary. Visit:

Transcription

1 NHA s Operational Excellence (OpEx) Program Program Information & Safety Reports Summary Visit: Northwest Hydroelectric Association Meeting October 30, 2014

2 OpEx Introduction OpEx is: NHA program and member benefit with a new website hydroexcellence.org A voluntary event reporting system that receives, distributes, archives, and catalogs operating experiences and any resulting best practices and lessons learned. The only Event Reporting program and database available to the hydro industry A clearinghouse of all hydro related information event reports, best practices, lessons learned, and technical information OpEx Scope & Focus: Event Reports, Best Practices, and Lessons Learned in four functional areas: Safety Dam, Employee, and Public Operations Maintenance Environmental Performance OpEx is not policy, legislative, or regulatory in nature

3 OpEx Purpose A foundational goal of OpEx is to prevent a defining event in the hydropower industry. The secondary benefits of this goal results in improved safety, strict environmental performance, and reduced O&M costs and unplanned outages. Sayano Shushenskaya Hydro Plant August 17, 2009 Failure South Fork Dam Catastrophic Failure Johnstown, PA Flood May 31, 1889 Watts Bar Hydro Plant Fire September 27, 2002

4 Benefits of OpEx Participation Tool for managing aging assets Educational resource for training a workforce in transition Forum for learning and collaborating with fellow industry members: Best Practices Lessons Learned Event Reports Avoiding similar events experienced by others employee injuries, forced outages, and others Saving limited financial resources NHA Member benefit

5 Results To Date Overview Achievements to Date 38 Event Reports from: 14 Utilities including 8 reports from the Federal sector, 1 from an equipment supplier Sample Reports Loose Generator Rotor Pole Wedges Lower Turbine Shrink Ring Crack Turbine Discharge Ring Repair Penstock Hydraulic Valve Seal Failure n = Equipment Maintenance Environmental Event Reports By Functional Area 4 1 These Event Reports contain: 115 Corrective Actions 60 Lessons Learned 48 Recommendations 7 13 Operations Safety Procedure Adherence Over 35 member companies are participating in OpEx

6 Public Landing Page Web Address:

7 OpEx Main Page

8 Best Practices

9 Resources

10 Results To Date Safety Specific Safety Event Report Received & Titles 1. Drill Press Injuries 2. Carbon Monoxide Near Miss 3. Near Miss Incorrect Prints for 480V Feeder 4. Injury Working on Fire Water Pump 5. Gantry Crane Movement 6. Work performed outside of clearance limits 7. Control Room Fire Part 1 Description of Event Two employees were working on a Fire Protection Service Water Pump. One employee was holding a flashlight while the other employee was attempting to remove the old bearing race with a hammer and punch. The employee holding the flashlight received a fragment of metal into the forearm. Immediate Actions: Work was stopped Notified Site Management The employee was treated and return to work with no restrictions Conducted a safety stand down with personnel 10

11 Results To Date Safety Specific Part II Cause Analysis On site investigation and interviews: Improper tool use. Part III Corrective Action Plan Ongoing Actions: Develop a Job Safety Analysis to be utilized while performing maintenance on the Fire pump Develop a detailed work package for removal of pump rotating element The fire protection pump is a critical component. Procure and maintain a pump rotating element as a critical spare. Part IV Lessons Learned & Recommendations The pump element should have been removed from the pump casing and a bearing puller used to remove the old bearing. Use brass when removing case hardened pump components. 11

12 Conclusion & Next Steps Register at: hydroexcellence.org As the industry contends with aging assets and an aging workforce, OpEx and the event reporting system will provide a trusted and reliable database of historical and current operational issues and serve as an educational and training resource for future personnel.

13 OpEx Contact Information Further Information Contact: David Zayas National Hydro Association Phone: ext. 20 e mail: david@hydro.org Jim Miller Signal Hydropower Consultants, LLC Phone: e mail: ljmiller sec@epbfi.com Thank you 13