24.04.2023
The program was implemented in four generating machines of two of the company’s hydropower plants and became a reference for the electric power sector
CTG Brasil implemented a specific safety risk management system for the modernization process of the Jupiá and Ilha Solteira hydropower plants. The company’s pioneering spirit was based on the development of specific safety operational procedures and the adaptation of the NRs (Regulatory Norms for Work Safety) requirements to meet the complex nature of the activity.
The management system implemented by CTG Brasil had as initial challenges the identification, mapping and dimensioning of the risks inherent to each stage of the work. In addition, the implementation of necessary measures to ensure the effective safety of the professionals and cause the least possible impact on the operation of the plants was considered.
“We created a flexible safety management strategy for hydropower plant modernization processes that allowed us to make adjustments as the activities progressed. We implemented procedures to maintain fluid interaction between the modernization and operation teams, managing points of conflict and ensuring the full completion of activities in parallel,” explains Aljan Machado, CTG Brasil’s Director of Health, Safety and Quality.
The main actions of the implemented management model were:
- Implementation of a specific organizational structure for Occupational Health and Safety;
- Comprehensive supervision and monitoring of critical tasks;
- Implantation of specific procedures for critical phases, such as commissioning and stress tests;
- Management of high risk activities (use of software and safety inspections);
- Simulated rescue at height before the execution of the activity;
- Training;
- Participation of safety professionals at the beginning of the planning of activities;
- Development and implementation of a safety technical support process for the companies that present the most deviations (Safety Mentoring);
- Creation of specific working groups for the main deviations;
- Engagement of the Modernization Deliberative Committee;
- Contractor access control;
- Collective protection projects with ARTs;
- Safety Performance Awards for contractors.
For the team involved in the project, one of the biggest learnings was the Preliminary Risk Analysis (APR), a phase in which the technical evaluation of possible risks that could threaten the health and safety of workers is done. “The APR has become an important management tool for the execution of any activity. Our field teams are only authorized to start work after APR verification and clearance. Besides reinforcing our focus on zero accidents, it optimized the time of the professionals involved and the deadline to be met in each step,” says Valdinei Miquelin, Operational Manager of Occupational Health and Safety.
The management system implemented by CTG Brasil achieved significant positive results that allow the company to replicate it for the modernization of other assets, besides making it a successful example for the entire electricity sector.
Results
Since it was started, the program has recorded more than three years with no lost time accidents – own employees and third parties, and a continuous reduction in the severity of injuries. The safety project found that, through the analysis of the management system information, it is possible to identify and prioritize the highest risk activities and optimize the distribution of the safety team in the work fronts. It also noted the permanent involvement of the leadership of CTG Brasil in the management of safety requirements and the treatment of deviations. CTG Brasil also recorded the reduction of the workforce turnover of the contractors.
Statistics 2020 – 2022
- 4 million hours worked
- 45 contractors
- 298 employees
- 7,245 inspections performed
- 3,908 deviations identified and treated
- 3,000 participants in the safety integration training sessions
With the project underway, the safety requirements for each stage of the modernization process were standardized: opening of the generating unit, removal of components, commissioning, and release to the National Electric System Operator (ONS).
The management system generated results not only in health and safety at the plants, but also boosted the evolution of the management of third-party companies involved in the modernization program. “We apply workshops, hold semiannual meetings and even offer mentoring to engage each of the contractors in the procedures. Our role is also to provide the necessary support for this supplier to improve its own safety management and, consequently, to evolve in quality and results, impacting the sector as a whole,” says Aljan Machado.
Modernization Project
The largest and most important hydroelectric plant modernization project in the country continues with full power until 2023. Conducted by CTG Brasil, one of the largest clean energy generators in the country, the modernization enters a new phase this year with a bidding process for the third lot, which covers the refurbishment of six machines of UHEs Jupiá and Ilha Solteira, three each.
Since it started, in 2017, 9 machines have already been renovated at the two plants. The first batch modernized four machines; the second and current batch completed the renovation of five machines and will deliver one in the first half of 2023 and another two by the first half of 2024. Considered the largest modernization program underway at a 100% national plant, the project will increase availability and reliability of operations and ensure the efficiency of the power generation system for another 30 years.
As part of the modernization project, CTG Brasil inaugurated a new Generation Operation Center (GOC) at the Ilha Solteira Hydroelectric Plant. The space now commands, monitors, and supervises 12 hydroelectric plants and two Small Hydroelectric Plants (PCHs) of the company, totaling about 7.6 GW distributed in seventy generating units.
