B&W Vølund
Enhancing Efficiency and Safety at Margam Green Energy Plant
Client:B&W Vølund, Margam Green Energy
Location: Wales, UK
Services Required:
• General Visual Inspection of the Flue Gas Stack (External and Internal)
• Non-Destructive Testing (NDT) Integrity Inspection of the Flue Gas Stack
• Asset Integrity NDT Inspection of High-Pressure Steam Main Pipework
• Internal General Visual Inspection of the Boiler Furnace
• Flue Gas Stack Repair and Confined Space Rescue
B&W Vølund
Introduction
Sutro Group was commissioned by B&W Vølund to perform a range of inspection and maintenance services at the Margam Green Energy Plant in Port Talbot, Wales. The 40MW wood-fired power station, which began commercial operation in 2019, required comprehensive inspection and maintenance as part of its scheduled outage to ensure continued efficient and safe operation.
Benefits and Savings
Utilisation of UAVs (drones) for inspections reduced the need for scaffolding, saving significant time. Traditional inspection methods would have taken approximately 6 days; using UAVs, the task was completed in 2-3 hours.
Confined space rescue provisions ensured compliance with safety regulations and prepared the site for emergency situations.
UAV inspections significantly cut down inspection costs. Traditional methods would have cost approximately £205k (scaffold erection, rope access, and dismantling), whereas UAV inspections cost around £2-3k.
Detailed inspections and immediate repairs maintained the plant’s operational integrity and prevented potential downtime.
Project Overview
The Margam Green Energy Plant generates renewable electricity for up to 75,000 homes and employs 30 people. Sutro Group provided critical services during the plant’s 2021 outage, including various inspection and maintenance tasks on the plant’s infrastructure.
Challenges
- Conducting thorough inspections in confined and potentially hazardous environments.
- Ensuring minimal disruption to plant operations while conducting necessary maintenance.
- Adhering to strict safety regulations, particularly regarding confined space entries and rescues.
Innovative Approach
Flue Gas Stack Inspection
Sutro Group utilised both rope access and UAV technologies to perform comprehensive visual inspections of the 65m high steel plate chimney. This approach allowed for full circumferential inspection without the need for extensive scaffolding.
Boiler Furnace Inspection
The use of the Elios 2 internal UAV for inspecting the boiler furnace negated the need for manned entry and scaffolding, drastically reducing both the inspection time (from several days to a few hours) and associated costs (from approximately £205k for scaffolding to £2-3k for UAV usage).
Conclusion
Sutro Group successfully executed a range of inspection and maintenance services for the Margam Green Energy Plant, ensuring the continued safe and efficient operation of the facility. The use of advanced UAV technology and rope access methods not only enhanced safety and efficiency but also provided significant cost savings. Sutro Group’s commitment to innovative solutions and stringent safety standards positioned them as a key partner in maintaining the integrity of critical energy infrastructure.
For more information on how Sutro Group can optimise your inspection processes, contact us today:
0800 069 9395
info@sutrogroup.co.uk
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