perspectives on wind turbine safety · technicians focus on systems “safety-ii” our framework:...
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Perspectives on Wind
Turbine Safety
Dr. Nat Janke-GilmanMeridian Energy Ltd.
NZ Wind Energy Association2 May 2018
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Safety first!
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Wind Turbines are dangerous!
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Date Location Event
2 Feb 2017Ramnagar wind farm,
IndiaContractor electrocuted in substation
15 Mar 2017Kilgallioch wind farm,
ScotlandContractor fell 5 m from yaw platform
27 Mar 2017La Bufa wind farm,
MexicoContractor fell 25 m from tower platform
29 Mar 2017Whitelee wind farm,
ScotlandMaintenance worker fell from nacelle to ground
31 Mar 2017Rayala wind farm,
IndiaWelding in turbine started a fire
18 Apr 2017Deerfield wind farm,
USAMobile crane contacted HV overhead line
3 May 2017Jamnagar wind farm,
IndiaMobile crane contacted HV overhead line
8 May 2017Esbjerg harbour,
DenmarkContractor pinned between blade and trailer
17 Jul 2017Binhai North H2
(offshore), ChinaFire in offshore substation, worker drowned
Fatalities during Feb–July 2017
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Date Event
2 Feb 2017 Contractor electrocuted
15 Mar 2017 Contractor fell
27 Mar 2017 Contractor fell
29 Mar 2017 Worker fell
31 Mar 2017 Welding fire
18 Apr 2017 Crane contacted HV
3 May 2017 Crane contacted HV
8 May 2017 Contractor pinned
17 Jul 2017 Offshore substation fire
Fatalities during Feb–July 2017
Key findings:
• Mostly contractors
• Not all in-turbine (substation, cranes, etc)
• Fall protection not applied
• Lock Out procedures not applied
• Hot Work procedures not applied
• General violations of existing procedures
• Unplanned work
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FAILURE RATE
TIME
BATHTUB CURVE OF HUMAN ERROR
NEW GUY
MISTAKES
OLD GUY
VIOLATIONS
2-3
YRS
20+
YRS
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Death of an Elevator Technician
• Wellington-based technician for Otis elevators
• Crushed to death, 2016
• Coroner’s inquest, 2018
• Pit switch not engaged(or tripped off)
• 27 years experience, Level 4 service tech
• Official procedure differed from
Actual procedure
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POLICEthe Techs
Evolution of a Safety Culture
Punish the crimes
TRAINthe Techs
Teach away the errors
SUPPORTthe Techs
Fix the systems and manage the problems
SAFETY
CULTURE
Stop counting errors and attributing
blame!
Focus on technicians
Focus on systems
“Safety-II”
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Our framework:Wind Turbine Safety Rules
To achieve Safety From The System:
1. all work in the turbine is planned work…
2. following an Approved Written Procedure…
3. which lists approved isolations and safety steps.
The primary goal is technician safety
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Job Safety Analysis
Worksite Safety Plan
Approved Written Procedure(or Routine Operating Procedure)
Work Instructions
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Job Safety Analysis
• About 30 generic JSAs
• Several individual task-based JSAs
• Hazards, Risks, and Control Measures
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Worksite Safety Plan
• Toolbox talk, before the job
• Summary of Hazards + Controls
• List of related documentation
• Emergency Rescue Plan
• Everyone signs on
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Worksite Safety Plan
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Worksite Safety Plan
Task-specific content is highlighted in blue
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Approved Written Procedure
• Safety checklist – during the job
• Isolations and safety steps (only)
• Includes regulatory requirements, like pre-use checks
Routine Operating Procedure
• No isolations, just a few safety steps
• General work only
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Approved Written Procedure
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Approved Written Procedure
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Work instructions
•How to actually do the job
•Also charts, diagrams, other notes
• Keep this information out of the other formal documentation
• Encourage techs to help build up this body of IP.
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Work instructions
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Work instructions
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Wind Turbine Safety Rules: Docs
JSA
WSSP
AWP(ROP)
WI
Plus:
• Meridian’s WTSR Rules(our booklet of the actual rules)
• Management Instructions(guidance for odd situations)
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Paperwork
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Wind Turbine Safety Rules: Roles
Authorising
Engineer
Safety
Specialist
ApprovalSafety
Review
Technical
ReviewDraft
Technical
Specialist(Siemens)
Technical
Specialist(Vestas)
Technical
Writer
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Wind Turbine Safety Rules: Roles
Competent
Technician
Authorised
Technician
“Basic permit competency”
Trained in:• safe turbine operation• isolations• boundaries of work
Routine Operating Procedure (general work, no isolations)
“Advanced permit competency”
Demonstrated competency in:• the WTSR rules• How to handle situations
where the rules break down
Approved Written Procedure (apply LOTO isolations)
…this is NOT technical competency
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But what about…
•Doesn’t having a script of isolations dumb it down?
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NO!
But what about…
•Doesn’t having a script of isolations dumb it down?
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But what about…
•Doesn’t having a script of isolations dumb it down?
•What if there’s no AWP written for this job yet?
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Then the
job waits
But what about…
•Doesn’t having a script of isolations dumb it down?
•What if there’s no AWP written for this job yet?
We’ve got people working on it…
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But what about…
•Doesn’t having a script of isolations dumb it down?
•What if there’s no AWP written for this job yet?
•What if, mid-job, I see something else to fix? Do I just leave it?
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YES
But what about…
•Doesn’t having a script of isolations dumb it down?
•What if there’s no AWP written for this job yet?
•What if, mid-job, I see something else to fix? Do I just leave it?
If it’s dangerous, lock it out. Otherwise, just raise a new work order.
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But what about…
•Doesn’t having a script of isolations dumb it down?
•What if there’s no AWP written for this job yet?
•What if, mid-job, I see something else to fix? Do I just leave it?
• Isn’t this less efficient?
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YES (we know)
But what about…
•Doesn’t having a script of isolations dumb it down?
•What if there’s no AWP written for this job yet?
•What if, mid-job, I see something else to fix? Do I just leave it?
• Isn’t this less efficient?
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Our framework:Wind Turbine Safety Rules
To achieve Safety From The System:
1. all work in the turbine is planned work…
2. following an Approved Written Procedure…
3. which lists approved isolations and safety steps.
The primary goal is technician safety
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POLICEthe Techs
Evolution of a Safety Culture(Safety-II)
Punish the crimes
TRAINthe Techs
Teach away the errors
SUPPORTthe Techs
Fix the systems and manage the problems
SAFETY
CULTURE
Stop counting errors and attributing
blame!
Focus on technicians
Focus on systems