Near catastrophe at Holyrood

Ashley Fitzpatrick
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No injuries, but machine repair will cost $13.2 million

The noise hit first — metal on metal. Then came the thick smoke.

It was about 6:40 a.m. on Jan. 11 and the failure in an internal system pushing lubricating oil into a massive turbine unit at the Holyrood Thermal Generating Station was causing the machine to chew itself up inside.

The sound was enough to bring power plant operator Matt Hutchings to the window of the control room. He was soon gearing up for emergency response, heading to fight some fire, he told The Telegram. As he did, a power outage was hitting much of Newfoundland.

With a blizzard raging outside, snow and salty spray had been causing problems with equipment at the switchyard feeding the Holyrood power plant. Those problems resulted in voltage issues inside, causing systems to switch to protective, isolating backups.

Put simply, the backup for the lubrication system on one of the plant’s three generators did not work as it was supposed to. The insides of the generator started to grind in just 28 seconds. That started the noise.

Within two minutes the fires started, releasing heavy smoke, as internal seals were breached and oil leaked into areas where it should not be. The oil ignited as it hit machinery running as hot as 1,000 F.

A safety video that is required viewing by every guest to the Holyrood power plant — including reporters who toured the plant on Wednesday — makes reference to an onsite team of emergency response technicians.

Only one emergency response technician was scheduled to work on the day the Unit 1 generator caught fire and they did not make it in to work because of the storm.

It left the six operators inside the plant to deal with the situation on their own.

The Telegram spoke briefly with Hutchings about what it was like to be one of the heroes of Holyrood, before being told he was not an official spokesperson for Newfoundland and Labrador Hydro.

One of the designated spokespeople is Terry LeDrew, a manager at the plant who has been on the job for 22 years.

LeDrew was upfront about the seriousness of the event.

“The building got pretty dark,” he said, noting the trouble outside caused a blackout inside before the facility’s emergency lighting kicked in.

Even so, when a piece of equipment — so heavy the cover is lifted off with an overhead crane — starts to shake, you feel it as much as see it.

“It danced,” LeDrew said, noting he had not seen a failure of this kind in 22 years on the job.

The generator normally powers down over the course of about 40 minutes, he said. In this case, it was locked up solid in seven.

“I know this is a bad-news story, but there would have been much more significant damage if we hadn’t had good intervention from our staff here,” he said.

“The operators are well-trained in response to this type of event, and they responded and put the fire out and prevented any further damage,” said Rob Henderson, vice-president of Newfoundland and Labrador Hydro and a second official spokesman.

There were no injuries.

In large part as a result of the emergency event at the Holyrood plant, 65,000 Newfoundland Power customers were left without electricity.

Within a day, the number of outages was reduced to about 6,300. Scattered outages were still being reported in the St. John’s-Mount Pearl area four days later.

At the station, Unit 1 required days to cool and six weeks to disassemble.

There are five bearings for the unit. All five were destroyed by the lack of proper lubrication.

As the investigation has progressed, individual unit parts have been removed, sandblasted and digitally tested, but that work continues.

Units 1 and 2 are from the same manufacturer and with similar hours of service. At this point, it’s unknown why the lubrication system on one failed and did not on the other.

Hydro’s estimated cost for finishing the investigation and getting Unit 1 back up and running is $13.2 million. That total includes investigative work completed to date, Henderson said.

He said there have been meetings with staff from the Public Utilities Board as Hydro’s investigation has progressed.

A detailed, formal application relating to the capital costs associated with the repair and reconstruction work was filed with the regulator even as reporters toured the power plant.

Henderson said the hope is to get repair work completed as soon as possible.

“Having this unit unavailable makes us unable to take the other units down to do the critical maintenance work that we need to do,” he said.

The goal is to have Unit 1 back in service in June, with the investigation finished and documentation filed with the board by July.

 

afitzpatrick@thetelegram.com

 

Organizations: Unit 1, Holyrood Thermal Generating Station, The Telegram Newfoundland and Labrador Hydro.One Newfoundland and Labrador Hydro Newfoundland Power Public Utilities Board

Geographic location: Holyrood, Mount Pearl

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  • fred squires
    April 05, 2013 - 09:17

    Thats a classic, who is the blame, plant operator or company who makes the generator.Surely when maintenance checks are applied the lubrication is number 1 on the list to take care of this expensive peice of equipment.the manager is reponsible to maintain this plant and report any concerns to the manufacturer about oil supplies to the generator.

  • doug
    April 04, 2013 - 14:47

    Well done to the operators at Holyrood for minimising the damages. But, why is Newfoundland Power looking to the PUB (and thus to we electricity users) to pay for their repairs? NFLD power is part of Fortis Inc, a publicly traded, profitable corporation. In fact, Fortis just announced a quarterly dividend of $0.34 per share, totalling some $65 million to their shareholders. That's over a quater of a billion annually! Surely they can afford to repair or replace their generator. If not, why are they not insured for such accidents?

  • wavy
    April 04, 2013 - 12:17

    "It left the six operators inside the plant to deal with the situation on their own. The Telegram spoke briefly with Hutchings about what it was like to be one of the heroes of Holyrood". The Fukushima Fifty: The Holyrood Half-case.

  • wavy
    April 04, 2013 - 10:54

    Wow, that's quite the story. Not to make light of the seriousness but that's one for the grandkids and drinking buddies. Must have felt like battling a mini Fukushima; a meltdown of a different sort. Thankfully, no one was hurt. Anyone who's had a portable generator or small engine run dry of oil knows what a state that turbine must be in. Locked. Up. Solid.

  • Winston
    April 04, 2013 - 09:17

    These units will operate for voltage support and Muskrat falls comes on stream. They are not part of the Holyrood shutdown, and will continue to essential equipment. We have a high winter heating load. Efficient heating would reduce the winter heating load with less need for these units, either for primary generation or voltage support. It is not just oil expense at Holyrood.

  • Maurice E. Adams
    April 04, 2013 - 07:04

    And why was there inadequate oil supply (and backup supply), or did you ask why there was inadequate backup oil supply to the bearings? What additional backup/procedure are needed (and will they be) put in place to protect the other generators?