Corus keeps power on

Scunthorpe, UK - The next three years are likely to be challenging for the Corus plant in Scunthorpe, with energy consumption among the major issues being faced by engineers tasked with optimising the cost effectiveness of the site’s production activities.

Key to this battle is the central power station, which provides the bulk of the site’s electricity. Much emphasis is, therefore, being given to ensuring the trouble-free operation of the six steam turbines for the power station that can generate up to 53 MW of energy for the plant.

“Energy prices remain high so it is in our own interests to reduce the need to draw from the National Grid by maintaining reliable equipment in our own plant,” said Wolfgang Hahn, manufacturing manager for the central power station at Corus Scunthorpe. “If we increase the reliability and availability of our equipment, we can increase the power generated to the plant and reduce our costs significantly.”

When turbine No. 5 was taken off-line for routine maintenance, cracks in the generator’s retaining rings were found, which presented serious safety risks to plant personnel, as well as the prospect of lengthy downtime and lost production. The discovery prompted a HAZOP (Hazard & Operability Analysis) study on an identical generator, turbine No. 4, which highlighted the need for an early-failure detection system.

Corus installed an online vibration monitoring device - a DTECT X1 system from Schaeffler - on the exciter end bearing and the turbine end bearing of turbine No. 4. The device soon detected a problem with one of the rotor blades.

“Our attempts to protect this generator paid off,” said Chris Smith, Scunthorpe’s plant condition monitoring engineer. “By picking up the blade failure early on, we were able to prevent the failure of the whole turbine. In lost generation alone, this machine is worth £35,000 a day.”