7EA BEST PRACTICE: Eagle Point

Portable CO2 cylinder skid eliminates ergonomic hazards

Challenge. Reduce the potential for personal injury in the handling of CO2 cylinders stored at each of the plant’s hydrogen-cooled generators for routine and emergency purging.

When individual cylinders are emptied, new ones must be moved from a storage area located far from the point of use. Each 175-lb cylinder has to be lifted and maneuvered into position inside the storage cabinet provided for each generator (Fig 1). Between eight and 12 cylinders are used during a routine purge.

This creates several hazards—in particular, ergonomic issues associated with awkward body positioning and pinch points. Plus, with relatively few operators on shift, the existing procedure can take excessive time in an emergency situation.

Solution. The operations department’s Don Stasio developed a solution by rethinking the existing cylinder handling system. He and co-workers designed a six-cylinder crate which can be moved by forklift. A 10-ft hose is used to connect cylinders in the crate to the generator for purging (Fig 2).

The crate remains outside the cylinder compartment during purging. Two cylinders are retained in the cabinet for emergency use. After a purge is completed, the empty cylinders are moved back to the storage area by forklift.

Results. The cylinder handling system is performing as intended, mitigating injury risk to plant personnel.

Project participants:

Don Stasio, plant operator
Jeff Hawksworth, maintenance planner
Frank Meade, plant manager

Eagle Point Power Generation Facility

Owned by Rockland Capital Assets
Operated by NAES Corp
250 MW, gas-fired 2 × 2 combined cycle located in Westville, NJ
Plant manager: Frank Meade