Case Study

Accidental Site Inspection at NTPC Thermal and Solar Power Installation Plant

Case Study / /

Introduction
The Specialty Products and Services (SPS) team conducted a detailed site inspection at the NTPC Thermal and Solar Power Installation Plant in Solapur District, Maharashtra. This state-of-the-art facility, operated by GE Power India Limited, recently experienced a fire outbreak in the chimney’s internal chamber. The primary objective of the inspection was to evaluate the extent of the damage caused by the incident and implement a safe and efficient repair strategy.
Inspection Findings
The SPS team’s meticulous inspection revealed that the internal chamber of the chimney had suffered extensive damage. The fire had severely burned electrical cables and pipes, leaving them charred and tangled. This, in turn, led to the accumulation of significant debris within the chamber. The compromised condition posed challenges for repair, especially given the confined space and elevated height of the affected area.
Solution Implementation
Rope Access techniques were strategically employed to address the situation. This method, known for its safety, versatility, and efficiency in confined and high-altitude environments, was deemed the most suitable approach for repairing the damaged chimney chamber. A highly skilled team of 15 professionals, equipped with advanced Rope Access gear, worked diligently to clear the debris and restore the damaged section.
The SPS team meticulously executed the cleaning and repair tasks, demonstrating unparalleled expertise and precision. Thanks to their rigorous efforts and the adaptability of Rope Access methods, the entire restoration process was completed in under 10 days—a remarkable turnaround time for such a challenging project.
Recognition
Abhishek Kumar Singh, Senior Manager at GE Power India Limited, commended the SPS team for their exceptional performance. He highlighted the effectiveness of Rope Access in enabling a safe and timely repair and praised the team’s commitment to excellence. This acknowledgment underscores the reliability and professionalism of the SPS team in handling critical repairs under challenging circumstances.
By leveraging Rope Access technology, the SPS team reaffirmed its capability to deliver superior results, even in complex industrial environments.

Download this case study as pdf here

Accidental Site Inspection at NTPC Thermal and Solar Power Installation Plant Read More »

Rehabilitation of RCC Water Tank at TSLPL Using Rope Access and Work at Height Techniques

Case Study / /

Introduction
The RCC overhead water tank at TSLPL plays a critical role in supplying water for process operations. Over time, structural distress, such as cracks in the ring beams and columns, threatened the integrity of the tank. A comprehensive rehabilitation was undertaken, leveraging advanced techniques like rope access and work at height solutions to ensure safety, efficiency, and effectiveness during the repair process.
The Issue
A visual inspection revealed extensive cracking in the tank. The outer side walls exhibited more pronounced cracks compared to the inner walls. Additionally, signs of chlorination and concrete degradation were evident inside the upper water tank. These issues compromised the structural reliability and functionality of the tank.
Structural Assessment
To evaluate the extent of the damage, non-destructive testing (NDT) was conducted, with rope access technicians enabling inspections of challenging, elevated areas. The tests included:
● Rebound Hammer Test to assess concrete hardness and strength.
● Carbonation Test to measure carbonation depth and detect deterioration.
● Ultrasonic Pulse Velocity Test to locate cracks and evaluate concrete quality.
● Rebar Mapping to identify the condition of reinforcement bars.
● Chemical Tests to analyse concrete composition.
The results confirmed structural weaknesses, with significant cracks and deteriorated concrete in various sections.

Solution Provided
The repair process employed rope access and work at height techniques, ensuring safe and efficient access to the damaged areas. Key steps included:
1. Concrete Removal: Degraded concrete was carefully chipped away.
2. Surface Preparation: Exposed steel was cleaned and treated with a rust remover compound.
3. Corrosion Protection: Two coats of epoxy-based zinc primer were applied to reinforce corrosion resistance.
4. Bonding Agent Application: An epoxy bonding agent was used to secure adhesion with the new material.
5. Polymer Modified Mortar (PMM): The cracks and damaged areas were restored using PMM, ensuring structural integrity and durability.
Conclusion
The rehabilitation project restored the RCC water tank’s strength and functionality. Rope access and work at height methods proved instrumental, enabling precise, safe, and efficient repairs in elevated and confined spaces. By addressing structural concerns with advanced materials and techniques, the tank was returned to operational reliability, ensuring its longevity and performance for years to come.

Download this case study as pdf here

Rehabilitation of RCC Water Tank at TSLPL Using Rope Access and Work at Height Techniques Read More »

Dismantling of COG Gas Pipeline at LD Heat Area

Case Study / /

Introduction
Specialty Products and Services (SPS) successfully dismantled a 40-metre-high, 72-metre-long Coke Oven Gas (COG) pipeline within a strict 24-hour shutdown window. The project, located in the high-risk LD#2 Heat Area, required precision planning and execution to address the challenges of working at height and ensuring safety in a hazardous environment.
Findings
● Project Scope: The pipeline, divided into 12 sections of 6 metres each, was situated 40 metres above the ground. The operation had to be completed within a critical 24-hour window after a 2-year wait for shutdown approval.
● Challenges: Working at height in the LD Heat Area posed significant risks, including exposure to flammable gases, high temperatures, and the need for precise rigging in an active industrial zone. The continuous movement of personnel and vehicles added to the complexity of the task.
Assessment
A comprehensive working at height risk assessment was conducted to evaluate the logistical and safety challenges. The assessment emphasised the importance of secure rigging points, crane operations, and strict adherence to safety protocols. A total of 24 team members were deployed in shifts to maintain steady progress while ensuring safety.
Solution Provided
● Strategic Planning: A meticulous plan was formulated to address the high-risk nature of the project. The team prioritised safety, efficient access to height, and precision rigging operations.
● Execution: Utilising crane support and precise coordination, the SPS team dismantled and safely lowered the pipeline sections within the 24-hour shutdown period. The operation minimised disruption to the plant’s activities, reflecting the team’s expertise in high-risk, time-sensitive projects.
Recognition by Customer
The Field Maintenance Mechanical Department awarded SPS a certificate of appreciation for its exceptional performance, dedication, and ability to overcome significant challenges in a high-risk environment. This recognition reinforces SPS’s reputation as a trusted partner for complex industrial operations involving access at height and stringent risk management.

Download this case study as pdf here

Dismantling of COG Gas Pipeline at LD Heat Area Read More »

Scroll to Top