Spill Control in Power Generation: Managing Hydraulic Oils, Fuels & Coolants

In the power generation and combined heat and power (CHP) sector, effective spill control is crucial for the safety of personnel and the environment. Facilities that handle hydraulic oils, fuels, lubricants, coolants, and maintenance chemicals must adhere to stringent regulations and best practices to prevent spills that can lead to hazardous situations and environmental damage.

1. Introduction & Context

Spill control is a significant aspect of operational safety in power stations and CHP plants. The presence of hydraulic oils, diesel fuel, transformer oils, coolants, lubricants, and water treatment chemicals poses risks that can lead to spills if not properly managed. According to the HSE Power Generation guidance, these substances can cause serious harm to both personnel and the environment, highlighting the need for comprehensive spill management strategies.

2. Regulatory Backdrop (UK-specific)

The UK’s regulatory framework for spill management includes several key regulations. The Control of Substances Hazardous to Health (COSHH) requires employers to control substances that can be hazardous to health, including oils and chemicals used in power generation. The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) specifically address the risks associated with flammable liquids.

The Environment Agency outlines pollution prevention guidance, stressing the importance of bunding and secondary containment for hazardous substances. For sites with significant oil and fuel inventories, the Control of Major Accident Hazards (COMAH) regulations apply, requiring further safeguards and reporting mechanisms.

3. Hazard Mapping for Power Stations & CHP Plants

Identifying potential spill sources is critical in the prevention of incidents. Common sources in power stations and CHP plants include:

  • Turbine hydraulic systems
  • Diesel backup generators
  • Transformer bunds
  • Lubrication skids
  • Pump and seal failures
  • Pipe flange leaks
  • Coolant handling areas
  • External fuel tanks and Intermediate Bulk Containers (IBCs)

It's also essential to assess spill pathways, especially regarding watercourses and floor safety around lubrication and cooling systems, to mitigate risks effectively.

4. Controls & Engineering Measures

Implementing robust controls and engineering measures can significantly reduce the risk of spills:

  • Bunding and Secondary Containment: Ensure that all hazardous materials are stored in bunded areas to contain any potential leaks.
  • Drip Trays: Use drip trays under machinery to catch leaks and spills. Explore our drip tray options.
  • Oil Interceptors and Bund Alarms: These systems help monitor and manage spills effectively.
  • Oil-Resistant Absorbent Fibres: Utilise absorbents specifically designed for high-viscosity hydraulic fluids. See our oil-only absorbents.
  • Drain Protection: Implement drain covers to prevent contaminants from entering water systems. Check our drain protection solutions.
  • Ventilation and Ignition Source Control: Maintain proper ventilation and control ignition sources in areas where flammable liquids are stored.
  • Earthing and Anti-Static Measures: Particularly in generator rooms, to mitigate the risk of fire.

Using the correct absorbents is vital. For example, oil-only absorbents are suitable for hydrocarbons, while universal absorbents can handle mixed liquids, and chemical absorbents are essential for coolants and other maintenance chemicals.

5. Choosing the Right Spill Kits for Power Generation

Selecting the appropriate spill kit is crucial for effective spill management. Match the kit type to the specific hazard:

  • Oil-Only Kits: Ideal for hydrocarbons; see our oil spill kits.
  • Universal Kits: Suitable for mixed liquids.
  • Chemical Kits: Necessary for spills involving coolants and other treatment chemicals; explore our chemical spill kits.

When choosing spill kits, consider their size, contents, and mobile spill stations. Position them strategically near turbines, generators, fuel stores, and workshops for easy access.

6. Procedures & Training

Effective spill management requires well-defined procedures and thorough training. Key components include:

  • Immediate Response Actions: Train staff on swift actions to contain spills, such as stopping the source and isolating pumps.
  • First Containment Steps: Use booms and pads for initial containment.
  • Drain Protection Deployment: Ensure staff know how to deploy drain covers effectively.
  • PPE and Safety: Emphasise the importance of personal protective equipment during spill response.
  • Night-Shift Procedures: Implement specific protocols for night shifts to ensure continued safety.
  • Contractor Induction: Provide spill management training for maintenance teams and contractors.

7. Waste Management & Documentation

Proper disposal of absorbents contaminated with hydrocarbons, diesel, coolants, and chemicals is essential for compliance with the Environment Agency's hazardous waste requirements. Establish protocols for disposal and ensure all staff are trained on these procedures.

Maintain documentation of near-miss reports, bund inspection logs, and spill response actions as evidence for audits. This documentation supports compliance with relevant regulations and demonstrates a commitment to safety and environmental protection.

8. Practical Tools

Implement the following practical tools to enhance spill management:

  • Spill Response Flowchart: Tailor a flowchart specific to power stations for staff reference.
  • Bunding and Containment Inspection Checklist: Regular inspections are vital for ongoing compliance.
  • Plant-Room Quick Reference Card: Provide a quick reference for staff to ensure immediate action can be taken when necessary.

9. Case Study

Consider a scenario where a hydraulic hose fails on a turbine lubrication skid, leading to a significant oil spill. Without adequate containment measures, the oil could flow into nearby drains, risking environmental contamination. However, by implementing proper bunding, using oil-only absorbents, and establishing a rapid response protocol, the facility can effectively contain the spill and mitigate further damage. This case illustrates the importance of investing in spill management solutions and training for all personnel.

10. FAQs

  • Can oil-only absorbents pick up synthetic turbine oils?
  • What’s the best spill kit size for a generator room?
  • Do I need drain covers even with existing bunding?
  • How often should spill kits be inspected?
  • What’s the correct absorbent for glycol coolant spills?

11. Conclusion

Robust spill control measures are essential to protect operational uptime, reduce environmental risks, and ensure compliance with UK regulations. By investing in effective spill management solutions, including Serpro’s spill kit ranges and bunded containment products, facilities can safeguard their operations and the environment.