Castell supplies safety interlocks to large hydropower project in China

More than 5bn yuan invested in new plant in Xianju

In a first for the company, Castell is participating in the construction of a Chinese hydropower plant.

More than 5bn yuan (£535m) has been invested in the hydropower plant project in Xianju, Zhejiang province.

Castell will provide multiple sets of FS industrial safety interlocks and key exchange boxes for the large project currently under construction in Xianju, Zhejiang province. These devices prevent the busbar earthing switch from connecting during maintenance on high-voltage switchgear, and so guarantee the safety of maintenance staff.

Tian Xinhai, Castell China sales manager, said: “This is the first time Castell has entered the Chinese hydropower field, which is of landmark significance to Castell’s business in China. While maintaining our leading edge in the fields of nuclear and thermal power, we will use the experience gathered from those fields to provide quality products and services for our Chinese hydropower clients.”

More than 5bn yuan (£535m) has been invested in the hydropower plant project in Xianju. The project will take five and a half years to complete. Upon completion, the system’s comprehensive thermal power peak load regulation range will be cut by 2.44%, reducing the system’s standard coal consumption by 155,000 tonnes. After being put into operation, the plant will participate in system frequency and phase modulation operations and act as an emergency system backup. It will improve power grid frequency and voltage stability levels, helping to ensure the grid’s safe and stable operation. The plant’s ability to receive large amounts of external power across long distances will be particularly important, and its installed capacity will increase the size of the East China and Zhejiang grids.

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Castell supplies safety interlocks to Tianwan Nuclear Power Plant

FS interlocks and key exchange boxes provided for Phase II project

Castell is to supply interlocking systems to the Tianwan Nuclear Power Plant Phase II project under construction in Lianyungang, Jiangsu province, China. Tianwan is the nuclear power plant with the highest unit capacity in China. To date, it is the largest joint technical and economic project undertaken by China and Russia.

Tianwan Nuclear Power Plant Phase II project in Lianyungang, China, uses Castell safety interlocking products to ensure the safety of maintenance staff

Castell will provide multiple sets of mini FS industrial safety interlocks and key exchange boxes for the China National Nuclear Corporation construction project. These devices prevent the busbar earthing switch from connecting during maintenance on high-voltage switchgear, thereby guaranteeing the safety of maintenance staff.

Since 2010, Castell has provided customised safety interlocking devices for six successive nuclear power projects in China. Project supporter ABB China recommended Castell to the China National Nuclear Corporation as part of this latest Power Plant Phase II project.

Christy Zhang, Castell senior sales manager for the China region, said: “Once again, Castell has retained the trust of its Chinese nuclear power industry clients. The company continues to establish its products’ leading edge within the high-end field of nuclear power.”

The unit capacity for the Tianwan Nuclear Power Plant’s Units 3 and 4, which are currently under Phase II construction, will be one million kilowatts. Units 3 and 4 are expected to be put into commercial operation in February and December 2018 respectively.

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Castell provides safety interlocks to Zambia’s largest power station

ZESCO chooses British firm as partner for Kariba North Bank extension project

Industrial safety specialist Castell has provided several K Locks and key exchanges boxes to the Kariba hydropower station North Bank extension project in Zambia.

Castell’s interlocks, installed in Zambia’s Kariba hydropower station more than 50 years ago, are still performing well today.

Photo caption: Castell’s interlocks, installed in Zambia’s Kariba hydropower station more than 50 years ago, are still performing well today.

In the early 1960s, Castell provided interlocks to the power station; more than half a century later, the interlocks are still performing well. When the station was due to add a north bank extension, project owner Zambia Electricity Supply Corporation (ZESCO) recommended Castell to the project contractor SINOHYDRO.

Castell’s interlocks force workers to follow a predetermined process when operating or maintaining machinery and equipment, to prevent human error and safeguard workers’ access to dangerous areas.

Christy Zhang, senior sales manager at Castell China, said: “It is an honour for Castell to provide safety interlocks to the Kariba North Bank extension project. The client’s trust in us stems from the long-term performance of our interlocks.”

The Kariba hydropower station is located in the middle of the Zambezi River, 125 miles from Lusaka, Zambia’s capital. The extension project has added two 180 MW generator units, taking the total capacity to 1,080 MW and making Kariba the largest power station in Zambia.

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Food manufacturer improves warehouse safety with Salvo™

Greencore installs drive-away prevention system at four UK sites

Leading convenience foods manufacturer Greencore has installed Castell’s drive-away prevention system Salvo™ at four UK sites. The interlocking device is providing loading bay safety at Greencore’s Kiveton, Warrington, Wisbech and Park Royal facilities.

Greencore has installed Castell’s drive-away prevention system Salvo™ at four UK sites

Part of the risk assessment process identified a potential for a drive-away from the loading bays. Although Greencore had systems and procedures in place to prevent this type of occurrence, the company investigated several potential safety systems to negate the risk, before deciding that Salvo™ was the right choice.

“Castell gave us the most competitive price and their product was the best suited to the task in hand,” said Simon Chamings, safety, health and environment officer at Greencore Kiveton. “Since installing Salvo™ we’ve had absolutely no problems whatsoever.”

Dave Massey, Greencore Kiveton’s transportation shift manager and a former HGV driver, was unequivocal in his verdict: “In terms of loading bay safety, it’s the best thing I’ve ever seen.”

The shunter fits a Salvo™ Susie lock to a trailer’s exposed emergency airline, which immobilises the trailer and releases a key from the end of the Susie. The shunter then inserts the key into the SCP+ control panel unit next to the bay door. Turning the key powers up the bay, and illuminates a green beacon inside the warehouse and a red one in the yard. While the bay door is open, the key remains trapped in the SCP+ and therefore the trailer cannot be moved. When loading or unloading has been completed, the process is reversed.

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NSK improves loading bay safety at Netherlands warehouse

Castell’s Salvo™ also protecting staff at UK facility

NSK, one of the world’s leading manufacturers of industrial and automotive components, has chosen Castell’s drive-away prevention system Salvo™ to protect staff at its warehouse in Tilburg, Netherlands.

NSK warehouse, Netherlands, Salvo, loading bay safety, Castell

NSK’s huge facility distributes more than 4,000 pallets a month across the whole of Europe and North Africa. Customers include Ford, Volkswagen, Siemens and Bosch.

Salvo™ has been installed on 12 loading bays, while NSK has also bought four Salvo™ Club steering wheel locks to safeguard deliveries made by rigid vehicles. There have been no reported health and safety incidents since Salvo™ was commissioned at the Tilburg site.

Having reversed their vehicle onto the relevant loading bay, drivers install the Salvo™ SGL lock on the exposed emergency airline coupling, releasing a trapped key. This key is then inserted and turned in the Salvo™ Control Panel (SCP+) on the outside of the bay. An amber beacon illuminates on the inside to indicate that the loading bay is now safe and ready to use. The loader opens the door, trapping the key in the SCP+ outside. While the door remains raised and the key trapped in the control panel, the trailer cannot be moved.

NSK has also installed Salvo™ at its distribution centre in Newark, UK.

The Health & Safety Executive booklet ‘Warehousing and storage: A guide to health and safety’ recommends interlocks as a safe system of work to combat drive-aways. Salvo™ also features as an example of a safe system of work in the Freight Transport Association’s ‘Loading dock safety guide’, produced in conjunction with the Institution of Occupational Safety & Health.

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Fyffes chooses Salvo™ for UK distribution centres

Fyffes, one of the leading importers and distributors of tropical produce, has installed Castell’s Salvo™ drive-away prevention system at its UK distribution centres.

Fyffes, Salvo, Castell, warehouse, safety,

Salvo™ is now protecting loading and unloading operations at the company’s Livingston, Wakefield, Coventry and Basingstoke sites – a total of 31 loading bays.

“The Salvo™ system is simple, robust and secure, and gives us confidence in the safety and security of our loading and unloading operations,” said George Kennedy, Fyffes’ General Manager (UK Depot Operations).

Drivers report to the transport office and are allocated a loading bay. After reversing their vehicle onto the bay, they return to the transport office where they leave their ignition key and collect the Salvo™ Susie for that loading bay. They then install the Susie on the emergency airline coupling, which releases a trapped key. This key is inserted and turned in the Salvo™ Control Panel on the outside of the bay. An amber beacon illuminates on the inside to indicate that the loading bay is now safe and ready to use. The loader opens the door, trapping the key in the SCP outside. While the door remains raised and the key trapped in the control panel, the trailer cannot be moved.


The Health & Safety Executive booklet ‘Warehousing and storage: A guide to health and safety’
recommends interlocks as a safe system of work to combat drive-aways. Salvo™ also features as an example of a safe system of work in the Freight Transport Association’s ‘Loading dock safety guide’, produced in conjunction with the Institution of Occupational Safety & Health.

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Bonmarché banishes drive-aways with Salvo™

Clothing retailer invests in interlocking system to improve warehouse safety

Bonmarché, the UK’s largest value womenswear retailer for women aged 50+ years, has improved the safety of its loading and unloading operations with the adoption of Castell’s Salvo™.

Bonmarche(building3)

The interlocking drive-away prevention system has been installed on all seven loading bays at Bonmarché’s Grange Moor head office, near Wakefield, West Yorkshire. Grange Moor, Bonmarché’s only distribution centre, handles an average of 140,000 garments a day, although this rises to 200,000 at peak times.

Third-party drivers arriving at Grange Moor report to security and receive documentation explaining how the Salvo™ system operates. They park in a holding area, where they are met by a supervisor who checks that they understand the information they have been given. Drivers are then asked to reverse into a particular loading bay, before disengaging their engine and fitting either a Salvo™ Susie or SGL lock to their vehicle’s exposed emergency airline coupling. This action effectively immobilises the trailer and releases a key, which the driver hands to a member of the warehouse staff. Inserting and turning the key in the control panel located next to the bay door powers up the bay and enables the door to be raised. Once the dock leveller has been correctly positioned, the driver is asked to pull the cab away, park in the holding area and wait there until further notice while unloading takes place.

Goods-out follows a similar procedure, except that Bonmarché’s warehouse staff fit the Salvo™ Susie or Salvo™ Club, an interlocking steering wheel lock, to the vehicle prior to loading.

The Health & Safety Executive booklet ‘Warehousing and storage: A guide to health and safety’
recommends interlocks as a safe system of work to combat drive-aways. Salvo™ also features as an example of a safe system of work in the Freight Transport Association’s ‘Loading dock safety guide’, produced in conjunction with the Institution of Occupational Safety & Health.

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