The Instituto Costarricense de Electricidad (ICE)
is a Costa Rican state-owned company in charge of power generation in several areas, such as geothermal, wind, hydro and combustion plants. In its constant search to modernize its processes, especially in the field of geothermal energy,
ICE has been implementing new technologies that optimize its operations and guarantee the safety of its workers.
Geothermal energy, as a renewable energy source, is essential for Costa Rica's sustainable development, as it reduces carbon emissions and harnesses the earth's internal heat to generate electricity in a clean and constant manner. By integrating geothermal energy into its energy matrix, Costa Rica strengthens its leadership in renewable energy and in reducing greenhouse gas emissions.
One of ICE's recent efforts in this field has been the automation and modernization of valves in geothermal wells, where the need to use portable actuators has been identified as a more viable solution, especially in rural and remote areas where infrastructure may be limited. These actuators allow operators to perform their tasks more efficiently and safely, improving working conditions in hard-to-reach locations.
In this interview, engineer Emmanuel Moreira, ICE's maintenance and operations manager, shares his experience with the implementation of modec portable valve actuators and how this technology has transformed field operations, not only optimizing technical processes, but also improving ergonomics for workers.
"ICE is a state entity that operates several companies related to energy, and in the geothermal area we have fields like Miravalles, Pailas and another one under development called Borinquen. Each field has production and reinjection wells, and we are in the process of modernizing some of the valves in these wells. Initially we thought about fixed actuators, but bringing the power lines to these rural areas was a bigger investment than the actuators themselves. That's how we found an opportunity with modec's portable actuators, which offer the necessary torque without the need for electrical wiring." Emmanuel Moreira (ICE)
ICE faced several challenges in their geothermal valve operations:
➡️Remote Locations: Many of their geothermal wells are located in remote areas, making traditional valve maintenance difficult and time-consuming.
➡️Safety Concerns: Manual valve operations can be physically demanding and pose safety risks to workers.
➡️Efficiency: ICE needed a solution to streamline their valve operations and reduce downtime.
Moreira also added that the wiring for fixed actuators was expensive in remote areas. Portable actuators were a more economical solution. They've analyzed the valves, handwheels, and torque needed. Actuators worked well in their wells and pipelines, transferring steam and brine.
ICE worked closely with modec to implement the Portable valve actuators. modec provided expert guidance and support throughout the process, ensuring a smooth integration into ICE's existing systems.
Modec: You use the JA73 battery-electric actuator. Why choose battery power when you sometimes travel long distances without electricity?
EM: We're an electric company with strong renewable energy policies. So, we always take fully charged equipment when we travel 100 km or more. The battery has performed well and has enough autonomy for our needs. The farthest site is 100 km away, and we've never had battery problems. The battery's autonomy has been sufficient for our operations.
Further we asked if the portable actuators could be useful in other ICE sectors, like hydroelectric or wind power.
E.Moreira replied that other departments within ICE, including hydroelectric and fuel-fired plants, have shown interest.
These departments also handle piping systems with important valves. He believes that other departments will likely acquire portable actuators in the future due to their potential to improve worker ergonomics.
The successful implementation of the technology in his department can serve as a positive model for others to consider using.
Emmanuel emphasized the importance of the equipment's approval, its satisfactory service, and the direct technical support provided by modec and Tecnosagot. This direct support, without intermediaries or language barriers, ensures reliability.
"ICE has a preventive vocation. The population of workers is aging and manual activities carry risks. That's why we look for tools that reduce physical strain, which in turn minimizes injuries and allows experienced workers to remain in their jobs. This is crucial because these operations, such as well stimulation, require highly trained personnel.
I insist, in geothermal, the workflow is not so clean, it brings in fouling. The operation becomes quite difficult, it is not like Oil and Gas, where the fluid is cleaner. In our case, there is a tendency that generates clogging. Overcoming this initial resistance is very necessary. The implementation of modec actuators helps us to consolidate the policy of caring for our workers." Moreira
The implementation of modec portable valve actuators resulted in significant benefits for ICE, including:
➡️Safety Concerns: Manual valve operations can be physically demanding and pose safety risks to workers.
➡️Enhanced Safety: By eliminating the need for levers and reducing physical strain,
Previously, ICE's operators performed these tasks manually with levers, often requiring two people. This led to musculoskeletal injuries, especially among the older workforce.
The actuators eliminated the need for levers, reducing the risk of injury. Their compact size and portability allowed technicians to carry them in their vehicles and perform operations more efficiently and ergonomically.
The positive impact of modec portable valve actuators on ICE's operations has led to increased customer satisfaction and overall success.
"Modec: How have the actuators affected the morale and productivity of ICE's workers?
Our workers are extremely satisfied with the modec actuators. They have made their jobs easier, safer, and more efficient. This has boosted morale and productivity," said Moreira.
ICE has recognized the importance of reducing physical strain on operators. Other industries that handle heavy valves or piping systems could also benefit from this technology.
For example, local state refineries that handle fuel transfer and companies involved in water supply and collection could benefit.
In the geothermal sector, there is potential for similar benefits in other Central American countries like Nicaragua, El Salvador, and Mexico, especially in older wells, concluded E. Moreira.
Modec portable valve actuators have been a great asset for ICE. They have improved geothermal operations and made it safer for workers. By solving the problems of remote locations and manual valves, modec has helped ICE provide excellent service and achieve their goals.
We would like to express our sincere gratitude to ICE for their trust and partnership.
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