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Understanding Site Hazards

Springfield, Illinois - City Water, Light and Power - Dallman Unit 31 – Nov. 10, 2007
Westinghouse Unit trips. Throttle and control valves close but not completely. “Blue Blush” issues causes pilot
valves not to seat, Throttle valve remained open .016” when valves showed closed. #1 control valve doesn’t
seat due to a jamming #2 valve stem.
Generator breaker opens. Within 30 seconds of unit trip, machine accelerates to an estimated 6,000 RPM
Within 39 seconds, major damage to the turbine, the complete destruction of the generator, a hydrogen
explosion, significant damage to building structures, and the destruction of three transformers takes place.

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Copyright 2009 General Electric Company. All Rights Reserved.
Understanding Site Hazards
• Thermowells: Incident where compressed air was
used to clean out a TW on a hot, operating unit. The
cold air weakened the TW and it failed…large steam
leak, could have killed someone. Never inject cold
air into a hot TW…best to do TW work when unit is
cold and offline.
• Witness Points: Asbestos insulation. Don’t disturb
insulation of unknown composition.

Around Units Operating • Pressure Transmitters: Station pressure transmitter


sensing line compression fittings (i.e. 1/2" Swagelok
• Hot Pipes/valves: Hot instrument sensing lines (GE connections). An incident occurred where the
or station). If the pressure transmitter has a small compression fitting on station HP FW transmitter
leak on a steam line, there will be no water leg and (~1500psia) was not seated correctly. When our IS
the sensing line will be extremely hot. Skin burns. attempted to tap into the drain to install our
pressure transmitter the line blew apart.
• Water Hammer causing pipes to shift position
violently. Damage to piping, hangars. • Isolation: Valve packing can blow out when
tightening valves. Never stand in front of the valve,
• X-rays: If welding is being done then they may be always to the side. Make sure the operator
taking x-rays. Ask and stay away. We had an tightening the valve does not stand over the valve
incident where the x-ray areas were not roped off. head. We do NOT open or close any station valves!

• Steam leaks, piping leaks, spills • Remote location: The ST engineers are always out
on our own for isolation reviews (top of boiler, under
• Fatigue, Heat Exhaustion : Temperatures at the DA condenser, etc). Could be very easy to get hurt and
level of over 120F on the handrails. Many times no one being able to find you for hours. Make sure
well over 100F on the turbine deck. people know the general location of where you will
be working. We don't travel with 2 way radio's but
• Rotating BOP Equipment, Energized Equipment we can get these at most plants.

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Copyright 2009 General Electric Company. All Rights Reserved.
Understanding Site Hazards

Southern Company Yates #7 - January 2003


During outage the left side MS inlet piping was found to have bulged.

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Copyright 2009 General Electric Company. All Rights Reserved.
Understanding Site Hazards

Texas - WAP Unit #8 – July 2003


Piece of RH pipe traveled over Admin Building an estimated 400+ yards, before hitting and bringing down two
(2) 345 kV transmission lines and falling in parking lot.
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Copyright 2009 General Electric Company. All Rights Reserved.
Understanding Site Hazards

Ghent Unit #1 – January 2009


Westinghouse unit, blows the lid off a Intercept valve. Note the valve is sitting on top of the turbine. The unit
ran a year with the wrong size nuts on the studs.
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Copyright 2009 General Electric Company. All Rights Reserved.
Understanding Site Hazards
• Air Hoses can break and whip, Machine Tools may
be operating nearby.
• Cuts, Abrasions, Burns, Hearing, Eyes, Toes,
Clothing. Always bring proper PPE. Plant may not
have items such as ear plugs or hard hats
available to borrow.
• Rotating BOP Equipment, Energized Equipment,
Confined Spaces, LOTO
Around Unit Disassembled • Nuclear Plants: Hot components have been found
• Cranes, Rigging, Cribbing & Equipment Racks: in the disassembly of steam turbines at PWRs
Heavy lifts have occurred over head with no plants with steam generator leaks.
warning. Diaphragm racks have failed with a LP • Asbestos: I may be in steam piping insulation,
diaphragm falling on a worker. generator insulation. Breaking steam flanges and
• What are others doing around you? There can be a joint bolting may disturb and become friable.
lot of activities that can affect you. Welding, Cutting into generator insulation can make
Grinding, Open Flames, Fumes, Rotor being rolled, airborne.
Hi-pot of generator. • Atmosphere: Blast Cleaning is an extremely noisy
• Fall hazards: Open Holes in turbine decks such as operation. If tent does not have negative pressure,
for MSV access. Horizontal Joints openings when blast media can escape to atmosphere and be very
unit is on the half shell. Don’t immediately trust dirty. Coal dust can be everywhere and easily
condenser cover plating. disturbed during an outage.

• Trip hazards: Air hoses, power cords. Limited floor • Fatigue, Heat Exhaustion : Temperatures can be
space in many powerhouses lead to a cluttered well over 100F on the turbine deck. High humidity
turbine deck full of disassembled components. environment, outdoor units in hot climate. Long
working hours on tight schedule. When we get
fatigued, we don’t always think clearly.
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Copyright 2009 General Electric Company. All Rights Reserved.
Understanding Site Hazards

Los Barrios Station – June 2008


Diaphragm racks of poor design. No lateral support, only a bolt in bottom holding the diaphragm is place. Bolt
pulled out of threads and diaphragm fell and severely injured a worker.

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Copyright 2009 General Electric Company. All Rights Reserved.
Understanding Site Hazards

St. Clair Station – January 2006


Cast Iron Hood broke when rigging through the manway holes.

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Copyright 2009 General Electric Company. All Rights Reserved.
Tools Available in an Emergency
Crisis Management

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Copyright 2009 General Electric Company. All Rights Reserved.
Hey!!!! Lets
be CAREFUL
out there!