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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Understanding Site Hazards
Around Units Operating
• Hot Pipes/valves: Hot instrument sensing lines (GE
or station). If the pressure transmitter has a small
leak on a steam line, there will be no water leg and
the sensing line will be extremely hot. Skin burns.
• Water Hammer causing pipes to shift position
violently. Damage to piping, hangars.
• X-rays: If welding is being done then they may be
taking x-rays. Ask and stay away. We had an
incident where the x-ray areas were not roped off.
• Steam leaks, piping leaks, spills
• Fatigue, Heat Exhaustion : Temperatures at the DA
level of over 120F on the handrails. Many times
well over 100F on the turbine deck.
• Rotating BOP Equipment, Energized Equipment
• 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.
• Pressure Transmitters: Station pressure transmitter
sensing line compression fittings (i.e. 1/2" Swagelok
connections). An incident occurred where the
compression fitting on station HP FW transmitter
(~1500psia) was not seated correctly. When our IS
attempted to tap into the drain to install our
pressure transmitter the line blew apart.
• Isolation: Valve packing can blow out when
tightening valves. Never stand in front of the valve,
always to the side. Make sure the operator
tightening the valve does not stand over the valve
head. We do NOT open or close any station valves!
• Remote location: The ST engineers are always out
on our own for isolation reviews (top of boiler, under
condenser, etc). Could be very easy to get hurt and
no one being able to find you for hours. Make sure
people know the general location of where you will
be working. We don't travel with 2 way radio's but
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
Around Unit Disassembled
• Cranes, Rigging, Cribbing & Equipment Racks:
Heavy lifts have occurred over head with no
warning. Diaphragm racks have failed with a LP
diaphragm falling on a worker.
• What are others doing around you? There can be a
lot of activities that can affect you. Welding,
Grinding, Open Flames, Fumes, Rotor being rolled,
Hi-pot of generator.
• Fall hazards: Open Holes in turbine decks such as
for MSV access. Horizontal Joints openings when
unit is on the half shell. Don’t immediately trust
condenser cover plating.
• Trip hazards: Air hoses, power cords. Limited floor
space in many powerhouses lead to a cluttered
turbine deck full of disassembled components.
• 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
• Nuclear Plants: Hot components have been found
in the disassembly of steam turbines at PWRs
plants with steam generator leaks.
• Asbestos: I may be in steam piping insulation,
generator insulation. Breaking steam flanges and
joint bolting may disturb and become friable.
Cutting into generator insulation can make
airborne.
• Atmosphere: Blast Cleaning is an extremely noisy
operation. If tent does not have negative pressure,
blast media can escape to atmosphere and be very
dirty. Coal dust can be everywhere and easily
disturbed during an outage.
• Fatigue, Heat Exhaustion : Temperatures can be
well over 100F on the turbine deck. High humidity
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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Tools Available in an Emergency
Crisis Management

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Hey!!!! Lets
be CAREFUL
out there!