Deep In The Heart Of Texas. Surge Pile Incident and Learnings

Transcription

1 Deep In The Heart Of Texas Surge Pile Incident and Learnings

2 Events: On October 27, 2010, a 4-man base contractor crew was preparing to perform maintenance on the Sandow 4 A coal pile telescopic chute. The cables on the coal spout were too long and required shortening. This could only be done from below the overhead conveyor. Due to the large amount of coal on the pile, excavating to grate and lowering the spout would have created the danger of high walls and possible engulfment. For this reason, a pad was constructed over the coal hoppers. Mounded coal was removed and a dozer repeatedly drove over the area to compact the material.

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4 Events: The dozer did not cause the pad to collapse and the pad appeared solid. Prior to allowing personnel onto the coal pile all related equipment was locked out. When the person walked over the B2 hopper the pad surface collapsed under him and he fell down the void formed inside the pad and landed on the grate.

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7 Rescue: The employee was pulled up to the surface by his co-workers using a welding lead and sustained minor injuries.

8 Emergency Responder Cardinal Rule #1

9 Loveridge Accident - Five Victims In 1986, five men died when bridged material underneath them collapsed into a hidden cavity on a surge pile in WV. The men had gone onto the pile on-foot to try to determine how best to repair the damaged overhead belt.

10 Causes: The potential of a void forming during pad construction was not considered. Employees were not aware of the existence of this type of a hazard prior to commencing the job. False assumption that since the pad was sufficiently strong to support a heavy dozer, it would support the weight of a person. The pressure exerted by a person is greater than that of a dozer A hidden void continued to form while compacting was in progress because the feeder gate had not been closed. No personal fall protection was used.

11 telescopic spout 'A' pile 25 feet thick coal pad leveled and compacted by dozer slide gate grated shaker feeder hopper B2 43B Conveyor

12 Void was collapsed at 16:15

13 Luminant Fossil Generation Standard Fleet committee formed. MSHA 30 CFR Surge and storage piles. No person shall be permitted to walk or stand immediately above a reclaiming area or in any other area at or near a surge or storage pile where the reclaiming operation may expose him to a hazard. OSHA 29 CFR An employee may not work on or beneath overhanging coal in coal bunkers, coal silos, or coal storage areas, unless the employee is protected from all hazards posed by shifting coal.

14 Luminant Fossil Generation Standard Management and employees understand hazards and controls associated with surge piles. Equipment is adequate for production demands at all times. Equipment capacity Equipment structure Communication equipment Emergency equipment Feeders Grizzles Feeder location and activity indicators

15 Luminant Fossil Generation Standard Standard Operating Procedures Pre Job Briefs Feeder Operation Coal Pushing Ramp Building Equipment Service

16 Luminant Fossil Generation Standard Standard Operating Procedures Elevated Work Platform Building SOP A pre-job briefing. Lockout overhead conveyor Operate the feeder and verify that coal is feeding properly into the feeder. Feed empty if possible. Close the feeder gate and lockout feeder. Fill in draw-hole. Compact coal while filling. Probe with excavator to confirm absence of voids. Confirm no leakage through feeder Use matting to improve footing.

17 Luminant Fossil Generation Standard Access Prohibition posted Emergency Response Plan Training and Orientation Performance Monitoring and Audits

18 Questions?