mitigating risk: work under suspended loads
TRANSCRIPT
![Page 1: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/1.jpg)
Mitigating Risk: Work Under Suspended Loads
Ralph Waldrep
![Page 2: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/2.jpg)
Problem Statement
• Employees communicated concern that work was being performed under suspended loads
• Necessary to determine and implement solutions to eliminate any work beneath suspended loads- Ensure employee safety, OSHA and company safety
policy compliance while completing outage objectives
• Challenge to overcome ‘this is how we’ve always done it’, but rather embrace the ‘what if we tried’ mentality
| 2
![Page 3: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/3.jpg)
Situation Prompting Employee Concern
• Raise shaft to the turbine assembly
• In turn, turbine assembly raises 0.5” off of the horizontal keys to allow key removal
• During this process employees would be exposed to suspended load hazards
| 3
Keys
Thrust Assembly
![Page 4: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/4.jpg)
Keys To Success
• Immediate response to employee concerns• Placed all affected work on hold • Assembled diverse, highly engaged, multi-
discipline team - (Field Employees, Projects, Safety, Engineering, etc)
• Identified additional items• Teamwork and Collaboration coupled with
innovative thinking• Outreach to industry partners for input and
potential solutions• documented and tracked each item to resolution
| 4
![Page 5: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/5.jpg)
Keys To Success Cont.
• Safety Over Production- Deviation from schedule and materials to address
concerns resulted in $1M added outage cost - Learning process resulted in 765 hours of outage
extension- Employees expressed appreciation multiple times
throughout the process
• Expectations, Lessons Learned and Best Practices incorporated into future work planning
• Success story shared throughout affected business units and beyond
| 5
![Page 6: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/6.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
Nose Cone Removal – Pickwick Hydro (PKH)
• Turbine unit placed in resting position on floor to eliminate suspended load
| 6
![Page 7: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/7.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
| 7
• Hydraulic jacks were utilized to remove cone from turbine assembly
• Jacks are controlled outside of Load Drop Zone using long hydraulic lines
Nose Cone Removal – PKH
![Page 8: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/8.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
Placing Turbine Assembly On “Tall” Pedestal – PKH
| 8
![Page 9: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/9.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
Placing Turbine Assembly On “Short” Pedestal – PKH
| 9
![Page 10: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/10.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
Technology Applied At Other Hydro Locations
| 10
![Page 11: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/11.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
Wheeler Hydro (WEH) Unit 9 – Rotor Install
| 11
![Page 12: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/12.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
| 12
WEH Unit 9 – Rotor Install Cont.
![Page 13: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/13.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
| 13
WEH Unit 9 – Rotor Install Cont.
![Page 14: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/14.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
| 14
WEH Unit 9 – Rotor Install Cont.
![Page 15: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/15.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
PKH - Telescoping Stands – Outer Head Cover
| 15
![Page 16: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/16.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
| 16
PKH - Telescoping Stands – Outer Head Cover
![Page 17: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/17.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
| 17
PKH - Telescoping Stands Fully Extended
![Page 18: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/18.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
| 18
PKH - Wicket Gate Removal
![Page 19: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/19.jpg)
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Breaker repair & refurb• Shop T/G outage support• Field CC Steam T/G outages• Field Simple Cycle CT & Generator outages • Field Transformer maint, refurb, repair, & testing
Core Services:• Shop Machining Services (rotating components)• Shop Motor refurb, repair, & test run (≥ 200HP) • Shop Hydro T/G outage support• Field Hydro T/G outage support• Field Transformer maint, refurb, repair, & testing
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Machining Services
• Dam Safety Services
• Roving Maintenance
• Electrical Field Services
Supplemental Services: (Examples)
• Shop Fabrication Services
• Field Non-Generation Projects (electrical, civil, mechanical)
• Roving Maintenance
• Electrical Field Services
| 19
QUESTIONS
?
![Page 20: Mitigating Risk: Work Under Suspended Loads](https://reader033.vdocuments.us/reader033/viewer/2022042421/626102649867e74dae1ea5fa/html5/thumbnails/20.jpg)