OSHA Inspection: COLUMBUS SOUTHERN POWER COMPANY

Issued

Nov 22, 2004

Abate by

Dec 25, 2004

Penalty

Initial $7,000 · Current $7,000

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not
furnish employment and a place of employment which were free from
recognized hazards that
were causing or likely to cause death or serious physical harm to
employees in that employees
attempting to free a frozen slag tap were exposed to the hazards of
explosion and superheated
steam:
On or about July 11, 2004, two employees received fatal burns while
attempting to free a frozen
slag tap on Unit #2, slag tank "A", when the slag tank failed severing one
of the boiler's header
supply tubes and releasing 600 degree Fahrenheit water under 1600 psi
pressure that flashed to
steam.
Among other methods, feasible and acceptable abatement methods to correct
this hazard include,
but are not limited to, the following:
a.Conduct an organized and systematic evaluation of the cyclone boilers
and
slag collection
system that will effectively identify potential causes and consequences of
safety and
health hazards. The evaluation should identify and evaluate the hazards
and recommend
for implementation controls for items such as:
The redesign of the unit or slag collection system to reflect current
industry knowledge
and/or Conesville Plant practice by methods such as, but not limited to,
the  engineering
of a single slag tank collection system, the redesign of the slag tap for
more efficient
operation, increasing slag tank vent flow to heat the slag tap, and/or the
installation of
refractory that would improve insulating characteristics.
The engineering of slag tanks to withstand pressures expected during
operation using
methods such as, but not limited to, the redesign of the slag tanks, the
reinforcement of
the slag tanks, and the use of pressure releasing devices. The tanks
should receive
periodic non-destructive inspections.
The implementation of remote instrumentation to minimize employee
exposure, such as,
but not limited to, cameras or light sensors to monitor slag tap
operation, remote
temperature probes to monitor slag tank vents to ensure their operation,
and the use of
remote combustible gas probes located in the slag tank to monitor
combustible or
explosive atmospheres.
b.Develop and implement written operating procedures that provide clear
instructions for
safely operating the cyclone boilers to ensure slag taps do not freeze
over to include
minimum unit load dependent on fuel quality, environmental factors, and
mechanical
factors such as overfire air.
c.Develop and implement written operating procedures that provide clear
instructions for
the safe operation of boilers when operating units with frozen taps and
when
attempting
to reopen frozen slag taps to include maximum period a tap can remain
frozen before the
unit is taken out of service.
d.Develop and implement an information and training program on the
specific safety and
health hazards identified in the assessment, emergency operations, and
safe work
practices applicable to the employee's job tasks.