Text For Citation: 01 Item/Group: 001 Hazard: BURNS

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.