Scenario training improves emergency response preparedness

James M. Hylko

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A key maxim of the military is "train like you fight, and fight like you train." The same applies to emergency response training, which should be a part of a plant’s routine operation. Don’t risk waiting until an accident occurs to test your response plan.

At approximately 8:30 a.m. on a Tuesday morning, the Paducah Gaseous Diffusion Plant (PGDP) was operating normally, and only routine plant maintenance activities were scheduled for the day (see sidebar). Facility maintenance employees and other contractors were beginning the day’s assigned work. Outside, a fully extended man-lift was being used to hoist a technician up to a malfunctioning ventilation stack on the roof of a building. A safety representative was on the ground observing the evolution.

While maneuvering the extended man-lift, a maintenance technician accidentally bumped the directional controls, thereby causing the man-lift to become unstable and tip over. The man-lift bucket struck and severed an overhead fluorine distribution pipe, a 2-inch air line, and a 1-inch nitrogen line as it fell to the ground.

Fluorine gas is a highly toxic, powerful oxidizing agent. It has a sharp, pungent odor and is corrosive to the eyes, respiratory system, and skin. Although fluorine gas is colorless, a release may appear white in color due to its interaction with moisture in the atmosphere that forms hydrofluoric acid (HF), which creates severe threats to worker safety. Inhalation of fluorine gas is extremely life-threatening for the same reasons.

The impact from the fall injured the technician and left him in need of immediate assistance. Within seconds, plant control room alarms blared the news that the fluorine and compressed air header pressures were quickly dropping. Another audible alarm indicated oxygen was present in the nitrogen line. Within seconds of the accident, the safety rep on the ground rushed over to assist the injured employee and both quickly exited the area by evacuating upwind. Once in a safe area, the safety rep reported the man-lift accident to the control room by radio.

Two maintenance employees driving a company truck in the vicinity of the accident were exposed to the fluorine release and attempted to immediately leave the area. The driver of the truck was overcome by the fluorine gas, lost control of the vehicle, and was injured after crashing into a utility pole. The passenger was able to report the vehicle accident over the radio to the control room.

The Paducah Gaseous Diffusion Plant

The Paducah Gaseous Diffusion Plant (Figure 1) in Paducah, Kentucky, is the only operating uranium enrichment facility in the U.S. The plant is leased and operated by the United States Enrichment Corp. (USEC), a wholly owned subsidiary of USEC Inc., and employs about 1,200 people. The plant’s primary mission is to use gaseous diffusion to produce low-enriched uranium fuel for commercial nuclear power plants in the U.S. and around the world.

1. One of a kind. The Paducah Gaseous Diffusion Plant is the only operating uranium enrichment facility in the U.S. The United States Enrichment Corp. operates the plant, which is leased from the U.S. Department of Energy. Courtesy: USEC

The Nuclear Regulatory Commission (NRC) provides regulatory oversight of USEC enrichment activities to ensure compliance applicable to gaseous diffusion plants. The NRC Operations Center is notified of an emergency by USEC if one occurs, and the NRC evaluates the protective actions to ensure that all reasonable and appropriate actions are taken to mitigate an emergency.

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