Xcel Energy Tragedy - Cabin Creek Hydroelectric Plant

Overview

Date: October 2, 2007
Location: 40 miles west of Denver, Colorado
Incident: Five contract painters trapped by a chemical fire inside a hydroelectric plant tunnel owned by Xcel Energy.

Cause of Fire: Combustible coatings and solvents blocked the only escape route, 1400 feet away.
Emergency Response: No properly trained responders available for rescue; workers had no escape.
Chemical Safety Board (CSB) Findings:
- Xcel Energy and contractor RPI Coating inadequately evaluated work dangers.
- RPI workers entered a confined space with flammable solvents, little training, and no emergency plan.

Cabin Creek Hydroelectric Plant:
- Located in a mountainous area, 6 miles from Georgetown, Colorado.
- Features a 4,000-foot tunnel (penstock) carrying water between reservoirs.
- Tunnel lined deteriorated; RPI contracted for recoating.

September 2007: Recoating project begins.
October 2, 2007: RPI workers bring 10 gallons of methyl ethyl ketone (MEK) into the penstock.
1:00 PM: Eleven workers start coating operation.
2:00 PM: MEK vapors ignite (likely by static electricity), causing a flash fire.
- Fire spreads rapidly, blocking five workers' escape.
- Fire extinguishers unavailable inside the penstock; trapped workers attempt to communicate for help.
2:11 PM: Emergency personnel arrive but lack training for rescue in confined spaces.
- Workers instructed to move deeper; they struggle with smoke inhalation.
3:40 PM: Specialized rescue unit arrives too late; trapped workers had already died from smoke inhalation.

Lack of rescue preparedness: Emergency responders untrained in confined space rescues.
Contractor Selection Issues: RPI had a poor safety record yet won the bidding process based on low cost.
Inadequate Oversight by Xcel Energy: Safety performance of RPI not adequately monitored.

Safety Regulations:
- Need for regulatory limits on flammable materials in confined spaces.
- CSB recommends Colorado develop firefighter training for confined space rescue.
- Call for OSHA to amend regulations for permit-required confined spaces.
Historical Context:
- Since 1993, 53 serious accidents linked to flammable atmospheres in confined spaces, resulting in 45 fatalities.
- Existing guidelines not sufficiently protective; need for clear safety limits.

Captain Steve Aseltine: Highlights challenges of confined space rescue.
Holmstrom: Emphasizes the importance of recognizing hazards and establishing safety limits.
Bresland: Calls for diligence in assessing risks and planning for emergencies to prevent future tragedies.

The tragedy at Xcel Energy's Cabin Creek Plant underscores the critical need for proper safety protocols, training, and regulatory oversight in confined spaces to prevent similar incidents in the future.