The West Winford Incident

by John Parker

  James began by saying that he had spent many hours poring over the power station records and had found what he believed was credible evidence for possible sodium hydroxide contamination of turbine steam, during the station’s commissioning period in 1965. Difficulties during commissioning of the sodium hydroxide dosing equipment, had resulted in several periods of considerable overdosing into the boilers. The Winford chemistry staff had been conscious of the need to maintain alkaline conditions during this, most important, early stage in the life of the plant. The presence of these high values, albeit only for short periods, at a time when the operation of the boilers was also being fine-tuned, could easily have led to sodium hydroxide being mechanically carried over in the steam. As the routine at the station settled down these problems were rectified. Consequently by the time Number 3 turbine was operational, the boiler water chemistry was strictly controlled and the turbine steam of high quality. He paused at this point awaiting comments.

  Joe was the first to respond and he said that he was pleased that at least the possibility of contamination of the turbine steam could be envisaged, which would support the suggestion that sodium hydroxide was responsible for the failure. It suddenly occurred to Dave that Joe, with the best will in the world, might not be completely unbiased. He represented the turbine manufacturers, after all, and it was in their interests to support the view that an operational problem was responsible for cracking, rather than any shortcomings at the turbine production stage. He did not voice this thought, however, but said that, though he agreed that James’ suggestion was interesting, he felt that it was likely to be just one of a number of possible explanations and he would wish to await the results of the various tests in progress before going public. Henry characteristically did not hurry his response. He was a thoughtful man. When Dave had finished, he thanked James and acknowledged that his observations were important and may prove to be pivotal in the failure scenario. However, he went on to add, he was not clear how this latest information fitted in with the features on the fracture surface to which Dorinda and James had attached such importance previously.

  “Well, now then,” began James in a rush. He was almost beside himself with his enthusiasm. Clearly this was just what he’d been waiting for. He reminded the others that he had spoken about features on the fracture surface of the failed Winford disc at the last meeting. These, he said, had been further examined and in the case of the overspeed ‘markers’, there was some evidence to suggest that approaching the crack tip, which was shortly before the final failure, the distance between these increased. This, he continued, indicated an increase in crack growth rate. There was a rustling of papers as everyone found the page. Additional support for this suggestion, he added with relish, was seen from a similar pattern of increased spacing between the staining marks. He’d also mentioned these at the last meeting as evidence of a chemical deposit build up, probably sodium hydroxide. This could possibly trigger an increment of crack growth. Using the overspeed ‘dating’ markers on the crack surface, he had been able to estimate the actual period when the crack growth rate increased and, comparing this with the details from the Winford Power Station’s operating log, this would correspond with a suspected operational error late in 1968.

  James’ excitement increased as he made this announcement and it was only with an effort of will that he managed to contain himself. The others waited in silence as he recovered his composure.

  He explained that the error mentioned in the log related to a trial that was being undertaken on Number 2 turbine at that time, which entailed dosing hydrazine directly into the LP turbine steam inlet pipe. By 1968, the dosing of hydrazine into the boiler water, in order to remove oxygen and increase alkalinity, was well established at Winford.

  He continued, “This chemical is prone to dissociate within the boiler system and loses its effectiveness later on in the steam cycle.”

  The trial mentioned was being conducted to evaluate the benefit of replenishing the hydrazine just as the steam entered the LP turbine. As this was only a temporary set-up for the duration of the trial, the dosing tank and pipework was not well labelled and colour coded in the usual way.

  “We suspect that on the evening shift of 14th November 1968, one of the junior chemists may have accidentally contaminated this temporary hydrazine dosing tank with a small amount of sodium hydroxide solution, which was intended for the adjacent permanent sodium hydroxide holding tank. It seems more than a coincidence, I’m sure you will agree, that the timing of this incident, corresponding approximately with the time of our observed increase in crack growth, provides a plausible hypothesis for the introduction of sodium hydroxide into Number 2 LP turbine, less than a year before the disc failure.”

  Silence.

  Henry was the first to respond. He could understand James’ enthusiasm at this discovery. It could, as he had said, offer a possible explanation for caustic contamination of the steam in the case of the failed turbine disc. The coincidence of the timing of this possible error, with features on the fracture surface, was compelling. He congratulated James upon the clearly tedious task that he’d undertaken into the history of the early turbines at Winford.

  Dave reminded the meeting that any hypothesis had to explain the presence of cracks in the discs on the spare rotor which had failed in the test at Runcorn. Dorinda responded to Dave’s remark by pointing out that the disc from the spare rotor, which had disintegrated during the Runcorn rig test, had previously been in service at Winford for around 30,000 hours before being refurbished and held as a spare. This rotor had accrued these hours in Number 1 turbine, from commissioning right through to the beginning of 1968 and therefore had been in operation during the early period of poor water/steam chemistry control. She continued by reminding Dave that it now appeared, from Joe’s recent results, that pre-existing defects could propagate during subsequent service in uncontaminated steam. This, they believed, could have been the case for vulnerable discs on the LP rotors in both Numbers 1 and 2 turbines. In the case of the failed rotor in Number 2 turbine, there was an extra suspicion of caustic contamination of the steam more recently due to a possible dosing error.

  She concluded by pointing out that not only the SSA, but also other electrical utilities, would be gratified to learn that the cause of the Winford incident could, at last, be fully explained. Operators would be especially relieved to learn that the disc cracking was confined to the first two turbines at Winford and was associated with incidents of steam contamination. Therefore they could feel confident about the continued running of all other turbines.

  Joe commented that on the face of it, this seemed a most plausible explanation for the West Winford incident, certainly the most plausible to date. He believed, however, that the details needed close inspection, not only by themselves within the sub-committee, but a mixture of academics and practical power station engineers, especially those with a knowledge of boiler operation. The whole hypothesis required verification and he felt that it was people such as the ones he’d mentioned, that could supply it. Dorinda said that she was pleased with the comments received and agreed completely with Joe. They had already addressed the need for wider comment and had initiated plans to hold a conference. This would take a few weeks to arrange, as they would wish to ensure that people of sufficient quality would attend and so, hopefully, arrive at an authoritative consensus. Dorinda concluded by adding that everyone realised how important it was for the whole of the power supply industry to solve this problem.

  Dave travelled home in something of a daze. On the one hand, he realised that the main point of the sub-committee was to solve the problem of the Winford failure as quickly as possible and so accepting the Slough hypothesis would be good news all round. Nevertheless, he was despondent from his own point of view. Whilst he felt that he had represented SSD well and had initiated a viable work programme in a timely manner, he had barely made any contribution to the experimental programme. He had had such high hopes, secretly
held, that this was his big chance to impress. He consoled himself with the thought that at least he had benefited by becoming acquainted with Professor Fletcher and the others, which wouldn’t do him any harm. He could only hope for other opportunities.

  16

  Sue’s next opportunity to continue with her research arose sooner than she had expected. Pam arrived at her door one morning to beg a cup of tea and a chat.

  “I haven’t spoken to an intelligent person for days,” her friend complained. “Sure, old Cummings is pretty competent as far as physical pleasures are concerned but when it comes to quantum mechanics, well, he just looks at me as though I were mad.”

  “Oh, dear!” replied Sue, “My physics education ended with a magnet and a pile of iron filings.”

  “Well, in that case, we’ll just have to settle for village gossip,” suggested Pam with a laugh.

  The two chatted pleasantly over their tea and biscuits and inevitably the subject of Sue’s latest family history finds was raised. She explained that, whilst she had discovered an enjoyable and absorbing pastime, it was also a frustrating one. It was a stop – start process, dependent upon trips to London. Pam delighted Sue by revealing that one reason for her visit was to offer to take her up to town for the day later that week, as she was planning to oversee some repairs to the flat. On reflection, she thought that, if Sue fancied a girls’ night out, they could go up the evening before. Sue, though tempted, declined. Her present relationship with Dave was such that she would prefer not to add to the tension, though, of course, she didn’t mention that to Pam. Accordingly it was agreed that an early start on the day would suit best.

  Pam’s mode of driving followed its usual pattern, which Sue would probably describe, oxymoronically, as controlled recklessness. Pam certainly knew her way around London which, combined with her positive driving style, ensured that she negotiated even the central areas with remarkable adroitness. On several occasions she drew grudging admiration from ‘cabbies’ as she weaved between them. After dropping Sue off in Chancery Lane, Pam continued on to her flat in Judd Street. She had given Sue directions to the flat, where they would meet at five thirty.

  The part of the Public Records Office which dealt with the census returns was located in a tall building in Portugal Street, which was a short walk from Chancery Lane.

  The most useful censuses for family historians were those for the three years 1841, 1851 and 1861. The hundred year confidentiality rule, meant that the 1871 was not due to be released to the public for several months.

  Sue found this first visit unnerving. The records were stored on rolls of microfilm which had to be read on a film reader. The indexing search system seemed complex, especially when a large town or city district was involved. Eventually, with help from others, Sue located and noted the necessary reference numbers needed to complete the request form required to order the desired roll of film.

  She wished to consult the 1851 census. Her first request was for records covering the village of Woolpit, in the hope of finding her Boughton ancestors. Whilst waiting for the film, she searched the Kensington index, looking for the address given on James Loomes’ birth certificate and, on finding this she ordered a second film.

  Sue was nervous when the box containing the roll of film for the Woolpit area arrived. She was all fingers and thumbs, attempting to load it on to the roller and feed the film through the lens mechanism and onto the take-up spool. She had noticed a list of place names written on the side of the film box and she correctly assumed that these were other Suffolk villages in the neighbourhood of Woolpit, which were included on the same roll, presumably filmed in the order listed. With great anticipation, she wound the film through quickly as the list indicated that Woolpit was about half way through the roll. At last, she slowed and there it was, Woolpit. After a few pages, that indescribable pulse of elation. Did she make a sound? Certainly she inwardly squealed.

  James Boughton – her, yes her, very own great, great grandfather, together with his wife Sarah and their family. Their son Thomas, her great grandfather, just as she’d hoped, was aged eight and born in Woolpit. James was born in a place called Pulham in Norfolk. Could that be the home of her more distant Boughton ancestors? She shakily made a careful note of everything on the page relating to this family and after rewinding, she returned the film to the desk clerk, hoping to collect the Kensington one. Alas, she was told, that it was already out being used by another researcher. What a nuisance. Couldn’t be helped. Time was moving quickly and as she didn’t wish to sit idly awaiting the return of that particular film, she decided to begin her search of the 1851 returns for Brighton, in an attempt to locate the two Caroline Pottens, one of whom was her great grandmother. She found the index giving the film reference number which covered Upper North Street, where one of the Caroline Pottens had been born, four or five years earlier. She put in her order and went back to check the indexes for the film number for Chichester Street, which was where the second Caroline Potten had been born.

  The first Brighton film arrived and after a long search through, checking the folio numbers at the top of the filmed pages, she found Upper North Street and spooled the film slowly forward to house number forty one. Another inward squeal. Thank goodness. The Potten family were still living there. She again made notes, though she already knew the basic facts about Caroline and her parents. There were six children listed with the youngest having the unusual name of Octavia who, in 1851, was eleven months old. She also learned that Thomas, her possible great, great grandfather was forty five at the time and had been born at Sedley in Kent, which might be another of her family bases.

  That was the last of her positive results, for that day at least, as the second Caroline was no longer at the Chichester Street address. So it looked as though she would have to systematically search through all the many rolls of film covering the Brighton area, which could take several hours. She rechecked at the information desk and found that the Kensington film had still not been returned, so she considered how best to use the remaining time. She was in a cheerful mood as she decided to make a start on the trawl through some of the Brighton census. She managed to complete a couple of spools of film. Even though the result was negative, it meant that she would have less to do in future.

  Time to make her way to Pam’s flat. Just one tube stop from Chancery Lane to Holborn and one on the Piccadilly Line to Russell Square. Following Pam’s directions, Sue found herself outside the tall red-brick, art deco building in Judd Street. She went up to the sixth floor. The corridor onto which she alighted was warm and richly carpeted. The flat was small but comfortable. They had a light tea, as Pam had suggested that they stop on their way home, at a pub she knew near Hungerford and have something more substantial. After phoning Dave to check that all was well, Sue agreed.

  *

  Though Dave had agreed to hold the fort, he was far from pleased. He was still feeling disappointed with the recent developments within the sub-committee. Tony had been sympathetic, when Dave updated him on progress, but felt that if the evidence from the Slough labs was sound, it was likely to satisfy the SSA management. They would consider this especially timely as, should the Tories win the forthcoming election, they would almost certainly be scrutinising the performance of the SSA very closely. They would be reassured to learn that the turbine failure was the result of a one-off incident, rather than being a widespread problem. Controlling steam chemistry was the key factor, but that had always been appreciated. Tony added that the Central Laboratory staff themselves must be confident of their hypothesis, having set up a conference to publicise it. Dave had to agree, although he was inclined to the view that the main purpose of the conference had more to do with ensuring that they would get the credit for providing the answer to the widely reported West Winford Turbine Incident. His objection to this, he would claim, arose on account of the many engineers and scientists who had worked so tirelessly through the previous winter. It was their work that had provide
d the Slough people with most of the evidence and in return they would probably not even rate a mention. His own personal annoyance at being side-lined didn’t help.

  So Sue’s absence from home did little to ease his feeling of disappointment. It was becoming increasingly apparent to him just how this obsession of his wife’s was assuming ever greater importance. He felt that he was now relegated in her eyes, to little more than the breadwinner and useful child-minder. An additional irritation, though he was loath to admit it, was her relationship with this Peter.

  When Sue finally arrived, her buoyant mood was quickly quenched by Dave’s evident ill humour. Although not venturing to criticise her and risk an argument, his restraint did not go unnoticed. After all these years he could not conceal such feelings from her. She knew well enough when an atmosphere was just waiting in the wings. On this occasion, she decided to avoid confrontation, though this resulted in prolonging the uneasy, cool, manner that existed between them. In retrospect, a row might have been preferable.

  The following morning Dave was surprised to receive a phone call from Henry Fletcher.

  “I’m calling to let you know that the Slough people have set the date for the conference. It is to be held on the 26th of June in London. In view of this, I have decided not to hold our usual monthly sub-committee meeting. We shall all be at the conference and should anything urgent arise, we can have a get-together there. Miss Sage is advising the others, but I wanted to speak to you on a separate matter.” Henry went on to say that he’d received an approach from the British Standards Institution, who were in the process of considering the situation regarding commonly used corrosion test methods. They wanted advice from experts on the desirability of standardising the variety of routine corrosion test methods, used throughout British industry.