The West Winford Incident

by John Parker

  Henry then asked an impatient Dave to introduce his draft report. Dave, bolstered by his pleasure at all the excitement within his own department over the last few days, made a competent presentation of his outstanding results. He concluded by asking the committee to agree to his report being submitted to the main Technical Committee’s press office, for approval and permission to publish. He sat back and rather childishly hoped that, in addition to impressing his colleagues, Pauline had also been pleased.

  “May I?” asked Dorinda, glancing towards Henry. Having received the slightest of nods, she expressed her grave doubts about the results obtained from the Winford test rig. In her view there were several potential flaws in the experiment, including the possible contamination of the specimens. This could have arisen in workshops, at the power station itself or during inspections. There was also the question of steam quality. She accepted that the bulk turbine inlet steam had been monitored throughout the trials and no contamination had been found. However, she and her colleagues felt that Dave did not fully appreciate all the aspects of their hypothesis, which had been presented at the conference. Their ideas on sodium hydroxide build up, she reminded them, were based upon the introduction of miniscule amounts of sodium hydroxide. Such amounts would not cause any concern to Dave’s chemistry colleague, but, by an alternate wetting and drying mechanism, this would gradually build up to significant levels and initiate a small crack. This process would be repeated as evidenced by the pattern of staining clearly found on the fracture surface. As Dave listened to Dorinda, his initial feeling of shock gradually gave way to anger, which he did his best to hide. He replied that he had confidence in the continuous steam quality measurements. He reminded the others that the technique used was much more sensitive than the normal methods used on modern power stations. If these were being questioned, what were the value of any measurements elsewhere?

  James, continuing Dorinda’s theme, pointed out that these improved techniques were not being used when the suspected period of contamination took place. Dave, determined not to give ground, countered by reminding his fellow members that he felt his confidence in the rig results was supported by the fact that his growth rates were very similar to those obtained by Joe in his laboratory rig, where contamination was unlikely. James accepted this, but it was the question of crack initiation that was the issue, not its growth. The vital step in the whole Winford failure came down to this: just how did the cracks start in high purity steam? He pressed Dave on this point. Could he explain how cracks initiated in disc steel operating in high purity wet steam? Dave had to admit that he hadn’t really got very far with his ideas on that aspect, but he still believed that his results were as valid as their own hypothesis. He became angrier and ended his argument by suggesting that Dorinda and James were biased towards their own tenuous theory. They didn’t want his results to be circulated as this would cast doubts upon theirs. Joe, who, together with Henry, had been a spectator during these exchanges, found it amusing to observe the two rival centres within the same organisation clashing publicly in this way. Henry was more preoccupied with the likelihood of having to make a decision of how to resolve the difficulties.

  To give Dorinda her due, she did not appear to take offence at Dave’s personal outburst. She merely reiterated that there was the possibility of contamination in Dave’s test and this should be addressed before proceeding. She continued by noting that their own hypothesis did not have the problem of explaining how cracks initiated, as everyone knew that sodium hydroxide would do this. All they had to suggest was a viable method of how it got there and this, she contended, they had done. Dorinda concluded by reminding Dave what he was asking the sub-committee to do. The frightening implication of his results was that many operating turbines around the world, were in imminent danger of blowing up, during normal operation. If the sub-committee agreed to circulate his report, they would be seen to be endorsing this possibility and therefore she felt that her colleagues were not being unreasonable in asking Dave to obtain some confirmatory evidence, to support his initial findings.

  Henry politely called a halt at that point, suggesting that further discussion could be continued outside the meeting and a decision with regard to publication could be made. He assumed that it would take Dave a while to prepare his report in publishable form. Despite Dave’s annoyance, he had little option but to go along with Henry’s suggestion. The ramifications of this debate occupied Dave’s thoughts for the remainder of the meeting, to the extent that his intention to try to have a quiet, private word with Pauline was forgotten. On his trip home he became calmer and gave some thought to the new situation and how he should proceed.

  Could his specimens have been contaminated, as had been suggested? He didn’t think so. After machining, the specimens had been carefully degreased and kept in a desiccator until the loading process and this had also been done under laboratory conditions. Following exposure, he had handed them to the NDT people making a point of requesting that only the two specimens selected for examination be subject to the dye-penetrant solution, the others would be protected. So that left the steam itself. According to Bunsen, no measurable contamination had occurred and Dave respected his opinion. No, he was confident, the results were valid. However, the difficulty was in convincing others of that. He could repeat the experiment, but that may not be enough. He really needed a different approach. Such an alternative course of action occurred to him and he began to plan his next move. He would have to work quickly.

  Firstly, assuming that the test rig results were valid and low strength steel could indeed succumb to stress corrosion cracking in high purity wet steam, there was no reason why it would not suffer the same fate in high purity hot water. It would be easy to carry out a standard laboratory stress corrosion test. He could use very high purity, laboratory grade, deoxygenated water, which would be free from contamination, and if the specimens were fully immersed, there would be no chance of concentration by evaporation occurring. That would be his next job.

  Secondly, he would put extra resources into the work he’d just begun, looking into possible ways that a crack might be formed in turbine disc steel in high purity hot water.

  *

  “So we’re at the bottom of your list of priorities as usual,” complained Sue when Dave announced that he wouldn’t, after all, be able to take any time off. She had spent part of the day making the final arrangements. “Well sod you, the rest of us are bloody well going.” Sue was shaking with anger.

  Dave, still smarting from his earlier setback, found it difficult not to enter into a full scale row and clear the air once and for all, but he realised that they would quickly lose their tempers, so he left the house and sought solace at The Marden Arms. He had a pint of 6X and reviewed his position. He had been under pressure since joining the SSA, one thing leading to another, with increasing urgency. He recalled recent events, with the preparations for the Winford trial. Firstly, the rush to obtain the necessary equipment and test pieces in time for the turbine outage, followed by the difficulties of getting everything set up on site. Added to this was Sue’s constant nagging. He brooded and became increasingly morose; the cheerfulness of the pub was at odds with his mood. He left abruptly.

  He drove aimlessly towards Marlborough and stopped at a small village pub. The smoke-filled bar was busy, mostly agricultural workers it seemed, but, being a stranger, Dave thought that he would be left alone with his thoughts. He ordered a pint and a whisky and found a vacant table in an alcove. He drank quickly and collected another pint. This did not improve his mood and he continued to feel sorry for himself. He had been so excited. All the hard work setting up the on-site tests, followed by the elation of the unexpected and significant results. The prospect of having a paper published, which would surprise many in the corrosion fraternity and have a major impact on power plant operators worldwide, had heightened his delight. All this was now being put under threat by those smug buggers at Slough.

  “Do
n’t want their own half-baked theory ditched. Well sod the lot of you!”

  He became aware that some of the locals were looking across at him. He hadn’t realised that he’d spoken out loud. They turned away and resumed their conversations and Dave ordered another pint and a small cigar. Sipping and smoking, his mood mellowed.

  “Mr Harrison? I thought it was you.”

  “Wha? Janet?”

  “You’re a stranger over here and on your own.”

  “Just felt like a change. Wife trouble actually, and after the week I’ve had.”

  Janet was sympathetic.

  “Anyway, how are you settling in amongst our typing girls? Can I get you a drink?”

  “A lager please.” She sat down.

  Dave collected Janet’s drink and another for himself. He was cheering up.

  “I’m really enjoying the work and meeting all you engineers and scientists. So interesting and such a change from the folk around here.” She looked across to the smoke-filled, crowded bar area.

  He drew his seat nearer. She was an attractive girl.

  “Well, we’re very pleased to have you with us. You’ve certainly brightened up that office.”

  Janet smiled. He took another swig and clumsily put his hand on her thigh. Her eyes widened, though not with alarm, but amusement. They sparkled. Dave grinned.

  There was a disturbance in the bar.

  “Bastard!”

  Dave turned to see a figure approaching. A young, heavily built fellow. He was red-faced, sweating. Dave stood, unsteadily, and turned towards him. A final rush and a swung punch. To Dave it seemed as if in slow motion. A massive fist approaching. He stepped away, alarmed. The drink was slowing his reaction. Just half a pace and he stumbled over the chair leg and fell backwards. He was lucky. By the time he had untangled himself, a couple of locals had pulled his attacker away whilst Janet berated him. They calmed the man and suggested to Dave that he should leave. He grumbled but complied. Janet followed him out apologising. He was a former boyfriend.

  Dave was shaken and realised through the beer haze that he was making a fool of himself so, after mumbling an excuse, he drove home. The experience had had a sobering effect.

  *

  It was an uncomfortable household as Sue and the girls began their packing, having modified the arrangements with Velma. Sue did her best to ignore Dave – she had heard him noisily arrive home last night. The female Harrisons set off early, as the journey would take the best part of the day, including breaks. This had the advantage of allowing Sue’s intense annoyance to abate. For the girls’ sake she pushed these thoughts into the background and willed optimistic ones in their place. She felt that she ought to include her daughters in her thoughts about the present difficulties.

  “I’m sorry that things are not very smooth at home just now, but I don’t want you to worry. Your Dad and I are going to set things right again very soon. Dad has been so busy lately and has had a lot to deal with at work. You remember the accident, when a man was killed, I am sure. Well this has made Dad’s job so important and he’s desperately trying to find the answer, so that other accidents won’t happen. Shall we try to cheer him up? A good start could be for us to take back some presents for him. A few sticks of rock and a ‘Kiss Me Quick’ hat. What do you think?”

  They arrived just before tea time and were enthusiastically greeted by Barry, Velma and their children.

  The location, Sue noted, was ideal for all the girls, as it was amongst the dunes and virtually on the beach. Velma announced that the forecast was fine weather for the week, and so they had all the makings for a perfect holiday.

  “Oh! Sorry, I was forgetting about Dave,” she quickly added.

  “He’s fine. Please don’t worry about him. He’s more than happy for us to be out of the way, just at the moment,” Sue replied.

  Barry and Velma exchanged glances, realising that this was a subject upon which Sue felt very strongly. Nevertheless it did, as Velma had predicted, turn out to be most enjoyable, with everyone being pleasantly occupied in their personal pursuits. The younger girls settled happily together, as usual, spending most of the daylight hours on the beach. Jo, being the eldest, had other interests she wished to pursue. She was now reading a good deal of young adult literature and also working to develop her artistic talents. Her focus was firmly set upon going to Art College. She had brought her brushes and paints and spent several days amongst the sand dunes at her easel. However, she didn’t divorce herself completely from the other girls, as she had always been happy amongst them. She joined in many of their energetic games and once absorbed into the noisy excitement, was in danger of allowing her maturity to slip.

  Sue was particularly pleased as, whilst she was in Norfolk, she decided to visit Pulham, which was the site of her Boughton family roots. She found Pulham to conform to her idea of a quintessentially English village. It had all the ingredients: village green with a pub at either end, thatched cottages and church. She was taken aback when she found the door of St. Mary’s locked. She checked the notice board and was relieved to find that, although the minister was absent, the keys were held by one of the church wardens, whose address was given. She found the appropriate cottage and the courteous occupier escorted her back to the church and led her into the vestry, where he unlocked the chest containing the parish documents. He asked how long she required and when Sue hesitated, he suggested that he would return in about three hours, if she had not returned the keys before then.

  Sue was overjoyed at being allowed this access, also that she was not under the pressure of being supervised. Although she had seen the old parish registers at St. John’s in Bremham, it was still a tremendous thrill to handle the very old parchment volumes of Pulham, with their spidery hand-written entries dating back to the sixteenth century. Having spent a few moments savouring this pleasure, she settled down to work. Her starting point was the baptism of James Boughton which, she estimated, would have been around 1805. She had decided not to look for his marriage, to Sarah Alexander, as this may have taken place in Sarah’s home parish. Sue scanned the pages carefully.

  “Yes!” That now familiar jolt of pleasure – James Boughton b. 8th Feb 1813. Son of Thomas and Harriet (Thorold). Thomas was an agricultural labourer. Sue had noted that there were quite a few other Boughtons listed amongst the entries. She decided that, rather than searching out selected entries, she would copy down any mention of a Boughton as she progressed. Later, in the comfort of home, she could attempt to build up the various family relationships. She worked steadily, each turn of the page moving her ever deeper into the past, filling several pages of her note book until, with a shock, she found that she had been busy for almost four hours. Carefully replacing the volumes upon which she’d been working into the chest, she returned the key to Mr Fiske.

  As the sun was still shining brightly, Sue decided to stroll around the churchyard, where she found several Boughton headstones amongst the well cropped grass. She made a note of the inscriptions and was just copying down the details of a George Boughton, when a lady, who was walking along the nearby lane, stopped and chatted. She confirmed that the Boughtons had been a well-known family around the area and added that a former resident had written a history of Pulham families. If Sue was interested and wanted to leave her address, she would make a copy of any references to Boughton and send them on. Sue was most grateful – people could be so thoughtful.

  The rest of the holiday was fun for all, the two sisters-in-law laughed a lot, the cousins became reacquainted as they updated each other with all developments ‘girlie’, as well as exploring the beach. Jo’s painting efforts were applauded by the others – she seemed to have talent, they agreed. Barry, meanwhile, took every opportunity to relax with a novel or the newspapers.

  “He reads to unwind,” Velma explained. Sue thought that it was a tip that Dave could well learn.

  19

  Dave’s hangover was not as severe as he’d expected, or deserved. His
lower back was sore as a result of his fall. Gritty and Ian were surprised to see him engrossed in his work when they arrived at the labs. He explained what had happened and how necessary it was for them to get some irrefutable evidence to support their hypothesis quickly. When they heard of the sub-committee’s reaction to his results, they were less severe in their assessment of the Slough scientists. They could appreciate the serious implications that publishing their results would have for power station operators. If it transpired that their conclusions were faulty – well it just couldn’t be thought of.

  “That’s as maybe,” grumbled a sceptical Dave, before outlining his plan to address the criticisms made, in relation to possible contamination in his rig trials. This would entail initiating additional laboratory tests. He wanted to expose stressed samples of disc steel, at four separate load levels, to hot, deoxygenated, high purity water.

  Specimens, each enclosed in a glass vessel, would be fitted into their standard test machines and hot high purity, deoxygenated, water would be circulated through the vessels. Fortunately they had all the necessary equipment and ample test pieces in stock already. They had sufficient test machines to accommodate three specimens at each load, i.e. twelve in all. Dave wanted the load on each specimen continuously monitored throughout these experiments, using a chart recorder. If cracking occurred in any specimen, it should be accompanied by a fall in load.

  He asked Ian to set up these tests immediately, whilst he and Gritty continued the vital task of investigating how cracks might initiate. This was the most difficult part of the process to explain and had been seized upon by the Slough people. Specimens of disc material would be prepared to obtain a highly polished surface. Some would then be immersed in hot sodium hydroxide, as it was known that this could cause stress corrosion and others in hot, high purity water. Samples would be removed after short immersion times to detect the first signs of corrosion. They were looking for signs of localised pitting, from which a crack might initiate and propagate under stress. Gritty and Ian sensed Dave’s mood and his manner impressed upon them the vital importance that he attached to these, comparatively trivial, laboratory tests – surely such things had been done before? If they had any doubts they cast them aside and responded positively to his ideas.