Rapid Response in a Remote Alpine Environment
TCB Industrial was contracted to perform an emergency investigation and repair of a turbine packing box at a remote hydroelectric facility located at approximately 4,500 feet elevation in the Sierra Nevada. The facility sits at the inlet to a high-altitude forebay and is typically inaccessible during winter months due to snow accumulation and seasonal road closures.
At the time of mobilization, the powerhouse access road and surrounding terrain were covered with four to five feet of snow. Despite these conditions, the urgency of the issue required immediate response to assess equipment condition, determine failure mechanisms, and execute repairs while minimizing outage duration.
Access Constraints and Logistical Planning
Due to seasonal access limitations, traditional ground transportation was not consistently available. TCB developed a flexible access plan utilizing a combination of helicopter transport and snow cat travel, selected daily based on weather conditions and visibility.
This approach required:
- Weight planning for personnel, tools, and rigging
- Daily go/no-go decision making tied to weather windows
- Redundant access strategies to avoid schedule standstills
When snow and fog conditions restricted air access, snow cats were utilized, adding approximately four hours of daily travel time. To preserve productive work hours, lodging logistics were adjusted to stage crews closer to the site during prolonged ground-access periods.
Safety and Clearance Management
Given the remote location and the nature of the work, safety planning was prioritized before mobilization.
Key safety controls included:
- Task-specific Job Safety Analyses developed and reviewed prior to site access
- Helicopter safety training for all personnel
- Formal clearance walkdowns and verification of isolation points prior to work
- Daily tailboard meetings conducted before transport to site
All work was performed under established lockout and clearance procedures to ensure personnel safety during investigation and component handling.
Investigation and Repair Execution
The scope of work began with a detailed investigation to determine the root cause of packing box performance issues. The team disassembled and removed components strategically to avoid unnecessary major disassembly of adjacent turbine elements.
This approach allowed:
- Identification of component failure without full unit teardown
- Preservation of critical interfaces
- Reduced exposure time in a challenging work environment
Following assessment, TCB proposed and implemented a repair solution that addressed the failure while maintaining alignment and fit-up tolerances. Repairs were completed efficiently, allowing unit reassembly to proceed without extended downtime.
Environmental Controls
As part of the repair scope, turbine guide bearing oil was removed and replaced. Environmental controls were established prior to work execution, including:
- Identification and protection of potential leak paths
- Strategic placement of spill kits
- Controlled handling and disposal of fluids
These measures ensured protection of surrounding waterways despite snow-covered conditions and limited access.
Real-Time Coordination and Decision Making
Due to the emergent nature of the work, a fixed outage schedule was not required. Instead, the project relied on daily coordination between:
- Project management
- Engineering support
- Field supervision
- Operations representatives
This real-time communication structure allowed immediate decision making as conditions evolved, preventing delays and enabling efficient sequencing of investigation and repair activities.
Project Outcome
The TCB team successfully completed the investigation and repair while avoiding a full unit disassembly. The unit was reassembled and returned to operational status without recordable injuries or environmental incidents.
This project demonstrated TCB Industrial’s ability to:
- Mobilize rapidly under extreme conditions
- Execute technically complex work in remote environments
- Adapt logistics and planning in real time
- Deliver safe, effective solutions under pressure
