Transformer Audit Hazard Mitigation Using STAR Protocol – EHS Case Study

Customer

Duke Energy

Location

Charlotte, NC

Highlights

  • STAR Protocol Prevented Injury in Hazardous Terrain
  • PPE Readiness Demonstrated Field Risk Awareness
  • Broader Awareness of Non-Utility Hazards Boosted Safety Culture

Identifying Hidden Hazards During Underground Loop Audit

The Challenge

While conducting an audit on an underground loop system with backyard-access transformers, a hazardous condition was discovered in a wooded area. Hidden beneath brush and debris were multiple wooden boards embedded with long, rusty nails—remnants of an old treehouse. These nails posed a high risk of puncture injuries or trip hazards to anyone walking through the area. With transformer access requiring on-foot navigation through this rugged terrain, the risk of stepping on unseen hazards was elevated. The combination of dense foliage and leftover construction materials significantly increased the likelihood of injury.

The Solution

The risk was mitigated by the crew’s adherence to the STAR protocol (Stop, Think, Act, Review):
  • Stop & Think: The field lead recognized the unusual terrain and took time to assess conditions before proceeding further.
  • Act & Review: Upon identifying the rusty nail hazards, the team exercised caution and adjusted their route while continuing the inspection.
Fortunately, the crew member was wearing puncture-resistant boots, which could have minimized injury if contact had occurred.

Key Benefits

  • Reinforced Use of STAR Protocol: The field application of STAR helped prevent potential injury before the hazard caused harm.
  • Proactive PPE Use: The use of appropriate footwear demonstrated good planning and helped mitigate an otherwise high-risk situation.
  • Hazard Reporting & Awareness: This event raised awareness of residual site dangers unrelated to current utility work.

The Results

  • No Injuries Reported: The hazard was identified before any incident occurred.
  • Field Safety Awareness Enhanced: Team members were reminded to stay alert, especially in wooded or overgrown access routes.
  • Actionable Feedback Provided: The situation was documented and shared as a reminder for future backyard or off-road transformer inspections.

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