Event Background: The construction of the project at a customer site, with their existing facilities in operations involving high temperatures, steam, water, compressed air and electrical power for their operating systems.
In our safety manual for the site, we had mapped all these safety hazards and had prepared our safety procedures and Job Hazard Analysis (JHAs) for all jobs involving such hazards.
The safety procedures, requirements, JHAs and daily safety work permits at site were communicated to the customer also.
We had reached almost the end of the project, with zero accident and zero lost day, with the customer, trying to commission their services for this project.
Event:
- One day the customer, without prior information to us injected steam in their header, without ensuring the Lock out of all the valves from the header. One of the valves was leading to the steam line under construction at our site. The line was completed in welding and pressure tested also and its insulation was going on.
One of the insulation worker reported at site, limbed to his position to start the job, while he was hooking his safety harness, his back touched the hot steam line and got burnt, he fell down as his harness was also not hooked.
- Received burn injuries and cuts on face and some muscle ruptures.
- Taken to first aid and then to hospital, was released after the doctor’s examination and bandaging.
- Was under treatment for 2 weeks.
Analysis:
- The customer did not inform us of their commissioning activity, failed to apply LOTO (Lock Out Tag Out) and communicate to us the information on the safety work permit in force at site.
- Did not also supervise the activity.
Core Competencies, Practices and Behaviors:
- Safety at site was compromised, knowing very well the hazards, the careless attitude of the customer and starting the job without the Tool Box Talk at site and without ensuring complete LOTO of all the valves, as they did not refer the complete piping drawing.
- Follow UP action: Every day in the evening the next day jobs were planned with customer and the safety requirements from each agency were chalked out with responsibilities fixed.
- In the morning a small at site meeting used to be held to discuss the plan and issues and then start the jobs.