BOILER SAFETY
CASE STUDY ON RECENT BOILER BLAST
KNOW SHUTDOWN
A successful plant
shutdown starts with a safe
workforce. A documented
procedure,
communication, and well-
trained team are key.
Restarting the operations
in full flow after a long
shutdown needs particular
and utmost
safety measures.
SIX WORKERS KILLED,
17 INJURED IN BOILER
BLAST AT THERMAL
POWER PLANT IN
TAMIL NADU’S
NEYVELI
WHAT?
At least six people have died and as many as 17 others
suffered serious injuries in a boiler blast at a Thermal
Power Station in Tamil Nadu’s Neyveli. This was the second
boiler explosion in two months at the same plant. The
mishap occurred at the fifth unit of the thermal power
station-II when workers were in the process of resuming
operations.
WHY?
The cause of the blast could not be ascertained. However, it
is suspected that overheating and high pressure might have
led to the explosion just like the previous incident.
HOW?
According to the sources, “Unit V shut down after it tripped
on the previous night of the incident . The workers and
engineering staff were attempting to revive it when a fire
broke out in the boiler, resulting in the explosion.
DISCLAIMER: This accident analysis is based on open source data and may differ from actual, purpose of this case
study is done for safety awareness. Anyone reading it only for their awareness purpose only.
POSSIBLE SAFETY MITIGATION SAFETY AUDIT

In this incident, various

experts in the field are
insisting that the
management undertake
safety audit which could
have avoided this accident
in the first place. 

PRIOR TO SHUTDOWN - SAFETY CHECKS

Drain- Transfer all the system fluid in dynamic inventories in static

holding tanks.
FLUSH- the system if fluid is handled is likely to jam rotary
equipment/ valve stem etc. Also, ensure no pockets of fluid in the
system at the drain/ bends
FILL – the system with suitable inert media
ISOLATE – the power supply to equipment
ENSURE– full draining of heat exchangers on secondary side (cooling
water)
•All the above activities must be based on approved SOPs &
documented in form of OTO (order to operate) / checklists.
P& IDs must be comprehensive, detailed, updated & should b e as
built and duly approved

STARTUP AFTER SHUTDOWN

HOW WE CAN HELP?
Lubricate all the valves and check its freeness check prior to
operation Safety Audits by Lead Auditors
Follow the startup SOP (after long shutdown) by checklist i.e with more than 20 years of
prepared by, checked by, approved by. expertise in auditing.
Understand the need of SOPs if the existing experienced Behaviour Based Safety
manpower is not available due to lockdown / left the job & Training for Top, Mid and Low
joined other company level management & BBS
Keep the bypass valve of steam traps open till steam starts Implementation people which
flowing. helps in improving safety
Take full protection against all the potential hazards like toxic culture and safe work behavior.
release, chemical, heat etc., by using proper PPEs Process Safety Management
Lineup one by one system and one by one equipment of each Training & Implementation
system For more information reach us
Before starting any rotary equipment give the start kick to at info@thesafetymaster.com
check direction of rotation and its freeness Consulting- thesafetymaster.com
While operating the rotary equipment, the behaviour of Online Course- thesafetyguru.online
equipment w.r.t temperature (including bearings ), pressure, Products- bookmysafety.com
current, vibrations must be observed for 15 minutes. Source Reference- The Hindu- Online News story