Accidents at Glance Power Plant

Thermal
Main Power
contractor name –Plant accidents
LTI# - Date of incident& learnings
Main contractor name – LTI#INDIA
- Date of incident
GMR
Main contractor name , Angool
– LTI# , Odisa
- Date of incident
Incident type Fatality
What happened
For carrying out coal bunker inspection it was decided to empty bunker completely. Hence
coal feeding was stopped, and Mill was in service. The operator at bunker floor was taking
bunker level after every 30 min. Once he was taking the measurement suddenly a fireball Photo:
came out of bunker and completely burned the operator. Finally the victim died. On Not available
investigation it was found that Feeder tripped on no coal on belt but Feeder outlet gate
didn’t close as its interlock was forced. It resulted high hot PA to directly come out from
the free passage of bunker. Also imported coal having high VM ignited easily causing fire
ball for few seconds.
Learning from Incident
 Never ever bypass any existing system.

 Stop bunker emptying process when coal goes below conical portion of bunker.
Empty the remaining coal manually by gravity by opening feeder back door with
proper arrangement
 Special attention must be taken on mill outlet temperature (go even upto 50-55 Deg
C) while operating with high VM coal
 Mill tripping on Mill outlet temperature must not be bypassed will MDV must get
closed with Mill tripping. In this case it was appeared that Mill outlet temperature was
forced.
Relience
Main contractor nameRoza
– LTI#power, Shahajahnpur
- Date of incident
What happened
While a Civil worker was simply carrying a long rod and going in a road Photo:
of a construction site , the rod touched the overhead 11 KV line and got Not available
electrocuted. The person died. It was later found that the height barrier
at that location had been removed for shifting some material one month
back, was not put back.
 Proper training must be given to all regarding the hazards about their
jobs. Generally we presume lot of things. JSA is very essential.
 Proper display board / barricading / height barrier must be ensured.
 If any height barrier is removed, it must be done with proper approval
and record. After completion of work it must be put back. It also
properly incorporated in PTW system
GMR
Main contractor name , Angool
– LTI# , Odisa
- Date of incident
Incident type High Potential
What happened
Two persons were doing the light fixing job in a constructed Central store which
was completely empty and unoccupied. The light was being fixed in each column
at around 5M height and each column was around 3M apart. Hence after fixing in
Photo:
one column the person was coming down then the stool with wheel was getting Not available
shifted to another column. But after carrying out for few columns, the person at
the top told his partner to shift the trolley while he is on the top. In the process
once he toppled and fell on the ground and got severe head injury. It took almost a
month for his recovery.
 Never do short-cut. A small mistake can lead to bigger problem

 The platform must be having railing with toe guard.
 It was such a simple job, nobody had given much attention. Any height work
must be properly monitored.
 No trolley should be moved while any person is on the top. There is high
likelihood that slight uneven floor can restrict the movement and there is a
chance of toppling.
Main contractor name –NTPC , Kawas
LTI# - Date of incident
What happened
It had happened in a township. The residents had complained that in the afternoon
while children plays the cars/bikes are plying at considerable high speed, hence
some speed breaker to be provided. The Civil fellow accordingly constructed the Photo:
speed breaker without putting any signage on that day . In that afternoon a bike Not available
rider didn’t see that and got an accident with head injury as he was not wearing
helmet.
 MOC is essential. Make any changes with proper approval.

 Any construction made in public place must be properly communicated and proper
signage must be provided immediately. In this case Civil had planned to put the
signage on next day.
 Always wear crash helmet while driving two-wheeler
 Illumination must be proper. It happened at 6 PM when street lights were not on as
timer was set at 6.15.
Main contractor name Reliance Power
– LTI# - Date of incident
What happened
When scaffolding pipes were Being stacked at storage area, one worker kept a
reinforcement rod inside one scaffolding pipe. Photo:
Not available
After two days, the same scaffolding material was issued for another gang to erect
new scaffold. During the erection, that reinforcement rod skidded from pipe and
fell on the worker standing 6 meter below. Pipe struck on the forehead of the
worker which caused immediate fatality.
 Nothing should be kept inside scaffolding pipe

 Scaffolding materials shall be inspected before using the same.
 Only skilled & trained persons should erect scaffolding .
Power
Main contractor name – LTI# plant
- Date of incident

What happened PHOTOGRAPH
During performing maintenance activities near Fan area one skilled

technician with full body harness approached very near to motor-
fan coupling. He accidently got stuck with rotating part.
 Never wear loose clothing/hanging full body harness while working near
rotating parts.
 Availability of coupling guard/Machine guard to be ensured.
 Job & location Specific job safety analysis to be prepared and discussed with
team before starting the job.
GEB,
Main contractor name Sikka
– LTI# - Date, Unit 2
of incident
Incident type High Potential Incident

What happened Photo: if available
This incident occurred at a Construction Site. While I was inspecting certain

Boiler Components in the well of the Boiler at 0.0M, a chipping hammer from
42M landed straight on my helmet. It ricocheted off the helmet and struck me
hard on the neck. Though there were no external injuries on my body, the
incident left me in severe shock for some time. Beside me, were two people from
the Contractor’s Agency who were standing without a helmet. Even a 0.1°
change in the angle of fall of the hammer could have resulted in the hammer
falling on either of them resulting in an avoidable fatality.
1. While entering site premises, use of PPE is mandatory. There shall be no

let up on this.
2. The people working at higher elevations should be advised to anchor the
tools with a rope so as to prevent free fall
Main contractor name APMuL,Mundra

What happened
During Erection of U#6 Boiler Pressure Parts Arch inlet influx header
(Approx. weight 11 T, fallen down from suspended position of 48 mtr to
ground floor). During falling the header also struck with other assemblies
suspended in furnace like wind box duct, SOFA Burner assy., Burner block
assembly etc. Incident happened on Sunday at around 5 PM. Nobody were
present at location. The slings by which header was suspended got melted
due to short circuit in nearby passing cables .
1. No load to be suspended for longer duration if not required.

2. The condition of slings and chain pulley blocks to be checked
frequently
3. No live cable to be present in surroundings of suspended load slings.
Main contractor name –APML , Tirora
Incident type Fatal

What happened
During Boiler Structure grating and Hand railing Erection work at our Organisation of Tirora Plant,
Incident happened.
Grating material are Shifted to the 40 mtr elevation with bundle for installation by rigging team.
Then Grating are spreaded to the Floor for fixing by Tag welding by same rigging team. After that
welder and fitter gone to the Position, found all the grating spreaded into position. Need to align
and Tag weld it. The welder and fitter started to one by one aligning and tag welding the grating on
the floor from one side. After some time ,there is a grating one side supported with beam and
another side supported with minimum clearance (10mm). It is not observed by fitter and welder.
When welder is moving into grating, little shake on grating and Grating freed from one side beam
and fell down from 40mtr elevation into 0mtr and the fatal incident happened.
1. Preparedness of Risk accessment and erection methodology before staring of work.

2. While working at 40 mtr Height, need to arrange Life line and wear Safety Full hardness.
3. Always Put a Grating Installation one by one with welding completion.
4. Loose Grating should not lay in position without Locking by Welding or bolting or winding . It
may chance to unknown person walk through.
Main contractor nameDB Power,
– LTI# - DateRaigar
of incident

What happened Photo: Not available
During erection of discharge duct of Induced draft fan work in progress at 15mtr.
height with proper safety arrangement. During the erection of duct 3 nos. of
workman standing upside erected duct other side but due to movement of
connecting duct (Hanging through crane) to joining duct there is a small jerk
while mating the connection joint. All of sudden they fall down from duct.
Fortunately due to proper use of Safety Harness and Life line, all were hang and
resulting no injury
1. During working at height use life line and wear safety harness.
2.Movement of heavy parts should be done smoothly and slowly.
Main contractor name – GEB,
LTI# - Sanand
Date of incident
Incident type Fatal

What happened Photo: not available
One of the Unit was under construction. Coal plant side Bunker construction
were completed and flooring work at bunker floor was also on verge of
completion. Some openings were there so same were covered by metal sheets
temporarily. While one of field engineer was passing through the covered
sheet, sheet fell down after tilting from his weight. Field engineer fell down in
bunker and got multiple injuries which results into his death.
1. Area hard barricading must be done.

2. If openings are covered then metal sheets are to be of proper thickness
and are to be welded properly.
3. Display boards for awareness regarding Hazard.
GSEL,
Main contractor name – LTI#Gandhinagar
- Date of incident
Incident type HIPO

What happened
During annual overhauling work , Boiler flue gas duct from Air preheater
outlet to ESP inlet duct maintenance work at @ 20 mtr height is under
progress with proper lighting arrangement. During movement of 2 nos of Photo:
workman in side the duct all of sudden he fall down from duct ; but due to Not available
wear of safety harness both were hang. Both person rescue was carried
out ; but they have no injury.
After rescue of person area was inspected and found that the duct was
eroded due to ash erosion.
1. During movement inside the duct always put the step with
proper care or check with rod or pipe by hammering of same.
2. Always tie the life line and wear safety harness inside the duct.
3. During work in confined space area more than one manpower
may go ; so in case of emergency person may rescue or help
may be called by third person.
Vedhandha
Main contractor , Balco
name – LTI# - Date540MW plant
of incident
Incident type Fatal

What happened
Boiler Front Water wall at 35mtr Insulation removal work in Vedhandha , Balco
540MW plant. Incidents detail is :
Scaffolding arrangement done by wooden bamboo for insulation removal in Photo:

front water wall side . All the Bamboo are wounding by Coconut rope. Three Not available
person gone to the location by safety belt with single hook. During moving
into step by step , they are removing the hook and shifting into another
position. That time ,one person removed the Hook and trying to hang
another place, suddenly slipped by his hand from scaffolding bamboo and
fell down from 35mtr height to 0meter. Fatal incident happened.
1. There is no life line prepared during moving from 0 meter.

2. Fall arrester also not provided
3. Full body hardness not available
4. Work pressure for handing over the plant for operation of plant.
5. Wooden Bamboo using are very risky and wounding rope can fire and release
from wound.
6. Proper SOP not Prepared and Not trained before start the work.
Main contractor name – GIPCL,Surat
Incident type Fatal

What happened
Two groups ( 5-6 workers each) were doing sheet fixing work on top of 2
different sheds erected for Coal storage. The two sheds were separated by Photo:
6 meter road. Each shed is having height of 20 meters and in each shed
Not available
the opening of 2 Mx2 M was provided on top of shed for lifting the sheets
from ground .They worked till tea time and come down to take tea .
After taking tea they were went up for doing their work . 1 workers was
talking with another worker working on another shed. During walking he
was not able to see the opening and fall from opening to ground. His legs
,and hands were found broken and rushed to hospital where he was
declared dead
1. All opening shall be made after proper approval and barricading

shall be done and danger board should be displayed
2. Life line shall be used and safety belt should be fixed while
traveling from one end to another end at height. .
JSW–power
Main contractor name plant,Bellari

What happened
During Unit annual over hauling work, APH B was under mechanical (internal
inspection) permit for its axial & radial seals setting work for which, APH
main motor power supply & it’s Air motor air supply were isolated. In the post
lunch session, one out-sourced mechanical maintenance person was working Photo:
inside the APH. But without his clearance or information, someone opened Not available
the Air Motor air supply & fled away. Due to this, APH rotated with high
speed & the person working inside got fatally crushed. Later it was found
that since that morning, maintenance team was rotating the APH by partially
opening the air supply which should have been in isolated condition as per
PTW.
1. Always ensure double isolations before issuing permit.

2. Air supply hose of APH Air motor, if available, should be disconnected during internal
inspection work.
3. Power supply cables should be disconnected till the internal work completion.
4. Rotation work, if required, should be done only by hand barring.
Main contractor name –MPEB,KORBA
Incident type Fatal
At one of the power station , CW duct was taken under

permit & the persons were working inside CW duct.
All of a sudden one CW pump of other unit tripped & Photo:
somebody opened wrong interconnection valve. Water Not available
filled in the duct. All working persons lost their life.
CW Main valve & Interconnection valves should be electrically isolated &

mechanically locked prior to PTW..
Main contractor name –CSEB, KORBA
Incident
Loss Time Injury
type
At one power station , an accident was caused

due to heavy pressurisation & steam formation
while applying water jet on such ash clinker/heap Photo:
Not available
which seams to be cold from outside but was
actually hot from inside.
The ash heap / clinker get cool from outside but retain latent heat
inside, so utmost care should be taken while putting water jet on it. Also
it should be avoided to enter in ash heaps looking cool from outside but
having very hot ash inside.
Main contractor nameRelaince Dahanu
What happened
At Relaince Dahanu plant Fatal accident occurred in main
stores in 2015-16.
Photo:
Hydra operator was loading metal sheets with two helpers.
Not available
While reversing hydra one of the helper got trapped in rear
wheel of hydra & died on the spot.
There was no reverse horn for hydra.
1. Reverse horn must for every vehicle.

2. Operator of hydra / Heavy vehicle must have daily tool box talk & must know
safety hazard & awareness regarding the operational activity they are doing
3. Overconfidence of Hydra operator & Hurry to finish the job early , violating
safety & carelessness lead to accident.
Mundra
Main contractor name – LTI# - Date of incident
Incident type HIPO
What happened
Incident happened at Mundra site during commissioning
period-
Hand railing work was planned on at 24 mtr height. welder Photo:
took electric supply from DB having multiple connections Not available
by removal of fuse and kept fuse nearby. He started doing
the cable connection for welding m/c. & same time
someone fixed the fuse in DB for his elect. Supply
requirement. welder both hand got burnt due to
electrical shock.
1. Do not make unauthorized electrical connection

2. PTW & Tagging system was not in place.
Main contractor nameJSL,Jajpur,odisa
Incident type FATAL
What happened :
Fabrication and Erection work of Trestle was going on for the CHP of new
unit (2X125 MW). Trestle frame was erected on its foundation and
remaining bracings were being lifted and welded at positions. Two welders Photo:
were sitting on Tie beams for welding cross bracings at 30 meters height. Not available
Suddenly a minor storm struck the area. Both the welders were tried to get
down but supervisor of agency told them to complete the welding they are
doing otherwise structure will fall down. They continued their welding till
the intensity of storm got increased. Trestle frame was trembling horribly.
They tried to get down but fear of fall made them stuck with trembling
trestle. Finally Trestle frame got down and caused FATAL of the two.
Learning from the incident:
1. If weather is not favorable don’t continue your work and go to safe

place .
2. Welding of Cross Bracings, tie Beam and gadget plates are to be done
prior to erect the structure.
Main contractor name –Lanco, Anpara
Incident type Fatal
WHAT HAPPENED
APH got fired at Lanco, Anpara, 2x 600 MW on 21 April 2011, during first light-up for
synchronization of the unit # 1 with oil firing. As Boiler installed at Lanco, Anpara was having front
and rear firing arrangement, hence total oil gun quantity is more as compare with corner fired
boiler. About 12-14 hrs. of light-up operation , smoke observed nearby APH area fallowed by a
massive APH fire. Immediately all unit light-up activities stopped.
LEARNING FROM INCIDENT
After boiler light-up, due care was not ensured to check any carryover of unburnt fuel oil due to
misfiring of oil gun. Also flame intensity of individual gun was not monitored. .
This APH fire may be saved….if….
1. Availability of oil carry over detector system at APH inlet flue gas duct.
2. Proper monitoring of oil gun flame intensity.
3. During first light-up of boiler, HFO temperature should be adequate for free flow.
4. During first light-up of boiler, both LDO & HFO duplex filters cleaning to be ensured
Kachch
Main Lignite
contractor Thermal
name – LTI# -Power
Date of Corporation,
incident mundra
Incident type MAJOR FIRE INCIDENT
What happened
In a lignite fired boiler, there were number of leakages from various coal pipe of coal
mill. The dust was continuously getting deposited all over the boiler structure. Due to
strike of housekeeping personnel due to some IR issues, it was not cleaned for five days.
On the sixth day, a heavy vibration on the boiler was experienced due to some foreign
metal in the coal mill leading to fall of dust in atmosphere all over which suddenly caught
fire and the whole boiler was engulfed in flame . The unit could be restored after nearly
3 months as all cables etc. had got burnt.
1. Coal dust leakages from coal pipes should never be neglected. They should be
invariably arrested immediately .
2. Fine Coal dust in atmosphere can become a explosive mixture and even a spark can
cause major fire.
MSEB,
Main contractor name – LTI# Chandrapur
- Date of incident
Incident type Fatal
What happened
In one of the power plant, one of the Operation engineers was on Plant
round. For maintenance work, one of the grills in the platform was
removed for carrying out some maintenance work. The Operation
engineer who was on round in the night shift fell from the opening
from 30 mtrs. to ground leading to a Fatal accident.
1. Whenever grill from platform or handrail is removed, proper hard barricading

should be done and the distance of the barricade from the opening should be
1.8 mtrs.
2. Whenever work is over, immediately the grills in the platform should be
restored back in place.
NTPC,
Main contractor name – LTI#Vindhyachal
- Date of incident
Incident type Fatal

WHAT HAPPENED
Vindhyachal Unit-10,NTPC,during commissioning stage alkali boil out was going
suddenly temporary piping for the said activities which were laid got busted at 40kg
steam pressure and whole working platform 17mtr and APH near by area got surrounded
with heavy steaming. Three workers were working in ducts area adjacent to APH tried to
run away from location to save themselves from steam burning but unfortunately
nothing was visible and all three person struck up in boiler area and finally found lying
dead on buckstay, near by floor and one fellow at below floor level.
LEARNING FROM INCIDENT
1. Whenever such commissioning activities are in progress ,near by area no work should
be allowed to perform and area should marked /cordoned for entry of any person.
2. All temporary piping materials must be checked before use for proper quality ,size and
grade for particular job so that such kind of incident of pipe busted do not take place.
Main contractor name – APRL, Kawai
Incident type Fatal
What happened
During project phase Hydra was being used to carry and shift
the material due to time constraint. One day while shifting the Photo:
material with hydra, boom of hydra was came in contact with Not available
6.6KV overhead transmission line which was laid through the
road side for cooling tower power supply. The helper holding
the material with hand got electrocuted and found dead after
medical examination.
1. Never use Hydra for shifting material/ material movement.

2. While moving the material with any means, it is to be ensured that all the
overhead transmission lines to be crossed are either dead or at sufficient
height as per IS.
3. Awareness to be ensured for safe distance to be maintained from overhead
transmission lines.
Main contractor name –Thermal Plant
Incident type Fatal

What happened
In one of the power plant 33KV breaker which was feeding power to township got tripped
on Earth fault at 20:30 hrs when there was heavy raining . Decision was taken to attend
the problem as township went into darkness. One Engineer & two technicians and 1 helper
were deployed for that work. Work was started at 23:00 hrs. 33KV Breaker which got
tripped was positioned at 5th when we count from LHS. Engineer & Electrician decided to
open the tripped panel from rear side for inspection. While counting from rear side the
Electrician had wrongly pointed 6th panel instead of 5th Panel from LHS which was live.
He opened the live 33KV panel and earthed the leads for discharge before commencing
work. Immediately breaker got flashed over with great intensity which killed 2 people on
the spot and remaining 3 were seriouly injured with more than 50% burn injuries. Later
they were shifted Appollo Hospitals ,Hyderabad which is 200 Kms from the Plant.
1. Permit system procedure was not followed strictly

2. Panel naming & numbers need to be written on the rear side also.
3. Proper LOTO system to be followed.
4. Suitable Arc suit to be used before starting any work.
Lanco
Main contractor name , Vijayvada,
– LTI# AP
- Date of incident
Incident type FATAL

What happened
In one of the power plant during construction, excavation was going on including
dewatering as the ground water table is high. There was a submersible pump in the pit
used for dewatering. Operator saw the discharge of the pump and he was in that the
pump is blocked with debris. He asked a helper to go inside and clean the debris after the
pump is put in off mode. After cleaning the helper told him to start from there itself. When
the operator started the pump and the helper got electrocution and fell down on water.
Immediately the supervisor went inside after put the pump in off mode. And taken in to
near by first aid centre and there after to the nearby hospital. But the doctor declared the
helper dead..
1. Cable got damaged in one place from which the helper got
electrocution.
2. The operator should ensure the cable continuity and pump
should start only after there is no manpower inside the
pit/water..
CLP- Date
Main contractor name – LTI# India
of incident
Incident type Fatal

What happened
Happened During Construction of Boiler.

Platform Grill was removed to facilitate lifting of components.
Area was barricaded.
Barricaded area was sufficiently larger than the hole .
A Hammer was fallen into the edge of the hole , but within the barricaded area.
A worker entered the barricaded area to collect the hammer and fell through the
hole.
• Barricaded area has to be restricted to Hole size. Oversize

barricading will provide space to people entry
• Hard Barricade to be practiced.
Main contractor name – APML, Tirora
Proper Vehicle Parking on High ways & National

Incident type highways.
What happened
One Tipper transporting coal from Umred to APML, Tirora one of its Tyre got
damaged. Driver parked on the left side to change the Tyre.
One of the other driver of the same transporter of another vehicle noticed the
same & parked the Tipper behind the vehicle to help the driver. Both the drivers
changed the tyre. Both drivers were having a chat, standing in between two
Tippers. One Truck at higher speed hit from behind the parked Tipper. Both the
drivers got squeezed between two tipplers as tipper rolled on & dashed with other
Tipper. Both drivers met serious injury & on the way to hospital, lost their last
breathe.
1. Vehicles are not to be parked on high ways.

2. If to be parked, then only in designated parking place.
3. If at all is to be parked , proper barricading to be done.
4. Vehicles once parked, proper stoppers are to be provided
5. Distance between two vehicles are to be maintained.
NTPC,Sibet,Bilaspur
Incident type Hypo incident

After completion of BTL repair work, hydraulic test of the boiler was going on.
One engineer found water falling in Eco hopper. He was all alone. He entered
with safety harness inside the boiler at Eco lower bank bottom on beam of Eco
hopper structure. Before anchoring the safety belt, he slipped from the structure
ABCD……..
due to wet ash & fell inside the Eco hopper.
He got badly injured with several fractures including backbone and bed ridden
for 6 months. Now he uses crutches.
1. Any single person shall not enter the confined space (boiler).
2. While entering any place where potential fall hazard is existing
then anchoring should be done outside the manhole prior to
entering.
3. It is compulsory to make scaffold prior to entering such places.
Main contractor name –NTPC KORBA
Incident type Fatal
During carrying out the OH in one clarifier, support stool at the bottom
alongwith scraper was removed. Any how the heavy shaft was hanging
due to tight bearing & gear assembly. Due to shortage of technical
knowledge of the team, they could not imagine that the shaft may fall
down. One person gone inside to take shaft dimension from bottom
side. Suddenly it got freed & fell down on the person. He trapped
underneath the shaft.
1. Going / standing under the hanging load is deadly

dangerous.
2. The team first technically analyse that how the work steps
should be carried out.
Chandrapur
Main contractor name – Super Thermal
LTI# - Date Power stn
of incident
Incident type Serious Incident (Outside Plant)
At Chandrapur Super Thermal Power stn, an incident reported in Wagon

Tippler area wherein serious injury occurred to the IP. During early
morning hour, the driver of the locomotive noticed that radiator is hot and
water level need to be checked. He asked his assistant to check the same.
As per SOP, any checking of locomotive from the top should be done in
Loco shed. But IP ignored SOP and climbed at the top of loco. As the
locomotive was on the main railway track over which high tension line
was passing, the assistant got electrocuted due to high voltage and fell
down from the top of the locomotive.
1. Strictly stick to SOP - For any repair / checking work, locomotive needs to
be shifted to loco shed away from high tension line.
2. PTW procedure to be followed.
Main contractor name – APML Tiroda
Incident type Fatal
What happened
At APML Tiroda during projects, one of the contractor's welder

tried to connect welding machine power cable in the 415 ACDB in
the night shift without knowing any electrical know how. As the
feeder was live, he succumbed a severe electrocution and died at
the spot. Incident happened in the midnight.
1. Even if the power supply is temporary type, it must be locked properly.

2. Contractor’s workmen must be given training regarding the hazards hidden in
electrical jobs.
Vedantha
Main contractor namealumina limited
– LTI# - Date , kalahandi
of incident
Incident type Fatal
What happened :
A Dumper was shifting soil from one location to another in front of swyd.
On my duty time I saw that suddenly there was a heavy flashover
happened at out side of swyd. After that I went to accident location &
saw that dumper hood was touched the 33kv line & Driver thrown out
away later cause death. Dumper got damaged. It was because that after
unloading soil dumper moved forward without down his hydraulic hood.
P
1. Vehicle move without complete job.

2. JOB to be carried out with safety procedure and supervision.
Main contractor name – APML,Tiroda
Incident type Fatal

What happened
It was hot afternoon of May 2009 at Tiroda. A welder was about to finish his task of China Colony
DTR fencing gate welding work. So he extended his work after lunch time. All other workers went
for lunch on time. At around 01:30 p.m. the empty thinner drum lying near by burst because of
pressurization due to evaporation of the small amount of thinner left inside the can. Thinner
splashed over his cloths and caught fire due to welding arc. He sustained serious burn injuries and
succumbed to burn injuries in Nagpur Hospital after 15 days.
This was the first fatal incidence at Tiroda site.
1. Empty thinner / paint / petrol / diesel can should not left in hot sunlight
2. Lid of the empty thinner / paint cans (scrap) should not be closed
tightly to avoid pressurization.
3. Empty thinner / paint can should be disposed immediately.
4. Check the area around you before starting the work for any unsafe
condition.
Main contractor name MSPGCL , Koradi
Incident type Fatal Incident (Outside Plant)
In one of the power plants at Nagpur region, material shifting activity was
under progress with the help of Hydra machine during construction
phase. During material shifting, the rigger holding the guide rope tied to
the material came under the front wheel of the hydra machine and got
seriously injured.
1. The length of the guide rope was too short.

2. The rigger has wrapped the guide rope to his hand.
3. The position of rigger was just ahead of the front wheel of the hydra
machine.
4. The road to be travelled was not accessed for undulation.
5. The hydra machine is only for loading / unloading of material. For material
shifting to longer length, trailer / tractor trolley to be used.
Main contractor name –APRL , Kawai
Incident type Vehicle Accident

What happened
Bulker driver suddenly take the bulker reverse without checking

the surrounding & hit the bike which was parked backside the
bulker. Bike rider & pillar jumped from the bike to safe themselves
& bike was crushed below bulker rear tires. Bike rider got minor
injury on his knee.
1.Ensure Safe distance between from vehicle

2.Avoid reverse driving
3.Helper along with heavy vehicle
4.Reverse Camera
Barmer
Main contractor name – LTI# -, Date
Rajasthan
of incident
Incident type Fatal Incident due to Soil collapse

What happened
24 inch UG pipe line laying job was in progress. Pipe

was hold by two numbers pick and carry crane.
Person was doing pipe welding job and stand in
excavated / trench area where pipe suppose to laid
down. Due to load and movement of vehicle Soil
collapsed , resulted crane unbalanced and pipe fell
on the chest of person.
1. No body should be in line of fire during job.

2. No one under the suspended load
3. Types of soil / angle of repose shall be maintained
4. Tandem lifting shall be avoided
5. Rescue plan shall be readily available for HRA
Main contractor namePanipat refinery
Incident type HIPO (Isolation)

What happened
Caustic dosing for Mixed bed regeneration was through Pump. While regeneration,
Operator observed that pump is not discharging the chemical. Thinking that there may
be chocking and without taking valid PTW, operator starts to loosen the bolts of NRV
at the discharge of Pump. Starts hammering the pipe line, as the line was pressurized,
suddenly chemicals comes out from flange and splash on his face. He washed his face
but not thoroughly, due to that some chemical remain in eyes, his eyes got damaged
and a person got permanent vision lose.
1. Valid PTW to be taken before start of any work.

2. Required PPEs to wear i.e. Chemical suit, face shield.
3. Always to avoid be in line of fire during chemical handling.
4. Always wash affected body part thoroughly with plenty of water, so that effect of
chemical may reduced and take immediate first add
Orient
Main contractor name cement
– LTI# - Date, of
Gulbarga
incident
Incident type Fatal Injury

During dewatering of a drain pit using a submersible pump , its
discharge got reduced due to suspected suction strainer
chocking. To check and clear the chocking, initially ,one worker
stepped into the drain pit. Immediately he got electrocution on
touching the pump. On seeing his co worker struggling for life,
the second worker run into pit and touched him resulting both
of them received electrocution.
1. Always ensure PTW, equipment's power isolation &

JSA before performing any job.
2. Always use proper PPEs while performing any jobs.
Main contractor name – APRL,Kawai
Incident type HIPO
What happened
One person was handling the 6 m long ladder on turbine floor.

He was just walking under the DSL supply line of EOT crane.
He was not aware that DSL is charged & just above his walking
path . This DSL was old designed live Agular naked conductor .
Suddenly his ladder touched the live conductor and he got
serious electric shock.
1. Always see surroundings before handling any oversize object for

any live conductor /critical equipment.
2. DSL live indication bulbs should be in healthy conditions to alert.
3. In new design insulated type DSL also there are chances at joints
where many time there is sufficient gap , which is making the DSL
naked and chances of such types of incidences.
Hindalco
Main contractor name –power plant
LTI# - Date , Renukoot
of incident
Incident type Fatal
What happened
At HIL coal yard, Coal unloading by 4 to 5 Dumpers was going simultaneous over Grizzly. For
unloading dumpers needs to take reverse to reach the grizzly cum unloading point. One Engineer
reached at site and start talking on walkie-talkie for co-ordination in-between Aerial Ropeway
control room near the unloading area. One Hywa Dumper hit to Engineer at the time of taking
reverse position for unloading, person was fell down and head was crashed by rear tyre and dead
at site.
1. Be alert in crowded area.

2. No back horn in the Hydra Dumper.
3. Avoid discussion in accident prone area.
4. Warning was not written in that area.
5. Engineer was transferred from one Maint. Function to Operation in
recent past.
6. Separate man and machine interference
Century
Main contractor Pulp
name – LTI#and Paper
- Date Lalkuan
of incident
Incident type Fatal Accident while cleaning Belt Conveyor Pulley
What happened
At Century Pulp and Paper Lalkuan in year 1995 during monsoon season fatal
accident in CHP happened while cleaning Belt Conveyor Pulley. During monsoon
season belt conveyor was slipping. On inspection person found that slurry coal
accumulated between conveyor and pulley , due to it belt was slipping. He started
cleaning the slurry without stopping conveyor and even do not informed regarding
belt slipping to Control room. While cleaning his hand got trapped between belt
and pulley , which ultimately resulted in death of IP.
1. No work to be carried out without Valid PTW.

2. Ensure the isolation before any work.
Thermal
Main contractor name – power
Incident type Fatal incident due to hitting with winch machine
What happened
There was a work of shifting of HT motor of Bunker floor going on in a power plant. Motor
was being shifted from ground floor to bunker floor for replacement with the help of a
winch. During the course of lifting ,the winch got dismantled suddenly from it’s anchor point
and dangerously got pulled away due to load and hit two persons nearby resulting in fatality.
The motor came down from a considerable height and got damaged beyond repair.
1. Proper assessment of the load and anchoring of lifting tool needs to be essentially done
before lifting any heavy load.
2. Inspection of lift tools and it’s test is most essential before use.
3. There should be nobody in the line of fire. The area where there is possibility of
movement of load/lifting winch should be invariably barricaded.
4. Critical jobs similar to this should be done under supervision of experienced persons
only.
Vedhantha
Main contractor name Balco
– LTI# - Date of ,incident
Korba
Incident type Fatal
What happened
On roof of turbine house sheet replacement work was going on due to old sheet got
damaged and water was leaking from the top. To start of the job life line network made
over the roof. One day in first half one worker was moving horizontally on roof without
following continuous anchoring method. As he stepped on the another damaged sheet
it got sheared from the overlapping edges and worker fallen down from roof to 12 mtr
turbine floor. Immediately sent to hospital but doctors declared dead.
1. Design standard to be followed while constructing new facility.

2. While working at height continuous hooking method to be followed.
Main contractorTorrent Power
name – LTI# , Ahmedabad
- Date of incident
Incident type Fatal
What happened
In Thermal Power Plant, one Unit was under annual overhauling. ESP
internal washing activity work under progress. During washing activity ,IP
slipped & fall inside ESP hopper. IP’s full body stuck inside hopper due to
slurry (ash+ water) inside hopper. Fatal incident occurred.
1. JSA & risk assessment required.

2. Proper inspection to be carried out of ESP hopper prior to work.
3. ESP hoppers should be empty (ash to be removed) prior to washing
activity.
4. Use of full body harness.
5. Hoppers drain point should be clear so no accumulation of water & ash.
Main contractor name –Thermal Plant
Incident type Fatal
What happened
40 Ton crane was engaged in material during the erection access was blocked and
taken valid permit. After the completion of erection crane was placed on worker
location in position. At 1:40 because job was done operator was gone for lunch but
key was available with helper Concrete transit mix came and he inform to his
concern person that access is block he come on spot and sages to helper to move
the crane and provide the access for TM. Helper stated under the influence of
engineer the helper started closing the out rigger without lower the boom. It topped
on the Portable container office which was closed to crane 2 engineer and 2 hse
person was taking lunch inside the trapped.
1. Key must be available with authorized person .

2. Helpers are allowed to operate the equipment .
3. Need to do properly planning
4. Need to communicated with concern supervisor/engineer.
5. Don’t force to any helper to do this.
Tata
Main contractor name steel
– LTI# , Jahajpur
- Date of incident
Incident type Fatal
What happened
During erection work of an piping duct by chain pulley block the chain got
damaged & the lifted material fell down upon personnel working below the
erection floor causing fatality of one person & severe injury to another.
Later upon investigation it was found that the load test certificate of the
chain pulley was expired & not renewed timely.
1. Never violate LSSR i.e. don’t work under suspended load.

2. Load test certificate of all Lifting tools should be regularly checked &
renewed through third party inspection.
Power
Main contractor name – LTI# plant
- Date of incident
Incident type Fatal

What happened
tie breaker jaw alignment from station bus to unit bus work PTW issued to EMD. The
station bus incomer breaker ,tie breaker and tie isolator at unit bus was racked out
for the work. Work complete at the end of morning shift ,the EMD engineer return
the PTW at CCR without confirming that tier breaker backdoor was open .The
second shift engineer inform the field engineer to charge the station bus, the field
engineer normalize the isolator at unit bus without confirming the tie breaker
backdoor was in open condition. EMD technician has some doubt and without
informing anyone he tries to inspect it with 24v bulb, as he was not aware that
isolator at unit bus was racked in condition and breaker was charged at one end
,bulb adaptor touch on live bus and flash over occurred. The technician and helper
with him got dead after 15 days hospitalization , two other are saviour burn injury
and are join duly after 03 months.
1. No Violation in permit system

2. Before normalization ensure the work is completed boxed up and no
one is working on equipment.
Mundra
Incident type Fatal
What happened
At Mundra during 660 project work, BOP area civil excavation work was
going on. Nearby this excavation one civil mixer machine came and
parked. The excavation depth was 3 to 4 meter, and due to land slapping
the mixer fallen inside the excavation, and 03 person came under
machine and its fatal accident.
1. Excavation area must be hard barricaded

2. No heavy vehicle allow nearby excavation area
3. Excavation safety standard must be followed
4. The machine etc. should be allowed at least 1.5 mtr away from the edge
Shreename
Main contractor Cement
– LTI#Power Plant,
- Date of Beawar
incident
Incident type HIPO
What happened
One lighting electrician working on boiler height 50 meter. After
attending the job he started to walk to come down, he was taking on
mobile. On walkway few gratings was removed for rectification job. He
suddenly fallen and dropped on next below level walkway. Luckily he
was fallen straight and also there was a walk way bellow the next level.
He was normal only on hand little scratch. But it is highly potential of
accident, at such a height
1. No walking during talking

2. Opening must have hard barricading
3. In staircase entry must be stopped while such type of working.
Vedanta
Main contractor name – LTI# -Power
Date of plant
incident
Incident type Fatal
What happened
Old AHU duct replacement work was going on in TG area at turbine floor. The old
ducts were cut and removed were shifted to 0 meter. The old ducts were lowered
from turbine floor with rope. At around 05:30 pm the persons in an urgency of
going home, they dropped one of the duct piece down. While doing so the duct fell
on one person who was moving below causing serious internal injuries. He later
died at the hospital.
1. Inadequate supervision of the work.

2. No barricading of area
3. Lack of proper safety tool box talks
Vedanta
Date of plant
incident
Incident type HIPO

What happened
ESP field rod insulator replacement work was taken up online. The field
was switched off and earthed. The technician had replaced the insulator
and removed the earthing. Since he had forgotten his plier he again went
inside the duct and during the process he got serious burnt and died on
the spot.
1. Earthing not ensured

2. Earth rods were not used for earthing
3. Cause of ESP field getting energized was not clear. It was suspected that due to
the charged gases from the previous field might have caused energizing of the
emitting electrodes. Hence no work in ESP was taken up online.
Vedanta
Date of plant
incident
Incident type Fatal accident
What happened
The coal was received both in rakes and trucks. The sampling of trucks were
done from heaps after the truck getting unloaded. In night shift while the
sampling was done for one of the heaps, the truck was reversed. The driver was
not aware of the sampling activity or the sampler did not see the truck getting
reversed. The sampler was crushed under the truck and died on spot.
1. No reverse horn in the truck.

2. No proper safety procedure available for sampling work
3. No supervision during sampling process
Vedanta
Date of plant
incident
Incident type Fatal

What happened
A contract worker was crushed to death in a conveyor belt of

CHP in Bokaro thermal Power station
1. Before starting any job on machine , isolation and LOTO to be ensured

2. Permit to work is must and should be adhered
3. Local push button and switch off must be ensure
4.Side guard on conveyors should be ensure
UPCL,Udupi
Incident type Fatal

What happened
In UPCL Unit-1 Platen Super Heater coil alignment and locking was in
progress at boiler roof. and few people were working in zero meter, below
the boiler furnace. The area below the furnace was not barricaded. When
I was about to enter the boiler furnace at zero meter, to go towards Unit-
2, one platen coil (3.5 MT) fell from boiler roof, crushing one of the person
working below.
1. Area barrication to be ensured

2. No other work should be permitted below the ongoing height work
3. Manual supervision to be ensured at the ground, during height work
Main contractor name – APL,
LTI# - Mundra
Date of incident
What happened
Three Fly ash bulkers were standing in a queue in front of RCC Silo for loading the fly ash.
Middle bulker driver (Dharamveer) was applying wet ash lumps for sealing at the rear side
of same Bulker. After completing sealing work, the middle driver instructed to first Bulker
driver to move, So that 3rd Bulker may come for filling. At the same time, the 3rd Bulker Photo:
driver moved in row and hit to the middle Bulker driver who was washing his hand at rain Not available
water logged on floor.
 Leaky container type bulker should not be allowed for loading.

 No bulkers should be standing in queue in loading area. They should stand in parking area and move
to loading area when the silo is free for loading. Possibility to be explored for deployment of traffic
marshal inside silo area for better control of bulker movement.
 To control the vehicle movement in silo area, limited bulkers should be permitted to enter inside the
silo area (four numbers at a time) others should be at outside plant gate.
 Proper bulker parking to be developed outside plant gate for better bulker management/checking.
 APL dumpers should not be parked in the silo premises.
 raffic safety awareness training to be given to all drivers at main gate at frequent interval & to be
documented.
 Practical approach for use of Safety reflective jackets worn by drivers while entering from silo gate
to be explored.
 Bulker driver should not get down from his vehicle from parking area to loading point.
 Single window to be implemented for documentation of loading process.
 10. Safety Interaction (SI) frequency to be increased in silo area.
 11. Water/ash should not be accumulated in the Integrated silo area floor.
Main contractor name –APRL - Kawai
Incident type Fatal

What happened
The Victim (Mr. Mukesh) went inside Apron Feeder for collecting fallen spanner
without PTW, alone and unnoticed. Afterwards, Victim was found at Belt Conveyor –
2B receiving chute which located at below 10 meter from Apron Feeder Floor. Photo:
Not available
 Apron Feeder Side Inspection window size and location to be reviewed to fit the purpose.
 Provision of funnel with sliding gate to be made on Apron Feeder for dumping accumulated
coal.
 Apron Feeder coffin box all top plate bolts to be secured fully.
 Safety Interaction (SI) shall be enhanced to cover all workforces.
 For surveillance , Identify / relocate important areas where remote monitoring required and
explore additional CCTV monitors
 A token penalty shall be imposed for not using Chin Strap of Safety Helmet.
Main contractor name –APL
LTI# -- Mundra
Date of incident

What happened
U 6 boiler was lit up at 07:45 hrs. OA guns and Mill-A were in service. Boiler hot
flushing was going on as per startup procedure. Condensate water was falling on
the roof top from flash tank vent. At 11:15 hrs, hot water fell down from boiler roof Photo:
top as the roof sheet got damaged.
Not available
M/s Heeru corrosion protection services persons were working below the roof
towards boiler area on scaffolding for painting of structures. Due to heavy wind
current in the direction towards boiler, the hot water fell on the persons causing
burn injury
 Any transient operation of the unit like cold startup, hot start up of the unit after over hauling, shut down of
the unit in planned manner.
 To review the protection and interlock protection system and necessary changes to be made.
 Install and commission all water level transmitter of high, low and middle level with appropriate alarms and
tripping of the same.
 More attention is to be given to the parameters of the flush tank and requisite alarm like high pressure to be
provided.
 No work shall be carried out in boiler during light up, hydro test.
 Internal inspection of the flush tank has to be a part of scope during every overhauling, welding quality of the
ring and buffle paltes be ensured.
 PTW to be surrended and reissued daily for long term no isolation permit. I,e, structural painting, lighting,
insulation work etc.
Main contractor name –UPCL - Udupi

What happened
Feeder 1A outlet gate was not closing during mill shutdown due to jamming of coal at discharge chute defect
was informed to MMD. MMD request for isolation of Coal feeder-1A to attend defect of discharge coal chute
jam via maintenance order no 70000019899. Operation department done isolations (Lock Out and Tag Out) of
Coal feeder-1A as requested by permit holder and PTW (permit no 100000558185) was issued by the Mr.
Bharat Mohan das Naik (shift charge engineer) on 28-12-2015 at 10:56 hrs. and handover to MMD Assistant
Manager Mr. Aneesh Robine Dsouza. On receiving the Permit, MMD Assistant Manager Mr. Aneesh went to the
M/s Percision’s Supervisor Mr. Babar Khan and instructed him to clear the discharge coal chute jamming from
outside and moved towards the other work location
Precision supervisor assigned work of coal feeder-1A discharge chute jamming to the Other supervisor Maksud
& Fitter Mr Ritesh Rajput. Fitter Ritesh Rajput went to the workplace along with helper Sundeep Kumar
Sharma, even though he was instructed to work from outside unexpectedly he positioned himself inside the
feeder chute and approached the work location along with restrain protection of full body harness. While
clearing the jam, he might have been slipped inside the discharge coal chute and suffocated. Immediately
MMD & Operation team reached at the spot and rescued, CPR given on the spot and shifted to the Siddhi
Vinayak hospital at padubidri and thereafter to Adarsh Hospital Udupi with continuous oxygen support with
assistance male nurse; Unfortunately he was declared brought dead.
 HIRA sheet & Standard Maintenance Procedure of Coal feeder maintenance work to be
reviewed.
 Work instructions to be given at the work place before start of works.
 Work supervision to be improved for such type of work
GCEL
Main contractor name – LTI# - GMR
- Date of incident

What happened
On dated 01/08/19 in A shift abnormal sound reported at Stacker reclaimer#1 tripper conveyor upper bend pulley. Mr.
Ranjan sahoo (Mech. Maint. In-charge- M/S Philips) send Mr. Jivan (Fitter- M/S Philips) to check 4A plumber block
around 1230 Hrs. Mr. Jivan confirmed to Mr. Ranjan that there is abnormal sound and plumber block heating. Feeding
was stopped at 1330 hrs. and around 1340 hrs. conveyor 4A stopped. After stopping of conveyor 4A at 1345 hrs. Mr.
Jivan and Mr. Thameshwar (Rigger- M/S Philips) hang one chain pulley block of 3 ton at one end of pulley as instructed
by Mr. Ranjan. On starting of B shift Mr. Sukul majhi (Rigger - M/S Philips) and IP (Fitter- M/S Philips) reached at the
location on instruction of Mr. Rajesh sahoo (Mech. Maint. Eng.- M/S Philips). Mr. Sukul majhi was on upper platform and
IP went to lower platform alone due to space constraint on the platform. Around 1456 hrs. Mr. Rajesh sahoo informed
Mr. Satyam (Desk operator - M/S Philips) at CHP control room to isolate the 4A conveyor. At 1500 hrs. while doing
maintenance work by IP, pulley plumber block bolt failed and pulley displaced from one side & hit to IP on face and
chest which resulted into fatality.
 Identification of Equipment for which preventive maintenance required needs to be revalidated as per OEM /
SOPs.
 JSA & RA to be prepared for all maintenance activity.
 Safe maintenance procedure (SMP) to be developed for all maintenance activity.
 SMP / SOP training to be imparted to all concerned employee & associate employee.
 All platform in CHP area to be identified which having insufficient space for maintenance and to be rectified
accordingly.
 Permit to work system to be followed strictly for each maintenance activity.
 Isolation procedures to be followed with LOTO system.
 Communication protocol is to be established between the contracting agency and the owner for any
maintenance job is being carried out.
 For checking of any abnormality in the running equipment safe procedure to be developed.
Rajiv Gandhi Thermal Power Plant (RGTPP) , Hariyana
What happened
The labourers were fixing a leakage at the bottom seal of the

unit when the boiler's clinker containing hot ash and burning
coal particles fell on them following a blast
• Ensure avoiding of accumulation of gas and free passes of gases like CO during such
operation. Monitore the profile of accumulation of gases and control feed during
such operation.
• Appropriate clothing must be ensure
• Process operation parameter should be watch
• Permit and risk assessment should be planned and performed
GLOBAL
Yambu Power
Main contractor name –plant
LTI# - –Marafiq , Saudi Arab
Date of incident
Incident type Fatal

What happened
For ESP field inspection PTW issued during shutdown. Proper earthing and related
isolations were made for pass A and PTW was issued.
Mistakenly person opened the B pass manhole and entered inside which was not
earthened and person who entered inside died onspot.
1. It is advisable to earth both pass fields to avoid such mistake.

2. Castle key arrangements to be made between earthing module and ESP
manhole doors.
3. In UPCL plant there is different nomenclature for fields and evacuation
system pass. So it is better to isolate both pass while issuing the PTW.
ESKOM'S
Main KUSILE
contractor namePLANT,
– LTI# Johannesburg, South Africa
- Date of incident

What happened
Eskom has confirmed that a worker has died at

the Kusile Power Station in
Mpumalanga after a crane collapsed on site.
 Ensure that surface level is maintained while placing the crane

 The operators competency should be ensure
 Load lifting permit must be ensure
 Load lifting should be done under the strict supervision of
competent supervisor
Safiname
Main contractor Thermal Power
– LTI# - DatePlant, Moracco
of incident

What happened
Four workers, three Moroccans and an Indonesian, were killed

while another was injured on Sunday night in a workplace
accident on the construction site of a thermal power plant in
the rural commune of Ouled Salman in Safi province
 Risk analysis for cave in hazard must be ensure

 Edge must be protected by shoring of excavated area
 Hazard communication program to be maintained
 Daily inspection of excavation site and immediate actions must
be ensure
Taean Power
Main Plant, name
contractor South–Chungcheong
LTI# - Date of Province,
incident South Korea

What happened
Kim Yong-gyun (24), an irregular worker who died when he got

caught in machinery during the night shift for Taean Power
Station.
All the moving machines / rotating parts should be

guarded
Ensure that man and machine interactions are
minimized
Duyên Hải
Main contractor Thermal
name – LTI#Power
- Date Plan, Vietnam
of incident

What happened
Power Generation Corporation 1, under the State-run Vietnam Electricity

Corporation, said in a press release that an accident occurred at 12:10 pm at a raw
water pumping station owned by the company. Initial results of an investigation
showed the deaths were due to gas suffocation during the sludge extraction
process
 Risk analysis should be ensure before deploying in such atmosphere

 Permit to work system should be followed
 Emergecncy preparation should be done in advance looking to the risk
 SCBA must be worn in case of emergency of job
 Area must be well ventilated and open to avoid accumulation of gases
Main ESKOM'S KUSILE
contractor name PLANT,
– LTI# - Johannesburg,
Date of incidentSouth Africa
What happened
Eskom has confirmed two people have been killed and another
injured in an accident at its Grootvlei Power Station near
Balfour due to steam pipe burst.
Condition monitoring of equipment should not be

tolerated
Process parameter monitoring's should be strengthen
Navapolatsk
Main contractor thermal
name – LTI# -power
Date ofstation,
incidentBelarus

What happened
An accident at the feed pipeline of Navapolatsk thermal power station took

place. The works for replacement of a valve were carried out by contracting
organizations. A steam and water mixture’s ejection happened, allegedly from a
feed pipeline which works with a temperature parameters of 196-1970. As a
result an abrupt pressure decrease took place in a water feed pipeline, which
caused stoppage of the mechanism, as water supply stopped.
 Isolation is must before carrying out any maintenance on any

equipment
 Risk assessment and communication should be ensured
 Permit to work system should be strictly adhere
Enerfab Corporation, Bruce Mansfield
Power Station, Western Pennsylvania power plant
What happened
Two contractors died after inhaling toxic fumes that also injured several other
workers in an underground pit at a western Pennsylvania power plant. 34-
year- old Kevin Bachner and 42-year-old John Gorchock, both of Pittsburgh,
were unable to make it out of the well and died. Three other workers were
able to make it to safety and were taken to hospitals
 Toxic atmosphere should be checked at interval of 2 hours

 Continuous monitoring equioment with warning should be used
 Prior Risk assessment should be ensure for such activity
 Such location should be considered as confined space and all guidelines
related with confined space should be adhered
Namname
Main contractor Ngiep–plant,
LTI# - Laos, Vietnam
Date of incident
What happened
Six Vietnamese workers were killed when a gas cylinder exploded

at the construction site of a hydropower plant in central Laos,
Vietnam's. The blast, which also injured two Vietnamese workers,
occurred at the Nam Ngiep plant in Laos' central Bolikhamxay
province.
 Cylinder should always be kept away from any hot surface ot its vicinity
 Cylinder should be kept and stored under the shed and well ventilated
area
 The accessories of gas cylinder like tube , regulator , flash back
arrestors, Torch etc should be periodically inspected
Danville Power andname
Main contractor Light,– LTI#
Applewood
- Date ofDrive in Pittsylvania County
incident
What happened
Samuel Thompson, a 63-year-old employee of Danville Power and Light, died

while working on a power line on Applewood Drive in Pittsylvania County.
Thompson and a co-worker were responding to a power outage in the area.
Thompson was in an elevated bucket truck when the electrocution occurred
 Before working on electrical charged equipment , isolation ( LOTO) should be

ensure
 Permit to work should be taken for working on electrical equipment / Energized
equipment
 Man lift operator must have competency and hazard communication program
should be organized
Tampaname
Main contractor Electric Company
– LTI# (TECO)
- Date of incident
What happened
Two workers at an electrical plant near Tampa, Florida were killed horrifically when a tank spilled
molten slag onto them. Four others were hospitalized with life-threatening injuries. The plant is
operated by Tampa Electric Company (TECO), the Tampa Bay area’s largest electrical utility service.
The company was purchased exactly one year ago to the day by Canadian energy company Emera
Inc. Christopher Irvin, 40, and Michael McCory, 60, were both killed, while Gary Marine Jr., 32,
Antonio Navarrete, 21, Frank Lee Jones, 55, and Armando J. Perez,56, all sustained life-threatening
injuries. Only one of the men was a TECO employee while the other five were employees of Gaffin
Industrial Services who were contracted to work at the plant
 Risk assessment should be carried out for such a high risk activities
 Workman shuld ensure that hot work protection clothes with other PPE’s like face guard are
worn
 Job should be performed under the strict supervision of experience supervisor
 Training and awareness should be carried out before deploying workmen on such job
 Condition monitoring of such equipment should be ensure periodically
First –Energy,
Main contractor name Pennsylvania
What happened
James George, 54, of New Castle, was killed in the incident. Officials said
George was in a bucket about 30 feet in the air when the truck became
unstable and tipped over
 Ensure that man lift is operated by a competent and skilled operator

 Stability of the equipment and ground condition should be checked before
starting the work at height
 Maintenance of equipment and its condition should be checked before
deploying the man lift at site
Enel Green
Main contractor Energy,
name – South
LTI# - Date of Austr
incident
What happened
A worker died after being trapped inside heavy machinery at

the Bungala solar power plant construction South Australia
 Road worth condition of such vehicles which includes reverse horn should
be ensure for such vehicles
 Unauthorized movement of workmen in the operation area of such
machine should be restricted
Tharname
Main contractor power plant
– LTI# - ,Date
Islamkot, ,Pakistan
of incident
What happened
A man fell off a wall while working at a power plant in the Thar coalfield here
on March 26. He later succumbed to his injuries. Ramoo Bheel, 30, was
resident of Kumbhario village located near Islamkot town and was employed
by the Sindh Engro Coal Mining Company (SECMC)
 Height work safety procedure by provising adequate size of scaffold

should be ensure
 Safety harness and life line for working at height should be ensure
 Height work permit should be taken before allowing workmen on height
GN Power
Main contractor name –Corp.
LTI# Alas-asin , China
- Date of incident
What happened
A Chinese worker of a coal-fired power plant operated by the GN Power Corp.

was killed by a steel beam that accidentally fell on his back. Lujun was
operating a crane to hoist an indoor water wall to the top of a new building.
But strong winds pushed the chain blocks, attached to the water wall, and
dislodged the beam that fell on Lujun
 In the event of heavy wind , load lifting should be avoided

 Load lifting plan with detailed risk analysis should be carried
out before lift any equipment
Westar
Main contractor name Energy,
– LTI# - DateKanasas,US
of incident
What happened
The largest electric utility in Kansas has shut down its biggest power plant following an
accident that left two workers with fatal burns. Westar said equipment with high-
pressure steam behind it apparently failed. Westar said the plant's three coal-fired
generating units are shut down while the "full circumstances" are reviewed. The two
men were in the area in which steam is transferred from the boilers to the turbines.
Unfortunately, equipment malfunctioned, filling the room with steam.
Condition monitoring of equipment intermittently

with monitoring of process parameter should be
ensure
Main contractorPike
name Electric
– LTI# ,- North incident,US
Date ofCarolina
What happened
An electrical lineman blasted Tuesday with thousands of volts of electricity has died
of his injuries in North Carolina. T.C. Simpsom was working on a power line in the
Mulberry community of Wilkes County, about 80 miles northwest of Winston-Salem,
when the accident happened. He died after spending two days in critical condition,
according to the department
• Electrical isolation procedure compliance should be ensure before

deploying workmen on HT line
• Permit to work system is must for such activities
• Only competent workmen having knowledge and skill for job should be
deployed on such activities
Electricity name
Main contractor maintenance company,
– LTI# - Date Sharjaha, UAE
of incident
What happened
A 33-year-old Asian worker died after he was electrocuted while carrying out
electricity maintenance at a villa in Al Madam area in Sharjah. he police said the
victim, who belonged to an electricity maintenance company, was sent for power
connection and maintenance work. While he was doing his job, the worker came in
contact with a strong electrical current and was electrocuted, the cops added.
• Only skilled worker should be deployed on such work

• Permit to work system should be followed
• Electrical should and hand gloves of adequate rating should be ensured
Zimbabwe
Main Electricity
contractor name Transmission and
– LTI# - Date of Distribution
incident Company
What happened
FOUR Zesa employees in Bulawayo escaped death by a whisker yesterday when

a circuit breaker they were working on caught fire and severely burnt them. The
accident happened along a sanitary lane between Leopold Takawira and Lobengula
Streets around midday.
• Arc flash suit must be worn while performing the task

• Electrical isolation of the equipment and earthing should be ensure before
starting the work on such equipment's
• Skilled and competency check is necessary before deploying such workmen
on job
GS E&R,
Main contractor name south
– LTI# Korea
- Date of incident
What happened
An explosion during a test run at a newly built coal-fired power plant in Pocheon,
Gyeonggi, left one worker dead and four others injured. According to police and fire
authorities, a 45-year-old employee of a subcontractor surnamed Kim was killed when
a conveyor belt in the plant’s basement carrying coal to the furnace suddenly blew up.
Four other workers suffered burns and are being treated at local hospitals, with one of
the victims suffering first degree burns on his body. Kim and two of the injured were in
the basement when the explosion occurred, while the other two were above ground
• Pre start up safety review considering process risk should be done

• Process parameters should be optimized and strictly monitore at the time
of initial stage of run of any equipment
Power– plant
Main contractor name LTI# - in Australia
Date of incident
What happened
Employee fatally injured while reinstating 6600V circuit breaker: An employee

has died while racking in a 6600V (6.6KV) circuit breaker at a power station. The causes of the
incident are still being established but it appears to have occurred when the 6.6KV circuit breaker
was being placed back into service. The employee was exposed to an arc flash, electrical
explosion, molten debris and super-heated gasses.
• Arc flash suit must be worn while performing the task

• Electrical isolation of the equipment and earthing should be ensure before
starting the work on such equipment's
• Skilled and competency check is necessary before deploying such workmen
on job
Main contractorLocation
name – :LTI#
Shippingport
- Date ofPA, Aug 2017
incident
What happened
Enerfab workers were doing contract work with Penn Energy at the plant. They were
working in a well-type area to remove an elbow joint from a pipe.Two men were in a pit
below, one was on a ladder and the other two were about 20 to 50 feet on a wall above.
When they removed the elbow joint, it released hydrogen sulfide gas. “The line was not
supposed to be charged, obviously. They got to the last bolt to crack it open and when
they did so, this nauseous gas…hydrogen sulfide type mixture immediately
incapacitated.
 Before starting the job , ensure that all lines are isolated
 Permit to work to be ensured .
 Risk analysis must be performed prior to doing the job
 PPE’s like SCBA must be worn
 Emergency planning to be done during such activities.
Location
Main: contractor
Aee Palo Seconame
in Toa–Baja,
LTI#PR- Date
, January 2011
of incident
What happened
Employee #1, a mechanic, was working at a thermoelectric plant

performing maintenance on a furnace. As Employee #1 opened
the hatch of the furnace vapor recycler, he was suctioned and
struck his head on a portion of the furnace. The furnace had been
shut down four days earlier to allow for the unit temperature to
cool in preparation for the maintenance. However, during the
cool-down process, the air molecules contracted. This created a
negative pressure inside the furnace system, which caused a
suctioning effect when Employee #1 opened the furnace hatch.
Employee #1 suffered a concussion from the force at which he
struck his head, and died.
 Pre start up safety review to be ensured

 Risk analysis to be done prior to carry out any job
• Location : Calpine Corporation
Main contractor name – LTI#in Bethlehem, PA
- Date of incident
What happened
A supervisor at an electric power generation plant was working in an area that was
undergoing work by a construction crew. The crew was rebuilding turbine chambers,
which called for the removal of the roof of the building and all of the floor grates
around the chamber. At the time of the accident, the work was almost completed,
and about 90 percent of the floor grates had been replaced. According to a
surveillance camera, the employee had climbed a 4.6-meter ladder to reach the
area, apparently gated, where he was assigned to replace a spark rod. He fell
through a floor opening, 6.1 meters above grade, and sustained massive head
trauma. He died of his injuries.
 Barricading must be ensure for warning of such opening

 Job safety analysis and PTW must be taken
 Safety net as secondary safety measures can be ensured
• Location : Camden County Energy Recovery Corp in Camden, NJ
What happened
On August 10, 2007, Employee #1 was crossing

an indoor work area. He was struck by and run
over by a loader that was backing up. Employee
#1 was killed.
 Reverse horn must be ensure

 The area in which such heavy earth movers are operated must be restricted from
unauthorized entry
• Location : Jersey Central Power & Light Company in Wrightstown, NJ
What happened
On August 10, 2009, a crew of seven employees was performing

routine maintenance on breaker T98 of a substation. The T98
breaker had been tagged out, switched, and grounded on both
sides. Employee #1 received an electrical shock when he accessed
breaker S19, which had not been tagged out, switched, or
grounded. He sustained second and third degree burns to over 80
percent of his body. Employee #1 was transported to a burn unit. A
coma was induced, and he remained in that state until his death on
August 16, 2009.
 Ensure lock out , tagged out and grounded all electrical related equipment while performing the job
on such equipments
• Location : Jersey Central Power & Light Company in Wrightstown, NJ
What happened
On August 10, 2009, a crew of seven employees was performing

routine maintenance on breaker T98 of a substation. The T98
breaker had been tagged out, switched, and grounded on both
sides. Employee #1 received an electrical shock when he accessed
breaker S19, which had not been tagged out, switched, or
grounded. He sustained second and third degree burns to over 80
percent of his body. Employee #1 was transported to a burn unit. A
coma was induced, and he remained in that state until his death on
August 16, 2009.
 Ensure lock out , tagged out and grounded all electrical related equipment while performing the job
on such equipments
Location
Main: contractor
Covanta Montgomery, Inc in-Dickerson,
name – LTI# MD
Date of incident
What happened
On July 31, 2009, Employee #1, an engineer, was inspecting the installation of an
ammonia tank and a pump at a power plant. The pump skid was to be installed on a
platform with a 4 ft by 8 ft floor opening in it. Employee #1 and an operations supervisor
were on a platform to review the specifications of the floor opening and to observe the
setting of the ammonia tank. While observing the crane setting the ammonia tank up,
Employee #1 stepped backwards and fell through the opening approximately 6 ft to a
concrete pit. He sustained head injuries and died three days later.
 Always ensure that the area is barricaded

 Safety harness must be worn
 Job safety analysis to be carried out
• Location : Arizona Public Service Co in Fruitland, NM
What happened
At approximately 3:30pm on January 13, 2009, Employee #1, a

Power Plant Operator, was killed when a 4-ft by 6-ft lagging
section (environmental control equipment) — which was filled
with fly ash collapsed. He died from asphyxia.
 Structure stability must be checked at required interval

 Ensure the equipment is designed as per dead load with worst scenario
 Process parameters must be monitored
Location : Allegheny Energy Supply in Masontown, PA
What happened
On November 4, 2007, an employee was operating a Caterpillar

D-9 dozer. The dozer tipped and fell over on its side. The
employee became buried in the coal that was coming out of the
doors to the Number 3 lowering well. The employee died from
asphyxiation from coal dust.
 Operator must be aware about the edge of hip

 When ever such operation is carried out , level of hip to be maintain
according to area of operation
Location
Main contractor name : Tampa
– LTI# - DateFLof, June 2017
incident
What happened
5 Employees of Tampa Electric, Gaffin Industrial Services, and

Brace Integrated Services Inc. died in the incident. The
employees were burned when a blockage inside a coal-fired
furnace broke free and spewed molten slag into the work area
 Process parameters monitoring and atomization

Main contractor Location : Ameren
name – LTI# Ue inof
- Date Labadie, MO,
incident
What happened
Employee #1 was conducting maintenance on a soot-blower lancer that was bent due to excessive heat of the
boiler at a coal-fired electric power plant .The task required a crew of two to rotate the lancer with a drill fitted
with a 24” extension rod, which was then inserted into the lancer port. Employee #1 attempted to rotate the
lancer, but the drill kicked back and struck her on the chest. Employee #2 asked Employee #1 if she was okay and
if she wanted him to take over the task. She shook her right wrist, replied that she was okay and proceeded to
rotate the lancer. Again, the drill kicked back and struck her on the head, knocking her hardhat off. Employee #1
slumped down to the floor, rolled to her right and leaned her head between the toe board and the mid rail, and
fell approx 80 ft off the platform.
 Ensure Isolation prior to work

 Ensure Risk analyisis
 Ensure absence of any residual energy
• Location : Baltimore Gas And Electric Company in Sykesville, MD
What happened
Employee #1 was working on an insulation project at the power

plant on the 1c Scrubber fan. The fan chamber that Employee #1
was working in became energized. The force of the air trapped
Employee #1 causing his death by suffocation.
 Isolation is must
 Confined space work permit must be taken
 Risk assessment must be ensured
Location
Main : Kansas
contractor name City Power- Date
– LTI# & Light
of Company
incident in Weston, MO
What happened
A pipe that was carrying boiler water at 350 degrees Fahrenheit and 2,500
pounds of pressure ruptured unexpectedly at a coal fired electric
generating station. Several employees were working a few yards away,
unplugging wet coal in a pulverizer. The other Employee #1 was struck by
the water and steam and was killed immediately. two nearby employees
were severely burned: Employee #2 died of burns in the hospital a day
later. Employee #3 was hospitalized.
 Condition monitoring of equipment's and pipelines

should be carried out periodically
• Location : Mirant Chalk
Main contractor name Point in Aquasco,
– LTI# - DateMD
of incident
What happened
Employee #1, a plant fuel and ash technician, was performing the duties
of a train brakeman during a coal unloading operation at a municipal
power plant.As empty cars moved out, Employee #1 made sure couplers
were locked.He was in radio contact with the train operator, who was
operating both the train and the car dumper device.In his last radio
transmission, Employee #1 stated thathe was going to check a coupling.
Radio contact with him was lost. Employee #1 was found lying
unconscious between rails under the train he was working on. He died
during treatment
 Rail safety measures must be taken

 SOP must be followed
• Location : Florida Power
Main contractor name & –Light
LTI#Company in Ft
- Date of Myers, FL
incident
What happened
Employee #1 and Employee #2 were assigned to do a maintenance

inspection and surveillance at a power generation plant. On the way
down after performing their assignment, both employees were on the
top set of stairs when the bracket connecting the top set of stairs broke.
The top set of stairs fell onto the set of stairs underneath. The two sets of
stairs gave way and the employees fell to a landing approximately 20 ft
below. Employee #1 received a cut to the neck during the fall, which
resulted in his death. Employee #2 broke a finger and suffered cuts and
scrapes. Employee #2 was treated and released.
 Structure stability must be checked at periodical

interval
• Location : Nstar Electric
Main contractor name and
– Gas
LTI#Corp in Cambridge,
- Date MA
of incident
What happened
On December 8, 2006, Employee #1 and a coworker were

energizing a 480 volt transformer when it exploded and caught
fire. They tried to evacuate the room as soon as they heard a
noise coming from the transformer. The coworker made it out;
however, firefighters found Employee #1 unconscious in a room
adjacent to the transformer. Employee #1 died of smoke
inhalation.
 Emergencies must be identified and training should be imparted accordingly

 Evaluate the exits of rooms in such scenario
Main Location : South
contractor nameCentral
– LTI#Power Company
- Date in Bainbridge, OH
of incident
What happened
Employee #1 and Employee #2 were troubleshooting a meter. As

Employee #1 pulled a terminal lug to switch it, he was
electrocuted. Employee #2 went and got high voltage gloves to
pull Employee #1 out of the circuit.
 No work should be performed on charged equipment. Proper

isolation must be ensured before carrying out any maintenance
work.
Main contractorEskom
name –Kendal, South
LTI# - Date Africa
of incident
Incident type Fatal

Eskom Kendal Reheat isolation valve gland blowing steam. 4.65
Mpa. Agency called to pull up gland. Snr Technician arrived
with 18 yr old tool boy. Agency went to plant directly. No plant
alive ptw. After failed attempt to pull up gland. Snr Technician
went to control room leaving boy behind. 2 mins later a bang
was heard and massive amount of steam was observed in
boiler. Snr Technician ran back and found boy under steam
path. He pulled him out and walked him to control room. 3 days
later died of steam burns. The boy tried to tighten gland but
actually loosen it and glands pop out.
1. Agencies to report to control room before work.

2. Ptw to be used as well as JSA
3. Tool box talk to all workers
4. Safety indication to all entering gate
5. Safe work practice for pull up glands
6. Supervision

Accidents at Glance Power Plant

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Accidents at Glance Power Plant

Uploaded by

Copyright:

Available Formats

Thermal

Incident type Fatality

Learning from Incident

 Never ever bypass any existing system.

Incident type Fatality

Learning from Incident

Incident type High Potential

Learning from Incident

 Never do short-cut. A small mistake can lead to bigger problem

Incident type High Potential

Learning from Incident

 MOC is essential. Make any changes with proper approval.

Incident type Fatality

Learning from Incident

 Nothing should be kept inside scaffolding pipe

Incident type Fatality

During performing maintenance activities near Fan area one skilled

Learning from Incident

Incident type High Potential Incident

This incident occurred at a Construction Site. While I was inspecting certain

Learning from Incident

1. While entering site premises, use of PPE is mandatory. There shall be no

Incident type High Potential Incident

1. No load to be suspended for longer duration if not required.

Incident type Fatal

Learning from Incident

1. Preparedness of Risk accessment and erection methodology before staring of work.

Incident type High Potential Incident

Learning from Incident

Incident type Fatal

Learning from Incident

1. Area hard barricading must be done.

Incident type HIPO

Learning from Incident

Incident type Fatal

Scaffolding arrangement done by wooden bamboo for insulation removal in Photo:

Learning from Incident

1. There is no life line prepared during moving from 0 meter.

Incident type Fatal

Learning from Incident

1. All opening shall be made after proper approval and barricading

Incident type Fatality

Learning from Incident

1. Always ensure double isolations before issuing permit.

Incident type Fatal

At one of the power station , CW duct was taken under

Learning from Incident

CW Main valve & Interconnection valves should be electrically isolated &

At one power station , an accident was caused

Learning from Incident

Incident type High Potential

Learning from Incident

1. Reverse horn must for every vehicle.

Incident type HIPO

Learning from Incident

1. Do not make unauthorized electrical connection

Incident type FATAL

Learning from the incident:

1. If weather is not favorable don’t continue your work and go to safe

Incident type Fatal

LEARNING FROM INCIDENT

Incident type MAJOR FIRE INCIDENT

Learning from Incident

Incident type Fatal