TPP - Accidents and Learning

Thermal Power
Main contractor Plant

name accidents
– LTI# & learnings - India
- Date of incident
GMR
Main contractor name, Angul
– LTI# -,Date
Odisha – 2013
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
came out of bunker and completely burned the operator. Finally the victim died. On
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 primary air to directly come out
from the free passage of bunker. Also imported coal having high volatile matter ignited
easily causing fire ball for few seconds.
Learning from Incident
 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 up to 50-55 Deg C)
while operating with high VM coal.
 Mill tripping on mill outlet temperature must not be bypassed and MDV must get closed
with Mill tripping. In this case it was appeared that mill outlet temperature was forced.
 Never ever bypass any interlock system.
Main Reliance
contractor Roza
name Power, Shahajahanpur
– LTI# - Date of incident - 2008
What happened
While a Civil worker was simply carrying a long rod and going in a road of a construction site
, the rod touched the overhead 11 KV line and got 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 display board / barricading / height barrier must be ensured.

 Removal of Height Barrier (for shifting material in above case) should be
done through Permit To Work (PTW) with isolation system and to be put in
place after the job completed.
 Proper training must be given to all regarding the hazards about their jobs.
APML
Main contractor name , Tirora
– LTI# - 2011
- Date of incident

What happened
During Boiler Structure grating and Hand railing Erection work , grating material was being Shifted to
the 40 mtr elevation with bundle for installation by rigging team. Then Gratings were 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.
 Preparedness of Risk assessment and erection methodology before starting of work.

 While working at 40 mtr Height, need to arrange Life line and wear Safety Full hardness.
 Always Put a Grating Installation one by one with welding completion.
 Loose Grating should not lay in position without Locking by Welding or bolting or winding . It
may chance to unknown person walk through.
GEB,
Main contractor name Sanand
– LTI# - Date -of1996
incident
What happened
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.
 Floor opening area hard barricading must be done.
 If openings are covered then metal sheets are to be of proper thickness to carry
intended load and are to be welded properly.
 Hazard signage to be provided.
Vedanta
Main contractor , Balco
name – LTI#540MW plant - 2008
- Date of incident

What happened
Boiler Front Water wall at 35mtr Insulation removal work in Vedanta , Balco 540MW plant.
Scaffolding arrangement done by wooden bamboo for insulation removal in front water wall
side . All the Bamboo are wounding by Coconut rope. Three 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.
 Fall arrester should be provided.

 Full body harness with double lanyard should be used.
 Wooden Bamboo using are very risky and wounding rope can fire and release from wound.
Coir rope should be avoided.
 Proper SOP not Prepared and Not trained before start the work.
 Proper ladder should be provided and worker should use three points of contact while
ascending or descending from ladder.
GIPCL,
Main contractor name – LTI#Surat
- Date -of2000
incident
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 6 meter road. Each shed is
having height of 20 meters and in each shed 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
 All opening shall be made after proper approval and barricading shall be done and
danger board should be displayed
 Life line shall be used and safety belt should be fixed while traveling from one end to
another end at height.
 Crawling ladder should be used on the MS/ asbestos sheet.
JSW
Main contractor Power
name Plant,
– LTI# - DateBellari - 2002
of incident

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 inside the APH. But without his clearance or
information, someone opened 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.
 Always ensure double isolations before issuing permit.

 Air supply hose of APH Air motor, if available, should be disconnected during internal
inspection work.
 Power supply cables should be disconnected till the internal work completion.
 Rotation work, if required, should be done only by hand barring.
MPEB,
Main contractor name KORBA
– LTI# - Date of- 1992
incident

What happened
At power station , CW duct was taken under permit & persons were
working inside CW duct.
All of a sudden one CW pump of other unit tripped & somebody opened
wrong interconnection valve. Water filled in the duct. All working persons
lost their life.
 CW Main valve & Interconnection valves should be electrically

isolated & mechanically locked prior to PTW.
 Positive isolation should be provided to all energy and key should be
with Job In Charge.
.
Reliance
Main contractor name – LTI#Dahanu
- Date of –incident
2015
What happened
A Fatal accident occurred in main stores. Hydra operator was loading metal
sheets with two helpers. 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.
 Reverse horn must for every vehicle.

 Operator of hydra / Heavy vehicle must have daily tool box talk & must know
safety hazard & awareness regarding the operational activity they are doing
 Blinker and buzzer should be provided at Hydra to aware the person in the
vicinity.
Main contractorJSL,
nameJajpur,
– LTI# - Odisha - 2008
Date of incident
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 were sitting on Tie beams for welding
cross bracings at 30 meters height. 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.
Learningfrom
the incident:
 If weather is not favorable don’t continue your work and go to safe place .
 Welding of Cross Bracings, tie Beam and gadget plates are to be done prior to
erect the structure.
Main contractor MSEB, Chandrapur
name – LTI# - 1994
- Date of incident
What happened
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.
 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.
 Whenever work is over, immediately the grills in the platform should be
restored back in place.
Main contractorNTPC,
name –Vindhyachal - 2006
LTI# - Date of incident
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
 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.
 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.
APMUL,
Main contractor name Mundra
– LTI# - Date of–incident
2008
What happened
During project phase Hydra was being used to carry and shift the material due
to time constraint. One day while shifting the material with hydra, boom of
hydra was came in contact with 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.
 Never use Hydra for shifting material/ material movement.

 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.
 Awareness to be ensured for safe distance to be maintained from overhead
transmission lines.
NTPC,
Main contractor name –Ramagundam - 1998
What happened
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 seriously injured with
more than 50% burn injuries.
 Permit To Work & Lock Out Tag Out system to be followed.

 Panel naming & numbers need to be written on the rear side also.
 Proper LOTO system to be followed.
 Suitable Arc suit to be used before starting any work.
Lanco
Main contractor name, Vijayvada,
– LTI# - Date A. P. - 2009
of incident
What happened
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, helper was
declared dead.
 Cable got damaged in one place from which the helper got electrocution.
 The operator should ensure the cable continuity and pump should start
only after there is no manpower inside the pit/water.
 Job Safety Analysis and supervision of work must be ensured.
Main contractor nameCLP India
– LTI# - Date- 2011
of incident

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.
APML,
Main contractor name Tirora
– LTI# -(Outside) - 2019
Date of incident
Incident type Fatality (Outside Plant)
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.
 Vehicles are not to be parked on high ways.

 If to be parked, then only in designated parking place.
 If at all is to be parked , proper barricading to be done.
 Vehicles once parked, proper stoppers are to be provided
 Distance between two vehicles are to be maintained.
NTPC,
– LTI# - 2002
- Date of incident
During carrying out the OH in one clarifier, support stool at the bottom
along with 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.
 Going / standing under the hanging load is deadly dangerous.

 The team first technically analyse that how the work steps should be carried
out.
 Job Safety Analysis should be done and followed.
 The Work must be carried out under proper supervision.
APML
Main contractor name Tiroda
– LTI# - 2010
- Date of incident
What happened
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.
 Even if the power supply is temporary type, it must be locked properly.

 Contractor’s workmen must be given training regarding the hazards hidden in
electrical jobs.
 ELCB should be provided and checked prior to the job.
Vedanta Alumina
Main contractor limited
name – LTI# , Kalahandi
- Date of incident - 2007
What Happened
A Dumper was shifting soil from one location to another in front of swyd.
On duty time witness saw that suddenly there was a heavy flashover
happened at out side of swyd. After that he 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.
 Vision should be clear while driving (Hydraulic hood should be down)

or if vision is not clear one helper should guide the path.
 JOB to be carried out with safety procedure and supervision.
APML,
Main contractor name Tiroda
– LTI# - 2009
- Date of incident
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.
NTPC
Main contractor name , Mouda
– LTI# - 2014
- Date of incident
Incident type Fatal Incident (Outside Plant)
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.
 The length of the guide rope should be long enough to maintain safe
distance.
 The rigger should not wrapped the guide rope to his hand but only should
hold firmly.
 The rigger should maintain safe distance between hydra machine.
 The road to be travelled should be accessed for undulation.
 The hydra machine is only for loading / unloading of material. For material
shifting to longer length, trailer / tractor trolley to be used.
Main contractor Barmer , Rajasthan
name – LTI# - 2015
- Date 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.
 No body should be in line of fire during job.

 No one under the suspended load
 Types of soil / angle of repose shall be maintained
 Tandem lifting shall be avoided
 Rescue plan shall be readily available for HRA
 Risk of Cave In should be included while working near
excavated area.
Orient
Main contractor cement
name – LTI# - ,Date
Gulbarga - 2017
of incident
What happened Photo: if available

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.
 Always ensure PTW, equipment's power isolation & JSA before performing any job.
 Always use proper PPEs while performing any jobs.
 ELCB should be provided.
 Cable with no joints and double insulation should be provided to submersible pump.
Hindalco
Main contractor power
name plant
– LTI# , Renukoot
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.
 Be alert in crowded area.

 No back horn in the Hydra Dumper.
 Avoid discussion in accident prone area.
 Warning was not written in that area.
 Engineer was transferred from one Maint. Function to Operation in recent past.
 Separate man and machine interference
Century
Main contractor Pulp
name and -Paper
– LTI# Date ofLalkuan
incident - 1995
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.
 No work to be carried out without Valid PTW.

 Ensure the isolation before any work.
Gandhinagar
Main contractor name – TPS
LTI# -–Date
Yearof not confirmed
incident
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.
 Proper assessment of the load and anchoring of lifting tool needs to be essentially
done before lifting any heavy load.
 Inspection of lift tools and it’s test is most essential before use.
 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.
 Critical jobs similar to this should be done under supervision of experienced persons
only.
Vedhantha
Main contractor Balco
name – LTI# , Korba
- Date - 2011
of incident
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.
 Design standard to be followed while constructing new facility.

 While working at height continuous hooking method to be followed.
 Crawling ladder should be used while working on the sheet/ asbestos.
Torrent
name – LTI#, -Ahmedabad - 2009
Date of incident
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.
 JSA & risk assessment required.

 Proper inspection to be carried out of ESP hopper prior to work.
 ESP hoppers should be empty (ash to be removed) prior to washing
activity.
 Use of full body harness.
 Hoppers drain point should be clear so no accumulation of water & ash.
Reliance
Main contractor name Refinery
– LTI# - 2018
- Date of incident
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.
 Key must be available with authorized person .

 Helpers are allowed to operate the equipment .
 Need to do properly planning
 Need to communicated with concern supervisor/engineer.
 Don’t force to any helper to do this.
Main contractor GSECL, Wankabori
name – LTI# - 2010
- Date of incident

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.
 No Violation in permit system

 Before normalization ensure the work is completed boxed up and no
one is working on equipment.
APMuL,
Main contractor name – LTI#Mundra
- Date of-incident
2010
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.
 Excavation area must be hard barricaded

 No heavy vehicle allow nearby excavation area
 Excavation safety standard must be followed
 The machine etc. should be allowed at least 1.5 mtr away from the edge
Vedanta
name – Plant
LTI# - Date of –incident
2008-09
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. Adequate supervision of the work required.

2. Hard barricading with signage should be provided.
3. Ensure proper safety tool box talks.
Vedanta
name – Plant
LTI# - Date - 2008-09
of incident
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.
 Earthing should always be ensured

 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.
 Confined space permit should be followed before entry inside confined space.
Vedanta
name – LTI# Plant
- Date - 2006
of incident
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.
 Reverse horn to be ensured prior to entry into premises.
 SOP of sampling activity should make and follow.
 No supervision during sampling process.
 Communication should be established with truck driver before sampling started.
UPCL,Udupi
Main contractor name – LTI# - Date-of
2009
incident
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
witness 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.
 Area barrication to be ensured

 No other work should be permitted below the ongoing height work
 Manual supervision to be ensured at the ground, during height work
APMuL,
- Date of -incident
2017
What happened
Three Fly ash bulkers were standing in a queue in front of RCC Silo for loading the fly ash. Middle
bulker driver 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 driver moved in row and hit to the middle Bulker driver who
was washing his hand at rain 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.
 Safety Interaction (SI) frequency to be increased in silo area.
 Water/ash should not be accumulated in the Integrated silo area floor.
APRL,
Main contractor name – LTI#Kawai - 2017
- Date of incident
What happened
The Victim 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.
 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
NTPC,
Main contractor nameUnchahar power
– LTI# - Date – 2017
of incident
What happened
An explosion of hot gas at a boiler at NTPC’s Unchahar power plant that killed 45 workers
was the result of an “error in judgement” by some of the plant’s experienced persons. The
plant’s Head of Operations, Head of Ash Handling Maintenance and Head of Boiler
Maintenance made a decision not to shut down a 500-megawatt (MW) boiler at
Unchahar to clear a buildup of ash prior to an over pressurization in the unit that caused
the gas release.
 Tripping of Unit to be ensured as per parameters mentioned in the SOP.

 The Plants should undergo regular inspections to ensure that all features are working
and intact.
Balco,
Main contractor name Korba
– LTI# - Date–of2009
incident
What happened
The 2009 Korba chimney collapse occurred in the town of Korba in the Indian state
of Chattisgar on 23 September 2009. It was under construction under contract for
the BALCO. Construction had reached 240 m (790 ft) when the chimney collapsed on top
of more than 100 workers who had been taking shelter from a thunderstorm. At least 45
deaths were recorded.
Civil Engineering:
 There were two chimneys but due to lack of joint model study led to different
stresses and strains being placed on them. Structural design should be thoroughly
checked looking at surrounding structures.
 Quality of Construction to be ensured and not examined properly.
Mechanical Engineering:
 Not filling opening in the concrete wall and continuous construction work for
raising height, freshly constructed section lacked the ability to bear the weight of
the slip form and fresh cement concrete. Sequence of activity to be ensured.
Electrical and Electronics (Lightning)
 Necessary precautions against lightning strike were found lacking, cables and
rebar were not welded together to conduct the lightning charge.. All required
lightning requirements to be ensured.
APMuL,
- Date of-incident
2016
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 top as the roof sheet got damaged.
Contracting agency 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 baffle plates be ensured.
 PTW to be surrendered and reissued daily for long term no isolation permit. I,e, structural painting, lighting,
insulation work etc.
UPCL,
Main contractor name – LTI#Udupi
- Date -of2015
incident

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. Operation department done isolations (Lock Out and Tag Out) of
Coal feeder-1A as requested by permit holder and PTW was issued by the shift charge engineer at 10:56
hrs. and handover to MMD Assistant Manager. On receiving the Permit, MMD Assistant Manager went to
the contractor Supervisor and instructed him to clear the discharge coal chute jamming from outside and
moved towards the other work location
Contractor supervisor assigned work of coal feeder-1A discharge chute jamming to the Other supervisor &
Fitter. Fitter went to the workplace along with helper, 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 hospital; Unfortunately he was declared 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.
 Effective supervision to be provided for such type of work
 Training to imparted to all contractors worker on Permit to Work
GCEL,
Main contractor name – LTI#GMR
- Date-of
2019
incident
What happened
In A shift abnormal sound reported at Stacker reclaimer#1 tripper conveyor upper bend pulley. Mech. Maint. In-
charge- (Contr. Agency), send Fitter to check 4A plumber block around 1230 Hrs. fitter has confirmed 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. Fitter and Rigger hang one chain pulley block of 3 ton at one
end of pulley as instructed. On starting of B shift other Rigger and IP (Fitter) reached at the location on instruction
of Mech. Maint. Eng. (Contr. agency). Rigger was on upper platform and IP went to lower platform alone due to
space constraint on the platform. 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.
RajivMain
Gandhi Thermal
contractor namePower
– LTI# -Plant (RGTPP)
Date of incident , Haryana - 2018
What happened
Labour 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. Monitor 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
Reliance
Main contractor name – LTI#Refinery - 2013
- Date of incident
What happened
When scaffolding pipes were Being stacked at storage area, one worker kept a reinforcement
rod inside one scaffolding pipe.
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.
 Stacking of material should be done as per SOP (in above case Reinforcement kept
inside the scaffolding pipe.)
 All materials should be inspected before using.
 Regular inspection shall be carried out by store department or any other (cross
department) to ensure all materials are kept properly and as per SOP.
 Only skilled & trained persons should erect scaffolding .
APRL
Main contractor name , Kawai
– LTI# - 2018
- Date of incident
Incident type Hipo MTC

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.
 Ensure Safe distance between from vehicle

 Avoid reverse driving
 Helper along with heavy vehicle
Ramgad
Main Gasname
contractor Turbine Power
– LTI# - Date Plant, Badmer - 2001
of incident
Incident type HIPO MTC
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
electric shock.
 Always see surroundings before handling any oversize object for any live conductor /critical
equipment.
 DSL live indication bulbs should be in healthy conditions to alert.
 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.
Shree Cement
Main contractor name –Power Plant,
LTI# - Date Beawar - 2008
of incident
Incident type HIPO First Aid
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
 No walking during talking

 Opening must have hard barricading
 In staircase entry must be stopped while such type of working.
Lanco,
Main contractor name Anpara
– LTI# - Date of- 2011
incident
Incident type Major Fire
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
 Availability of oil carry over detector system at APH inlet flue gas duct must be ensured.
 Proper monitoring of oil gun flame intensity to be ensured.
 During first light-up of boiler, HFO temperature should be adequate for free flow.
 During first light-up of boiler, both LDO & HFO duplex filters cleaning to be ensured
Kutch
Main Lignite name
contractor Thermal Power
– LTI# Corporation,
- Date of incidentMundra - 2003
Incident type Major Fire
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.
 Coal dust leakages from coal pipes should never be neglected. They should be
invariably arrested immediately .
 Fine Coal dust in atmosphere can become a explosive mixture and even a spark can
cause major fire.
Main contractor APMUL – Mundra
name – LTI# - Date of – 2010
incident
Incident type Lost Time Injury
What Happened
Incident happened at Mundra site during commissioning period‐

Hand railing work was planned on at 24 mtr height. welder took electric supply from
DB having multiple connections 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.
 Do not make unauthorized electrical connection

 Lock Out Tag Out procedure must be followed.
Main contractor NTPC
name –,LTI#
Kahalgaon
- Date of – 2005
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 speed breaker without putting any
signage on that day . In that afternoon a bike 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.
NTPC,
– LTI# - 2010
- Date of incident

What happened
At one power station, an accident was caused due to heavy pressurisation

& steam formation while applying water jet on such ash clinker/heap
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.
NTPC,
Main contractor Sipat,
name – LTI# - Bilaspur - 2018
Date of 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 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.
 Any single person shall not enter the confined space (boiler).
 While entering any place where potential fall hazard is existing then
anchoring should be done outside the manhole prior to entering.
 It is compulsory to make scaffold prior to entering such places.
MainChandrapur Super
contractor name Thermal
– LTI# - Date ofPower
incidentStn - 2019
Incident type Lost Time Injury (Outside Plant)
At Chandrapur Super Thermal Power station, 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 contractorPanipat Refinery
name – LTI# – 2012-13
- Date of incident

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.
 Valid PTW to be taken before start of any work.

 Required PPEs to wear i.e. Chemical suit, face shield.
 Always to avoid be in line of fire during chemical handling.
 Always wash affected body part thoroughly with plenty of water, so that effect of chemical may
reduced and take immediate first add
GMR
Main contractor , Angool
name , Odisha
– LTI# - Date - 2013
of incident
Incident type Loss Time Injury
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 one column the person
was coming down then the stool with wheel was getting 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 contractorGSEL,
name –Gandhinagar - 2002
Incident type High Potential Near Miss Incident
What happened
During annual overhauling work , Boiler flue gas duct from Air preheater outlet to ESP inlet
duct maintenance work at @ 20 mtr height was under progress with proper lighting
arrangement. During movement of 2 nos of workman in side the duct all of sudden they fall
down from duct ; but due to 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.
 During movement inside the duct always put the step with proper care or check with
rod or pipe by hammering of same.
 Always tie the life line and wear safety harness inside the duct.
 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.
 During confined space job there should be one standby person at all time during the
job and rescue plan should be attached with confined space permit.
Main contractor GEB, Sikka
name – LTI# -,Date
Unitof2incident
- 1991
What happened
This incident occurred at a Construction Site. While inspecting certain Boiler Components in
the well of the Boiler at 0.0M, a chipping hammer from 42M landed straight on engineer’s
helmet. It ricocheted off the helmet and struck him hard on the neck. Though there were no
external injuries on his body, the incident left him in severe shock for some time. Beside the
person, 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.
 While entering site premises, use of PPE is mandatory. There shall be no let up on this.
 The people working at higher elevations should be advised to anchor the tools with a rope so as
to prevent free fall
 To prevent fall of material from height, Safety net must be provided just below where height work
in progress, area below must be barricaded to prevent any unauthorized entry, people working at
higher elevations should be advised to anchor the tools with a rope so as to prevent free fall.
Main contractorAPMuL, Mundra
name – LTI# - Date –
of2010-11
incident
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 .
 No load to be suspended for longer duration if not required.

 The condition of slings and chain pulley blocks to be checked frequently
 No live cable to be present in surroundings of suspended load slings.
 All lifting tools and tackles should be checked by competent person and they
should be provided with color code and colour of tools and tackles to be
change every year.
Thermal Powername
Main contractor Plant accidents
– LTI# & learnings - Global
- Date of incident
Yambu Power name
Main contractor plant––Marafiq
LTI# - Date ,of
Saudi Arab – 2005-06
incident

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 on spot.
 It is advisable to earth both pass fields to avoid such mistake.

 Castle key arrangements to be made between earthing module and ESP manhole doors.
 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.
 Confined space entry permit should be released for such job and register to be
maintained for entry/ exit.
 Job inside confined space should be done always in the presence of standby person.
 The confined space where entry is not allowed should be marked with “Confined Space
Entry Restricted” in local language understand by everyone
ESKOM'S KUSILE PLANT,
Main contractor Johannesburg,
name – LTI# South Africa - 2015
- 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
 Third party inspection of crane by competent person.
 Trained and certified rigger should be deployed for the job.
 Lifting plan should be prepare before executing heavy/ critical lifting
MainSafi Thermal
contractor Power
name – LTI# Plant, Morocco

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. According to local authorities, the accident occurred at around
8.15pm following a technical problem in the building site’s the elevator.
 Risk analysis for all potential job hazard must be ensure

 Elevator shall be checked by competent person and load should be displayed
on it.
 Illumination level should be check in night, if job has to be carried out in night
shift.
 Preventive maintenance of the equipment should be checked as per OIM
recommendation.
Taean Power
Main Plant, South
contractor nameChungcheong Province,
– LTI# - Date of incidentSouth Korea - 2018

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
 Illumination level should be check in night.
 Procedure for Lone worker should be made.
 Breaks should be given to the person doing shift duty minimized
Duyên
Main Hải Thermal
contractor name – Power Plan,
LTI# - Date Vietnam - 2018
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
 Emergency 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
ESKOM'S KUSILE name
Main contractor PLANT, Johannesburg,
– LTI# South Africa - 2015
- Date of incident
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.
 Process parameter monitoring's should be strengthen
 Pressure Safety valve in the line should be checked at fix interval for its healthiness
and proper functioning.
 HAZOP should be done for the plant after every five years or for any change in the
process.
Navopolatsk thermal power station, Belarus –
Main contractor name – LTI# - Date of incident
Year not Confirmed
What happened
An accident at the feed pipeline of Navopolatsk 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
Main contractor
Power Station,name – LTI#
Western - Date of incident
Pennsylvania power plant - 2017
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 every 2 hours
 Continuous monitoring equipment 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,
- Date Vietnam - 2017
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 or 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
 Cylinder should be handled carefully in the trolley by providing safety cap on its valve.
 Register should be maintained to monitor hydro test and condition (Corroded)of
Cylinder in the plant.
 Training should be imparted to the workers handling compressed gas cylinders on
storage, loading/ unloading and transportation of the cylinder.
 Proper supervision while shifting cylinders at height is required.
Danville Power and Light, Applewood Drive in Pittsylvania County -
2017
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
– LTI# Company (TECO) - 2017
- 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 should 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
LTI# - Date of incident - 2017
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 name –Energy, South
LTI# - Date Australia - 2018
of incident
What happened
A worker died after being trapped inside heavy machinery at the Bungala
solar power plant construction South Australia
 Ensure proper guarding on the machine.

 Safety Inspection of the site during construction should be done
weekly basis to identify hazard.
 Training should be imparted to the person “Working safely at
Construction Site”.
 Effective supervision is required.
Tharname
Main contractor power plant
– LTI# , Islamkot,
- Date ,Pakistan - 2018
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. IP, 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 providing 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 Corp.
name – LTI# Alas-asin
- Date , China - 2018
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
 The lifting equipment's must be inspected before for their adequacy.
 System of Competency check of crane operator should be adhere
Westar
Main contractor name – LTI#Energy,
- Date ofKanasas,
incident US - 2018
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
 Safety Valve should be checked for its healthiness.
 Study should be done that no steam should entered lifts/ elevators in
case of leakage. Opening of the steam outlets should not be towards
lifts.
Pike Electric
Main contractor name –, North Carolina
LTI# - Date , US - 2018
of incident
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 maintenance
Main contractor company,
name – LTI# - Date of Sharjaha,
incident UAE - 2018
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.
 Isolation of power should be ensured.
 Electrical hand gloves of adequate rating should be ensured.
Zimbabwe
Main Electricity Transmission
contractor name and Distribution
– LTI# - Date of incident Company - 2018
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 – LTI# south Korea
- Date of - 2018
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

 Area must be well ventilated and all combustible dust must be removed
and ventilated before deploying manpower in such area
 Explosion proof equipment's only should be installed in such area and
their integrity should be check periodically.
Power
Main contractor plant
name in Australia
– LTI# - 2018
- 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

 Develop / Review procedures for operation of switching and racking HV metal clad
switchgear
 Carry out risk assessment for potential arc flash hazard
 Develop SMP of HV electrical apparatus
 Ensure employee training and authorizations system
 Review procedures such as access to HV electrical apparatus
 Training in the selection and use of personal protective equipment like arc flash suit
Shippingport
Main contractor name PA
– LTI# - Date of -incident
2017
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
 Confined space entry work Permit should be ensured when working more than 1.5 meters
depth.
 Risk analysis must be performed prior to doing the job
 On line air mask should be wear with proper battery bank of air cylinders.
 Emergency planning to be done during such activities.
 Gas test (Oxygen & chance of gas which can be present) should be ensured before the work .
 Continous Gas monitoring meter should be kept with the entrant for Continous monitoring gas
level.
 Person entering should wear Safety harness and rope should be tied with harness for
emergency rescue
Aee Palo
Main contractor Seco
name in- Toa
– LTI# DateBaja, PR -
of incident 2011
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
Main Calpine Corporation
contractor name – LTI# -in Bethlehem,
Date of incident PA - 2011
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
Camden County Energy Recovery Corp in Camden, NJ -
2007
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
 Blinker with buzzer should be provided on loader/ forklifts.
 Designated Pedestrian pathways should be marked and followed.
 Traffic Risk survey should be done in the company.
Jersey Central Power & Light Company in Wrightstown, NJ -
Main contractor name – LTI#
2009 - Date of incident
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 and try out (LOTOTO) procedure.
 Ensure all electrical related equipment are grounded while performing the job on such
equipment's
 Effective supervision is required while working at high voltage.
 Electrical PPE’s should be wear while working at high voltage.
Covanta
Main Montgomery,
contractor name – LTI#Inc in Dickerson,
- Date of incident MD - 2009
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
 Detailed risk assessment and JSA should be performed for such an activity.
 Trained workman should be deployed on such jobs
Arizona Public name
Main contractor Service Co- in
– LTI# Fruitland,
Date of incidentNM - 2009
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
Allegheny Energy
Main contractor nameSupply
– LTI# - in Masontown,
Date of incident PA - 2007
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
 Training to imparted at fixed interval to the drivers of dozer.
 Proper illumination to be ensured if job is being performed in night hours.
Main contractor Tampa Electric,
name – LTI# - Date FL - 2017
of 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
Ameren
Main contractor nameUe in Labadie,
– LTI# MO - 2011
- Date of 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 analysis
 Ensure absence of any residual energy
Baltimore Gas And
Main contractor Electric
name Company
– LTI# - Date in Sykesville, MD -
of incident
2008
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
Kansas City Power
Main contractor & Light
name – LTI# Company in Weston, MO - 2007
- Date of incident
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
Mirant Chalk
Main contractor name Point
– LTI# -in Aquasco,
Date MD - 2007
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
that he 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
Florida Power &
Main contractor Light
name Company
– LTI# - Date ofin Ft Myers, FL - 2006
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
 Ensure regular Quality inspection of welding and structure as per norms
Nstar
Main Electricname
contractor and–Gas
LTI#Corp
- Datein
of Cambridge,
incident MA -
2006
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 (Action to be
taken during smoke in room)
 Evaluate the exits of rooms in such scenario
 Job Safety Analysis of the Job should be done to identify all hazards included.
 Such scenarios should be covered in drills for quick response during emergency.
South Central Power
Main contractor name –Company in incident
LTI# - Date of Bainbridge, OH - 2005
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.
 Proper training and retraining should be done of employees.
 There should be proper supervision .
 PPE’s required while working with high voltage should be used and kept every time near
by when working with high voltages.
Eskom
Main contractor Kendal,
name – LTI#South Africa
- Date of - 2014
incident
What happened
Photo: if available
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. Ensure PTW used as well as JSA
3. Ensure Tool box talk to all workers
4. Safety induction to all entering gate
5. Safe work practice for pull up glands
6. Ensure effective Supervision

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Thermal Power

Main contractor Plant

Incident type Fatality

Incident type Fatality

Learning from Incident

 Proper display board / barricading / height barrier must be ensured.

Incident type Fatality

Learning from Incident

 Preparedness of Risk assessment and erection methodology before starting of work.

Incident type Fatality

Learning from Incident

Incident type Fatality

Learning from Incident

 Fall arrester should be provided.

Incident type Fatality

Learning from Incident

Incident type Fatality

Learning from Incident

 Always ensure double isolations before issuing permit.

Incident type Fatality

Learning from Incident

 CW Main valve & Interconnection valves should be electrically

Incident type Fatality

Learning from Incident

 Reverse horn must for every vehicle.

Incident type Fatality

Incident type Fatality

Learning from Incident

 Whenever grill from platform or handrail is removed, proper hard

Incident type Fatality

Incident type Fatality

Learning from Incident

 Never use Hydra for shifting material/ material movement.

Incident type Fatality

Learning from Incident

 Permit To Work & Lock Out Tag Out system to be followed.

Incident type Fatality

Incident type Fatality

Happened During Construction of Boiler. Platform Grill was removed to facilitate

Learning from Incident

 Barricaded area has to be restricted to Hole size. Oversize barricading will

Incident type Fatality (Outside Plant)

Learning from Incident

 Vehicles are not to be parked on high ways.

Incident type Fatality

Learning from Incident

 Going / standing under the hanging load is deadly dangerous.

Incident type Fatality

During projects, one of the contractor's welder tried to connect welding

Learning from Incident

 Even if the power supply is temporary type, it must be locked properly.

Incident type Fatality

Learning from Incident

 Vision should be clear while driving (Hydraulic hood should be down)

Incident type Fatality

Learning from Incident

Incident type Fatal Incident (Outside Plant)

Learning from Incident

Incident type Fatal Incident due to Soil collapse

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

Learning from Incident

 No body should be in line of fire during job.

Incident type Fatality

What happened Photo: if available