Scald Injuries During Steam Pipe Maintenance

Brief Summary

Two workers were scalded while replacing a leaking gasket on steam pipework in a factory boiler room. The regulator found failures in task risk assessment, lack of a documented safe system of work, inadequate isolation and lock off, poor access for the task and insufficient supervision. The case is a reminder that routine maintenance on live steam systems needs specific planning and verification to prevent serious injury.

What Was The Incident?

The workers were replacing a leaking gasket in an isolation valve on steam pipework in a boiler room. They worked from a gantry that did not give safe reach to the valve and stepped onto the boiler to complete the task. When the gasket was removed they were splashed with hot water from the pipework and suffered scald injuries. One worker had four to five percent subdermal burns and the other had nine percent subdermal second degree burns. The regulator found the employer did not carry out a task specific risk assessment, did not document a safe system of work, did not use suitable isolation and lock off procedures, allowed work at height without adequate fall prevention measures and lacked proper supervision and monitoring.

What Was The Outcome?

The employer pleaded guilty to breaching Section 2 of the Health and Safety at Work etc. Act 1974. The penalty was a fine of A3594,000. The employer must also pay prosecution costs of A35,834, a victim surcharge of A32,000 and A36,000 in compensation to the injured employee. All sums are to be paid by 4 January 2027. The prosecution was brought by the regulator.

Key Points To Consider

Risk assessment and job documentation. Review and record task specific risk assessments, method statements and permits before work starts. Require written isolation certificates and verification that isolations are effective before any intrusive work on steam systems.

Isolation and lock off procedures. Confirm formal isolation and lock off procedures are in place, documented and enforced. Train staff and contractors to follow the procedures and verify the isolation immediately before maintenance begins.

Access equipment supervision and competence. Make sure access platforms provide safe reach to the work and that work at height is planned and supervised. Check competence of workers and contractors and use supervision and monitoring to make sure agreed controls are followed.

HSE Prosecution Link