Manufacturing Company Fined After Two Workers Scalded During Steam Valve Maintenance

Brief Summary

An HSE prosecution followed an incident in which two men were scalded while replacing a gasket on a steam isolation valve. The employer failed to risk assess the task, did not document a safe system of work, and did not use suitable isolation or lock off procedures. The case shows how basic planning and controls for isolation and work at height can prevent serious injury and avoid large enforcement costs.

What Was The Incident?

Two men were replacing a leaking gasket on an isolation valve in the boiler room. The gantry did not provide access to the specific valve so both stepped off the gantry and worked on top of the boiler. When the gasket was removed hot water was released and both were splashed, sustaining scald injuries. One suffered about 4 to 5 percent subdermal burns and the other about 9 percent subdermal second degree burns. HSE found the employer had not risk assessed the task or documented a safe system of work, isolation and lock off procedures were not used, work at height controls were inadequate and supervision and monitoring were lacking.

What Was The Outcome?

The employer pleaded guilty to breaching Section 2 of the Health and Safety at Work etc. Act 1974. The company was fined 594,000, ordered to pay 5,834 in prosecution costs in full, a 2,000 victim surcharge and 6,000 compensation to an injured worker. All sums are to be paid by 4 January 2027. The prosecution was brought by the Health and Safety Executive.

Key Points To Consider

Risk assessment and written safe system of work. Review planned maintenance tasks and produce a documented risk assessment and method statement for each job. Use permits to work and isolation certificates so everyone understands the hazards and required controls before work starts.

Isolation and verification before intrusive work. Confirm and record isolations and apply mechanical lock off where needed. Prove the integrity of isolations before any work that could release energy or hazardous substances proceeds.

Access planning supervision and competence for work at height. Make sure access equipment allows the task to be done without stepping into unsafe positions. Assign competent staff, plan supervision and monitor that safe procedures are followed during high risk maintenance.

HSE Prosecution Link