03/12/2015
A control system fault at Tata, an international steel giant, nearly cost an employee his life after he was showered in scalding molten metal in a massive explosion at its Rotherham plant in 2012.
The Facts of the Incident
On 9th March 2012, a control system fault caused 25 tons of molten metal to spill from a furnace. The injured man and a co-worker started to hose the molten metal with water to cool it, and upon doing so, a massive explosion occurred, covering the victim in scalding hot metal.
The victim spent three weeks in an induced coma and required painful reconstructive surgery and skin grafts on his face.
The Cause of the Explosion
The Sheffield Crown Court heard that a temporary fix had been applied to the furnace control system a few weeks before the accident after a fire had damaged it. On the morning of the incident, the workaround had been removed as it was thought the fault had been fixed.
Leading up to the explosion, molten metal was being poured from the furnace into a ladle underneath for the first time since the removal of the temporary fix. As the molten metal poured an alarm activated, locking the furnace into position. A furnace worker tried the emergency return, which should have returned the furnace and stopped the molten metal discharging, but this failed.
After the ladle had been filled and automatically moved away, the furnace continued to discharge a further 25 tons of molten metal into a pit below.
The HSE Investigation
Upon investigation, the HSE found that Tata lacked any procedures for dealing with spillages of molten metal, had undertaken no assessment of the dangers and risks, and there was no safe system of work in place.
It is well known that molten metal will explode if water becomes trapped under its surface, as the water rapidly turns to steam vapour when confined, which will cause a sudden rise in pressure and result in a massive explosion.
The Sections of the Health and Safety at Work etc. Act 1974 that were Breached
Tata Steel UK Ltd was fined a total of £180,000 and ordered to pay £82,979.26 in costs after pleading guilty to two breaches of the Health and Safety at Work etc. Act 1974. These sections were:
1. Section 2(1) of the Health and Safety at Work etc. Act 1974 which states: “It shall be the duty of every employer to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all his employees.”
2. Section 3(1) of the Health and Safety at Work etc Act 1974 which states: “It shall be the duty of every employer to conduct his undertaking in such a way as to ensure, so far as is reasonably practicable, that persons not in his employment who may be affected thereby are not thereby exposed to risks to their health or safety.”
The company no longer uses water to cool molten metal spillages.
Fisher Scoggins Waters are a London based law firm who are experts in construction, manufacturing and engineering matters. If you have recently had a health and safety incident occur in your workplace, please phone us on 0207 993 6960.