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View of leak on exchanger

Incident Description:

A contract worker sustained minor burns to the face while conducting hot work (buffing) on exchanger piping.

What Was the Problem:

Ineffective job planning, hazard assessment, energy isolation and job supervision led to a flammable atmosphere being present during the hot work activity of buffing.

What Happened:

Flammable vapors entered the immediate workspace from a section of pipe that was not isolated. The source of the flammable material is suspected to have come from a low point in the piping, downstream of the isolation points but upstream of where the blinds were to be installed.

Given the overnight ambient temperature followed by the morning sun heating the pipe, the butane began to flash off.

What Was the Impact?

The contract worker sustained minor burns to the face that required first aid treatment.

The event was reported to Alberta Occupational Health & Safety under the requirements of a workplace incident – unplanned fire with potential to cause serious injury (Report serious injuries, illnesses or incidents | Alberta.ca).

Incident Learnings:

Self applied pressures impacted decision-making and work execution, resulting in errors being made with respect to the Life Saving Actions, procedures and practices.

  • Inadequate job planning, energy isolation, hazard assessment and failure to follow procedures resulted in an unplanned flash fire that injured a worker.
  • The work scope was unclear and not documented, which led to a safe work permit being issued for multiple work tasks and communication breakdown between multiple workers.
  • The energy isolation process of blinding was not fully completed.
  • A flammable atmosphere was detected when breaking system integrity, which eventually dissipated. As work progressed, intermittent flammable atmosphere was detected and was not properly reported or investigated.
Corrective Actions:
  • Provide additional coaching to ensure adequate oversight:
    • Ensure work scope is clearly identified on work permits
    • Ensure hazards and controls are identified and implemented
    • Ensure adequate supervision of work – based on risks and hazards
    • Ensure proper job plans are developed with appropriate subject matter experts (SMEs)

Learning Before Serious Harm

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Learn from Past Events

Explore Safety Alerts to see how incidents occurred and what can be done differently. Applying lessons from past events helps workers and leaders recognize hazards before they lead to serious harm.

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