Worker Burned After Tank Explodes — Company learns why machine-specific LOTO procedures are needed

A busy R&D company was working on a sustainability project involving alternative fueling options for a piece of equipment at their facility. The project was long awaited, had underwent much research and was finally at the testing stage which involved a new fuel source being pumped into a propane tank that was already onsite. The project manager, Steve, and maintenance man, Rob, were in charge of oversight on the fueling of the propane tank.

When the Job Began

With no machine-specific procedure established, Steve began by locking out the lines of the tank based off of his knowledge and proceeded with loading the new fuel. However, as luck would have it, the truck dispensing the fuel was having issues with the pump stalling, so, after multiple attempts, Steve and the truck's driver decided to call it quits. The driver disconnected, bled the lines, and left.

Before leaving, Steve told Rob how to re-energize the tank and left for the day.

Rob began removing locks from the tank, but to his dismay, when he removed the final lock a large fireball explosion erupted, trapping Rob between the tank and fire.

Rob began removing locks from the tank, but to his surprise, when he removed the final lock a large fireball explosion erupted, trapping Rob between the tank and fire.

The Consequences

Trapped, Rob used his arms to shield his face from the fire on instinct. He was lucky enough to only suffer minor burns to his forearm, but recovery was long and painful. Returning to work, he was left unable to do many of the projects he previously did because of heat sensitivity to his burns.

Rob eventually left the company.

Lessons Learned

Unfortunately, Rob and leaders of the company were forced to learn the hard way of the importance of an updated lockout tagout program (LOTO), ensuring machine-specific procedures are developed and accurate.

If the company had machine-specific procedures in place at the time of the incident, Steve and Rob would have known how to properly deenergize a vaporizer that was attached to the tank system that ultimately served as the ignition source for the fire.

After this incident, they worked with Cardinal's consulting experts to revamp their program, ensuring that every piece of equipment had an accurate machine-specific procedure. Employees also received training and audits for Authorized Employees.

Does Your Facility Have LOTO Machine Specific Procedures? Are Your Employees Using Them?

Let Cardinal help you avoid dangerous events such as this. Ensure that all your Machine Specifics are in place and accurate. Cardinal also conducts all employee training and helps workers and leaders understand why following these procedures are life critical requirements.