A 21-year-old man was killed while testing a high-pressure valve, in an incident that led to his employer being fined £150,000.
Lewes Crown Court heard that Philip Locke was employed by Flowserve (GB) Ltd, a company that manufactures pumps, valves and seals, and automation for the power, oil, gas, chemical, and other industries.
Philip Locke was carrying out a quality-control test on a valve to make sure it didn’t leak. It is thought that during the test, the vent valve became detached from the pressure-testing machine and hit Mr Locke at high speed in the chest.
It is also believed that the pressure in the system as Mr Locke was carrying out adjustments to the valve was around 380 bar. HSE investigating and prosecuting inspector Russell Beckett told SHP: “The company thought that they were testing the valve just under hydraulic (water) pressure but, actually, half of it was full of air, so there was an increased amount of energy inside the test valve.”
He went on to explain that even had the tests been purely hydraulic-based, the company should have taken increased precautions, as there is still a danger of loose parts “missiling”. Under pneumatic (air) testing, if the valve has a fracture, parts can even shatter and explode under the forces.
The HSE investigation found that the company had failed to carry out a sufficient risk assessment. Had it done so, it would have been alerted to the fact that the machine contained both air and water, said the inspector.
The vent valve had not been installed correctly and there was no guard in place on the rear of the machine, which would have prevented the vent valve injuring Mr Locke when it separated from the machine at high pressure. According to the inspector, the company should have looked at ways to protect workers from the risk of “missiling” incidents by, for example, segregating areas more effectively, or installing guards.
Pleading guilty to a breach of s2(1) of the HSWA on 4 June, Flowserve (GB) Ltd was fined £150,000 and ordered to pay full costs of £66,838.
In mitigation, the company said the failure was not committed for profit and it has since changed the way it carries out its tests. It has also made itself aware of HSE guidance on safety measures in pressure testing and now undertakes suitable risk assessments.
Summing up the case, inspector Beckett said: “This case highlights some key lessons for Flowserve and companies like it. As this case tragically shows, this type of work needs to be properly managed when machines are being used, as well as when they are just being tested, in order to reduce risks.”
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