Drum explosion – residual vapours

A drum explosion occurred due to residual flammable substance. A Kent company who supplies road safety products has been fined after a worker suffered life-threatening injuries when a drum he was working on exploded.

Maidstone Crown Court heard how 41-year-old AF, an employee of Highway Care Limited, was using a plasma cutter to cut up a drum that had previously contained a flammable substance. AF suffered life-threatening injuries when the drum exploded in his face causing complex head and brain injuries. He has permanently lost vision in his right eye and now has very limited vision in his left eye.

An investigation by the Health and Safety Executive (HSE) into the incident which occurred in August 2012 found that the company failed to ensure the health and safety of their employees.

Highway Care Limited pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc. Act 1974 and was fined £660,000 and ordered to pay costs of £33,358.46

HSE Inspector Caroline Fullman said.

“AF has been left with devastating injuries that will impact on the rest of his and his family’s lives. This incident could have resulted in a fatality.

“If a welding torch or plasma cutter is used on a tank or drum that has contained or contains a flammable substance, it can explode. It only takes a small amount of residue to create a potentially flammable atmosphere.

“AF wants others to learn of the risk of hot work on drums and tanks – he was previously unaware of the risk.”

The HSE has published a short guide on Hot work on small tanks and drums – unsurprisingly, the crux of the matter is risk assessment.

Flammable liquids and vapours such as petrol, diesel, fuel oil, paints, solvents, glue, lacquer and cleaning agents are found in many places of work. If a welding torch or powered cutter is used on a tank or drum containing flammable material
(solid, liquid or vapour), the tank or drum can explode violently. People have been killed or seriously injured by such explosions. Tanks and drums that seem to be ‘empty’ usually still have residues in the bottom, in seams and other crevices. Just a teaspoon of petrol in a drum can be enough to cause an explosion when heated and turned into vapour.