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Case 2 Date: 04.07.2019 Time: 11:45 hrs.

Incident

A trailer loaded with flue gas duct of weight approx. 9 tons reached sector -7, HGU site from Laydown area
for erection. 600T and 50T cranes were deployed for unloading the duct from trailer. While unloading the
duct from trailer bed (Height-1 Meter), two of lifting lugs got detached from weld joints of the duct and
duct fell on ground.

Detach lifting lug

Root Cause

Failure of weld joint of lifting lugs due to poor workmanship.

Recommendations

1. Welding of Lifting lugs shall be witnessed & certified by TPIA / OEM w.r.t load of equipment and relevant
certificate to be submitted along with the supply of material. Same to be suitably incorporated in
ITP / QAP.
2. Ensure Visual Inspection of all Lifting Lugs and weld joints to verify each lifting lug's strength prior to use.
Weld strengthening to be done if required.
3. During lifting operations always be prepared for the possibility that the load could drop or an object
could fall off. The safety rule stating that personnel are not to go under the load. Not to lift the load over
the top of personnel and to keep a safe distance at all times should be reinforced.

Case 3 Date: 11.07.2019 Time: 06:40 hrs.

Incident

Sparking observed in 3.5 core power cable coming from SS#9 near sector-12, power supply was isolated
from S/S # 9. The insulation of underground power cable have got damaged during excavation job carried
out at said location on previous day, and due to moisture ingress inside the cable, sparks generated.

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