A global chemicals manufacturer has been fined £400,000 after a contractor narrowly escaped serious injury during a high-pressure steam release at a major production site in Huddersfield, UK.
Syngenta Ltd was sentenced following an incident on 6 November 2023, when a 59-year-old mechanical fitter was exposed to an uncontrolled release of high-pressure steam while carrying out maintenance work. The contractor was working under the company’s control and direction at the time. The incident was reported to the Health & Safety Executive as a dangerous occurrence.
Syngenta operates a large agrichemicals manufacturing facility where several production processes rely on high-pressure steam systems. The incident occurred during the planned replacement of a faulty steam trap on small-bore pipework within the steam distribution network.
Uncontrolled Stream Release
Steam traps are designed to automatically remove condensate and air from steam systems. However, during the maintenance task, the valve used to isolate the work area failed suddenly, resulting in the uncontrolled release of high-pressure steam as the fitter began separating a bolted flange.
An HSE investigation identified multiple failures in the system of work in place. The isolation valve and flange bolts were found to be heavily corroded and in poor condition. Due to widespread corrosion across the steam distribution system, it had become routine practice to cut flange bolts using a battery-powered reciprocating saw rather than unscrewing them with a spanner.
HSE investigators highlighted that cutting flange bolts significantly reduces the ability to control any unexpected trapped pressure or material remaining in pipework, increasing the risk of serious injury during maintenance operations.
Syngenta pleaded guilty to failing to ensure that work equipment, including the isolation valve and flange bolts, was maintained in an efficient state, efficient working order and good repair.
Poor Risk Assessment
The investigation also identified deficiencies in the company’s risk assessment process.
Despite known corrosion issues, Syngenta’s risk assessments failed to recognise the increased risk of relying on a single isolation method. The company also pleaded guilty to failing to make a suitable and sufficient assessment of risk, contrary to regulations.
Sentencing Syngenta at Leeds Magistrates’ Court on 28 January, the court imposed a £400,000 fine and ordered the company to pay £8,288 in costs.
HSE Inspector David Welsh said: “If a safe system of work had been in place at the site when the maintenance was being carried out, this dangerous incident would not have happened. The company did not appreciate the extent of the risk posed because of the way the work was being done.”
He added: “Syngenta not only failed to produce an appropriate risk assessment but also failed to maintain work equipment in a safe condition, which meant this was a dangerous accident waiting to happen.”
