An investigation report into an incident where a crew member was severely scalded by steam onboard a chemical tanker.
The incident
On 28 January 2024, an able-bodied seafarer (AB) on board Chemical Hunter was severely scalded by steam. The accident happened during cargo tank washing and steaming operations. Chemical Hunter had just left the port of Altamira, Mexico, when the accident occurred. The vessel returned to port where the injured crew member was transferred to a hospital. Despite the first aid given on board and the more specialized treatment in the hospital, the injured crew member succumbed to his injuries about two weeks after the accident.
The investigation found that the AB suffered fatal steam scalding due to the structural failure of a steam valve. The failure led to a catastrophic release of steam, causing severe injury to the individual. A metallurgical examination of the failed valve body and its fragments concluded that the most likely cause of failure was fatigue. The valve showed signs of significant wear and stress, which contributed to the breakdown.
Additionally, the steam valve exhibited signs of corrosion and delamination of its protective paint. The examination revealed multiple pre-existing cracks that were in the process of developing on the valve body. These cracks were a significant factor in the valve’s eventual failure, as they compromised its structural integrity over time.
The metallurgical analysis further indicated that the crack growth was likely accelerated by stencil marks on the valve and the uneven geometry of the valve body. These defects may have created localized stresses, further exacerbated the crack propagation and led to the eventual failure of the valve.
In conclusion, the master’s decision to return to Altamira and land the injured AB ashore, in agreement with the Company, was considered appropriate. This decision likely ensured that the injured individual received timely medical attention and minimized further risk to the crew and vessel.
Safety actions taken during the course of the safety investigation
Fleet Management Limited took a number of safety actions including:
- Initiated its own internal investigation into the accident on board the vessel.
- Issued a Circular Fleet Alert to all its managed vessels.
- Imposed a mandatory requirement on all deck and engine room staff to complete a training module on steam handling operations.
- Shared a QHSE alert on the outcome of the Company’s investigation across the fleet.
- Required all vessels to prepare ship-specific instructions for lining up the steam system for heating or steaming.
- Reviewed the Cargo Operation Manual and Job Hazard Analysis, and included guidance to consider the findings of the internal investigation.
- Drafted a critical safety task analysis process to be incorporated into the SMS during its next revision.
Recommendations
Fleet Management Ltd is recommended to:
- 02/2025_R1 – Examine all steam valves and mountings in their fleet, using NDT techniques, if necessary, to verify their integrity.
- 02/2025_R2 – Circulate the findings of the safety investigation within its fleet.
Full advisory at the following link.