History of Boiler Accidents in India.

[YAGAY andSUN]

Introduction: Boilers are an essential component in various industrial sectors such as power generation, manufacturing, chemical processing, and food industries. They are used for generating steam or hot water to drive turbines, heat processes, and generate power. However, the use of boilers carries significant risks, as any failure or malfunction can lead to catastrophic accidents resulting in fatalities, injuries, and property damage.

In India, boiler accidents have been a significant concern due to the lack of stringent safety measures, poor maintenance, lack of operator training, and non-compliance with safety standards. The country's industrial growth and widespread use of boilers in factories have contributed to a rise in incidents, especially in the early stages of industrialization.

What is a Boiler?

A boiler is a closed vessel used to heat water or other fluids to generate steam, which is then used to produce power or to heat materials. Boilers are a critical part of various industries, such as:

• Power plants (for steam generation)
• Chemical plants (for reactions requiring heat)
• Textile and food industries (for heating processes)

Boilers operate under high pressure and temperature, which makes their failure highly dangerous. They can explode or cause severe injuries when not maintained properly.

Legislative Framework

India has enacted various laws and regulations governing boiler safety and prevention of accidents in industrial settings.

1. Indian Boilers Act, 1923

The Indian Boilers Act, 1923 is the primary legislation to ensure the safety and maintenance of boilers used in industrial operations. It regulates the design, construction, operation, and maintenance of boilers.

• Section 3: Requires the registration of boilers before they can be used.
• Section 7: Requires regular inspection and certification by qualified authorities to ensure boiler safety.
• Section 10: Covers the operation of boilers by trained personnel and mandates their maintenance.
• Section 11: Outlines provisions for the investigation of accidents.

2. The Factories Act, 1948

The Factories Act, 1948 aims to regulate working conditions and safety measures in factories. It mandates that boilers be operated under strict safety norms, including:

• Section 38: Ensures that all machinery, including boilers, is safe and maintained.
• Section 41B: States that the factory owner must ensure adequate safety provisions are in place.

3. Boiler Operation Engineers (BOE) Rules, 2011

This set of rules governs the qualification of engineers operating boilers and ensures that only qualified personnel handle the operations and maintenance of boilers in factories.

• The BOE Rules focus on training, qualifications, and regular certification of engineers responsible for operating boilers.

4. The National Building Code (NBC), 2005

The NBC also provides guidelines on safety and the structural design of industrial buildings, including boilers and boiler houses.

Reasons for Boiler Accidents in India

Boiler accidents are caused by a variety of factors, ranging from mechanical failure to human error. Common reasons for boiler accidents include:

1. Poor Maintenance

• Inadequate inspection and cleaning of boilers lead to the build-up of debris, corrosion, or scaling, which can weaken boiler components.
• Failing to conduct regular maintenance checks or replace defective parts can lead to dangerous failures.

2. Operator’s Error

• Unqualified personnel operating boilers can cause accidents due to lack of proper training in handling emergencies or operating machinery safely.
• Inadequate response to warning signals or malfunctioning components can escalate issues.

3. Design Defects

• Faulty design or poor construction of boilers can lead to weaknesses, making them prone to failure under high pressure or temperature.
• Inadequate safety features such as pressure relief valves and emergency shut-off mechanisms contribute to the risk.

4. Overloading

• Operating the boiler beyond its rated capacity can result in overheating, pressure build-up, or failure of structural components.

5. Corrosion and Wear

• Boilers subjected to high-pressure steam generation can suffer from corrosion or erosion over time, weakening components and increasing the risk of explosions.

6. Improper Water Treatment

• Boilers require proper water quality to function safely. Poor water treatment can result in the formation of scale or corrosion inside the boiler, which can affect its efficiency and safety.

Year-wise & Industrial Sector-wise Data on Boiler Accidents in India

Data on boiler accidents in India, although fragmented, highlights the following trends:

Year-wise Data (Approximate figures for illustration):

• 2010-2015: An average of 35-40 boiler accidents occurred annually across various industries.
• 2016-2020: Reports indicate a reduction in accidents due to stricter compliance and improved safety measures, with approximately 25-30 accidents annually.
• 2021-2023: The number has further decreased to around 20-25 accidents per year, with more stringent enforcement of safety regulations.

Industrial Sector-wise Breakdown:

• Power Sector: Boilers in thermal power plants are prone to failure due to overloading and improper maintenance. About 30% of boiler accidents occur here.
• Chemical and Pharmaceutical Sector: These industries involve hazardous chemicals and processes requiring high-pressure steam. About 20% of accidents occur in this sector.
• Textile and Food Processing: Boilers used for heating and steaming have a high failure rate due to improper maintenance. About 15% of accidents are reported in these sectors.
• Sugar and Paper Industries: Boilers in sugar mills and paper manufacturing units often face accidents, contributing to 10-15% of incidents.

Casualties and Collateral Damages

• Casualties: Boiler accidents can cause fatalities, and most accidents result in severe injuries such as burns, fractures, and respiratory issues. Historically, these accidents have caused a loss of over 100 lives annually, depending on the severity of the accident.
• Collateral Damages: Accidents often lead to significant property damage, including the destruction of machinery, building structures, and loss of goods. The economic impact can run into millions of rupees, not including legal and insurance costs.

Reporting of Boiler Accidents

The Indian Boilers Act, 1923 mandates the reporting of accidents to authorities within a specified time frame. Factory owners are required to:

• Notify the boiler inspector and local authorities about any accident.
• Submit a detailed investigation report to understand the cause of the accident.
• Maintain records of all inspections, repairs, and accidents.

Liabilities of Factory Owner

The factory owner has specific liabilities under Indian law, including:

• Duty of Care: Ensuring that all safety measures are implemented and the equipment is maintained regularly.
• Compensation: The owner must provide compensation for injuries or fatalities caused by negligence in maintaining boilers.
• Penalties: Non-compliance with the Boiler Act or failure to maintain proper safety records may result in penalties, legal actions, and even suspension of operations.

Indian Standards Applicable to Boilers

India has established IS standards for boiler construction, operation, and maintenance, including:

• IS 10496: Standard for water treatment in boilers to prevent scaling and corrosion.
• IS 6592: Standard for safety valves used in boilers.
• IS 14491: Code of practice for the operation and maintenance of boilers.

These standards set the benchmark for designing, maintaining, and operating safe boiler systems in India.

Steps to Mitigate Boiler Accidents

1. Regular Inspection and Maintenance: Ensure that boilers are regularly inspected by qualified boiler inspectors, and that maintenance is done to prevent corrosion, scaling, and leaks.
2. Employee Training: Provide comprehensive training to operators on safety protocols, emergency response, and efficient boiler operation.
3. Safety Devices: Install safety valves, pressure relief valves, and temperature control systems to prevent overpressure and overheating.
4. Water Quality Management: Implement proper water treatment practices to avoid scaling, corrosion, and contamination inside the boiler system.
5. Adherence to IS Standards: Ensure compliance with Indian Standards for boiler operations, safety measures, and maintenance.
6. Emergency Preparedness: Develop an emergency response plan that includes evacuation procedures, first aid measures, and access to fire-fighting equipment.

Way Forward

1. Stronger Enforcement of Regulations: There is a need for stricter enforcement of the Indian Boilers Act and related safety regulations, with penalties for non-compliance.
2. Technological Advancements: Encourage the use of smart technologies, such as IoT-based monitoring systems to track boiler performance, temperature, pressure, and other critical parameters in real-time.
3. Public Awareness: Increase awareness among factory owners about the importance of boiler safety and the legal consequences of neglecting boiler maintenance.
4. Government Initiatives: Governments at both Central and State levels should enhance the safety infrastructure in factories, including providing subsidies for safety upgrades.

Conclusion: In India, Boiler accidents in factories have historically caused significant loss of life and property. However, with the introduction of stricter legislation, safety standards, and improved awareness, the occurrence of such accidents has decreased. It remains crucial to enforce existing laws, encourage compliance with safety standards, and invest in modern technologies to prevent future boiler accidents. Through proper training, regular inspections, and a strong commitment to safety, the risk of boiler accidents can be significantly reduced in India's industrial landscape.

Note: As of February 27, 2025, the Boilers Bill, 2024 has not yet become an Act. The bill was introduced in the Rajya Sabha on August 8, 2024, and subsequently passed by the Rajya Sabha on December 4, 2024. However, it has not yet been passed by the Lok Sabha. Until both houses of Parliament pass the bill and it receives the President's assent, it cannot become law.