Industry: Manufacturing · Country: United Kingdom · Date: 08 Oct 2025 · Incident type: injury
An electrician received a significant electric shock while carrying out maintenance on a motor control panel in the production facility. The panel was believed to have been isolated following a verbal communication from a colleague, but the isolation was incomplete – the panel remained energised at 415V. The electrician made contact with a live busbar while removing a faulty contactor. He sustained burns to his right hand and forearm and lost consciousness briefly. A colleague activated the emergency stop and called emergency services.
An electrician received a significant electric shock while carrying out maintenance on a motor control panel in the production facility. The panel was believed to have been isolated following a verbal communication from a colleague, but the isolation was incomplete – the panel remained energised at 415V. The electrician made contact with a live busbar while removing a faulty contactor. He sustained burns to his right hand and forearm and lost consciousness briefly. A colleague activated the emergency stop and called emergency services.
Working on live electrical equipment. Verbal isolation confirmation accepted without physical verification using test equipment.
Lockout/Tagout (LOTO) procedure not followed. No formal isolation certificate issued. Electrician relied on verbal confirmation rather than testing with approved voltage indicator. LOTO training had not been refreshed in 3 years.
Injury type: Electrical burns to right hand and forearm – hospitalised for 5 days
1. Absolute rule: all electrical work requires a formal isolation certificate and physical proof of isolation before work begins. 2. LOTO training refreshed for all maintenance personnel – annually thereafter. 3. Voltage indicator probes issued to every electrician as personal equipment. 4. Supervisors to audit LOTO compliance as part of daily safety walkround.