Creeping risk: On industrial accidents and neglect of risks

UPSC Syllabus: Gs Paper 3- Disaster and disaster management.

Introduction

Industrial accidents in India reflect a pattern of creeping risk, where failures build slowly due to weak monitoring, unsafe practices, and poor labour protection. The Sakti boiler explosion, which killed 20 people, shows how risks accumulate during unstable operations. Such incidents reveal gaps in inspection, safety systems, and accountability, where accidents are treated as routine outcomes instead of preventable failures.

Nature of Industrial Accidents: Gradual Build-up of Risk

1. Non-sudden technical failure: Boiler explosions do not occur suddenly; they develop due to overpressure, scaling, mismanaged water levels, and revival stress that build up over time.
2. Unstable operating phases: Risk becomes higher during post-restart, newly commissioned, or under-capacity operations, where systems are not stable.
3. Thermal and pressure imbalance: Failures occur due to temporary thermal and pressure imbalances during such unstable operating conditions.
4. Recurring pattern across incidents: Similar conditions were seen in Visakhapatnam (2020) and Neyveli (2020), which shows that risk builds in a repeated manner.

Causes of Industrial Accidents in India

1. Regulatory and inspection failures

• Static inspection system: The current system allows boiler certification for up to one year, even though conditions change daily.
• No phase-specific oversight: The regulatory framework does not increase monitoring during restart or unstable operational phases, where risks are higher.
• Weak enforcement capacity: Inspectorates are often understaffed, underfunded, and lack technical expertise, which weakens enforcement.

2. Policy and governance issues

• Focus on ease of doing business: The system promotes self-certification and scheduled third-party audits, which reduces surprise inspections.
• Wrong incentives: The system penalises downtime instead of unsafe operations, which discourages maintenance shutdowns.
• Limited monitoring approach: The framework focuses on fabrication standards instead of continuous monitoring and auditing, which limits safety checks.

3. Technical and operational failures

• Poor maintenance practices: Industries often neglect regular inspection and repair, which leads to equipment failure and malfunction.
• Inadequate risk assessment: Many units fail to carry out proper hazard identification and safety audits, which allows risks to remain hidden.
• Ageing infrastructure stress: Industrial expansion is pushing older plants to operate close to their limits, which increases the chances of failure.

4. Labour and workplace issues

• Contract labour vulnerability: A large number of workers are migrants hired through subcontractors, which creates unclear responsibility in case of accidents.
• Lack of training and awareness: Many workers do not have proper knowledge about hazardous materials, machinery, and emergency procedures.
• Language barriers in safety: Safety manuals and signage are often not available in workers’ native languages, which reduces understanding.
• Weak legal accountability: The OSH Code, 2020 does not clearly fix criminal liability on principal employers for safety lapses in contractor operations.

5. Structural safety culture problems

• Poor safety culture: Many organisations do not prioritise safety, which leads to violations of protocols and unsafe practices.
• Fragmented responsibility: Operators and contractors often shift blame after accidents, which weakens accountability.
• Informal sector risks: A large part of industrial activity takes place in the informal sector, where regulation is weak and risks are higher.

Impacts of Industrial Accidents in India

1. Human and health impacts

• Loss of life: Industrial disasters cause immediate deaths, as seen in the Sakti incident.
• Severe injuries: Many survivors suffer from burns, respiratory damage, and long-term disabilities.
• Inter-generational effects: Exposure to toxic substances can cause long-term health problems across generations.

2. Environmental impacts

• Air pollution: Gas leaks release toxic substances into the air, which can spread over large areas.
• Water contamination: Chemical leaks and discharge pollute rivers and water bodies, making them unsafe.
• Soil degradation: Hazardous substances make agricultural land infertile and unsafe for crops.
• Biodiversity loss: Toxic exposure harms plants, animals, and entire ecosystems.

3. Economic and social impacts

• Loss of livelihoods: Industrial shutdowns lead to job losses and reduced income for workers.
• Economic disruption: Accidents disturb local economies, supply chains, and investor confidence.
• Impact on agriculture: Contamination affects crop production and farmers’ income.
• Displacement of people: People living in affected areas are forced to leave their homes, causing social disruption.

Initiatives Taken to Prevent Industrial Accidents in India

1. Legal and regulatory framework

• Factories Act, 1948: This Act provides rules for worker safety, health, and welfare, especially in hazardous industries.
• Environment (Protection) Act, 1986: This Act gives the government powers to protect and improve environmental quality.
• Hazardous Chemicals Rules, 1989: These rules require industries to prepare safety reports, emergency plans, and public information systems.
• Boiler Accident Inquiry Rules, 2025: These rules have been introduced to improve accident investigation, but their impact on structural issues is still uncertain.

2. Disaster management and preparedness

• Chemical Accidents Rules, 1996: These rules mandate off-site emergency plans and crisis groups at different administrative levels.
• Guidelines on Chemical Disaster Management (2007): These guidelines focus on risk mapping, emergency planning, and regular mock drills.

3. Insurance and labour protection

• Public Liability Insurance Act, 1991: This Act ensures immediate relief to affected persons without requiring proof of fault.
• OSH Code, 2020: This Code aims to improve safety and working conditions through audits and employer responsibility, though gaps remain.

Way Forward

1. Strengthening regulation and enforcement

• Dynamic inspection system: The system should shift from annual certification to continuous monitoring and real-time audits.
• Increase inspection capacity: Authorities should improve staffing, funding, and technical expertise to ensure better enforcement.
• Strict penalties: There should be strong penalties and faster legal action for safety violations.

2. Improving safety culture

• Safety as a core value: Organisations should treat safety as a central priority in all operations and decisions.
• Encourage reporting: Workers should be encouraged to report risks and unsafe conditions without fear.

3. Technological and planning measures

• Use of advanced tools: Industries should use data-based systems and predictive tools to identify risks early.
• Better industrial zoning: Hazardous industries should be located away from densely populated areas.

4. Worker-centric reforms

• Training and awareness: Workers should receive regular training on safety and emergency response.
• Language accessibility: Safety information should be provided in workers’ native languages for better understanding.
• Clear accountability: The law should ensure direct responsibility of principal employers for safety lapses in contractor operations.

Conclusion

Industrial accidents in India show that risks build slowly due to weak regulation, poor safety practices, and labour neglect. These are not isolated events but systemic failures. Addressing them requires continuous monitoring, strict enforcement, and worker-focused reforms. Without such changes, industries and regulators will continue to treat accidents as a normal cost, which will keep endangering human lives and the environment.

Question for practice:

Examine the causes, impacts, and regulatory gaps responsible for industrial accidents in India, and suggest measures to address the creeping risk in industrial safety.

Source: The Hindu