2.8 Case Study 3 - Arc Flash Accident

Scene Title: A Dangerous Assumption
[Opening – Shop Floor, Electrical Panel Nearby]
Visual: John checks his tools near an open motor panel. Liza approaches.
Liza:
“Hey John, is the area safe to work”
John (shrugs):
“It’s a quick task. I’ve done it dozens of times. I know what I’m doing.”
Liza (serious):
“That’s exactly what Ayaan thought—before he and Neil lost their lives working
on a live panel.”
John - Can you please explain what happened?
[Voiceover – Timeline: 26 Dec 2018, Night Shift]
Narrator:
Liza -
Ayaan, an Electrical Engg, asked his Manager for permission to stay back in the
night shift for a compensatory off. Rechal the Manager agreed but ask Ayaan
not to work on cable termination job.
Ayaan agreed. Neil joined him for the night shift.
[Visuals: Quiet panel room, Ayaan and Neil at work, opening MCCB panel]
Ayaan - Neil let us finish the cable job.
Neil (hesitant): “Are you sure? Rechal said no.”
Ayaan (persuasive):
“Neil, come on. Just cable termination—shouldn’t take long. I really need
tomorrow off.”
Neil - Thing twice Ayaan.
Ayaan:
“It’s a small job nothing complicated. Let’s get it done.”
Liza - They opened the panel and started working.
The panel had two compartments—one isolated, one live. But Ayaan believed it
was safe enough.
They removed the metal partition to pull a stiff cable through—thinking it was
a minor adjustment.
As the cable went through the plate, and when they were trying to fix the plate
it contacts the live busbar in the lower compartment.
There’s a massive arc flash.
Flames. Smoke. Screams.
Both Ayaan and Neil suffer severe burns to face and body. Ayaan died the next
morning. Neil passed away days later.