[13] In 2000 the Hospital called for expressions of interest in relation to the servicing of Boiler No 1 and Boiler No 2. ASH was selected. The service contract commenced on 1 July 2000 for a period of two years.
[14] The contract was for three monthly, six monthly and annual inspections in accordance with Australian Standards.
[15] Mr Boden was the Director of Coltit Pty Limited (trading as ASH). Mr Davies was employed by ASH as a technician. Mr Davies had been employed by ASH from about July 2000. Mr Davies was a qualified unrestricted licensed electrician.
[16] Mr Boden and Mr Davies discussed ways of doing the job. Mr Boden discussed the design with Mr Davies. Mr Davies explained to Mr Boden how he was going to do the job namely by using a vero board with blocking diodes.
[17] Mr Baylis had the authority to approve what was being undertaken and the issuing of the work orders and the methodology to be employed by ASH.
[18] Mr Davies stated that he had a conversation with Mr Baylis about the work, prior to Mr Davies undertaking the design and installation of the lamp test circuit. Mr Davies stated that he told Mr Baylis that he was going to use a diode board and explained how it worked.
[19] Mr Baylis stated that he did not recall the job being discussed in any great length. He did not discuss the methodology. He may have discussed the lamp test circuit. He may have discussed the use of a diode circuit. He may have authorised ASH to proceed and install it as an out of contract item.
[20] The installation of the lamp test circuit required modification of the circuitry of Boiler No.2 to allow for its incorporation. It was undertaken as an out of contract item beyond the scope of the plant maintenance agreement.
[21] Mr Baylis did not approve the design.
[22] Prior to 30 November 2000 Mr Davies bought vero board, diodes and wire for the construction of the lamp test circuit. Mr Davies marked up the circuit diagram of how he intended to wire the lamp test circuit into Boiler No 2.
[23] Mr Davies carried out a test of the vero board with a multimeter and based on the test/s that he performed he believed that the lamp test circuit had been constructed properly in the workshop of ASH, prior to attendance at the Hospital.
[24] Mr Davies attended the Hospital on 30 November 2000 at 9.00am and signed the Sign In/Sign Out Book situated at the control room. Mr Davies was issued a key to the boiler plant room in which Boiler No 1 and Boiler No 2 were situated (the plant room) from the Building Maintenance Supervisor on duty.
[25] Mr Davies went to the plant room and took Boiler No 2 off line and shut it down before working on it.
[26] Mr Davies commenced the installation of the lamp test circuit into the existing wiring of Boiler No 2, by connecting the wires to the boiler in line with the numbering as per the schematic wiring diagram.
[27] Mr Davies had not completed the installation of the lamp test circuit into the existing wiring of Boiler No 2. Mr Davies did not have an actuating switch or button to facilitate the operation of the actual lamp test function and intended returning the following day with the necessary equipment to complete the work.
[28] Davies then tested and proved that, with the exception of the wire to be connected to the operating switch/button, each of the new wires he had installed went to the correct light fittings on the control panel using his multi-meter. He reconnected power to Boiler No 2, and checked that power was being supplied to the control panel. He then held the bared end of the wire that was proposed to be connected to the button or switch to a live power source and observed that most of the lights on the control panel were illuminated. Two or three of the light globes were not illuminated, so using his multi-meter he tested them and found that power was being supplied to the wire at the back of the light fitting.
[29] Although Mr Davies cannot remember which globes were not functioning he is pretty sure that the globe for the Flow indicator was one of the ones that did not illuminate when tested.
[30] Mr Davies left the wire to be connected to the operating switch/button exposed and not attached to any button/switch. Mr Davies did not insulate the end which was exposed. This wire did not have power connected to it and was not live.
[31] Mr Davies then attempted to restart Boiler No 2. He pressed the start button, and observed Boiler No 2 initiate the controller start-up cycle. Mr Davies observed that the pumps cut in, and he watched the water level in the sight glasses go up to full. However Boiler No 2 then faulted itself, and shut down as Mr Davies had not turned on the gas supply.
[32] He reconnected the gas supply and re-started Boiler No 2 and observed it in operation for approximately ten minutes, turning it off and on several times to check it was functioning and starting satisfactorily. By this time it had built up pressure and Davies opened the crown valve and put it back on line with Boiler No 1 and left the plant room.
[33] The Defendant did not advise Mr Davies to contact anyone to carry out checks before bringing Boiler No 2 back on line.
[34] Mr Davies then returned to the Building Maintenance Control Room; returned the plant room key to Mr Tietze, Building Maintenance Supervisor on duty; spoke to Mr Tietze; signed out and left the Hospital at 3.35 pm.
[35] At approx. 4.05pm, Mr Tietze received a pager message advising him that a person was trapped in an elevator. Shortly after, Mr Tietze received a message via his pager that Boiler No 2 had faulted.
[36] Mr Tietze proceeded to the plant room first, as this was on the way to where the person was trapped in the elevator.
[37] Once in the plant room, Mr Tietze checked Boiler No 2 to ascertain why it had faulted. He looked at the sight glasses and noted the water level was satisfactory. The lights on the control panel indicated that the Burner Fault and the Master Reset were both tripped out. Mr Tietze attempted to reset the boiler but it would not initially reset.
[38] He opened the control panel and noticed the wiring loom had not been secured and was hanging loosely. He then looked inside at the controller to see at what stage of the operation cycle it had faulted, and then re-checked the water levels. .He pushed the reset buttons again, and this time they appeared to hold.
[39] Boiler No 2 did not appear to Mr Tietze to be initiating a restart, so at approximately 4.11pm he decided to attend to the person trapped in the elevator and then come back to the plant room.
[40] After releasing the trapped persons from the elevator and on attending another plant room to isolate the elevator, Mr Tietze began to receive messages on his pager.
[41] Using an internal phone he responded to the messages on his pager. He was advised by the Maternity Ward Delivery Suite Front Desk, which is located immediately below the plant room, that they had heard a large bang, there was dust and a smell of gas".
[42] Mr Tietze immediately went to the plant room. Through the door he was able to observe that Boiler No. 2 had suffered major damage. He saw a lot of dust and debris, steam escaping, and he could smell gas.
[43] Mr Tietze turned off the main gas valves, which were located outside the plant room, and he then pressed the emergency shutdown buttons, located insider the plant room doors, which electrically isolate the two boilers. He then went into the plant room and shut off all services on the boilers.
[44] At about 4:50pm on 30 November 2000, Mr Ian Lovell took two photographs of the plant room, photographs 1 and 2.
[45] On 1 December 2000 Inspectors Wade and Sandall attended the Hospital and inspected the plant room. Much of the debris had been cleared from the room, and substantial work had been done through the night to re-commission Boiler No 1 so that the Hospital could continue with surgery and other essential services.
[46] During the inspection, Inspector Wade took possession of the door of the control panel from Boiler No. 2, including the wiring and vero board modifications installed by Mr Davies the previous day, and all the indicator lights. These were forwarded to TestSafe Australia for examination and testing.
[47] Both Inspectors took photographs on 1 December 2000.
[48] Michael Kabriel, Electrical Engineer, of TestSafe Australia was provided with the control box door and, burner controller from Boiler No 2. Subsequent to his examination and testing, he identified a short circuit between two of the diodes on the 240 volt ac input side of the vero board. The two diodes were identified as being connected to wire 23 (feedwater flow panel indicator light) and wire 40 (gas burner indicator light) He prepared a report dated 11 April 2001.
[49] Subsequent testing by Ajay Maira of TestSafe Australia established that both the globe and the light fitting of the feedwater flow panel indicator light were fully functional.
[50] Mr Davies was not the holder of a Certificate of Competency for the operation and use of boilers as prescribed by the Occupational Health and Safety (Certificates of Competency) Regulation 1996.
[51] Mr Davies main role as a technician was "Break-down work on electric, gas and oil fired burners, fault finding, general service - mechanical and electrical. Installation". Mr Davies had served an apprenticeship as an electrical fitter/mechanic. He had an electrical trades certificate, an unrestricted electrical contractor's license and a WorkCover ticket for Skid Steer and Forklift.
[52] His work experience included:-
(i) L & S Gilmore doing motor rewinds, general electrical installations and maintenance, and marine work;
(ii) Varleys - doing similar work, bigger installation projects;
(iii) F J Walkers - as an assistant plant engineer, mainly looking after maintenance crews and the electrical side:
(iv) James Watt - initially as an electrician and progressed through working in the workshop, building wiring switchboards, into the office estimating and design, and workshop supervisor;
(v) Own business as an electrical contractor doing mostly industrial and commercial work, burner control work on heated spray booths;
(vi) For a plumber - doing electrical work and general maintenance work around farms.
[53] Mr Davies' experience in boilers consisted of working on gas burners in spray booths. He had some experience at Varleys doing marine work on boilers, restricted to the electrical side not the mechanical side. The mechanical side was learnt at ASH and the electrical side from working with James Watt building switchboards, which often incorporated burner controls into the switchboards He knew the operation of Boiler No 2 having serviced it in the past with other technicians and with Dave Boden.
[54] Prior to 30 November 2000 Mr Davies had not seen "the internals" of Boiler No 2, namely the mechanics of the combustion chamber and water tubes.
[55] Mr Davies had no experience as a boiler operator, nor had he had experience in modifying the circuitry of boilers He had not constructed a Vero board for a boiler before.