Had a keg king element blow on me yesterday during a brew. It was towards the end of the boil and I was about 10m away when it happened. Pretty scary. My GFCI tripped but there was quite a loud bang and some smoke from the element. Basically the insulation seems to have melted just where it joins the body of the element and let the neutral and live wires touch. I had already retired an older keg king element because I could see some fraying at the same point, but this one was bought about a year back and I was careful to inspect it before each brew day. There was no sign of any fraying before this happened, and it has only seen about 15 brews. Disappointing.
Hope no one gets hurt by these elements
Here's a website worth looking into, may some someone from being hurt.
http://www.productsafety.gov.au/content/in...AnUnsafeProduct
It would mean you would probably need to hang onto the element for them to inspect, so you won't be able to swap it over for a replacement. But do you really want another with these issues?