It's quite possible that this happened in the scene where the monkeys are released, which is a visually busy scene, and someone falling could easily be lost in the busyness, or look like it was intentional.
Regarding the flying rig, yes it can be assumed (or guaranteed) that it is regularly tested and that harnesses and wires are routinely replaced. It certainly isn't the exact same equipment that was there when the show opened.
And to clarify the Stephanie J. Block info, in Toronto (the opening of the 1st National) the plan was for Elphaba to fly in at the top of No Good Deed, instead of rising from the trap as it is done on Broadway. (the tour doesn't have a downstage elevator or trap) In tech, she was hooked up to two separate wires, one on each hip. It was automated, and one wire went and the other stayed static. She basically was being pulled at the same time as being anchored.
Updated On: 8/28/15 at 11:08 PM