Can sudden shutdown of pc can make BAD sector in HDD?

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I agree. Really old drives had this problem, but all newer drives have capacitors that will hold a charge long enough to park the heads when they sense a power cut.
Improper shutdown can screw Windows up so it won't startup properly next time, or it can cause errors to the filing system, but I've never heard or experienced it causing any kind of hardware damage or creating bad sectors on the hard drive in all my 20 years of using and fixing computers.
 

jayadratha

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Old means how old?? I have segate ST3500418AS which is 2.5years old. Is this have this security?
 


If it's sata, then no worries. We're talking ~10 years ago or so. Most drives that old are dead or replaced by now. I do have some drives that old and operational, but I'd expect most people have all newer drives. I just threw that answer out there just in case you did have an old drive.