Bryan Haywood

Reporting, Investigation, Causal Analysis, Corrective Actions, and Tracking Process

This “process” must be in place within any SMS Incident Management Element, including a Process Safety Management System.  This process is used for ALL UNPLANNED events, not just EHS-related events.  Although this process appears simple, it can be full of challenges and very error-prone, eroding trust and credibility. There can be variations in each step…...

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Line Break gone bad (Flammable gasoline/hydrocarbons)

On May 23, 2023, @ 9:00 a.m. Employee #1 and Employee #2, both maintenance workers for a petroleum refinery, were troubleshooting an automated valve in the “Prime G Unit.” Flammable gasoline/hydrocarbons in the piping and flange portion of the automated valve were released, causing an explosion, and fire…. Membership Required You must be a member...

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OSHA issues PSM citations @ paint manufacturing plant (Flammable/Reactives & $290K)

OSHA issued $290,358 in proposed penalties following an August 2023 explosion at a paint factory in Garland, TX. One employee was injured in the explosion at the factory. OSHA issued one repeat and eight serious citations. The repeat citation was a $161,310 proposed penalty. The proposed penalties for the eight other citations are $16,131 each…....

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Pulling back the curtain on WHY workers fail to comply with “Cardinal Rules”

I want to thank Marcin Nazaruk for sharing this report with his LinkedIn connections.  The document below is a MUST READ and DIGEST for all safety professionals, but certainly for those who manage high-risk workplaces.  Equinor – the Norwegian Oil and Gas Company, with associated companies such as ConocoPhillips, Vår, or Aker BP, as part…...

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Safety Thought of the Week (Todd Conklin)

When a person responds as if the worker has become stupid, that response is more about the organization than the worker in question We must battle the need to believe that when a worker has some type of bad outcome, that adverse outcome happened because the worker became momentarily incompetent. Our thinking is driven by…...

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Safety Thought of the Week (Todd Conklin)

When a person responds as if the worker has become stupid, that response is more about the organization than the worker in question We must battle the need to believe that when a worker has some type of a bad outcome, that adverse outcome happened because the worker became momentarily incompetent. Our thinking is driven…...

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Defining and Quantify the terms “Adjacent and Near”

The word “adjacent” may be small in terms of letters used to spell it, but it has an enormous impact on the world of process safety.  Both OSHA’s Process Safety Standard (1910.119) and EPA’s Risk Management Plan (Part 68) use the word “adjacent.”  Here is how Webster defines “adjacent” adjacent (adjective): not distant: nearby It…...

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Control measures to be taken if physical contact or airborne exposure occurs

A great and reliable resource to help comply with… 1910.119(f)(1)(iii)(C) Control measures to be taken if physical contact or airborne exposure occurs;   https://www.cdc.gov/chemicalemergencies/factsheets/ammonia.html    … Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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OSHA’s presentation on its proposed Emergency Response standard (Keene State College – OSHA Training Institute Education Center, Region 1 Video)

CLICK HERE for the pdf slides OSHA’s NEW Proposed Rule 1910.156 Emergency Response rule from OTI Education Center on Vimeo…. Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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Documenting a HAZLOC; Defining and Quantifying MATTERS!

This week, OSHA posted an LOI regarding terms used in the PSM Standard, and this LOI has generated some discussions amongst some SAFTENG members, most notably… How are we required to document our HAZLOCs?  In OSHA’s LOI, it referenced 1910.307 Hazardous Locations standard which simply states: (emphasis by me) 1910.307(b) Documentation All areas designated as…...

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Classic “error trap” – Trap Door Design (2)

When you see it… Another “error trap,” which is actually and literally an “error trap waiting to get tripped.” Some may simply say… “this is an accident waiting to happen“ An “error trap” is defined as “a condition or circumstance that provides fertile ground for mistakes to happen.“… Membership Required You must be a member...

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Torque MATTERS, FATAL failure of NG filter system at Power Plant

On June 18, 2021, at 6:30 p.m. an employee was working for a firm that operated electric power generation facilities. He was working at a natural gas-fired power plant. He and a coworker were restoring a natural gas filter system at the power plant by aligning valves after a maintenance crew had replaced filter media…....

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