Bryan Haywood

Shop Pressure Testing piping with Nitrogen leads to asphyxiation

At 8:04 a.m. on May 11, 2023, an employee, 58, working for an oil and gas support services company, was found dead. On 5/10/23, the night before, the employee had instructed his coworkers from other contractors to go home, and he would finish the job up. This was the last time anyone had spoken to…...

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Relied on Robot Cage Door Interlock; Operator closed the door and started the robot, killing the maintenance tech

At 10:35 a.m. on December 2, 2024, Employee #1, 18, was performing maintenance on a sensor inside a robotic enclosure. As he entered the area, the robot was stopped by the entrance sensors. While he was cleaning the sensor, a coworker reset the machine from the control panel, unaware that Employee #1 was still inside…...

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Maintenance Tech By-Passes Guard Interlock – Machine Operator turned the machine from manual to auto and reactivated the machine, killing Tech ($145K)

At 11:00 a.m. on June 7, 2024, an employee, 50, working as a machinery maintenance technician for a frozen food manufacturer, was troubleshooting a ring remover since food trays were getting stuck. The employee bypassed the magnetic safety interlock gates and crawled underneath the conveyor. A coworker, the machine operator, was not aware that the…...

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Nitrogen backflows into the “breathing air” system (Fatality)

At 11:43 a.m. on February 24, 2025, Employee #1, 61, was spray painting aircraft parts while wearing a supplied air respirator. Nitrogen backflowed into the breathing air system, displacing oxygen and asphyxiating the employee. Employee #1 was fatally injured…. Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log...

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“Used Container” explodes during cutting

A 53-year-old male was working alone in the workshop while using an oxyacetylene torch to cut a piece of steel. The employee used two “empty” barrels of Methanol as a work rest while cutting the steel. The oxyacetylene flame or sparks ignited the internal vapors of one of the barrels, resulting in a deflagration and…...

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Equipment Opening Gone Bad (Railcar Manway)

At 8:00 a.m. on January 19, 2021, two (2) employees (42 and 52) were preparing to take a sample. As they were loosening the manway bolts, an explosion occurred. The employees were hospitalized for burns to the hands, arms, and lower back, as well as a fractured left femur. Awaiting Citations… Membership Required You must...

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Rail Car Implosion Fatality

Updated on 8/26/25 A 38-year-old male was fatally injured when a railcar he was servicing imploded, collapsing downward and striking the employee, resulting in fatal crushing injuries. There were no witnesses. Damage to the railcar rendered the investigation findings inconclusive. Investigators said the plant manager told them he heard a loud explosion outside and found…...

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Your Human Factors, Process Safety Tip of the Week

Ensure your “units of measure” are CONSISTENT If the sight-glass for LEVEL is in Inches = the SOP needs to state INCHESIf the TEMPERATURE Gauge/Panel reading is in Degrees C = the SOP needs to be in Degrees CIf the PRESSURE Gauge/Panel reading is in PSIG = the SOP needs to be in PSIG… Membership...

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Three workers killed in water tank explosion

THE WORK WE DO INSIDE A PRCS can create a Hazard! Three workers killed in a water tank explosion (PRCS Entry Fatalities) Initial investigations suggest the combination of cleaning agents and high temperatures triggered the fatal reaction…. Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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Pressure Test gone bad (Steam Vessel failed during pressure testing)

Six (6) workers were injured when an air tank exploded at an industrial filter production plant. Two (2) of the workers received treatment at a local hospital with major injuries to their faces and heads. According to authorities, an air tank that was being tested exploded at 11:14 a.m. at the industrial filter manufacturing plant…....

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PRCS Fatalities (Sewer, H2S, 1 entrant and 3 “would-be rescuers”)

Manhole workers likely died from hydrogen sulfide poisoning, asphyxiation. The male workers, all in their 50s, were inspecting a sewage pipe in Gyoda City on Saturday. Police say they believe one of them fell in first, and the rest followed while trying to rescue him. All of them were later confirmed dead…. Membership Required You...

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Arc Flash Incident Highlights Critical Need for Voltage Verification During Electrical Maintenance

An arc flash incident occurred during electrical maintenance activities on a 480V motor control center (MCC) aboard a fixed offshore facility in the Gulf of America on March 21, 2025. Two contractor technicians were troubleshooting a tripped MCC bucket Figure 2) when an arc flash occurred. One technician, despite wearing Category 2 arc-rated Personal Protective…...

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