Bryan Haywood

PRCS Fatality (Plastic Tank w/ liquid whey) – Single Entrant w/ Asphyxiation

At 4:45 p.m. on August 14, 2015, Employee #1, a maintenance worker, was lowered into a 12-foot tall 8,000-gallon polyethylene tank using a rope with a loop to stand on and the other end connected to a rough terrain forklift operated by the manager of the farm. The tank was used to store liquid whey…...

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PRCS Fatality (Railcar) – Single Entrant and 2 would-be rescuers

At 9:30 a.m. on November 8, 2015, an employee was cleaning the inner lining of a railcar that was previously transporting latex. The employee lost consciousness while inside of a railcar with an oxygen-deficient atmosphere. First responders attempted to rescue the employee but could not revive/resuscitate them. A second employee who entered the railcar lost…...

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Line Break gone bad (Contractors and Phosgene)

At 2:30 p.m., Employee #1, Employee #2, and Employee #3 were tasked with dismantling a scaffolding level within a containment dome (identified as PMDI A-3600). During their dismantling work, at approximately 80 feet above the ground, alarms specific to phosgene gas were triggered. The process within this Dome was the manufacturing and using phosgene to…...

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Hazard Mitigation: Distance and Barriers (Hot Work)

A recent accident has me explaining the fundamentals of our profession that so many seem to have lost in the past decades.  You have a hazard; DISTANCE yourself from that hazard If you can not put DISTANCE between you and the hazard, then a BARRIER is necessary Our Hot Work Programs are a perfect example…...

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OSHA issues Hazard Letter regarding cannabis production and grinding process

On January 11, 2022, OSHA began an inspection at your facility located at XXXXXXXXXXX, MA. The inspection revealed that employees in Flower Production were exposed to occupational quantities of whole and ground cannabis and were not provided effective information and training on the hazards involved in the cannabis production and grinding process. On January 7,…...

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EPA issues RMP citations @ gas processing plant (NH3, SO2, C₄H₁₀, H2 & $174K)

Respondent is the owner and/or operator of a gas processing plant that has on-site for use/storage 55,126 pounds of sulfur dioxide, 8,240 pounds of anhydrous ammonia, 130,000 pounds of butane, and over 10,000 pounds of hydrogen.  Respondent has three RMProgram level 3 covered processes, which store or otherwise use sulfur dioxide, butane, and hydrogen. Sulfur…...

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Permit-Required Confined Space Fatality (Engulfment)

At 7:00 a.m. on March 25, 2022, an employee entered a grain bin. The grain bin was 28 feet in diameter. The center of the bin had floor grate(s) with a conveyor underneath turned on to move grain. The grain was not flowing, so the employee entered the bin from a top hatch and climbed…...

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Line Break gone bad (boric acid and zinc oxide)

At 10:15 a.m. on February 16, 2022, Employee #1, 27, removed a flange from an overhead pipe as part of a multi-employer pipe replacement project. He was not aware that a different pipeline had been locked out. A heated slurry solution of boric acid and zinc oxide was released from the pipe he was working…...

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Exhaust Ventilation for Flammable Atmospheres and “Safe Locations”

Flammable processing areas are required to have exhaust ventilation per 1910.106(e)(3)(v).   But we continue to see serious errors in the ventilation design basis, specifically where the vapors are being exhausted. The OSHA standard simply states the vapors must be exhausted to a “safe location,” but this phrase is not defined nor quantified in 1910.106…....

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We have come a long ways in HAZMAT (Crescent City, IL & Waverly, TN)

Listen to this 1980 news recap of the 1970 Crescent City, IL LPG BLEVEs.  Talking about Railcar design and labeling needs.  It seems like crazy times compared to what we have now.    … Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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Pressure Testing gone bad (Hydrostatic Testing Fatality)

At 4:15 p.m. on January 28, 2022, an employee was assisting in hydro-testing a joint of steel pipe (39.5-feet long, 9 5/8 OD, 1580 psi).  While pressurized, the employee walked into the testing area. At the same time, the plug on the pipe failed, leading to the pipe striking the employee. The employee was killed…...

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Line Fire – Pressure Relief Devices (PRD) must discharge to a SAFE location

At 4:51 a.m. on January 15, 2022, Employee #1 and Employee #2 (Millwrights) were assigned to replace a pump in a Methylene Diphenyl Diisocyanate (MDI) Unit at the Di-Chlorination Column at approximately 2:00 a.m. The discharge line for this column discharges about a foot off the ground right next to the pump where the employees…...

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