Bryan Haywood

Fatal flash fire in water tank (PRCS)

On or about May 28th, 2020 at approximately 15:30 hours three (3) employees were exposed to fire and explosion hazards when a remediation repair (on a produced water tank) involved a grinder for preparing the surface and a heat gun for preparing an epoxy on a tank which had accumulated hydrocarbon vapors from the produced…...

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WRONG CHEMICAL – WRONG CONTAINER Fatality (Reaction produced Cl2)

At 6:15 a.m. on May 22, 2020, an employee and a coworker were in the process of transferring chemicals from totes on a delivery truck into tanks inside the facility. The deceased employee was responsible for hooking up a hose to the fill line on the building and monitoring the transfer from inside the facility…....

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Manhole entry kills entrant and almost killed a “would-be rescuer” (H2S and O2 deficiency)

At 9:00 a.m. on May 29, 2020, Employee #1 and #2, coworkers, discussed entry into a manhole to clear a blockage. Employee #1 entered into the manhole without personal protective equipment, without training, and without performing any air quality testing. Employee #1 successfully placed the line to clear the blockage and began to climb out…....

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Our response to the PHA phrase “never happened before”

If you have ever participated in or facilitated a Process Hazard(s) Analysis before you have certainly heard the phrase “never happened before” and the implication that we would be wasting our time if we spent any more time discussing the scenario.  As a facilitator, it is our responsibility to force the discussion, as we should…...

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EPA and OSHA are getting serious in their RMP enforcement efforts, especially with NH3 refrigeration and refinery piping inspections!

Those that follow my PSM & RMP Citations / Analysis postings most likely have noticed a significant change in the level and depth that EPA and OSHA are conducting their RMP and PSM inspections.  They have cited many more RAGAGEP issues and now dig deep into PHA’s and SOP’s than they ever had before.  This…...

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Best personal and professional advice from Claude

A bit of advice for some of you younger safety pro’s that I learned from my very first plant manager, who by the way was the kind of plant manager every young and inexperienced safety engineer needs out of school!  Claude Bloom was a “people manager” who just happened to also run a chemical plant…...

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State of IL is regulating “Ammonia Safety Training” as of April 2022

Under a new Illinois state regulation, 8 IAC 215, anyone who works on a farm and handles anhydrous ammonia must complete Certified Grower Training by April 2022 and do a refresher course every three (3) years thereafter. This includes those workers who are either classified as a “Certified competent attendant” or a “Certified grower” as…...

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With the changing political winds in D.C. comes changes to OSHA and our safety programs

This week we will see a new administration take over the reins in D.C., and after four tumultuous years under President Trump for OSHA and the CSB, we stand to see some serious shifting in both agencies.  OSHA has had a “wish list” ever since the last year of the Obama Administration, which some got…...

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EPA RMP citations @ refinery (Flammables & $344K)

Respondent is the owner and/or operator of a Refinery that uses, handles, and/or stores more than a threshold quantity of Flammable Mixture and Hydrogen fluoride/Hydrofluoric acid, which are regulated substances, as specified at 40 C.F.R. ยงยง 68.115 and 68.130. From August 15 to August 18, 2016, authorized representatives of the EPA conducted an inspection of…...

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EPA RMP citations @ power plant (NH3 (Anhydrous and Aqueous) & $13K)

I usually do not post such small cases, but this 540-megawatt electrical generation facility is sort of unique as it uses 87,840 pounds of anhydrous ammonia in a closed refrigeration system used to cool gas turbine inlet air and increase power output. It also uses 44,840 pounds of aqueous ammonia to reduce NOx emissions by…...

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Breaking down the 2021 Big Sky, MT BLEVE, frame-by-frame

Since my post earlier this week I have received several comments and questions as to whether this “explosion” was in fact a Boiling Liquid Expanding Vapor Explosion.  So I took the video and did a frame-by-frame examination of the event and I can say without question this was a classic BLEVE event.  As we can…...

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First 2021 BLEVE event – LPG 1,000-gallon Tank

On January 6, 2021, at 2:30 PM the Big Sky fire Department was dispatched to a concrete batch plant for a vehicle fire that was reported to have spread to a large commercial structure. While en route to the incident responders were notified that there had been an explosion and that a propane truck was…...

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