Bryan Haywood

BLEVE in Sidney, MT on 6/25/2025

A picture-perfect BLEVE caught on drone cam. A storm chaser captured this fire and BLEVE as he was traveling to chase a storm in Canada. This was in Sidney, MT, and may be the best training video showing a BLEVE (he has even slowed down the footage so we can see it in slow-motion)…. Membership...

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Why NH3 must be evacuated to “reclassify” a Condenser from a PRCS to a NON-PRCS

I have debated this many times and finally just gave up on the industry to do the right thing. And yes, there is a line item in NFPA 350, that I have requested the NFPA to address. But for me, in all my years, we would evacuate the NH3 from the condenser coils and lock…...

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PSV inlet pipe failure (6# NH3 release inside Machinery Room)

A piping fitting failed, resulting in the release of approximately 5 pounds of ammonia (NH3) in the machinery room. The nipple (fitting) between the oil separator and its relief valve cracked and failed to hold ammonia in the piping, resulting in the activation of the exhaust ventilation system. Fittings made of certain materials are incompatible…...

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Another “Torque Matters” event (16-pound NH3 Release from Oil Separator)

In an ammonia refrigeration system, ammonia in a gas state is compressed from the compressor to high-pressure, high-temperature ammonia gas. The compressed gas heats as its pressurised. The hot gas enters an oil separator, where the ammonia gas and compressor oil is separated so that oil is not carried over with the ammonia gas to…...

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OSHA issues GDC citation for “hose attached to PRD discharge” ($9K)

This is becoming more common these days; I never encountered it in my career at any of my facilities, as it’s not just a matter of sound engineering. The response I usually get during audits, PHAs, Engineering Code Design reviews is… “show me in the code that says I can’t use a hose on the…...

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OSHA getting better educated on the Combustible Dust Process Hazards

Last month, Federal OSHA issued a three (3) part GDC citation for a Polishing and Sanding Area’s combustible dust system. Specifically OSHA took issue with the Design and Operation of the Combustible Dust Collection system:… Membership Required You must be a member to access this content.View Membership LevelsAlready a member? Log in here...

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What does AI say about too high of QNFT results?

I have written several articles on Fit test Records with QNFT results, exceeding 10,000. I have seen number as high as 500,000. And to be honest I’m not sure why the makers of the QNFT machines even have the ability to record numbers over 10,000, as most of these manufacturers will state anything over 10,000…...

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Which comes first: Fit testing or Training?

Not meant to be a trick question, but we see this failure often, especially when the facility utilizes “test vans” for their One-Stop safety testing that includes Audiograms for HCP requiremenrts and Fit Testing for the RP program. This applies ONLY to those doing Quantitative Fit Testing (QNFT). If we are doing QNFT, such as…...

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Another cooling tower and another PRCS

Another international brand of cooling towers/evaporative condensers is marketing their product as if it is NOT a Confined Space or a Permit-Required Confined Space. For those who follow my safety rampages, know how this enrages me! As shown by the pictures below, this Cooling Tower is without question a Permit-Required Confined Space (PRCS); however, as…...

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E-Stops: Process Safety vs Machine Safety

I see this all the time… E-stops on Hazardous Materials process located at the point of the expected/intended failure point, such as a loading/unloading station. Many safety pros have experience with E-stops as a safety device for machinery/equipment, in which the E-stop is located at the point of potential entrapment inside the machine/equipment. Even ANSI…...

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PRCS Fatality (H2S and CO w/ $204K in citations – ALL contested)

On September 13, 2024, at 7:31 a.m. Employee #1, a 34-year-old, was working inside a 9-foot-deep sewer manhole in Minnesota. The employee was performing a construction task to cement the end of a pipeline, sealing an old sewer line. The employee was NOT wearing a harness or hooked up to a tripod, and was working…...

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Line Break Gone Bad (Pressure)

On February 16, 2022, at approximately 10:00 a.m., Employee #1, 28, was disconnecting a pipe and failed to release the pressure inside the pipe. When Employee#1 removed the screws from the pipe flange, the flange broke off and struck the employee’s leg resulting in a tibia fracture. The employee was hospitalized for treatment. No OSHA…...

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