Bryan Haywood

Fatal flammable liquid (Alcohols, (Ethanol), n.o.s.) transfer (Tanker to tote)

At 1:00 p.m. on July 24, 2019, two (2) employees were filling a tanker truck from a portable bulk container (IBC) when a flash fire occurred. Employee #1 was standing on top of the ethanol tanker truck and his body, clothing, the tanker, tote, and hose caught on fire. Employee #1 attempted to slide down…...

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Flammable Liquid transfer WITHOUT a spring-loaded CLOSE valve

At 3:11 p.m. Employee #1, who had worked with the company for three months as a forklift operator/ repacking, was working alone in the repacking area making a transfer of acetone (flammable liquid) from an elevated 793-gallon stainless steel intermediate bulk container (tote) to a 350-gallon stainless steel tote on the floor. In order to…...

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EPA RMP Program 2 citations @ agricultural storage and supply facility (NH3 & $20K w/ $25K SEP)

Respondent owns and operates an agricultural storage and supply facility. On August 16, 2016, an accidental release of anhydrous ammonia occurred at Respondent’s Facility when filling a storage tank. The release resulted in the hospitalization of an employee. 22. On or about March 12, 2019, representatives of the EPA conducted an inspection of Respondent’s Facility…...

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Ammonia Refrigeration, flange connections, gaskets, and torque (EPA Region VI)

Many years ago I had an open debate with a “grandfather of refrigeration” on his turf in front of about 30 other refrigeration professionals and the debate was about “flange connections”, ASME B16, and TORQUE and how it all applied to covered processes regardless of what the HHC/EHS was, including anhydrous ammonia in a refrigeration…...

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Air-Line respirator with Auxiliary bottle has an APF of 1,000 or 10,000?

So what is the Assigned-Protection Factor (APF) for an air-line respirator, commonly used inside PRCSs which has, or has the potential to have an IDLH atmosphere?  Is it 1,000 or 10,000?  I have always been taught/trained that the simple air-line respirator (Pressure-demand/Positive pressure mode) WITHOUT the Auxilary/Back-up cylinder the APF is 1,000, but the addition…...

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What does a “suitable telltale indicator” look like when we have a dual relief system (Part II)

My January article “What does a “suitable telltale indicator” look like when we have a dual relief system” was a hit as I received numerous requests for information on how to get these special gauges.  As I promised each of you in the ammonia refrigeration industry, here is what I have used on my NH3…...

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Bypassing safety devices is a no-no! (BSEE Alert)

On December 30, 2019, the Bureau of Safety and Environmental Enforcement (BSEE) Inspectors working offshore discovered that a level safety high had been improperly deactivated with a zip tie, resulting in the issuance of a P-103 incident of noncompliance (INC). There have been multiple instances across the Gulf of Mexico in which operators have failed…...

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Pressure Relief Valve Testing on Pneumatic Systems (USCG Bulletin)

Although this Coast Gaurd Bulletin is specific to maritime vessels, it can and should be applied to relief valves on land as well.  There are some really good practices in this bulletin, such as when to perform the test in-situ vs. bench testing.  The incident happened when a relief valve on the associated compressor was…...

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Supplied Air Entry into PRCS requires IMMEDIATE rescue

At 4:30 p.m. on March 26, 2019, a contractor working at an asphalt refinery in AL entered a Permit-Required Confined Space to take a video of a reactor section when he lost air supply and was asphyxiated.  OSHA cited the industrial contractor for failing to ensure personnel outside the PRCS were capable of providing effective…...

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Worker connected breathing hood into a Nitrogen system rather than breathing air system

At 8:30 a.m. on June 15, 2019, a worker employed by a painting contractor was setting up equipment to abrasive blast electrode holders. He connected the abrasive blasting hood to a line that was supplying nitrogen rather than one supplying compressed air. He inhaled nitrogen instead of breathable air and was asphyxiated…. Membership Required You...

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Pressure testing water piping inside valve pit kills two workers

Sometime in the late afternoon of July 3rd, two workers entered the water main vault at the intersection of Highways 70 and 100 in North Carolina. The two were employees of a Backhoe and Landscaping business and were working with several employees to extend a 24″ main water line. While the vault they entered and…...

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How does a 10-day old water valve pit obtain a 9.2% Oxygen atmosphere?

Another Fatality OSHA Case file involving a Water Valve Pit (Hazard Information Bulletin regarding Asphyxiation Hazard in Pits: Potential Confined Space Problem) – a SINGLE entrant (the job foreman), a would-be-rescuer, and potentially another would-be-rescuer.  The water valve pit was 7 ft in diameter and 16 ft deep.  The vault contained a 12″ water main…...

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