Bryan Haywood

PRCS Fatalities (One (1) Entrant and three (3) would be rescuers)

Three workers (30, 35, and unknown age) died while another was hospitalised after a suspected gas leak at a lubricant-manufacturing factory. The accident occurred around 8:30 pm when employees entered a chamber for routine maintenance and were exposed to toxic fumes. The hospitalised worker was stable. Company manager said one of the workers lost consciousness,…...

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Pressure Test Gone Bad (Hydrostatic Test)

WORKER BADLY INJURED: FIFE FIRM BACK IN DOCK AND FINED A worker sustained horrific injuries after being struck by highly pressurised water during hydraulic testing on machinery. His employer has been fined £161,250 ($218,460) for breaching health and safety law. A testing booth should have remained automatically locked when it presented a danger to employees…...

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PRCS Fatality (Underground Gas Tank – unknown if it was a HAZ ATM or Medical; Several “would be rescuers” entered)

RIP 🙏 The tank was emptied while the fuel pumps were being remodeled. After the man collapsed, the workers were unable to pull him out of the confined space about 10 to 15 feet below the surface. “The other workers were trying to get down in that hole and take them out. It’s obviously not…...

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Leak Test Gone Bad

Employee #1, a welder, was inside a double-walled, approximately 5.5 ft in diameter steel tank to perform leak tests. A contractor had installed new stainless steel piping to the 1,000-gal blending tank, and initial use of the tank revealed some leakage where the new pipe entered the bottom of the tank. To perform the leak…...

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Golf carts need to be managed as a Powered Industrial Truck (PIT)

It is my professional opinion that “golf carts” need to be managed as a Powered Industrial Truck (PIT). I have seen firsthand three (3) serious accidents resulting in life-altering injuries. We see fatalities like this one several times a year: https://www.nbcboston.com/news/local/worker-at-nh-storage-facility-dies-after-being-pinned-under-golf-cart/3803079… Membership Required You must be a member to access this content.View Membership LevelsAlready a...

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Load Testing failure (8/2025)

Many of us do load testing on our cranes and such and rarely do we have a failure. But when things do fail, they do so CATASTROPHICALLY, as shown below when this ship loading/unloading system failed during its load test…… Membership Required You must be a member to access this content.View Membership LevelsAlready a member?...

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Pressure Testing Gone Bad (Fatality – Flange bolts not torqued properly)

On March 6, 2018, a 49-year-old pipefitter was hit in the chest by a pressurized 12-inch diameter polyvinyl chloride (PVC) pipe during a hydrostatic pressure test of a fire suppression system. The sudden pipe movement was attributed to a pipe joint connection failure in a buried section of the pipeline. The failure was due to…...

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For all the safety experts on “metrics” decrying leading and lagging indicators as “bureaucracy” and a “waste of time”…

Imagine driving a vehicle without a dashboard. No feedback whatsoever as to how well you and the vehicle are performing. Sure, we can do it, but without feedback on our performance and the vehicle’s, I doubt we’d meet the state’s defined and quantified standards for “safe operation of a motor vehicle.” Just consider speed as…...

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Line Break Gone Bad (NG Fatality)

Natural gas was released into the basement of the Realty Building and caused an explosion in Youngstown, Ohio, after a member of a scrap removal crew cut into a steel pipeline. Although the cut pipeline had not been marked or otherwise identified as containing natural gas, it did contain gas, pressurized at about 38 psig,…...

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Pressure Testing Gone Bad (Submarine Ballast)

This is not only about a failed pressure test gone bad, but it is an excellent example of how “contributing factors” play a role in accidents. Deviating from the test plan, changing the time frame in which the test is to be conducted due to a noise ordinance, etc., played a role in this multimillion-dollar…...

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OSHA to revise the medical evaluation provisions for FFRs and loose-fitting PAPRs

The Occupational Safety and Health Administration (OSHA) intends to update the medical evaluation provisions currently required by the Respiratory Protection Standard (29 CFR 1910.134) for filtering facepiece respirators (FFRs) and loose-fitting powered air purifying respirators (PAPRs). This action will be deregulatory and / or burden reducing to employers whose employees wear such devices. This rulemaking…...

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