Free – Page 48 – Safety Engineering (SAFTENG)

OSHA is proposing to remove some medical evaluation requirements in the Respiratory Protection Rule for certain types of respirators

August 16, 2025 / Free, OSHA Compliance, Respiratory Protection / Bryan Haywood

This proposed change would only impact filtering facepiece respirators (FFRs) and loose-fitting powered air-purifying respirators (PAPRs). OSHA is proposing an update to the Respiratory Protection Standard to amend the medical evaluation requirements specified in paragraph (e) where an employee is required to wear either a filtering facepiece respirator (FFR) or loose-fitting powered air-purifying respirator (PAPR) […]

Shop Pressure Testing piping with Nitrogen leads to asphyxiation

August 15, 2025 / Chemical Process Safety (PSM/RMP), Free, Hazardous Materials, OSHA Compliance / Bryan Haywood

At 8:04 a.m. on May 11, 2023, an employee, 58, working for an oil and gas support services company, was found dead. On 5/10/23, the night before, the employee had instructed his coworkers from other contractors to go home, and he would finish the job up. This was the last time anyone had spoken to

Relied on Robot Cage Door Interlock; Operator closed the door and started the robot, killing the maintenance tech

August 15, 2025 / Free, Lockout Tagout, LOTO Accidents, LOTO/GUARDING FATALIties, OSHA Compliance / Bryan Haywood

At 10:35 a.m. on December 2, 2024, Employee #1, 18, was performing maintenance on a sensor inside a robotic enclosure. As he entered the area, the robot was stopped by the entrance sensors. While he was cleaning the sensor, a coworker reset the machine from the control panel, unaware that Employee #1 was still inside

Maintenance Tech By-Passes Guard Interlock – Machine Operator turned the machine from manual to auto and reactivated the machine, killing Tech ($145K)

August 15, 2025 / Free, Lockout Tagout, Lockout/Tagout Accidents (includes Machine Guarding), LOTO Accidents, OSHA Compliance / Bryan Haywood

At 11:00 a.m. on June 7, 2024, an employee, 50, working as a machinery maintenance technician for a frozen food manufacturer, was troubleshooting a ring remover since food trays were getting stuck. The employee bypassed the magnetic safety interlock gates and crawled underneath the conveyor. A coworker, the machine operator, was not aware that the

Nitrogen backflows into the “breathing air” system (Fatality)

August 15, 2025 / Free, Hazardous Materials, OSHA Compliance, Respiratory Protection / Bryan Haywood

At 11:43 a.m. on February 24, 2025, Employee #1, 61, was spray painting aircraft parts while wearing a supplied air respirator. Nitrogen backflowed into the breathing air system, displacing oxygen and asphyxiating the employee. Employee #1 was fatally injured.

“Used Container” explodes during cutting

August 14, 2025 / Free, OSHA Compliance / Bryan Haywood

A 53-year-old male was working alone in the workshop while using an oxyacetylene torch to cut a piece of steel. The employee used two “empty” barrels of Methanol as a work rest while cutting the steel. The oxyacetylene flame or sparks ignited the internal vapors of one of the barrels, resulting in a deflagration and

Equipment Opening Gone Bad (Railcar Manway)

August 14, 2025 / Chemical Process Safety (PSM/RMP), Free, OSHA Compliance / Bryan Haywood

At 8:00 a.m. on January 19, 2021, two (2) employees (42 and 52) were preparing to take a sample. As they were loosening the manway bolts, an explosion occurred. The employees were hospitalized for burns to the hands, arms, and lower back, as well as a fractured left femur. Awaiting Citations

Rail Car Implosion Fatality (Steaming Car)

August 14, 2025 / Free, OSHA Compliance, Permit Required Confined Spaces / Bryan Haywood

Updated on 8/26/25 A 38-year-old male was fatally injured when a railcar he was servicing imploded, collapsing downward and striking the employee, resulting in fatal crushing injuries. There were no witnesses. Damage to the railcar rendered the investigation findings inconclusive. Investigators said the plant manager told them he heard a loud explosion outside and found

Your Human Factors, Process Safety Tip of the Week

August 14, 2025 / Chemical Process Safety (PSM/RMP), Free, Human Factors Engineering / Bryan Haywood

Ensure your “units of measure” are CONSISTENT If the sight-glass for LEVEL is in Inches = the SOP needs to state INCHESIf the TEMPERATURE Gauge/Panel reading is in Degrees C = the SOP needs to be in Degrees CIf the PRESSURE Gauge/Panel reading is in PSIG = the SOP needs to be in PSIG

Three workers killed in water tank explosion

August 14, 2025 / Free, Hazardous Materials, OSHA Compliance, Permit Required Confined Spaces, Uncategorized / Bryan Haywood

THE WORK WE DO INSIDE A PRCS can create a Hazard! Three workers killed in a water tank explosion (PRCS Entry Fatalities) Initial investigations suggest the combination of cleaning agents and high temperatures triggered the fatal reaction.

Pressure Test gone bad (Steam Vessel failed during pressure testing)

August 14, 2025 / Chemical Process Safety (PSM/RMP), Free, OSHA Compliance / Bryan Haywood

Six (6) workers were injured when an air tank exploded at an industrial filter production plant. Two (2) of the workers received treatment at a local hospital with major injuries to their faces and heads. According to authorities, an air tank that was being tested exploded at 11:14 a.m. at the industrial filter manufacturing plant.

PRCS Fatalities (Sewer, H2S, 1 entrant and 3 “would-be rescuers”)

August 14, 2025 / Emergency Response, Free, OSHA Compliance, Permit Required Confined Spaces / Bryan Haywood

Manhole workers likely died from hydrogen sulfide poisoning, asphyxiation. The male workers, all in their 50s, were inspecting a sewage pipe in Gyoda City on Saturday. Police say they believe one of them fell in first, and the rest followed while trying to rescue him. All of them were later confirmed dead.