OSHA Compliance

Why we NEVER give up the key(s) to our LOTO lock(s)

At approximately 6:30 a.m. on March 06, 2012, Employee #1 was prepping to perform maintenance on a pug mill. Employee one was involved in performing the job duty of replacing the ends of worn paddles with new ones at the time of the incident. Employee #1 began working on the collect auger and requested the…...

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OSHA issues Serious Citation in PRCS Death for NOT performing “Freshair Setup” and “bump testing” meter

In a recent PRCS involving a fatality, one of the OSHGA citations issued under 1910.146(d)(4)(i) was related to not following the meter manufacturer’s use requirements related to “bump testing” the meter before each day’s use… 1910.146(d)(4)(i) Testing and monitoring equipment needed to comply with paragraph (d)(5) of this section; Text For Citation: 01 Item/Group: 002…...

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Analysis of Leak Testing Planning for Carbon Dioxide Piping Systems

This is an EXCELLENT document to help us understand the risks associated with pressure testing Carbon Dioxide (CO2) piping. It compiles all my previous posts on the need for and methods of pressure/leak testing our hazardous materials piping systems. Many people are skeptical of a redneck from Western KY on these matters, so I thought…...

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Leak Test Gone Bad (Hydrostatic of AL tank)

A welder died when struck by a piece of a hydraulic tank that came apart after being pressurized with air and water to check for leaks. The welder had removed the tank the previous day to repair a leak. On the day of the incident, the victim filled the tank with water and used an…...

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Leak Test Gone Bad (using oxygen as test media)

Polish Authorities have determined that the heat pump explosion that killed two people last year was caused by using oxygen to carry out a leak test. The heat pump explosion on August 20, 2024, killed two people: an engineer (30) who was servicing the unit and the property owner (45). They were said to have…...

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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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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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