Worker dies when he accidentally hooked his respirator hooded coverall into an N2 connection

We have seen this life-threatening failure at least once or twice in our work! Most facilities have NO IDEA of how close they were to killing an employee. Some claimed it’s “common sense”, but trust me, these fatalities happen more often than most think. Hence, OSHA has required the following since its 1998 revision of the RP standard:

1910.134(i)(8)
The employer shall ensure that breathing air couplings are incompatible with outlets for nonrespirable worksite air or other gas systems. No asphyxiating substance shall be introduced into breathing air lines.

On February 5, 1985, employee #1 was assigned to perform an operation involving the reintroduction of toner in a blender room of the tower manufacturing department. Employee #1 was last seen alive at approximately 8:15 pm. At approximately 8:35 pm, two (2) other employees entered the blender room and found employee #1 unconscious on the floor.

Employee #1 was wearing a yellow full-body coverall with an attached hood and face shield. The coverall was manufactured by Durafab, Inc., style 2130z. It was the “bestoshield suit,” described as a respirator hooded coverall.

An air hose was taped to the respirator, and its other end was connected to a nitrogen (N2) gas line via a quick-connect fitting. The county coroner determined the cause of death to be asphyxiation by the inhalation of nitrogen gas.

The quick-connect fittings in the blender room were the same size and type for the nitrogen gas lines as for the compressed air lines. In addition, the nitrogen and compressed air gas lines were of the same color and, excluding the identifying name, of similar labeling.

Source: https://www.osha.gov/ords/imis/establishment.inspection_detail?id=1515220