One of the top items from our process safety audits, PHAs, assessments, etc. is the lack of vehicle protection around critical equipment/infastructure.  Number one target in process plants is overhead piping!  It seems no matter how high we put it, it will get hit.  Already this year we were told that the pipe bridge over the main raod was "high enough" and that no height signs or protection systems were needed.  Months later the safety manager sent me a picture of a dump truck stuck under that same pipe bridge with its bed fully up.  The accident cost them a reportable release, a visit by EPA (still awaiting the damage assessment from that visit) and around $300K in damages, not counting the lost production!  Case in point... keep in mind this vehicle was traveling at a higher rate of speed than those in our plants, but the force is great even at 10-15 mph.

 

DISCLAIMER:  No worker was seriously injured (luckily) in the making of this video.

WARNING!  Viewer Discretion Advised.

 

VIEWER DISCRETION IS STRONGLY ADVISED!  This video is extremely graphic by way of the sounds and viewer discretion is advised.  You may want to turn down the volume.  The video is a classic example of flammable liquid flash fire and it is the only reason why I am sharing it.  Keep your eyes on the white car at the bottom of the screen.  Gasoline has a flash point of -50F and its vapor is heavier than air and can travel great distances across the ground to find an ignition source, which can be less than 1 mJ.  A running car or even a hot engine/exhaust can be enough to ignite the vapor, as shown by this video.

 
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