Articles

Bryan Haywood, M.S.
Founder & CEO

Bryan Haywood has over 30 years of experience in the chemical process safety and emergency response fields.  He began his career as a firefighter/EMT while attending Murray State University, where he obtained his BS in Occupational Safety and Health.  Bryan received his Masters in Safety Engineering in 1996.  Bryan is also a graduate of General Electric's Management Development Institute - Crotonville (2000), as well as GE's Six Sigma (Greenbelt).

During his career, Bryan developed, implemented, and managed safety management systems for five Fortune 500 companies that were required to comply with OSHA’s Process Safety Management Standard and EPA’s Risk Management Plan Rule.  Four of these management systems achieved OSHA VPP status and, as a consultant, he has played a major role at additional sites obtaining VPP designation.  As a safety professional in the chemical and semiconductor industries, he held positions ranging from Safety Engineer to Corporate Safety and Health Manager with Westvaco, Great Lakes Chemical, General Electric Plastics, BFGoodrich Specialty Chemicals, and SUMCO Corporation.

Bryan focuses his safety consulting efforts in the Chemical Process Safety arena, where he has extensive experience in:

• Developing and implementing overall PSM/RMP management systems
• Facilitating Process Hazards Analyses (PHA)
• Developing and implementing Mechanical Integrity Programs
• Developing and implementing Operating Procedures
• Developing and implementing Safe Work Practices (Hot Work, Permit-Required Confined Spaces, Line Break-Process Opening, Permit-to-Work Systems, Energy Control (LOTO), PPE, Respiratory Protection, etc.)
• Developing and implementing Incident Investigation procedures and assisting with critical investigations as a subject matter expert
• Process Safety Training (1-day Basic Overview, 3-day Intermediate, and 5-day Advanced course(s)
• Safe Work Practices Training 
  • Permit-Required Confined Spaces (PRCS)
  • Control of Hazardous Energy (LOTO)
  • Respiratory Protection (including a 1.5 day Administrator Course)
  • Hot Work
  • Line Break
• Emergency Preparedness, Training, and Response
  • HAZMAT response training
    • Awareness, Operations, Technician 24-hr, and 40-hr versions), Specialist, Incident Command
• PSM/RMP and Health & Safety Auditing
• An expert on RAGAGEPs such as NFPA, ASME, API, IIAR, ASHRAE, ANSI, Chlorine Institute, International Fire Code(s), NBIC, and dozens more.
• Process Safety and Occupational Safety & Health Training 

Bryan also has extensive experience with Emergency Preparedness and Response (Industrial Fire Brigades, HAZMAT, Confined Space, and High-Angle Rescue), hazardous materials management, fire water and foam protection systems, flammable liquids and gases (FLAGs), and combustible dust(s).  Bryan has obtained over 6,000 hours of technical training in Industrial Firefighting, Hazardous Materials, Technical Rescue (Confined Space, Trench, High-Angle), and Incident Command from recognized training organizations such as Texas A&M’s National Emergency Response and Rescue Training Center, Louisiana State University Fire and Emergency Training Institute,  U.S. Fire Administration’s National Fire Academy, The Security and Emergency Response Training Center, The Chlorine Institute, and the U.S. Department of Energy’s Nonproliferation Test and Evaluation Complex.  Bryan shares his nearly three decades of emergency response experiences, in both private industry and public sector fire service, with hundreds of students each year in the SAFTENG emergency response training courses taught around the world.

Bryan now runs his world-renowned and award-winning safety website (www.SAFTENG.net) and consulting business (SAFTENG), providing safety consulting services around the world. The SAFTENG.net website receives over three million visits a year from an ever-growing list of who’s who in the safety profession. Over 100 companies and organizations sponsor the SAFTENG.net website with Corporate Memberships so that safety professionals and management teams within their organizations will have access to the library of real-life safety photos, training presentations, safe work procedures, the Daily Incident Alerts Database, and over 8,000 articles offering safety compliance advice and risk management protocols. In all, more than 20,000 safety professionals in more than 70 countries around the world, as well as regulatory agencies such as Occupational Safety & Health Administration (OSHA), National Institute of Occupational Safety & Health (NIOSH), Environmental Protection Agency (EPA), The U.S. Chemical Safety Board (CSB), United Kingdom's Health & Safety Executive (HSE), Australia's Work Safe Victoria, British Columbia’s WORKSAFE, and many other government agencies around the world utilize the works of Bryan on a daily basis. 

Bryan was an adjunct instructor at the University of Cincinnati's College of Aerospace Engineering and Engineering Mechanics, Fire Science Program, where he taught Safety Management and Emergency Management courses from 2007 - 2017.

Bryan is a Professional Member of the American Society of Safety Engineers (ASSE) and The American Institute of Chemical Engineers (AICHE) and has taught the ASSE "Process Safety" courses for the past several years, teaching pre/post-conference courses and SeminarFest courses.

Bryan's work has been featured in several books and publications, including:

1. Hazards of Nitrogen Asphyxiation, U.S. Chemical Safety Board (CSB), 2003, Hazard Investigation Safety Bulletin No. 2003-10-B
2. Lockout/Tagout in Process Heating, March 2003
3. High-Pressure Injection Injuries, Firehouse®, Ron Moore, a contributing editor, September 2003
4. Operating Experience Summary, U.S. Department of Energy Office of Environment, Safety and Health, OE Summary 2006-07, June 16, 2006
5. Guidelines for Hazard Evaluation Procedures, Third Edition, American Institute of Chemical Engineers—Center for Chemical Process Safety (CCPS), 2008
6. Learning from incidents: A practical application; Process Safety Progress, an AICHE publication; Trish Kerin, December 2008
7. HUMAN FACTORS BRIEFING NOTE No. 12, Human error and non-compliance, Energy Institute, 2011
8. How Risk Assessment Fails — Again, This time at DuPont, Doug Nix, September 2011
9. HUMAN FACTORS BRIEFING NOTE No. 12, Human error and non-compliance, Energy Institute, 2011
10. The Safety Professional's Role: In Support of Industrial Facilities Operations and Maintenance (O&M), December 2013, by Edward Tokarski
11. Construction Killing Conditions, TJ Lyons, December 1, 2013
12. The Safety Professional's Role: In Support of Industrial Facilities Operations and Maintenance, December 27, 2013, Edward Tokarski
13. Important Information Regarding Bleach and FR Clothing, Tyndale USA, January 17, 2014
14. Keep a sense of vulnerability for safety sake: seven recommendations for keeping a sense of vulnerability at your chemical processing or refining site; Roy E. Sanders, Chemical Process Safety (Fourth Edition), 2015
15. Chemical Process Safety, Learning from Case Histories, Fourth Edition, August 2015, by Roy E. Sanders
16. Implementing Process Safety Management for Ammonia Refrigeration, Second Edition, 2015
    
17. IDEM’s REPORT OF ABOVEGROUND STORAGE TANK RULES AND REGULATIONS PURSUANT TO SEA 312, November 2015
18. U.S. National Poultry Research Center’s Safety & Health Newsletter, Volume 5, November 2015
19. Worker Safety: Stimulate a Sense of Vulnerability - Take seven steps to combat complacency that can compromise process safety, Roy E. Sanders, October 2015
20. Chemical Process Safety Fundamentals with Applications Solution manual, IChemE Safety Centre, 2016 featured my technical article The fundamentals behind “line breaking” 
21. Williams Olefins Case Study, U.S. Chemical Safety Board (CSB), 2016
22. Review of Global Regulations for Anhydrous Ammonia Production, Use, and Storage, SYMPOSIUM SERIES NO 161 HAZARDS 26, IChem 2016 (Exponent Inc.)
    
23. ExxonMobil Baton Rouge Safety Bulletin, U.S. Chemical Safety Board (CSB), 2017
24. Non-Condensable Gas System Explosion at PCA DeRidder Paper Mill Investigation Report, U.S. Chemical Safety Board (CSB), 2018 
25. The Use of Liquefied Petroleum Gas (LPG) as a Fuel for Commercial Vehicles in Ghana, Current Journal of Applied Science and Technology 29(2): 1-8, 2018; Article no. CJAST.41531 (Past name: British Journal of Applied Science & Technology, Past ISSN: 2231-0843, NLM ID: 101664541)
26. Process Safety Management: Optimized Models Influenced by Organization Culture, Rose-Hulman Institute of Technology, Taehoon Lee, 2018
27. Managing Employee Participation based on OSHA’s Process Safety Management Requirements, Noor Diana Abdul Majid, Dzulkarnain Zaini and Azmi Mohd Shariff; Centre of Advanced Process Safety (CAPS) 2018, Universiti Teknologi PETRONAS, 32610 Seri Iskandar, Perak Darul Ridzuan, Malaysia
28. Occupational deaths from Similar Causes; Why?; Society of Petroleum Engineers, 2019
29. Hot Work Dangers and Safety Measures, PetroHab, Samer Al-Azem, 8/2019
30. Is an Ammonia Evaporative Condenser a Permit-Required Confined Space, Condenser, February 2020
31. F-Gases: Trends, Applications and Newly Applied Gases in the Czech Republic, April 2020, Markéta Müllerová, Eva Krtková, and Zuzana Rošková, Atmosphere, EISSN 2073-4433, Published by MDPI AG; 2020
32. Evaluating Your Ammonia Refrigeration System to determine if certain equipment is a Permit-Required Confined Space, Refrigerating Engineers & Technicians Association (RETA 2020) Conference
33. Hand Sanitizers – What You Need to Know, Independent Suppliers Group, Frank Hoard, Director - Facility Supply Channel, 2020
34. Hot Work at Senior Living Communities: Protect Property and Lives, Nationwide Mutual Insurance Company, January 2021
35. Refinery Explosion Analysis - Chevron Pembroke Amine regeneration unit explosion; May 2020; Przemyslaw Mamon, University College Cork
36. Fire During Hot Work at Evergreen Packaging Paper Mill Incident Brief, U.S. Chemical Safety Board (CSB), 2021
37. Drone-Assisted Confined Space Inspection and Stockpile Volume Estimation; Ahmad Alsayed, Akilu Yunusa-Kaltungo, Mark K. Quinn, Farshad Arvin, and Mostafa R. A. Nabawy;
    Department of Mechanical, Aerospace and Civil Engineering, The University of Manchester, Manchester M1 3BB, UK
38. Fatal Acid Release at LyondellBasell La Porte Complex in La Porte, Texas, U.S. Chemical Safety Board (CSB), 2023

Bryan has been a regular instructor and presenter at safety conferences around the country on topics such as Process Safety, Permit-Required Confined Spaces, LOTO, Safe Work Permitting, Leading Safety Metrics, Contractor Safety, and many others that involve working in high-risk industries.

• AICHE CCPS (2007)
• Ohio Safety Congress and Expo (2012-2017)
• ASSE SeminarFest Instructor - Process Safety (2014-2019)
• ASSE Conferences (2013-2017, 2019)
• Refrigerating Engineers & Technicians Association (RETA 2020)
• ASSE Permit-Required Confined Spaces (4-Part Series @ SW OH Chapter)
• Michigan Safety Conference (2016)
• Indiana Safety Conference (2013)
• Various Client "Safety Days" (2005-2017)

Bryan works with Industry Groups such as The Chlorine Institute (CI), the American Society of Mechanical Engineers (ASME), the Center for Chemical Process Safety (CCPS), The International Institute of Ammonia Refrigeration (IIAR), and the American Society of Safety Professionals in an effort to improve safety within the facilities that utilize their codes and standards.   He currently sits on several codes/standards committees and safety committees within some of these trade groups.

See our Testimonials and Client Feedback to see what clients and former employers say about Bryan's safety knowledge, abilities, and passion for protecting workers.

DENNIS A. COLLINS

Senior Safety Engineer

Assistant Area Director (retired)

OSHA Cincinnati Area Office, Region V

Dennis has over 39 years experience in the safety field, having worked for the Occupational Safety and Health Administration (OSHA) from 1972 until 2006.  In his time with OSHA, Dennis spent 25 years as a Compliance Safety and Health Officer (CSHO) and 8 years as the Assistant Area Director of the Cincinnati Area Office – Region V.   As the Assistant Area Director of the Cincinnati Area Office, Dennis had first level supervisory responsibilities over the CSHO’s in the discharge of their duties, as well as conducting compliance inspections for Region V.  Dennis also was directly involved in the following areas as the A.D.:

• Voluntary Protection Program (VPP) assessments and approving certifications
• Targeted Inspection Programs
• Team Leader on over 70 fatality investigations and participated in hundreds more
• Lead Informal Conferences with employers
• Negotiated settlement agreements with employers
• Team Leader on Chemical Special Emphasis Inspection Program in Region V
• Team Leader on Petro Chemical Special Emphasis Inspection Program in Region V

As a CSHO for 25 years, Dennis conducted over 1,500 of wall-to-wall OSHA compliance audits, as well as OSHA’s targeted inspections and investigated employee safety and health complaints.

 Over his 34 years with OSHA, Dennis became an OSHA resource for all regions in the general industry standards and their applicability to all types of work environments. Although Dennis has expertise in all general industry compliance matters, Dennis’s true expertise lies in Lockout/Tagout, Confined Spaces, Machine Guarding, Emergency Egress, Fire Protection, and Flammable Liquids.

 Over his 39-year career, Dennis graduated from Miami University with BS in History & Political Science and went on to complete Graduate Programs in Environmental Health & Safety Management at the University of Cincinnati.  Dennis also attended numerous training courses through OSHA and in the civilian sector.

Gurmukh Bhatia

Chemical Engineer

Gurmukh (pronounced Ger-Mook) is a recently retired chemical engineer from a Fortune 500 Company with an international presence in over 125 countries, where he most recently held the position as Corporate Director, Process Safety & Chemical Security.  In his 45+ year career, Gurmukh has executed all aspects of plant operations and design engineering; managed projects; built and enhanced global process safety programs; and developed and delivered global training programs.

He is passionate about

• Process Safety Auditing (Certified Process Safety Auditor (CPSA) by the Board of EHS Auditor Certifications (BEAC)
  
• Establishing PSM programs followed by training, mentoring, coaching
• Developing and implementing Management of Change processes
• Motivating key people to implement process safety principles – “It is the right thing to do and it makes good business sense.”

He is proficient at effecting

• Simplifying complex concepts through training, mentoring, coaching
• Hazard and Operability Analyses (HAZOP) – facilitation and training.
• Chemical Safety & Security (CFATS) – common sense compliance.
• Flammable & combustible liquids – Safe storage, handling, and review of hazardous areas.
• Programs to assure vessel mechanical integrity and safe corrosive materials handling.
• Chemical design engineering and process engineering.
• Client use of Microsoft Office tools, PSM and enterprise risk management tools.

What he can do for you

• Provide PSM compliance auditing services.
• Build an OSHA compliant PSM program or enhance an existing one.
• Develop a robust Management of Change tool that meets the requirements of OSHA’s PSM Standard.
• Assist with the developing a mechanical integrity program compliant with OSHA’s PSM Standard.
• Provide training and mentoring so that the PSM program, the Management of Change tool, and the mechanical integrity program are sustained by practitioners at the facility.

Gurmukh and I have worked together for 15+ years in the process safety arena.  He is one of my "go to" engineers when I needed expert engineering advice in matters related to process safety.   He is also starting his own consulting buisness, so feel free to contact him directly if you prefer:

RISK & PROCESS SAFETY CONSULTING (RPSC LLC)
+1 (234) 263-7890
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