105,313Records 71,083Employers 85,290Hospitalizations 27,770Amputations 2015-01-01 2025-10-31
Safety Incidents OSHA Severe Injury Reports · 2015–2025

Phillips 66

Other fall to lower level 6 to 10 feet · Fractures

Federal OSHA recorded a severe workplace injury at Phillips 66, 900 Central Avenue , MADISON, ILLINOIS 62060 on — Fractures, affecting the nonclassifiable.

An employee was ascending a steel fixed ladder. The employee fell approximately 7 to 9 feet to the ground below. The total elevation change was 9 1/2 feet high. The employee suffered a head laceration and broken bones and was hospitalized.

Hospitalized Nonclassifiable Ladders-fixed

Phillips 66

An employee was responding to a gas leak on a second-stage piping that contained natural gas. After identifying the leak, he began to walk toward his truck when the pipe ruptured, causing a fire. The employee sustained second- and third-degree burns to his ears, neck, back, and arms.

Phillips 66

An employee opened a valve to see if a drum was free of hot residual oil. The oil was plugged behind the open valve, but the plug dissolved. Hot oil (300-400 degrees F) splashed out of the drum's receiving receptacle and onto the employee's right thigh and right arm, as well as the right sides of the employee's abdomen and face.

Phillips 66

An employee was injured by an arc flash while working on a live electrical panel. The employee received burns to the face and hands.

Phillips 66

An employee was clearing the pump to get the turbine ready for maintenance. While flushing the heavy coker gas oil (HCGO) pump, some HCGO got reintroduced into the pipe. When the hot oil (700 degrees) touched the water in the sewer drain, it flashed back and burned the employee. The employee suffered second degree burns to the abdomen and third degree burns to both hands and knees.

View Phillips 66's full OSHA safety record →

Petroleum Service Corporation

An employee was preparing a tank car for loading while chipping away solidified product in the manway opening of the tank car. A pressure noise within the tank car startled the employee, causing him to stumble backward and fall approximately 10 feet over the guard railing at the chemical loading rack to the ground. The employee suffered fractured vertebrae, a fractured right wrist and ankle, and a dislocated jaw.

Absolics Inc.

An employee was installing an electrical tray remover from a ladder. As he was descending, his missed a step and fell 6-7 feet to the floor. The employee suffered a head injury.

American Residential Products, Inc.

Two employees were installing spray foam insulation in the attic of a new residential construction. The injured employee fell 8 feet from an A-frame ladder to the floor. The employee suffered lacerations, abrasions, and a head injury.

Berkheimer Maintenance

An employee was on a raised platform attaching wires to electrical boxes. The employee fell approximately 8 feet to the floor below and struck an exit sign on the way down, resulting in an injury to his face.

High-Tec Industrial Services, Inc.

An employee was in a forklift man basket fixing a garage door opener when they fell approximately 8 feet to the concrete ground below. The employee suffered head and back injuries as well as kidney bruising.

poet bio refining of macon

An employee was ascending an 8-foot aluminum extension ladder to access and replace a hypochlorite pump located on top of a 7-foot chemical tank. When he reached approximately 5 feet on the ladder, the ladder shifted and twisted to the right. The employee fell from the ladder and landed on his right side. The employee sustained a compound fracture to his right leg just above the ankle, dislocation of his shoulder, and a torn rotator cuff. The employee was hospitalized.

Phillips 66 Company dba Phillips 66 Refinery Wood River

An employee was taking a butane gas sample as part of the hydrocarbon refining process. A component disconnected and the butane ignited, resulting in first- and second-degree burns to the employee's forearms and to their face, including their cheeks, chin, and neck.

CITGO Petroleum Corp Lemont Refinery

An employee was driving a carry deck/small crane when its boom made contact with an overhead support beam. The employee was jostled in the cab and suffered a concussion.

NuGen Energy, LLC

An employee was inventorying hammer mill screens when the screens fell on the employee. The employee sustained a laceration to their leg requiring hospitalization.

Bechtel Energy Headquarters

An ironworker was maneuvering a mobile elevated work platform (MEWP) into position to install a structural beam. The employee was pinned between another structural steel beam that was already installed and the MEWP control box cover. The employee was hospitalized with a laceration to their lip, dislodged teeth, and a fractured jaw.

Takeda Pharmaceuticals U.S.A., Inc.

An employee fell while moving a water canister, resulting in fractures to four fingers on her right hand.

Great Dane Ltd. Partnership

An employee was changing a die in a press when the die slipped and crushed the employee's left index finger. The employee sustained an open facture of the tuft of the left distal phalanx and a partial amputation.

Olympia Food Industries Inc.

An employee was mixing sauce using a sauce barrel mixer when his left little finger was amputated.

AbbVie Inc.

An employee was driving a boom lift (in the lowered position) in an exterior dock area. The lift s left wheels rolled onto base plates that covered a 3-foot-deep sump pit. The base plates failed, and one side of the lift dropped. The employee's left leg was caught under the lift basket, and he suffered a fracture to the lower leg including the ankle.

TSA Processing - Montgomery

A temporary employee was carrying a nail gun through the warehouse when it hit his leg, activated, and fired a nail into the leg.