Every day, workers in petroleum and coal manufacturing face some of the most dangerous conditions in industry, with a historically high rate of serious and fatal incidents. Catastrophic events—ranging from burns and explosions to crushing injuries—can change lives in seconds. Yet, as severe as these hazards are, research shows that most of the leading injuries are avoidable with the right systems in place.

4 types of incidents account for the vast majority of serious injuries and deaths in these facilities: burns, caught-in machinery accidents, vehicle strikes, and exposure to harmful substances. Each one is driven by a mix of operational complexity, and human error.

The good news is that a forward-looking safety program, grounded in proven protocols and empowered by video intelligence, can substantially reduce these risks. Video AI can alert teams in real time to unsafe acts, environmental hazards, and compliance gaps, helping supervisors and frontline staff address issues before they escalate.

In this guide, we’ll break down the top 4 injuries that occur in petroleum and coal manufacturing—and, most importantly, show how facilities can reduce their likelihood.

The cost of safety negligence in petroleum and coal manufacturing

Penalties for avoidable occurrences serve as a major warning. In the past five years, fines for major safety violations in petroleum and coal manufacturing have ranged from a median of $5,839 to a maximum of $125,000, with an average penalty of $12,315 per incident.

Many incidents are avoidable—one that could have been stopped with better systems, training, or real-time detection. By investing in anticipatory safety monitoring and compliance technology, organizations minimize risk, avoid needless penalties, and—most importantly—help keep workers safe.

The top 4 avoidable injuries in petroleum and coal manufacturing

Let’s break down the 4 injury types where video intelligence helps mitigate serious risks.

1. Burns from Hot Objects, Substances, and Chemicals

Scenario:
A refinery technician opens a valve on a pressurized line. Without warning, hot naphtha sprays out, causing second-degree burns to the face and arms. In another case, a maintenance worker makes contact with an unshielded section of a high-temperature pipe, resulting in severe burns.

Root causes & impact:
Burns are the single largest injury category, accounting for roughly 40% of all cases in the sector (Source: OSHA). Root causes include contact with hot surfaces, steam, asphalt, and caustic chemicals, often during line breaks, maintenance, or leaks. Lapses in PPE use and shield maintenance are frequent contributors. These injuries can require long-term hospitalization and may result in permanent scarring or death.

How video intelligence helps:
Video AI systems can monitor hot work zones for missing PPE and notify supervisors if a worker enters a restricted no-go zone near hot equipment. Real-time video review allows safety teams to investigate occurrences and identify recurring unsafe behaviors, such as unauthorized entry during chemical transfers.

2. Caught-In or Crushed by Machinery

Scenario:
An operator performs maintenance on a conveyor belt without proper lockout/tagout. The belt suddenly starts, pulling the worker’s hand—and then arm—into the machine, leading to traumatic amputation.

Root causes & impact:
Nearly all amputations in the sector involve machinery, with events often linked to bypassed guards or skipped lockout/tagout (LOTO) procedures. Caught-in events are a leading cause of fatality and hospitalization, impacting both the individual and their team.

How video intelligence helps:
Video intelligence systems can alert teams when workers enter hazardous no-go zones during machine operation. Reviewing footage after an occurrence clarifies whether LOTO protocols were followed, helping teams address procedural gaps.

3. Struck By or Crushed By Vehicles and Equipment

Scenario:
A forklift operator reverses in a crowded loading area. A pedestrian, obscured by stacked drums, is struck and pinned, suffering multiple fractures.

Root causes & impact:
Struck-by incidents are common in busy yards and inside plants, especially where pedestrian and vehicle paths cross. Lack of spotters, poor visibility, and inadequate separation are frequent causes. These events cause crushing injuries, amputations, and death.

How video intelligence helps:
Video platforms can monitor vehicle corridors, notify teams when pedestrians enter vehicle-only corridors or when vehicles enter pedestrian-only zones. Reviewing these events helps teams redesign layouts and implement better controls.

4. Exposure to Harmful Substances or Environments

Scenario:
A lone worker opens a tank “thief hatch” to take a manual sample. Toxic hydrocarbon gas escapes. Within minutes, the worker collapses—no one else is nearby.

Root causes & impact:
Manual sampling without monitoring, lack of buddy systems, and missed PPE use are at the heart of these incidents. Exposure can cause poisoning, respiratory failure, or fatal asphyxiation.

How video intelligence helps:
Video AI can detect when workers enter hazardous no-go zones and verify if they are wearing required PPE, such as hard hats or safety vests. Video review after an event helps confirm if buddy protocols were followed.

Obstacles and impact of the injuries

How technology strengthens workplace safety

Let’s look at each injury-related hurdle and the practical ways video intelligence makes a difference.

1. Burns from hot objects, substances, and chemicals

Safety pain point:
Hot surfaces, chemical lines, and pressurized systems are everywhere. Traditional spot checks and signage can’t catch every lapse.

Tech Solution:
AI-powered video systems, like Spot AI, monitor hot zones 24/7. They detect workers entering restricted areas without proper PPE and provide evidence for root cause analysis. Timely notifications let supervisors intervene before an event escalates.

2. Caught-in or crushed by machinery

Safety pain point:
Bypassing machine guards or skipping LOTO steps happens fast—and the consequences are permanent.

Tech Solution:
Video AI can be configured to notify supervisors as issues arise when someone accesses hazardous zones near machinery. After an occurrence, reviewing footage can help determine if proper procedures like LOTO were followed, supporting better training and accountability.

3. Struck by or crushed by vehicles and equipment

Safety pain point:
Fast-moving equipment and blind spots mean pedestrians and vehicles often mix in dangerous ways.

Tech Solution:
AI video platforms can be configured to notify teams if a pedestrian enters a vehicle-only area. Analyzing these patterns lets managers adjust layouts for better separation and retrain teams on safe crossing points.

4. Exposure to harmful substances or environments

Safety pain point:
Manual tank gauging and solo work heighten the risk of toxic exposure—especially when protocols aren’t followed.

Tech Solution:
Video analytics can monitor hazardous areas for unauthorized entry and check for required PPE, such as hard hats and safety vests. After occurrences, examining video helps confirm whether safety steps were followed and identify where breakdowns occurred.

Practical implementation of safety technology in petroleum and coal manufacturing

Adopting video intelligence doesn’t mean starting from scratch. Most petroleum and coal manufacturing facilities already have camera systems in place—Spot AI’s platform, for example, bridges on-prem cameras to a secure, cloud-native dashboard, making integration seamless.

• Integrate with existing safety protocols: Use video intelligence to monitor for specific hazards tied to your risk profile—burns, vehicle movement, or confined space entry.

• Engage the frontline: Empower supervisors and workers to use timely notifications and trend analysis to drive day-to-day improvements.

• Customize alerts and analytics: Focus on the injury types that matter most in your facility. Review incident footage for continuous improvement.

• Evaluate based on your needs: Choose platforms that offer open APIs, unlimited user seats, and a unified dashboard—making it easy to scale as your safety program grows.

To be effective, technology must be paired with strong procedures, training, and a culture where everyone is responsible for safety.

Make every shift safer

With proven safety protocols and video intelligence, petroleum and coal manufacturing leaders can strengthen safety and compliance. See Spot AI in action to discover how video AI helps your team address issues before they escalate.

Frequently Asked Questions

What are the biggest safety hurdles in petroleum and coal manufacturing?

The sector faces high risks from burns (thermal and chemical), machinery-related amputations, vehicle strikes, and exposure to hazardous substances. Complex processes, hazardous materials, and high-pressure equipment increase risk profiles.

How can we reduce the likelihood of machinery-related injuries like amputations?

Strict adherence to lockout/tagout (LOTO) procedures and machine guarding is essential. Video AI analytics can notify supervisors if workers enter hazardous no-go zones near machinery, supporting real-time intervention and training.

What’s the role of technology in guarding against chemical exposures?

Video analytics can verify PPE compliance (like hard hats and vests) and monitor for entry into hazardous no-go zones. After any occurrence, footage provides valuable context for investigation and improvement.

How to get started with safety technology in petroleum and coal manufacturing?

Begin by evaluating your current camera infrastructure and safety priorities. Choose a solution that integrates with your systems, focuses on your top injury risks, and offers real-time analytics and alerts. Involving safety teams and frontline workers in the rollout is key for effective adoption.

What is the best video analytics for workplace safety?

The most effective systems are practical, scalable, and proactive. Look for a platform that integrates with your existing cameras, provides a unified dashboard for all sites, and offers unlimited user seats to empower your entire team. Key capabilities include real-time alerts for critical events like no-go zone breaches and missing PPE, which help your team address issues before they escalate.

About the Author

Joshua Foster is an IT Systems Engineer at Spot AI, where he focuses on designing and securing scalable enterprise networks, managing cloud-integrated infrastructure, and automating system workflows to enhance operational efficiency. He is passionate about cross-functional collaboration and takes pride in delivering robust technical solutions that empower both the Spot AI team and its customers.