Pipeline transportation is the backbone of our energy infrastructure—but it’s also a high-risk work environment. The sector faces a substantial rate of nonfatal injuries, putting it among the more dangerous industries in the country. The stakes are high: severe incidents like excavation damage, equipment strikes, and heat illness don’t just send workers to the hospital—they can cost millions, trigger regulatory penalties, and even result in fatalities.

What’s behind these numbers? The same handful of injuries keep cropping up, often for the same reasons: missed signals, rushed procedures, and gaps in real-time oversight. But in 2025, we’re no longer limited to just manual checks and after-the-fact reviews. Modern video intelligence platforms now give safety teams better visibility—helping spot risks, support safety protocols, and intervene to reduce risk.

In this guide, we’ll break down the top 3 injuries that can occur in pipeline transportation and, most importantly, how to mitigate them. We’ll show how combining strong safety programs with the right technology—like video analytics—can turn your cameras into a frontline defense for your crews, your compliance record, and your bottom line.

The cost of safety negligence in pipeline transportation

Avoiding injury is critical for mitigating major financial and reputational fallout. OSHA and PHMSA penalties for pipeline transportation safety violations are steep, with maximum fines reaching $85,000 and an average penalty of $9,229 per incident. The median penalty sits at $5,839. A forward-looking safety system—one that combines strong protocols with real-time monitoring—can address many of these incidents before they escalate.

The top 3 injuries in pipeline transportation and how to mitigate them

1. Struck-by and caught-in/between equipment

Scenario:
A crew is performing maintenance on a pipeline valve. One worker steps away to grab a tool, not realizing a crane is repositioning overhead. Suddenly, a shifting load strikes his hand, causing a severe crush injury.

Root Causes & Impact:
Incidents where workers are struck by or caught in equipment account for 28% of total pipeline injuries (Source: OSHA Pipeline Incident Database, 2024). They often involve moving pipes, cranes, or heavy machinery—especially during maintenance or material handling. Amputations and severe fractures are common outcomes: over a quarter of reported injuries in pipeline operations are amputations, mostly fingers or hands (Source: OSHA Workplace Injury Analysis: Pipeline Transportation Industry).

How video intelligence helps:
Video analytics can monitor equipment zones and alert supervisors when workers enter hazardous areas, or if procedures—like lockout/tagout—aren’t followed. Reviewing incident footage helps identify patterns and retrain crews. Spot AI, for example, enables rapid incident review and sends timely alerts when workers enter designated no-go zones around machinery, making risk mitigation practical.

2. Burns—thermal and electrical

Scenario:
During an emergency shutdown, a worker reaches over an energized panel to reset a breaker. An arc flash erupts, causing severe burns to the face and hands.

Root Causes & Impact:
Burns—whether from fire, hot substances, or electrical arc flash—are a leading injury type in pipeline transportation, accounting for at least 13 incidents (Source: OSHA Workplace Injury Analysis: Pipeline Transportation Industry). These incidents often occur during electrical work, tank cleaning, or when hazardous materials ignite. Many result in hospitalization or, in the worst cases, fatalities.

How video intelligence helps:
Video systems can monitor high-risk work like electrical maintenance or hot work permits, helping verify that required PPE like hard hats and safety vests are worn. In the event of an incident, rapid video review pinpoints procedural gaps. Real-time alerts flag unsafe practices—like entering an energized area without authorization.

3. Hazardous material exposure

Scenario:
During pipeline cleaning, a vapor cloud escapes from a valve. Workers are slow to recognize the hazard, leading to acute toxic exposure before the area is evacuated.

Root Causes & Impact:
Exposure to hazardous substances—like hydrogen sulfide or chemical vapors—makes up 15% of pipeline-related injuries (Source: NIOSH Pipeline Sector Report, 2023). These events are particularly dangerous during confined space entries or emergency response scenarios. Inconsistent gas monitoring and bypassed safety steps are common factors.

How video intelligence helps:
Video analytics can help verify compliance for specific PPE like hard hats, monitor confined space entries, and detect when unauthorized personnel enter hazardous zones. Reviewing incidents helps teams retrain on hazard recognition and emergency protocols. Real-time alerts can notify supervisors if workers enter restricted areas without authorization.

Hurdles and impact of the injuries

How technology strengthens injury mitigation

Struck-by and caught-in/between equipment

The safety hurdle: Heavy machinery, moving pipes, and dense worksites create constant risk of crush injuries—especially where visibility is poor or procedures are rushed.

Tech solution: Video AI analytics automatically watch for workers entering danger zones or bypassing safety barriers. Real-time alerts notify supervisors quickly, so they can intervene to reduce risk. Spot AI’s platform helps safety leaders quickly review footage, spot patterns, and adjust training—making every camera a tool for insight-driven safety.

Burns—thermal and electrical

The safety pain point: Arc flash, hot work, and hazardous substance handling require strict PPE and lockout/tagout compliance—but busy crews may cut corners.

Tech solution: Cameras equipped with AI can help verify that all workers in high-risk zones are using required PPE like hard hats and safety vests . If a worker enters a hazardous area without protection, rapid alerts prompt supervisor action. Video review after any incident makes root cause analysis fast and reliable.

Hazardous material exposure

The safety obstacle: Confined space entries and emergency cleanups are high-risk for toxic exposures—especially if PPE is skipped or gas monitoring is inconsistent.

Tech solution: AI-powered cameras can help verify that specific PPE like hard hats are worn and track who enters/exits confined spaces. Real-time alerts warn if workers violate entry protocols. Incident footage streamlines investigations and helps inform future training.

Practical implementation of safety technology

Rolling out new safety technology in pipeline transportation integrates with your existing workflows. The best solutions, like Spot AI’s platform, are designed to work with existing camera systems and integrate with your current safety protocols. Here’s what works:

• Plug-and-play integration: Capable video intelligence can bridge legacy and new cameras, so you maximize past investments.

• Support for unlimited users: Make video insights accessible to everyone on your safety, operations, and compliance teams.

• Open APIs: Seamlessly connect video analytics data with your other safety management systems.

• Compliance first: Look for solutions that help you document adherence to OSHA and PHMSA standards, making incident investigations and audits faster and more transparent.

When evaluating a solution, ask: Will it help me spot the root cause of our top injury risks? Can it provide timely alerts to help mitigate incidents before they escalate? And does it make your team’s job easier, allowing them to focus on safety?

Ready to build a safer pipeline transportation operation?

Effective safety in pipeline transportation sends every worker home safe, every day. Video intelligence platforms are a frontline safety tool that helps you identify hazards before they escalate, avoid costly penalties, and build a strong safety culture.

Curious how real-time video insights can help strengthen your pipeline safety program? Request a demo to see Spot AI in action and explore how video AI can support your team’s safety goals.

Frequently asked questions

What are the most common injuries in pipeline transportation?

The leading injuries include struck-by and caught-in/between incidents (especially involving heavy equipment), burns from thermal or electrical sources, and hazardous material exposures. Amputations and fractures are prevalent, especially during maintenance and material handling.

How can video intelligence help mitigate injuries on a pipeline site?

Video intelligence platforms monitor worksites in real time. They can identify unsafe behaviors, help verify PPE compliance, spot incidents, and alert supervisors to potential risks. Reviewing incident footage also accelerates root cause analysis and training improvements.

What are key obstacles in implementing safety technology for pipeline operations?

Key roadblocks include integrating new tech with legacy camera systems, ensuring data security, and training teams to use video analytics effectively. The best platforms offer plug-and-play hardware, unlimited user seats, and open APIs for seamless integration with existing safety programs.

How does technology support regulatory compliance?

Video intelligence helps document adherence to OSHA and PHMSA requirements, simplifies incident investigations, and provides an auditable record for safety protocols, PPE use, and access control. This can be crucial during audits or after a reportable event.

What’s the best way to start with video safety technology in pipeline transportation?

Start by identifying your top injury risks and reviewing your current camera infrastructure. Then, choose a video intelligence platform that can bridge your existing systems, deliver real-time alerts, and offer user-friendly incident review tools. Consult with safety technology experts to tailor the solution to your specific operational needs. Request a demo to get started.

What makes a real-time video analytics platform effective for safety?

The most effective platforms move beyond simple recording to provide actionable insights. Key features include AI-powered alerts that notify supervisors of risks like no-go zone entry or missing PPE before an incident occurs, rapid search tools to find root causes in minutes, and seamless integration with your existing cameras. The best systems also offer unlimited user access, empowering your entire safety, operations, and compliance teams to collaborate.

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.