Yep, during a frac job. The hose separated from the metal head, swung up and whacked a guy on his helmet. Knocked him flat and hurt his back, but, due to the pressure bleeding off and the lack of anything hard at the end, he just had some cuts (and maybe a concussion) from the plastic inserts in the helmet.
I do have three disgusting ones, though:
Some time ago, just as remote telemetry was becoming a thing on drilling rigs, separate contractors would come out to install sensors to tell things like torque, weight on bit, and RPM. One day the RPM sensor went down. Guy from telemetry company came out.
The senor for this was a laser that hit a little target in the cellar (below the derrick floor). It had fallen off.
Dipshit, instead of waiting 45 minutes for us to shut down, stepped over the safety barricade and went down in the cellar – mind you WHILE THE RIG IS RUNNING.
This is the mechanical equivalent of wandering around a car engine while you are driving down the highway. Lots of moving bits and pieces.
Dipshit then – because, you know, safety first — clips on his fall protection harness and makes his way over to a giant rotating hunk of steel.
Said giant rotating hunk of steel has an arm on it so you can lift it off with a crane.
Said arm caught his – safety first! — fall protection harness and pulled him into the rotating head.
Whereupon he was flossed in half by a steel cable.
I found his legs and hips. The other bits were stuck to the superstructure.
Have many more:
the use of a Wal-Mart lamp to see what the BS&W that accumulated in the bottom of a natural gas bullet tank. That was a heck of an explosion.
The guy who decided he could stop rolling drill pipe with his hand on a pipe rack (it weighs many tons)
The guy who stepped where it said “don’t step” and landed in a var of boiling ethylene glycol
The dude who decided not to use a torque tool on a drill pipe head and had his skull cleaved off by a 22" wrench
And many more.
Think of this when you complain about the price of gasoline, please.