Activity
Fluid Transfer
Transfer of process fluids between tanks, vehicles or equipment.
Newest 100 Documents
All 199 in search- 202622 Jan
Mechanic got burns due to fire in portable generator
A marine mechanic sustained minor right-arm burns after spilled petrol ignited during portable-generator refuelling at a dock workshop. Dragging the generator produced a friction spark. The flash identifies missing rubber bushings, absent procedures and risk assessment, inadequate maintenance and housekeeping, and difficult access to fire extinguishers.
- 2025Sep
Several errors lead to a hydrogen leak & fire — Process Safety Beacon, September 2025
This bulletin examines a hydrogen filling incident in Santa Clara in which a trainee inadvertently restarted filling while piping was dismantled for repair. Escaping hydrogen ignited, producing a deflagration and jet fire. It emphasises isolation procedures, authorised repairs, understandable controls and clear instructions for newer employees.
- 20253 Apr
BSEE Safety Alert 498 - Explosion and Fire Incident
A liftboat explosion during separator draining injured two workers with burns. Gas accumulated on deck and a generator surge triggered ignition. The alert examines tank sealing, unsuitable gas detectors, failed air-intake shutoff controls and delayed medical evacuation, recommending that operators consider improved procedures, inspections, testing and emergency arrangements.
- 202424 Jun
BP - Husky Oregon Chemical Release and Fire
Investigates the fatal naphtha release and flash fire at the BP-Husky Toledo Refinery in Oregon, Ohio. Examines cascading process disturbances, vessel overflow, manual draining, misleading level indications and alarm overload. Recommendations address engineered overfill safeguards, abnormal-situation procedures, stop-work practice and alarm performance, alongside shortcomings in applying earlier incident lessons.
- 202418 Jun
Carriage of methanol – dangerous goods – without proper certification
A workboat transported methanol for refuelling a LIDAR buoy at an offshore wind farm without the required dangerous-goods compliance document. The flash describes inadequate vessel suitability, omissions in contractor risk assessment and apparent lack of awareness. It explains certification requirements for methanol carriage and fully fuelled buoys.
- 202427 Mar
Implosion of chemical tank
A chemical tank on a vessel imploded after pumping created a vacuum with its manual air inlet valve unopened. Around two cubic metres of monoethylene glycol spilled onto the deck and into the sea; nobody was injured. The flash examines unfamiliar replacement equipment, supplier assurance, documentation, familiarisation and management of change.
- 202419 Mar
MSF: Chemical handling – eye burn
A biocide splash from a hose during pneumatic pump checks reached a person on the deck below, causing a small eye burn despite safety glasses. The flash identifies inadequate risk assessment and missing access safeguards, and calls for relocation of chemical transfer, review of assessment and renewed toolbox discussion.
- 202321 Dec
KMCO LLC Fatal Fire and Explosion
Investigation of the fatal isobutylene explosion and fire at KMCO’s Crosby facility. Metallurgical testing established pressure-driven brittle fracture of a cast-iron y-strainer. The report examines thermal-expansion hazards, manual versus remote isolation, emergency-response roles and alarm use, identifying weaknesses in hazard evaluation and response that contributed to the incident and its severity.
- 202313 Nov
Positive: Master stopped unsafe fuel transfer whilst vessel alongside rig
A supply vessel halted fuel transfer after its watch officer spotted welding on an adjacent semi-submersible rig. The flash highlights prompt bridge intervention, reporting and positive recognition by rig management. It identifies missing communication about hot work despite mandatory confirmation of simultaneous operations through the Safety Zone checklist.
- 20236 Jul
Intercontinental Terminals Company (ITC) Tank Fire
Investigation of the March 2019 tank-farm fire at ITC’s Deer Park terminal, following a circulation-pump seal failure and butane-enriched naphtha release. The report examines pump maintenance, gas detection, emergency isolation, fire spread, containment failure and regulatory exemptions, with recommendations addressing mechanical integrity, tank-farm design and process safety management.
- 202322 May
Unexpected H2S Detection at Offshore Facilities
This alert summarises unexpected hydrogen sulphide detections at offshore facilities producing from fields classified as H2S absent. Cases involve production equipment, cargo tanks, defoamer transfer and ballast-tank cleaning. BSEE recommends considering atmospheric testing, stagnant-tank inspections, crew drills, routine sampling and risk assessments addressing bacterial generation of the gas.
- 202327 Mar
Leak of oil-based mud
A vessel preparing to transfer oil-based mud to shore spilled about 20–25 litres through tank ventilation during hose pressure testing. A deteriorated valve seal prevented full closure. The flash describes deck containment, toolbox communication, valve replacement, monthly manifold-valve cleaning and clearing residual chemicals or mud from transfer lines.
- 202316 Feb
Fluid Transfer Transport
Hazard alert addressing toxic and flammable vapours, hydrogen sulphide and oxygen displacement during vacuum loading and offloading of produced fluids. It assigns responsibilities to facilities, hauling companies and drivers, covering atmospheric monitoring, training, conductive hoses, bonding and grounding, safe vent discharge and prevention of diesel-engine runaway.
- 2023
Standards for offshore helicopter landing areas (Version 9.1, 7 January 2026; publisher status Current)
Sets criteria for offshore helicopter landing areas on installations and vessels, alongside wind-turbine winching arrangements. Covers structural loading, obstacle protection, surface friction testing, lighting, motion monitoring, meteorological reporting, rescue and fire-fighting, fuel-system design and maintenance, and passenger preparation. The January 2026 amendment introduces arrangements for temporary safety-critical equipment unserviceability.
- 2022Oct
Communication – the heart of safe operations — Process Safety Beacon, October 2022
A solvent-transfer incident illustrates how unclear maintenance status and informal lockout arrangements can undermine safe restart. An operator was sprayed with solvent from an improperly tightened flange but was not injured. The bulletin emphasises work permits, communication between groups, participation in hazard reviews and following restart plans.
- 20225 Sep
Chemical burns to body
A recently joined vessel engineer suffered a severe chemical burn while decanting carbon remover for purifier maintenance. Posted instructions were not followed and chemical PPE was not worn; a less hazardous alternative was available. Lessons emphasise comprehensive familiarisation, supervised induction, competence assessment and confidence to stop unsafe work.
- 2022Aug
What’s an Acceptable LEL Detector Reading? — Process Safety Beacon, August 2022
This bulletin examines a fatal tank explosion during emptying by vacuum truck, where work continued after a reading of 67% of the lower explosive limit. It explains vapour accumulation and sludge hazards, emphasising calibrated gas testing, compliance with testing limits, bonding and grounding, and recognised tank-cleaning practices.
- 202220 Jan
Hose management and chemicals: crew person felt ill
An engineer coughed and felt unwell while flushing a hose before filling a cooling-water system, with no long-term ill-effects. The member attributed the incident to poor hose management: residual cooling agent remained after previous use. Actions included separate hoses for cooling agent and non-potable water, plus flushing and drying before storage.
- 202125 Nov
Hydrogen sulphide detected in a bilge tank
A vessel crew stopped bilge-water transfer after noticing a rotten-egg smell; a multi-gas meter detected 453 ppm hydrogen sulphide at the vent. The flash describes accumulated tank residue, delayed specialist cleaning, gas routing away from accommodation, continuous monitoring and respiratory protection, alongside lessons on machinery-space cleaning practices.
- 202131 Aug
Near Miss – Damaged Rig Hose
A near miss during receipt of contaminated oil-based mud from a rig revealed detached hose lining trapped between connections. The flash identifies potential back-pressure hose failure and environmental consequences if flow were blocked, and calls for hose condition and certification checks, visual inspection before use and stop-work intervention.
- 2021May
Catastrophic failure of marine loading arm
This safety alert describes a marine loading arm collapse following failure of a pantograph pivot pin. Inaccessible servicing points contributed to missed lubrication and corrosion. It calls for structured inspection and maintenance planning, prompt checks of structural components, verification of completed work and periodic review of maintenance arrangements.
- 202117 Mar
Electric shock due to water in electrical equipment
During freshwater supply to a vessel, water escaped from a galley sounding pipe and wetted cooking equipment. A steward received a mains electric shock but was unharmed. The flash identifies unassessed spill risks and delayed drainage, and recommends open drainage, revised risk assessments and communication of equipment maintenance requirements.
- 202124 Feb
Failure to Follow Procedures Results in Pollution Incidents
BSEE describes two Gulf of Mexico pollution incidents involving open valves during well workover and synthetic-based mud transfer. The second investigation remained ongoing, with preliminary findings indicating procedural non-compliance. Recommendations address flow-path understanding, valve labelling, physical verification before start-up, defined responsibilities and lockout/tagout barriers for overboard mud-system components.
- 20206 Dec
Injury caused by closing fire flap
A crewman sustained a left-wrist wound when a fire damper closed during improvised filling of an expansion tank through ventilation trunking. The flash contrasts this method with the approved portable-pump arrangement and highlights non-routine risk assessment, adherence to procedures and management of change where approved systems are not functional.
- 202023 Oct
MSF: Grub screws and perished valves – trouble with methanol transfer
This flash describes unrecognised methanol discharge to sea during vessel cargo transfers. An incorrectly retained spool piece and passing valves allowed flow through the flushing line; a grub screw restricted one valve’s closure. Recommendations address recorded cargo receipt confirmation, transfer-system configuration checks and updating planned maintenance.
- 2020Oct
Process Safety Fundamentals (IOGP Report 638)
Guidance introduces ten Process Safety Fundamentals for upstream operations, with downstream applicability also proposed. It addresses procedures, barriers, operating limits, isolation, ignition sources, change and unexpected conditions. Implementation guidance emphasises organisational engagement and coaching, supported by analysis of fatal and non-fatal process safety events and discussion of performance indicators.
- 202025 Aug
High potential near miss: Nitrogen hose failure during transfer of gas
A nitrogen transfer hose detached from its ferrule, releasing approximately 165,000 litres into a pipelay HPU room and reducing oxygen to approximately 17.4%. The degraded hose was absent from the hose register and maintenance regime. The flash recommends rated whip restraints and hose inspections, and records restricted-access signage and low-oxygen alarms.
- 202012 Jun
MSF: Water-based mud spill on deck
A mud-transfer hose separated from a vessel manifold at an offshore installation, spilling approximately 2,500 litres onto deck. Incompatible threads allowed corrosion to weaken the connection. The crew contained and recovered the mud without environmental loss. Actions address thread compatibility, planned maintenance and visual pre-use inspections.
- 202022 May
Sewage spilled onto the quayside
A vessel-to-truck sewage transfer spilled 30–40 litres onto a contained concrete quayside, without discharge to sea. Preliminary causes included an incorrect hose connection, an unchallenged unsafe condition, missing radio communication and an incomplete checklist. Actions addressed compatible connections, whip checks, equipment condition, radios and transfer checklists.
- 202013 May
Preventing Static Discharge
This alert describes static discharge contributing to offshore flash fires involving injuries and facility damage. It explains bonding and grounding, connection quality and the limitations of plastic containers. Recommendations address metal buckets, slow liquid discharge, grounded storage tanks, worker training and adherence to written procedures.
- 2020Apr
MAIB Safety Digest 1/2020
A collection of lessons from accidents involving merchant vessels, fishing boats and recreational craft. Cases examine distracted navigation, grounding, machinery fires, hazardous tank atmospheres, cargo handling and overboard emergencies. Discussions cover passage planning, maintenance, atmospheric testing, lifejacket performance and emergency drills, retaining uncertainty where accident causes remain unresolved.
- 2020Mar
March, 2020 - Vacuum Trucks can Catch Fire and Explode! — Process Safety Beacon, March 2020
This bulletin describes a vacuum truck explosion at a Californian wastewater facility involving incompatible substances, followed by fires and evacuations. It explains flammable vapour and static electricity hazards during vacuum collection, and highlights permit completion, material compatibility checks, grounding and bonding, and separation of vent discharge from ignition sources.
- 202030 Jan
Explosion and fire on-board the chemical tanker Stolt Groenland
This safety flash summarises preliminary MAIB findings on explosions and fire aboard Stolt Groenland during ship-to-ship styrene monomer transfer at Ulsan. Investigators considered deck rupture from over-pressurisation followed by vapour ignition the probable explosion mechanism. The incident caused extensive vessel damage and injuries to crew and firefighters.
- 201917 Dec
Midland Resource Recovery Explosion
This investigation examines two fatal explosions during draining of chemically treated gas odorizers at Midland Resource Recovery in West Virginia. It identifies failures to characterise vessel contents and manage reactive chemistry hazards, while leaving the exact reactions unresolved. The report discusses operating procedures, overpressure protection and gaps in regulatory coverage.
- 20192 Oct
Safety Alert 367 - Saturated Glycol Handling Leads to Fire
A production-platform fire followed unattended glycol reboiler start-up after an extended shut-in. BSEE attributed ignition to high water content and rapid heating, which flooded the still column and expelled fluids onto the stack. Recommendations for consideration address advanced training, attended start-up, circulation before heating and stack insulation.
- 201930 Sep
UK HSE prosecution following 2011 fatal explosion in oil refinery
This safety flash reports HSE prosecution following a fatal refinery explosion in Pembrokeshire during tank emptying with a vacuum tanker. Four workers died and another was seriously injured. Investigators considered ignition of a highly flammable tank atmosphere the most likely initiator and identified longstanding safety-management failures.
- 201924 Sep
Safety Alert 366 - Dangerous Levels Of H2S Detected At Offshore Facilities
BSEE describes three hydrogen sulphide releases during offshore pipeline flushing and well abandonment, including incidents at non-sour facilities. One worker experienced dizziness and nausea. The alert recommends considering gas monitoring, detector calibration and bump testing, job safety analysis, rescue preparedness and gas-buster safeguards during potentially hazardous operations.
- 201811 Apr
Tank Gauging Hazard Alert
This alert explains how opening storage-tank thief hatches can release concentrated hydrocarbon vapours, creating oxygen-deficient, toxic and flammable conditions. It addresses tank gauging, sampling and fluid handling, outlining exposure assessment, gas monitoring, worker training, remote or closed gauging arrangements, ventilation and stopping unsafe work.
- 201819 Mar
Accidental Mixing of Different Fuel Oils
A vessel at anchorage experienced accidental mixing of ultra low sulphur and heavy fuel oils after transfer valves remained open overnight. Gravity transfer contaminated the fuel. The flash identifies inadequate oversight and procedural compliance, describes sampling for laboratory analysis, and records renewed reference to procedures and their display near the operating panel.
- 2018Feb
Runaway Reactions Caused by Contamination — Process Safety Beacon, February 2018
This bulletin examines two explosions involving contaminated process materials: heated organic residue in pipework and crude methacrylic acid in a rail tank car. It explains reduced decomposition temperature, corrosion-related contamination and insufficient inhibitor, and recommends material identification, suitable construction materials, cleanliness and adherence to contamination-prevention procedures.
- 20183 Jan
MGPI Processing, Inc. Toxic Chemical Release
This case study investigates an incorrect sulfuric acid delivery connection to a sodium hypochlorite tank at MGPI in Atchison, Kansas, producing a chlorine-containing cloud. It examines unloading equipment design, pipe identification, procedure compliance, training, remote shutdown, control-room ventilation and escape respirator access, alongside community emergency planning and subsequent preventive changes.
- 2018
Fatalities in Oil and Gas Extraction (FOG) Special Topic Report 2018
NIOSH summarises eight fatalities and ten hospitalisations during 2015–2016 involving ignition, inhalation or suspected inhalation of hazardous gases and vapours during fluid handling at oil and gas sites. Tables distinguish exposures, fires and explosions, activities, fluids and reported outcomes, including cardiac deaths with possible work exposure.
- 201715 Dec
Bow thruster room flooded during fresh water transfer operation
Fresh-water transfer flooded a vessel’s bow thruster room through an unclosed sounding pipe after a cadet changed the tank filling sequence. The flash identifies inadequate risk assessment, absent crew discussion, neglected bilge alarm and failure to follow the emergency plan, with lessons on watch-keeping, handover and trainee supervision.
- 20177 Dec
Environmental Alert 003/2017
An environmental alert describes a chemical release to sea during storage-tank commissioning. A design–construction discrepancy left the overflow lower than expected; filling above it and subsequent syphoning caused the release. Duty holders should verify overflow positions and may prudently consider water first fills with robust monitoring where possible.
- 201721 Sep
Failure of pipework in fuel tanks
Seawater leaking from pipework running through a vessel’s fuel tank raised the tank level. Subsequent fuel transfer was followed by a separator trip, and checks found water in the system. The flash identifies pipework failure and highlights visual inspection and ultrasonic baseline thickness measurements.
- 201721 Sep
Property damage: Platform supply vessel collided with legs of jack-up rig
A platform supply vessel struck a jack-up rig leg after its starboard engine and thrusters tripped following water transfer, while the hose remained connected. The flash identifies fuel-oil pump seal failure and weather-side working contrary to procedures, and highlights simultaneous-operations risk assessment and planned maintenance.
- 201711 Aug
High potential near miss: failure of valve on gas bottle
A naval gas-bottle refilling near miss involved a valve expelled from a high-pressure cylinder, with the charging whip and valve remnant striking a wall. Analysis identified corrosion-induced cracking and material fatigue. The flash describes valve replacement, age tracking, whip securing, cleanliness procedures and consideration of further training.
- 201712 May
LTI: Contact with refrigerant gas causing hand injury
An engineer sustained severe freezing burns to both hands after inadvertently opening a valve while checking a vessel’s operating air-conditioning system. The flash examines ratchet direction, exposure to released refrigerant, inadequate task assessment and unsuitable gloves, and sets out actions concerning training, permits, discharge arrangements and prompt injury reporting.
- 201720 Apr
AirGas Facility Fatal Explosion
CSB investigates the fatal nitrous oxide explosion at Airgas in Cantonment, Florida, on 28 August 2016. Probable initiation involved transfer-pump heating during trailer loading, although the initiating event remains uncertain. Analysis examines flame arrestors, interlock design, pump changes and process safety management, alongside earlier explosions and recommendations for inherently safer design.
- 201728 Mar
Vessel activities near platforms – two incidents
Two vessel incidents near fixed platforms illustrate failures in fuel-system restoration and steering control. An AHTS vessel blacked out and drifted away after generators tripped; another vessel struck a flare bridge during personnel transfer following rudder feedback-unit failure. Actions address bunkering procedures, handovers, emergency-generator checks and communications.
- 2016Mar
Safety Device or Control Device? — Process Safety Beacon, March 2016
This bulletin distinguishes routine process control from independent safety protection through a steam-locomotive example and a tank-overflow incident. It explains how reassigned operator duties turned a backup shutdown into primary control, and recommends clear procedures, training, calibration and scheduled testing of safety devices.
- 2016Feb
Mechrecovery Man
User manual for a browser-based calculator estimating advancing skimming systems’ oil recovery potential for planning, rather than actual spill performance. It explains encounter, recovery and storage inputs, decanting and offloading assumptions, continuous and batch spill scenarios, worked comparisons and equations, including limits imposed by maximum effective swath.
- 201521 Oct
Caribbean Petroleum Corporation (CAPECO) Refinery Tank Explosion and Fire
Investigation of gasoline tank overfill at CAPECO’s petroleum terminal, followed by vapour-cloud ignition and multiple tank fires. It examines unreliable float-and-tape gauging, absent independent overfill safeguards, drainage valves, filling procedures and emergency preparedness. Comparisons with earlier incidents inform recommendations addressing regulatory gaps and automatic overfill protection.
- 201516 Jan
S92 helicopter pressure refuelling incident
This safety flash describes a near miss during helicopter pressure refuelling, circulated by Oil and Gas UK. An interruption to the aircraft’s fuel supply introduced a fuel–air mixture, closing tank vent valves. The resulting pressure build-up caused the sponson to rupture.
- 2015
Fatalities in Oil and Gas Extraction (FOG) Special Topic Report 2015
NIOSH summarises nine fatalities recorded during 2010–2014 involving crude oil tank gauging, sampling and fluid transfer at well sites. Case narratives examine possible petroleum vapour inhalation, oxygen displacement and reported medical findings. The report describes its surveillance sources and exclusions, while retaining uncertainty about contributing factors and unresolved causes of death.
- 20144 Apr
Oil spill incident
A vessel’s fuel delivery hose parted during transfer to a shore-side road tanker, spilling diesel onto the deck and into the sea. Investigators believed a closed receiving valve caused pressure to rise. Lessons address receiving-party readiness, connection certification and inspection, deck-opening protection and an operational remote pump stop.
- 201322 Oct
Unrecognized Hazard Results in Laceration to Leg
A derrickman emptying a rig’s brine tank subsequently flushed a hose and pump. Pressure accumulated in the choked hose, which slipped from his hand and swung into his leg. Despite prior planning, a permit and job safety analysis, he only recognised the nozzle’s cut after completing his shift.
- 201312 Sep
MSF: Bulk hose entanglement with Azi-pod propulsion unit
This safety flash describes a hose becoming entangled with an Azi-pod propulsion unit while preparing to supply water to a platform. The planned connection was at the starboard aft manifold. After crane lowering, the hose sank near the stern cut-away above the propulsion units.
- 20139 May
Near-miss: Failure of gas quad fitting
A gas-bank equalisation transfer in an ashore yard suffered a cracked, incorrectly specified low-pressure fitting failure. A fragment struck a nearby workshop wall, and inadequate whip checks allowed hose damage. No injuries occurred. Lessons address pressure ratings, thread awareness, training, risk assessment, hose restraint, restricted access and real-time pressure measurement.
- 201330 Jan
Vessel to Vessel Transfer Hose Whiplash Results in Fatality
An alert describes a fatal incident during base-oil transfer to an offshore drillship. A hose became tensioned during manifold connection, detached and whipped into a seaman, knocking him overboard. He was recovered by rescue boat with multiple injuries and evacuated by helicopter to hospital, where he died.
- 201229 Nov
Environmental Alert 002/2012
An FPSO crude offloading trip relaxed filter seals, allowing debris carried by backflow to contaminate the sealing surface. Restarting released crude onto deck after the bund overflowed, with potential for pollution at sea. The alert identifies absent surveillance and advises operators to review offloading systems and take necessary mitigating action.
- 2012Apr
What if you unload the wrong material into a tank? — Process Safety Beacon, April 2012
This bulletin describes a chemical delivery connected to the wrong storage tank, producing toxic gases and prompting evacuation and sheltering. It examines similar labels, identical connections, procedural changes and missing checks, and recommends clearer identification, connection verification, qualified workers and management of procedural changes.
- 201219 Jan
Malfunctioning Pump Results in 3rd Degree Burn Injury
An employee suffered third-degree burns from hot drilling fluid while disconnecting a clogged transfer-pump suction line. Although the pump had been switched off, pressure blew the hose off when the cam-lock connector was released. The crew had previously experienced unresolved suction-line clogging problems.
- 201127 Oct
Oil spill in port whilst discharging waste oil
This safety flash describes an oil spill during waste-oil discharge from a vessel to a barge in port. Pumping paused for a crew change, and the incoming engineer received assurances that discharge could resume. Failure to follow established procedures was considered a root cause.
- 201120 Sep
DuPont Belle Toxic Chemical Releases
Final investigation of methyl chloride, oleum and phosgene releases at DuPont’s Belle plant in January 2010, including a fatal phosgene exposure. It examines rupture-disc alarms, sample-line corrosion, PTFE transfer-hose failure and maintenance scheduling, supported by metallurgical testing and dispersion modelling. Recommendations address change management, hazard assessment and phosgene safeguards.
- 2011Jul
OCE15 - Potable water and legionella control
Guidance for offshore dutyholders on preventing potable-water contamination and legionella exposure. It addresses system design, temperature control, bunkering-hose hygiene, automated biocide dosing and scheduled water testing. Tank cleaning precautions, respiratory protection, chemical handling, maintenance records, dermatitis surveillance and worker training are also covered.
- 2011Mar
OCE10 - Chemical injection
Guidance for managing chemical exposure from offshore chemical injection systems. It addresses bunded storage, dedicated transfer lines, rated hoses, dry-release couplings and sequential calibration of pump heads. Operating procedures, maintenance, tank-level alarm checks, spill response and worker training are covered; breach of containment is outside its scope.
- 2011Mar
OCE24 - Cementing
Guidance for offshore well cementing addresses exposure to cement dust, wet cement and additives. It covers chemical storage, job planning, equipment checks and pressure testing, alongside respiratory and skin protection. Cleaning, decontamination, personal air monitoring, dermatitis surveillance and worker training support the recommended exposure controls.
- 201122 Feb
Safety Alert 292 - Synthetic Base Mud (SBM) Inadvertently Discharged Overboard
During mud-pit cleaning, 98 bbl of synthetic base mud was inadvertently discharged into Gulf waters. The alert identifies outdated schematics, mislabelled valves, crew unawareness of line alignment, inadequate supervisory checks and a generic job safety analysis. Recommendations address piping verification, task-specific responsibilities and consideration of lockout arrangements and operational training.
- 201127 Jan
Broken right hand index finger
A deckhand suffered a fractured index finger when a pressurised manifold cap was ejected during tank deballasting aboard a vessel. The flash examines an incorrect assumption about line readiness, a damaged Avery Hardoll connection and an absent non-return valve, emphasising procedural compliance and stopping work after abnormal conditions.
- 201021 Jul
Veolia Environmental Services Flammable Vapor Explosion and Fire
This CSB case study examines a solvent-recovery explosion and fire at Veolia’s West Carrollton facility that injured four workers and damaged neighbouring properties. It analyses atmospheric relief arrangements, occupied-building siting and emergency response. The initiating overpressure cause remained uncertain; recommendations address closed relief systems, hazard analysis and safer building separation.
- 201019 May
Assessment of the adequacy of venting arrangements for cargo oil tanks on FPSO and FSU installations
This HSE alert examines cargo oil tank venting on FPSO and FSU installations following a vapour ignition fire. It addresses changing hydrocarbon concentrations, dispersion during calm weather and nearby equipment effects. Duty holders should assess hazardous exposure and ignition risks, with possible controls including weather-related operational restrictions, re-inerting and vent modifications.
- 2009Sep
INDSPEC Chemical Corporation Oleum Release — INDSPEC Case Study
This case study analyses an oleum tank overflow at INDSPEC’s Petrolia facility, producing sulfuric acid mist and prompting community evacuation or shelter-in-place. It examines an alternative pump power supply that bypassed automatic shutdown, undocumented weekend practices and shortcomings in hazard analysis, change management, operating procedures and safeguard evaluation.
- 2009Sep
Overflow + Ignition = Tank Farm Fire! (Part 1) — Process Safety Beacon, September 2009
This bulletin describes a flammable-liquid storage tank overflow after both its level gauge and high-level alarm failed. An explosion and spreading fire followed, with a responding truck believed to provide ignition. It emphasises close transfer monitoring, capacity checks, procedural completion and prompt reporting and repair of failed instruments.
- 2009Aug
Never underestimate the hazard! — Process Safety Beacon, August 2009
A bulletin describes a fatal laboratory fire during transfer of approximately 2 oz. (60 ml) of t-Butyl Lithium, highlighting hazards from small chemical quantities. It stresses training for sampling, appropriate protective clothing and equipment, emergency equipment familiarity, suitable sample containers and carriers, and safe handover to qualified laboratory personnel.
- 2009Mar
Fatality caused by unloading the wrong chemical into a storage tank! — Process Safety Beacon, March 2009
A chemical delivery was directed to the wrong storage tank without checking the shipping papers. Mixing sodium hydrosulphide with ferrous sulphate generated toxic hydrogen sulphide, killing the driver. The bulletin stresses material identification, unloading procedures, personnel training and clear labelling, and suggests considering connections designed to hinder unloading mistakes.
- 2009Feb
More lessons from fire while filling containers — Process Safety Beacon, February 2009
This bulletin revisits a fire during ethyl acetate filling that spread to an adjacent warehouse. It examines inadequate fire separation and absent suppression, explains spill containment benefits without attributing this incident to containment failure, and recommends properly designed filling areas and change reviews for unusual operations.
- 2009Jan
Fire while filling portable container! — Process Safety Beacon, January 2009
This bulletin revisits a fire during ethyl acetate filling into a portable steel tote. It explains how free-falling liquid can generate static charge and recommends bottom filling or dip pipes, with initially restricted velocity. Further measures include bonding, earthing and hoses designed for flammable liquids.
- 2008Dec
Static Electric Discharge Causes Fire — Process Safety Beacon, December 2008
Describes a fire during ethyl acetate filling at a chemical distribution facility. Isolated metal nozzle components likely accumulated static charge and sparked to the tote, igniting vapour. Explains bonding and grounding, regular ground-connection checks and minimising liquid free fall when filling containers with flammable liquids.
- 2008Sep
Barton Solvents Flammable Liquid Explosion and Fire — Case Study
This case study examines a fire and explosions during ethyl acetate filling at Barton Solvents in Des Moines. Static discharge from unbonded metal components likely ignited vapour near a portable tank opening. It analyses nozzle and hose suitability, bonding and grounding, dip-pipe filling, and inadequate fire separation and suppression.
- 2008Sep
Little General Store Propane Explosion — Final Investigation Report
Investigation of a fatal propane explosion at a West Virginia convenience store during preparations for tank-to-tank transfer. The report examines withdrawal-valve failure, tank placement, inspection and audit weaknesses, technician training and delayed evacuation. Valve examination and flow testing support the analysis, supplemented by comparisons with five other propane incidents.
- 2008May
CAI / Arnel Chemical Plant Explosion — Final Investigation Report
Investigation of the CAI/Arnel explosion in Danvers, Massachusetts, examines solvent boiling in an unsealed heated mix tank and vapour accumulation after ventilation shutdown. It analyses operating safeguards, procedures and regulatory oversight, using laboratory testing and blast reconstruction. The ignition source remained unidentified; recommendations address safer indoor heating and hazard review.
- 2008Mar
Do your shutoff systems actually work? — Process Safety Beacon, March 2008
A chemical feed tank overflowed despite its high-level shutoff interlock because liquid downstream of the closed valve could still fill the tank. The bulletin explains the importance of valve location and switch height, and recommends testing complete safety systems rather than individual components.
- 200826 Feb
Fatality While Trying to Fill Up Casing
A crew filling casing to test the shoe used a rubber hose supplied by a high-pressure mud pump. A low standpipe connection trapped lost circulation material. Following absent nozzle flow and a 2,000 PSI pressure spike, the hose kicked upwards, striking workers; one died and four sustained non-life-threatening injuries.
- 200720 Dec
Failure of a high pressure gas charging hose
A high-pressure charging hose ruptured during gas decanting for a small-craft diving system. Recoil sheared the valve fitting anchoring its whip check, causing restrained flailing. Isolation prevented injury or further damage. The flash urges consideration of anchoring reviews, hose inspection, alternative restraint designs and service-life assessment.
- 2007Dec
Oil Tank Fire Caused by Static Discharge — Process Safety Beacon, December 2007
A floating-roof tank exploded and burned during diesel filling after previously containing petrol. The bulletin describes NTSB findings linking unsafe filling and content-change procedures to static ignition in a flammable vapour space. It highlights operating procedures, change review and filling-velocity limits until the fill pipe is sufficiently submerged.
- 2007Jul
Fire Caused by Hose Repaired with Duct Tape! — Process Safety Beacon, July 2007
A methanol transfer on an offshore oil platform led to fires on two decks after leakage from a split hose previously repaired with duct tape. One man sustained second-degree burns. The bulletin emphasises management of change for temporary repairs, equipment inspection before use and separation from ignition sources.
- 2007Jun
Emergency Shutdown Systems for Chlorine Transfer — Safety Bulletin
This bulletin contrasts chlorine transfer hose failures at DPC Enterprises and Honeywell, showing how emergency shutdown performance affected release consequences. It explains excess flow valve limitations, recommends reliable detection and isolation arrangements with periodic testing and maintenance, and examines regulatory gaps in chlorine railcar unloading.
- 200727 May
Mud Overflow Incident
This alert describes drilling fluid overflowing from a trip tank during filling. The driller moved on to another task without monitoring the incoming fluid. The overflow return line was unable to handle the fluid volume, and the tank subsequently overflowed.
- 2007Mar
Formosa Plastics Vinyl Chloride Explosion — Final Investigation Report
Investigation of the fatal vinyl chloride release, explosion and fire at an Illinois PVC plant. It examines reactor valve interlock bypassing, operator access to status information, safeguard assessment and missed learning from earlier incidents. Emergency procedures, training and deluge limitations underpin recommendations for stronger process safeguards and preparedness.
- 2007Feb
DPC Enterprises Glendale Chlorine Release — Final Investigation Report
Investigates a chlorine release during railcar-to-trailer transfer at DPC’s Glendale facility. Scrubber over-chlorination initiated bleach decomposition and prolonged toxic emissions. The report examines procedural safeguards, hazard analysis, operator training and emergency response, including police respiratory protection, and recommends stronger safeguards, revised procedures and independent auditing.
- 20061 Dec
Maintenance – Trapped Pressure
This alert describes nitrogen transfer between cylinders using partially filled cylinders to replenish others. After closing the cylinder valves, an assistant vented the line by loosening a connection with a wrench. A further nitrogen release during disconnection startled him; his head struck the cylinder rack, chipping a tooth.
- 200621 Nov
Flash fire in gas supply equipment onboard dive support vessel
An oxygen-decanting incident aboard a dive support vessel produced an explosion and flash fire, causing superficial burns and equipment damage. Investigation identified three equally likely possible causes without establishing a direct cause. Reported measures included replacement pipework and valves, a dedicated oxygen line, non-destructive testing, valve-opening signs and regular oxygen cleaning.
- 20069 Nov
Safety Alert 245 - Serious Fire Caused by Methanol Sprayed from Duct-Tape Repaired Hose
Methanol escaping from a split, duct-tape-repaired hose during gravity transfer ignited on two decks, causing one worker second-degree burns. Sunlight and barely visible combustion delayed recognition. The alert recommends checking transfer components, avoiding transfer above ignition sources, and establishing written procedures supported by pre-operation job safety analysis.
- 200630 Apr
Burns caused by release of steam and boiling water from overheated pump
During filling and pigging, a centrifugal pump overheated and water flashed to steam, raising pressure and violently separating its suction hose from the fitting. A nearby worker suffered second-degree leg burns. The company recommended evaluating procedures and piping systems for high-volume centrifugal pumps to ensure fitness for purpose.
- 200630 Apr
Isolation of fuel tanks
A vessel in dry dock accidentally received fuel in a tank prepared for hot work, spilling around seven cubic metres of marine diesel onto the dock. The flash examines ineffective isolation despite permits and lockout/tagout, and recommends blind flanging, recorded isolation tags and communication of open-tank status.
- 20062 Mar
Safety Alert 239 - Casing Bleed-down into Plastic Drum Results in Fire on Platform
An offshore platform fire began during casing-fluid bleed-down into a plastic drum. Investigators identified static electricity as a possible ignition source. The alert contrasts the drum with required grounded metal containers, describes fire-system failures and containment, and recommends reviewing relevant policies and stressing strict adherence.
- 20052 Sep
Labeling of Containers – Hazardous Material Incident
An employee decanted methanol into a plastic container labelled for drinking water and kept it in his truck’s side box. Having forgotten its contents, he drank from it the next day and received hospital treatment for methanol poisoning. The alert concerns hazardous material container labelling.
- 20051 Apr
Modified Equipment – Battery Leads
This alert presents an employee’s hazard identification observation rather than an injury or near miss. Modified vehicle-refuelling equipment used an extension cord to connect a 12-volt battery to a 12-volt DC fuel pump. The account highlights employee use of the rig’s HAZID system.
- 20043 Aug
H2S Inhalation: Man Fell from Tote Tank Resulting in an LTI
This alert describes hydrogen sulphide inhalation and a fall from a tote tank during waste-fluid transfer on deck. After hearing laboured breathing and losing radio contact, the engine room operator activated the emergency stop and checked the worker, finding him face down with visible signs of head injury.