Activity
Inspection and Maintenance
Inspection, servicing and maintenance of assets.
Newest 100 Documents
All 2,243 in search- 2026Sep
Shell Polymers Furnace Explosion and Fire — Furnace Explosion and Fire at Shell Polymers
Investigates the June 2025 furnace explosion and fire at Shell Polymers Monaca following coke-trap cleaning. Inadvertent opening of isolation valves allowed cracked gas to enter the firebox and ignite. The report examines reliance on administrative safeguards, safety instrumented system bypasses, alarm suppression and confusing valve interfaces, recommending engineered protection and improved interface design.
- 202612 Aug
Crane Failure Highlights Crane Inspection Gaps
Two platform crane incidents involved failed sheave bearings, a falling boom and a dropped cable and load block. Inspection gaps included omitted pin removal and inadequate lubrication checks. The alert recommends considering revised inspection criteria, scheduled inspections, training to recognise mechanical distress and lift planning around vessel interfaces.
- 202612 Aug
Improper Use of Hand Tools and Unplanned Deviations from Job Tasks Results in Injuries
Two construction workers sustained facial lacerations during bolt removal: one from an ejected pneumatic rivet-buster piston during troubleshooting, the other from reciprocating-saw kickback after changing tools and removing a face shield. The alert recommends considering pneumatic isolation, manufacturer instructions, job safety analysis updates and stopping work when tasks or protective equipment require reassessment.
- 202610 Aug
United States Steel Corporation Clairton Plant Coke Oven Explosion
Investigates the fatal Clairton coke works explosion during high-pressure water washing of a cast-iron isolation valve. Overpressurisation caused valve failure and a coke oven gas release. The report examines maintenance procedures, hazard assessment, occupied-building siting and process safety governance, supported by valve examination and causal analysis.
- 202621 Jul
Bio-Lab Inc. Conyers Fire and Chemical Release
Investigation of the Conyers chemical-storage warehouse fire and release examines sprinkler corrosion, water-triggered decomposition and emergency response. It identifies sprinkler component failure as the most likely initiating water source, analyses storage and ventilation shortcomings, and recommends corporate safeguards and broader reactive-hazard coverage. Supporting work includes AcciMap analysis and chemical testing.
- 20261 Jul
Inspect A2B Systems and Wire Rope Terminations to Prevent Crane Hazards
A lift boat crane incident involved a detached anti–two-block weight, corroded wire rope and falling components. Recoiling rope struck a nearby diver, causing minor injuries. The alert recommends considering termination maintenance, pre-use and periodic inspections, adjusted replacement intervals in corrosive environments, and competence assurance under API RP 2D.
- 20261 Jul
Mechanical Failure of LACT Pump Caused Fire
An offshore production facility fire followed LACT charge-pump misalignment after motor replacement. Excessive vibration loosened casing fasteners, allowing oil leakage; coupling failure caused further damage. The alert identifies omitted angular alignment and incorrect bolt torques, and recommends manufacturer-compliant installation, personnel training, review of post-installation surveillance and investigation of abnormal operation.
- 20261 Jul
Verify Riser Fin Retention Systems Before Prompts Riser-Handling Operations
Two thermoplastic fins detached during slick-riser handling, creating dropped-object near misses. Findings identified inadequate retention tension, omitted torque verification and 48-hour re-torque, deficient refurbishment and inconsistent checklists. BSEE recommends manufacturer-specified securing checks, design improvements, procedural discipline, vendor acceptance assurance and dropped-object risk assessment.
- 202618 Jun
Fall overboard from the crab potting vessel Amadeus (TH7) with the loss of 1 life
Investigation of a fatal fall overboard during manual crab-pot hauling on Amadeus in the North Sea. It examines low bulwark protection, biomechanical demands, almost certain significant fatigue, absent flotation and ineffective recovery arrangements. Findings address deficient safety management and regulatory oversight, with recommendations on fall prevention, handling assessment and work–rest monitoring.
- 20266 Jun
Poorly Maintained Crane Components Result in Multiple Personnel Injured During Transfers
Two offshore personnel-basket transfer incidents involved uncontrolled crane auxiliary-line descents and injuries. Investigations identified uncorrected component deficiencies in one case and inadequate hoist brake adjustment in the other. The alert recommends considering timely maintenance, loaded brake checks, wire-rope fouling checks, stop-work interventions, clearer transfer communications and verified medical evacuation arrangements.
- 202621 May
AW139 Tail Rotor Duplex Bearing Failure Discovered During Maintenance
AAIB investigates a tail rotor duplex bearing failure on AW139 G-CIMU, discovered during maintenance at Norwich Airport after offshore passenger operations. Forensic examination could not establish the initiating cause. Rig testing discounted removal damage, while flight-data analysis identified pedal-position trends. The report examines inspection limits, condition monitoring and critical-part regulatory assurance.
- 202614 May
Machinery damaged through improper maintenance technique
An offshore vessel audit identified a fuel oil purifier that failed to self-discharge. Investigation found incompatible component swaps and bowl damage from improper dismantling without specified tools. The flash highlights adherence to manufacturer instructions, compatible genuine parts, planned maintenance intervals, repair records and stop-work authority.
- 202614 May
MSF: Fast Rescue craft (FRC) washed overboard and lost at sea
An unexpected wave washed a vessel’s fast rescue craft overboard after driving it upwards against its davit. Worn, under-dimensioned lashings tore apart, and the hook arrangement suffered impact-related deformation. The flash describes subsequent recovery, enhanced securing inspections, possible additional heavy-weather lashings and planned replacement of lashing straps.
- 20266 May
Catastrophic engine failure and subsequent fire on board the site investigation vessel Kommandor Susan
Investigates a diesel generator failure and engine-room fire aboard Kommandor Susan during sea trials in the Firth of Forth. The report links premature bearing wear to substitute components and inappropriate extended service intervals, examines contractor oversight, and describes successful firefighting alongside emergency anchoring difficulties caused by dependence on electrical power.
- 2026May
GEC Type VMX High Voltage Switchgear (including GEC Alsthom, Alstom or Areva T&D)
HSE safety notice addresses partial discharge and vacuum interrupter integrity in legacy GEC VMX high-voltage switchgear. Following a disruptive circuit-breaker failure involving arcing and fire, it recommends checking applicable design modifications, maintenance records and substation environmental conditions, alongside discharge surveys, integrity testing and revised access risk assessments.
- 202628 Apr
BSEE Safety Alert 516 - BSEE Identifies Compressed Gas Cylinder Hazards During Risk-Based Inspections
Following reported cylinder-failure explosions, BSEE inspected 20 Gulf assets and identified gaps in cylinder marking knowledge, inspection programmes, maintenance and contractor assurance. The alert presents findings on storage, corrosion and recharging, and asks operators and contractors, where appropriate, to consider improved labelling, documented inspections, overpressure protection and training.
- 202628 Apr
Failure of moonpool railing system caused man overboard situation in moonpool
A degraded removable railing post failed when a crew member lost balance beside a moonpool. They caught a guidewire and were rescued with a boathook, sustaining a dislocated shoulder. The flash examines inspection omissions, unclear responsibilities and ineffective hazard follow-up, recommending secured barriers, preventive maintenance and pre-task assessment of barrier failure.
- 202627 Apr
Prevent Fires by Inspecting Cords, Plugs and Welding Leads Before Use
This alert reviews three incidents involving melting welding leads, flames at a cord connection and a tubing bender plug with a loose prong. It warns against applying water to potentially energised conductors and recommends that operators and contractors consider pre-use inspections, suitable electrical protection, hazard assessment and safety briefings.
- 202615 Apr
BSEE: Exterior Walkway separates from temporary living quarters, putting workers at risk
An offshore accommodation walkway detached while three workers stood outside their room; all remained safe. Temporary quarters had served for 23 years, with inadequate inspections and degraded tab welds. The flash presents BSEE recommendations for operators to consider long-term design needs, revised inspection programmes and non-destructive weld testing.
- 202615 Apr
Death of seafarer due to fall from crane cabin
A seafarer cleaning a cargo crane cabin on an anchored vessel fell 12 m to the deck and died. The investigation identified probable window seal failure following removal of protective grating. Possible corrosion and glass weakening are discussed, alongside lessons on barrier integrity, structural inspection, routine-task risk assessment and warning signage.
- 202615 Apr
UK HSE: electrician seriously injured on onshore wind farm
An electrician sustained life-changing injuries during substation maintenance at an onshore wind farm. The investigation identified departure from a prepared switching programme and inadequate checking and change approval processes. The flash highlights safe work systems, management of change, coordination of parallel tasks, electrical-work review and supervision.
- 20262 Apr
Foundering of the fishing vessel Freedom II (CN 111)
Investigation of Freedom II’s foundering off western Scotland identifies suction-pipe fatigue failure as the most likely flooding source. It examines overwhelmed and unavailable pumps, progressive flooding, seawater isolation, emergency preparedness and delayed distress alerting. All crew were recovered uninjured; actions already taken led to no new recommendations.
- 202631 Mar
Ageing assets and life extension
Guidance on managing ageing assets and extending facility life through lifecycle planning, performance monitoring and integrity assurance. It presents a plan-do-check-act self-assessment framework, ageing modes analysis, competence arrangements and independent verification. Regulatory duties and health and safety representative involvement are discussed, alongside a Northern Endeavour corrosion example.
- 202631 Mar
Hazard identification and risk assessment guidance note
Guidance for titleholders on assessing well integrity risks throughout the well lifecycle. It discusses subsurface assessment, independent design review, qualitative and quantitative analysis, FMECA, bow-tie methods and risk registers. Risk profiles inform monitoring and maintenance regimes, anomaly management, change assessment, and planning for well suspension and abandonment.
- 202631 Mar
Offshore Inspection Guide Electrical Power Systems
An inspection guide for assessing electrical power systems and duty holder compliance. It addresses generation, distribution, protection, portable equipment and safe electrical work, with condition-monitoring methods including partial-discharge analysis, thermography and insulating-oil assessment. Performance scoring supports regulatory intervention planning; ATEX equipment is excluded.
- 202631 Mar
Planning for proactive decommissioning
This information paper explains lifecycle planning for petroleum decommissioning, including progressive removal, permanent well abandonment and increasingly detailed permissioning submissions. It outlines regulatory expectations, alternative end states, long-lead procurement, continued maintenance and changing risk profiles, alongside environmental monitoring and completion reporting to demonstrate that obligations have been met.
- 202631 Mar
Well integrity control measures and performance standards guidance note
Guidance for developing and implementing well operation management plans addresses selection, assessment and assurance of well-integrity controls throughout the lifecycle. It explains links between risk assessment and measurable performance standards, periodic effectiveness reviews, functional testing, procedural assurance, contingency measures and relief-well planning, with quality checks for documented control performance.
- 202624 Mar
MSF: High potential near miss during FRC maintenance
During sling replacement aboard a vessel, a fast rescue craft slipped from its davit cradle. Two crew members jumped into the sea and were recovered unharmed. The flash describes inadequate securing, a failed bowsing-line carabiner and gaps in work planning, including missing procedures, risk assessment and permit authorisation.
- 202624 Mar
Person injured when pry bar slipped
A crew member fractured a right-hand knuckle after a pry bar slipped while refitting a dislodged vehicle track. The flash discusses circumstantial pressure from worsening weather, amendments to the job safety analysis and the possibility that impact gloves might have reduced injury severity without preventing it.
- 202617 Mar
Failure of A-frame fold-down platform
A hinged A-frame platform failed during sheave-block load checks aboard a vessel alongside for mobilisation, leaving a crew member suspended in their harness with minor injuries. The flash identifies missing cotter pins, hinge design flaws and galvanic corrosion, alongside omitted change management, scheduled maintenance and platform inspections.
- 202617 Mar
Unsafe handling of gas cylinders
A Chief Mate identified unsecured compressed gas cylinders on the quayside before planned gas cutting and welding during vessel maintenance. The flash discusses contractor awareness, perceived time pressure and unavailable securing arrangements, highlighting approved racks, restraint, contractor coordination and crew confidence to stop unsafe work.
- 202617 Mar
Working in a confined space without a Permit to Work
A safety walk-round identified crew removing pipes inside a sewage tank without a confined-space entry permit. Work was stopped and treated as a near miss. The flash examines assumptions arising from the tank’s clean appearance, missing entry safeguards and inadequate hazard identification, and stresses following procedures and confirming confined-space work with supervisors.
- 20263 Mar
BSEE: Falling corroded crane component results in near miss
A corroded crane boom cable runner fell approximately 16 m during maintenance on an offshore platform, landing approximately 6 m from personnel. The flash describes outstanding inspection repairs, incomplete hazard identification and absent barricades, with lessons on inactive equipment, dropped-object controls and workforce involvement in pre-job planning.
- 20263 Mar
Cook temporarily trapped in freezer
A vessel’s cook became trapped in a walk-in freezer when the unsecured door closed during adverse weather and the internal release button was inoperable following moisture ingress. Crew opened the door externally without injury. Actions included weekly maintenance inspections, greasing the release mechanism, revised entry procedures and crew training.
- 20263 Mar
Dropped object: falling shim plate while lowering A-frame
A shim plate fell 15 m onto a crane cabin roof while a vessel’s A-frame was being lowered. The unsecured plates had remained in place through dirt and corrosion. The flash examines earlier modification and maintenance, missing hazard analyses, subsequent securing, and checks for components affected by changing crane inclination.
- 2026Mar
Decontaminate Before Opening! — Process Safety Beacon, March 2026
A contractor suffered acid burns when residual hydrogen fluoride escaped during flange maintenance after incomplete piping decontamination. The bulletin examines missing drawings, vacuum and nitrogen purging, and reduced protective clothing. It stresses field verification of isolations, clearing trapped material and retaining full protection until piping is proven free of hazards.
- 2026Mar
Production PINCs
Numbered regulatory inspection questions address production safety systems, well barriers and casing-pressure diagnostics. Checks cover shutdown valve operation, gas and fire detection calibration, firewater pumps, pressure relief and protective devices on process equipment. Conditional approval requirements and specified testing intervals support inspection of production facilities and subsea components.
- 2026Mar
Shared G-PINCs (Mar 2026) — General
General regulatory inspection questions address facility identification, operational safety, approvals, incident reporting, engine safeguards and equipment marking. Welding and burning checks cover equipment condition, authorisation outside approved areas, fire-watch arrangements, gas surveillance and precautions around wells. Entries identify regulatory authorities and enforcement actions.
- 202626 Feb
Dow Louisiana Operations Explosions
Investigation of the Dow Plaquemine explosion examines work lights left inside a reflux drum during turnaround. Degraded light debris punctured a rupture disc, admitting ethylene oxide into air-containing relief piping. The report analyses vessel closure practices, loss of nitrogen inerting, inadequate monitoring and relief routing that enabled propagation into the drum.
- 202623 Feb
PEMEX Deer Park Chemical Release
CSB investigation of a fatal hydrogen sulphide release during refinery maintenance in Deer Park, Texas. Workers opened the wrong flange on active piping. The report examines equipment identification, permit scope and hold points, interacting maintenance operations, contractor reassignment and operational discipline, recommending clearer marking and work authorisation arrangements.
- 202613 Feb
BSEE: Miscommunication and trapped pressure causes injury during valve maintenance
An offshore valve-maintenance incident injured a worker when trapped gas pressure ejected a bonnet flange. This flash summarises BSEE findings on incomplete authorisation, inadequate isolation verification, miscommunication, unsafe scaffold use and omitted retaining nuts. Recommendations emphasise confirming zero stored energy, reviewing task assessments, following manufacturer instructions and considering two-person working.
- 202613 Feb
Missing protection – progressive wear on hydraulic hoses causes damage
An inspection identified hydraulic and fuel hoses rubbing against surrounding surfaces and sharp edges, with abrasion and missing insulation. The flash discusses routing clearance, securing, protective sleeves and routine inspection to address progressive wear and potential leaks, fire and machinery failure. It also highlights unsecured deck plates.
- 202613 Feb
Positive: damage to Fast Rescue Craft davit wire rope caught before failure
Routine checks revealed a fracture at the socket termination of a fast rescue craft davit wire rope before failure occurred. An authorised service provider inspected and repaired the rope. The flash emphasises monthly maintenance, checks before every use, attention to load-bearing components and discussion of defects during crew safety meetings.
- 202613 Feb
Small engine room fire – flammable object ignited
A small flammable foreign object ignited during post-drydock engine load testing. The crew stopped the engine, isolated fuel and extinguished the fire; nobody was injured. The flash identifies poor housekeeping and absent post-maintenance checks, emphasising machinery-space cleanliness, checks before load testing and regular emergency drills.
- 20266 Feb
BSEE Safety Alert 514 - Verify Megger Testing and Termination Prep to Prevent Seawater Pump Motor Fires
A seawater pump motor fire followed termination repairs. Findings identified insulation testing at a lower voltage than required, resistance below the work-pack threshold and inadequate semiconductor-layer preparation. BSEE recommends considering adherence to repair instructions, verification of test arrangements and results, correctly rated testers and worker understanding of resistance units.
- 20265 Feb
BSEE Safety Alert 513 - Exterior Walkway Separates from Temporary Living Quarters, Putting Workers at Risk
Three workers escaped harm when an offshore platform’s third-floor walkway detached from temporary living quarters used for 23 years. The alert examines inadequate welded support, corrosion, material fatigue and inspection weaknesses. BSEE recommends considering long-term use in design, revised inspection programmes and non-destructive testing alongside visual checks.
- 2026Feb
Pollution PINCs
This regulatory inspection guide presents pollution compliance questions with cited authorities and enforcement codes. It covers offshore discharges, well solids disposal, contaminant collection, sump operation and pollution inspections. Further checks address spill response equipment testing and monthly inspection, record keeping, and spill containment and drainage on artificial islands.
- 202629 Jan
Flooding and foundering of stern trawler Opportune (LK 209)
Investigation of Opportune’s foundering east of Lerwick following uncontrolled engine-room flooding. Seawater pipework failure was considered the most likely cause, but remained unconfirmed. The report examines pipework inspection, inaccessible sea inlet valves, lack of remote bilge-pump operation and flood preparedness. All eight crew were rescued uninjured from liferafts.
- 202622 Jan
Fall from a pilot ladder while attempting to board the cargo vessel Finnhawk from the pilot vessel Humber Saturn with loss of 1 life
Investigation of a fatal pilot boarding accident involving Finnhawk and Humber Saturn. A probable cardiac event preceded the fall, while recovery-platform failure left the injured pilot partially immersed for over 40 minutes. The report examines medical fitness assessment, hydraulic defects, maintenance, cold-water protection and rescue training.
- 202622 Jan
Petrol driven equipment left stored in an emergency generator room
A vessel safety round identified a petrol-containing snowblower stored in the emergency generator room, creating fire and explosion risks and obstructing access to critical equipment. The equipment was relocated. The flash recommends designated storage for flammables and keeping machinery spaces clear, with storage procedures and inspections identified for review.
- 202622 Jan
Some positive findings and good practices
This flash presents four positive marine safety observations: thorough safety-zone entry checks on a PSV, a fabricated mesh guard protecting an open mud-tank hatch during ventilation, simulator-based officer training in Papua New Guinea, and crew-led deck upkeep. It reinforces procedural discipline, hatch protection, competence development and maintenance beyond dry-dock schedules.
- 202615 Jan
Fatal injury to a deckhand following a chain failure on the scallop dredger Honeybourne III (PD905)
Investigation of a deckhand’s fatal injury aboard Honeybourne III after a quick-release chain failed and a towing block fell during fishing-gear retrieval. The report examines chain bending, wear, material properties, inspection competence and suspended-load exposure, supported by laboratory testing and finite element analysis. It records company actions and regulatory oversight deficiencies.
- 202612 Jan
NTSB: Engine room fire – put things back properly after maintenance
An IMCA flash summarises a fatal engine-room fire aboard a dredging vessel. NTSB attributed the probable cause to lubricating oil spraying from a generator and igniting off a nearby running engine after a plug was not reinstated. Lessons emphasise post-maintenance inspection, correct reassembly and local test starts where appropriate and practical.
- 2026Jan
Well Operations
An inspection guide presenting compliance questions for well operations under Subpart G, with regulatory authorities and enforcement codes. It covers casing and liner integrity, surface and subsea blowout preventer configuration, pressure and function testing, maintenance and records, alongside specific requirements for coiled tubing and snubbing systems.
- 20255 Dec
Falling Corroded Crane Component Results in Near Miss
A corroded crane boom cable runner fell approximately 50 feet during maintenance on an offshore platform, landing approximately 20 feet from personnel. The alert identifies uncompleted inspection repairs, incomplete hazard identification and absent barricading, and recommends considering improved job safety analysis, supervision and maintenance follow-through.
- 20254 Dec
BSEE Safety Alert - 510 - Blackout and Weather-Driven EDS Incidents Underscore the Need for Stronger Operational Discipline
This alert examines two emergency disconnects on a dynamically positioned drillship: a blackout during damper maintenance involving the wrong control panel, and loss of position during severe weather. Both resulted in pollution. Recommendations invite operators to consider clearer controls, competence verification, closed-loop communication and proactive weather-related operational adjustments.
- 20254 Dec
Fire hazard: missing splash tapes on fuel hose connections
This safety flash describes missing splash tapes on engine fuel hose connections in newly delivered and older vessels. It explains their role in preventing fuel spray reaching hot surfaces, identifies commissioning omissions and failures to reinstall tapes after maintenance, and stresses acceptance checks and restoration of safety details.
- 20254 Dec
Fire in the engine room – fuel spray fire
Fuel sprayed onto hot surfaces of a starboard main engine after maintenance left return-pipe bolts missing and protective barriers absent. Crew extinguished the fire without injuries or pollution, but water mist failed and shutdown actions were delayed. Lessons emphasise post-maintenance checks, splash protection and familiarity with emergency equipment.
- 20253 Dec
BSEE Safety Alert - 509 - Miscommunication and Trapped Pressure Causes Injury
An offshore contractor was injured when trapped gas pressure ejected a bonnet flange during control-valve maintenance. The alert identifies unverified isolation, missing authorisation, miscommunication, unsafe scaffold use and omitted retaining nuts. Recommendations address zero-energy verification, collaborative job safety analysis, operational support, fall protection and adherence to manufacturer procedures.
- 2025Dec
CHIRP Superyacht FEEDBACK 8 (December 2025)
Superyacht incident reports examine a failed mooring attachment, captain harassment, generator starter battery explosions, collision at anchor, unsafe pilot boarding arrangements, unprotected work aloft and defective life rafts. Commentary discusses battery capacity and ventilation, engineering handovers, equipment servicing and testing, reporting concerns and organisational safety culture.
- 2025Dec
Health Safety Insight 2025
Annual review of UK offshore energy health and safety, centred on 2024 performance with historical comparisons. It examines hydrocarbon releases, maintenance backlogs, injury trends, medical assessment outcomes and evacuations, including mental health. Offshore aviation analysis covers fleet utilisation, helicopter safety indicators and the inclusion of wind operations.
- 2025Dec
Office PINC List
An office compliance checklist pairs regulatory questions with cited authorities and enforcement codes. It covers operational approvals, structural records, financial security, well-control competence, spill preparedness, drilling and decommissioning. Further checks address pipeline maintenance and reporting, reservoir conservation, production measurement, and geological and geophysical permits and data submissions.
- 202517 Nov
Broken equipment repaired or replaced
Five cases describe defects affecting a dock firefighting pump, immersion suit zip, emergency exit handle, ventilation flap seals and lifejacket storage box hinges. Repairs, replacement and additional inspection arrangements restored readiness. The flash highlights potentially serious cumulative consequences of minor defects and suggests considering regular checks of safety equipment details.
- 202517 Nov
Condensation Hazard on Electrical Panel (440V)
An inspection found condensation dripping onto a 440V electrical panel in a vessel’s engine room. The flash explains how chilled surfaces above the panel and absent protective measures allowed water contact. It highlights potential electrical consequences, preventive design measures and regular checks beyond scheduled inspections.
- 20257 Nov
ATSB: Undocumented modification contributed to steam burns
An oil tanker maintenance team suffered burns when hot condensate escaped during steam valve bonnet removal. The ATSB found insufficient cooling time and an undocumented drain-line modification that likely weakened isolation. The flash highlights formal management of change, recording and assessing changes, adequate cooling and visual confirmation of isolation.
- 20257 Nov
Hull crack arising from vibration
An aluminium vessel continued operating despite propeller vibration, later developing a skeg crack and water ingress into the steering room. Crew fitted a cement box, and management required repairs. The flash highlights aluminium’s susceptibility to repetitive stress and urges investigation of changed or increased vibration.
- 2025Nov
PPE only works when you wear it correctly! — Process Safety Beacon, November 2025
This Beacon examines a California refinery release during pressure-gauge replacement, where ineffective isolation and absent respiratory protection increased harm from hydrogen sulphide exposure. It explains limitations of personal protective equipment and stresses task-specific procedural requirements, correct use, pre-use inspection and regular checks of condition and respirator cartridge expiry.
- 2025Nov
Water Management
Inspection guidance for assessing offshore dutyholders’ potable-water arrangements and legionella controls. It covers system-wide risk assessment, written control schemes, hose disinfection, biocide dosing and chemical and microbiological monitoring. Success criteria, performance scoring and enforcement expectations support inspectors’ judgements on legal compliance and occupational health protection.
- 202527 Oct
LTI: serious injury to thumb when pipe fell during maintenance
A vessel engineer sustained partial thumb amputation when a grey water pipe fell about 1.4 m during dismantling, trapping his thumb against a supporting clamp plate. The flash examines inadequate securing and hand positioning, recommending primary and secondary retention and a workplace culture that enables staff to challenge unsafe practices.
- 202527 Oct
On a more positive note…
Fleet visits identified positive safety practices, including an engaging bridge toolbox talk reinforcing stop-work authority before entry into a 500m zone. The flash highlights well-organised inspection and maintenance of life-saving equipment, advance preparation of firefighting clothing and boots, and the importance of regular drills and crew training for emergency readiness.
- 20252 Oct
Crane cab access platform collapsed
A vessel crane’s cab access platform collapsed as the operator climbed the ladder, causing a fall partially mitigated by its enclosure without injury. Hidden weld cracking and corrosion caused the failure. The flash questions inspection access, alternative testing and contractor oversight, and stresses surface preparation before repainting.
- 20252 Oct
Dropped object due to over-ridden limit switch
A vessel crane operator bypassed limit switches while raising the hook for an overboarding lift. A mini beacon struck the clump weight and fell to the deck; a restraint and sensor cable also parted. Nobody was injured. The flash examines knuckle-boom configuration, override decisions, safety-system verification and safer equipment design.
- 20252 Oct
Positive: Worn mooring lines spotted and replaced before they parted
Hourly inspections aboard a vessel alongside during strong winds identified a mooring rope close to breaking. The crew replaced it and placed wooden boards beneath ropes rubbing against a bridge structure. The flash highlights vigilance during adverse weather and proposes jetty protection to reduce rope friction.
- 20252 Oct
USCG: Lithium-Ion battery system installations
Summarises USCG advice following a lithium-ion battery bank fire on a passenger vessel caused by overheated, loosely crimped lugs. Discusses thermal runaway, toxic off-gases and suppression difficulties, alongside engineering review, battery management, condition inspections, maintenance, crew competence and fire drills. No injuries and minimal vessel damage were reported.
- 202525 Sep
Cuisine Solutions Ammonia Release
CSB investigates an ammonia refrigeration release at Cuisine Solutions in Sterling, Virginia, which injured workers during evacuation. Relief-valve testing and dispersion modelling examine overpressure, liquid aerosol and unsafe discharge. The initiating upset remains undetermined. Recommendations address relief-system assessment, process-data retention, ammonia alarms and emergency preparedness.
- 202518 Sep
Auxiliary engine room fire on board the ro-ro cargo ship Finnmaster
Investigation of Finnmaster’s auxiliary engine room fire during departure from Hull. Partial fuel injection pump coupling failure and leaking hot exhaust preceded fuel hose failure and ignition. The report examines defective emergency power, incomplete carbon dioxide suppression, maintenance and supplier assurance, system testing and crew response. No injuries were reported.
- 202517 Sep
SWL plate dropped from crane block
A safety flash describes a 0.9 kg SWL plate falling from an auxiliary hook block onto a vessel’s main deck, with its fall height unconfirmed. Suspected galvanic corrosion caused rivet failure. It highlights missed inspection hazards, undocumented fittings, checks of other plates and a brought-forward third-party DROPS inspection.
- 202517 Sep
UK HSE: oil company fined after serious failure of elevator
An IMCA safety flash describes three workers encountering water while descending in a lift on the FPF-1 platform for inspection work. They stopped the lift and returned safely without injury. Hardware failures, incorrect operating procedures and absent water alarms were identified; enforcement included a £300,000 fine and an improvement notice.
- 202517 Sep
Uncoordinated Emergency Shutdown due to pipe failure
A tanker cargo discharge stopped when a duty AB activated emergency shutdown after observing a minor leak, without coordinating with the cargo control room. Copper tubing had failed through vibration fatigue. The flash describes revised shutdown procedures, coordination training and periodic vibration risk assessments, with tubing dampers or supports under consideration.
- 202511 Sep
BSEE Safety Alert 507 - Improper Use of Equipment and Tools Increases Risk of Fires and Explosions Offshore
BSEE identifies recurring offshore tool misuse involving live electrical circuits, explosive atmospheres and high-pressure or high-temperature systems. Cases include unsuitable hand tools and a plumber’s plug used during welding. Recommendations address competence evaluation, tool ratings and tracking, maintenance, pre-work audits, qualified inspections and authority to halt unsafe work.
- 20254 Sep
BSEE: Electromagnetic lifting device dropped steel plate
This safety flash summarises a BSEE incident in which a steel plate detached from a worn magnetic lifting device, fell approximately 1.2 m and injured two workers’ feet. It discusses inadequate task hazard analysis and stop-work culture, alongside recommendations for inspections, load testing, power stability and electromagnetic lifter operating procedures.
- 20254 Sep
MSF: Grease gun hand injury
A crew member suffered a grease injection injury through a glove while disconnecting a battery-powered grease gun hose during tensioner maintenance. The flash reports a malfunctioning pressure release valve and possible handling and training shortcomings. Lessons emphasise manufacturer instructions, pre-use hose and nipple inspections, suitable gloves and consideration of safer tools.
- 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.
- 202514 Aug
Brazil: diver permanently disabled after decompression illness
A Brazilian diver suffered permanent disability following decompression illness after underwater inspection and maintenance at 26 m. The flash describes a malfunctioning hyperbaric chamber, delayed treatment elsewhere, and deficiencies in emergency planning, transport and communication. It highlights related IMCA guidance on therapeutic deck decompression chamber operations.
- 202514 Aug
Head Injury in Engine Room
A Chief Engineer suffered a head laceration after striking a sharp lighting protection grille rod in an engine room. The grille stood 168 cm above deck and had unprotected ends. The flash discusses overlooked installation hazards, absent head protection, and considering hazard hunts, design changes, padding, marking and reminders.
- 202514 Aug
Injury sustained while operating steel lifting magnet
A crew member suffered a cheek cut requiring fifteen stitches when a steel lifting magnet’s spring-loaded lever recoiled during adjustment. The flash also describes an earlier chin injury involving the same magnet. It examines lever accessibility, maintenance gaps and faded warnings, recommending regular inspection, fault reporting and equipment suitability evaluation.
- 202511 Aug
BSEE Safety Alert 505 - BSEE Risk-Based Inspections Reveal Increase in Slip-Trip-Fall Hazards on Offshore Facilities Inspections
BSEE reports findings from a Performance-Based Risk Inspection of 19 offshore assets following an increase in slip, trip and fall injuries. Findings address training gaps, obstructed walkways, sharp edges, simultaneous operations, safety boots and faded markings. Recommendations invite operators and contractors, where appropriate, to consider improved hazard checks, housekeeping, training and footwear maintenance.
- 20251 Aug
BSEE Safety Alert - 504 - Malfunction of Rental Generator's Engine Air Shutoff System
A rental generator fire on an offshore platform followed a closed right-bank air flap, allowing unburnt diesel and excess oil to accumulate and ignite with heat from the operating left bank. The alert recommends considering improved maintenance checks, alarm verification, training and procurement assurance, including independent testing of each emergency air flap.
- 202531 Jul
Near miss: High voltage arc inside tether termination manifold
A dislodged HPU conductor caused arcing inside an ROV tether termination manifold. Subsequent checks identified reduced insulation resistance and gas, whose origin was unconfirmed without testing. The flash examines unapproved termination lugs and records re-termination, system testing and recommendations to assess crimping tools and review procedures and gas-venting precautions.
- 20259 Jul
Hose Recoil Strikes Banksman
During scheduled replacement of a potable-water bulk hose on a MODU, a crane lifted one end while the hydraulic reel paid out the hose for deck coiling and backload. The hose separated within a ferrule near the lifting point, recoiled towards the bulk loading station and struck the banksman.
- 20253 Jul
High potential incident: Worker injured when opening a flanged assembly
A worker dismantling emergency shutdown valves on deck sustained a forehead wound when trapped line pressure expelled a gasket. The flash identifies missing pressure checks and monitoring after isolation, alongside water ingress during subsea diving work. Actions included supervised pre-start checks, pressure-checking and venting hold points, and closer line monitoring.
- 20253 Jul
LTI: Hand injury during capstan maintenance
A crew member suffered a serious hand injury while greasing a vessel capstan when rotation trapped his hand between an underside wire clamp and the deck. The flash examines difficult access and grease-gun design, describing grease-point extensions, clamp removal, revised maintenance procedures and wider inspections for line-of-fire hazards.
- 20253 Jul
Unsafe use of electrical equipment in cabins
Crew aboard a vessel used two-pin chargers directly in three-pin accommodation sockets without suitable adaptors. This flash explains potential socket damage, loose connections, arcing, overheating and fire. It recommends compatible adaptors, crew guidance on plug compatibility, regular socket checks, appliance testing and tagging, and easier reporting of concerns.
- 2025Jul
Hydrocarbon Active Fire Protection
An inspection guide for offshore hydrocarbon fire protection, setting out regulatory expectations, success criteria and dutyholder scoring. It examines firewater pumps, ring mains, deluge coverage and chemical dosing, with emphasis on corrosion, marine growth, system availability, as-found testing and investigation of recurring blockages.
- 202520 Jun
BSEE Safety Alert 503 - Personnel Burned by Fire due to Improper Venting of Gas Starters on Engines
BSEE describes two flash fires during attempts to start gas engines driving pipeline pumps. Improperly secured or absent starter exhaust piping allowed gas to accumulate before backfires ignited it, burning workers. Recommendations address safe exhaust routing, component checks, training, startup and maintenance procedures, gas detectors and consideration of temporary fire watches.
- 202519 Jun
Fatal accident on the beam trawler Cornishman with loss of 1 life
Investigation material examines the fatal failure of Cornishman’s trawl quick-release chain, including corrosion, side loading and material properties. Technical annexes document magnetic particle inspection, metallography, hardness and break-load testing. Recommendations address inspection, fabrication quality and consideration of alternative release designs; an annex discusses the separate Honeybourne III accident.
- 202518 Jun
BSEE: Umbilical termination failure leads to dropped ROV
An ROV dropped to the seafloor during recovery when its umbilical parted at the cursor rail transition. Faulty resin casing and improperly arranged armoured strands compromised the attachment despite a previous successful pull test. BSEE recommends termination inspection procedures, re-termination training and pre-job connection checks. No personnel harm or seabed asset damage occurred.
- 202518 Jun
Dropped object hazard: access hatch to the communication dome
A scheduled mast inspection identified a detached communication-dome hatch. Its primary securing mechanism had failed, while an undersized secondary lanyard used adhesive pads that detached. The flash recommends mechanically fixed, appropriately rated secondary retention, anti-loosening measures, planned maintenance and procedural double checks after work.
- 202518 Jun
Lock out/Tag out and unauthorised electrical connections/disconnections
This flash describes missing electrical and mechanical lockouts identified during a vessel engine-room audit, alongside unauthorised electrical disconnections and bypasses. It emphasises suitable lockout devices, documented approval of temporary modifications, restoration checks and clear handovers. Possible links to dynamic positioning trials are presented as assumptions rather than established causes.
- 202518 Jun
MAIB: Is your Lead-Acid battery safe?
A barge crew member escaped injury when four lead-acid batteries exploded during generator starting. The steel locker contained the explosion. Investigation identified batteries unsuitable for continuous float charging. The flash highlights documented maintenance and replacement records, ventilated battery stowage and corrosion-resistant, flame/explosion-proof compartment lighting.