Activity
Pressure Testing
Applying pressure to verify strength, integrity or leak tightness.
Newest 100 Documents
All 149 in search- 2026Feb
Well Workover
This regulatory inspection guide presents compliance questions for oil and gas well-workover operations. It covers prior approval, well-control fluid replenishment and measurement, crown-block safety checks, mud-pit level warnings, tubing and wellhead requirements, wireline leakage prevention, and pressure testing of newly installed lubricators against expected shut-in surface pressure.
- 2026Jan
D-PINCs (Operators Version - Jan 2026) — Drilling
A regulatory checklist for oil and gas drilling, linking numbered compliance questions to statutory authorities and enforcement actions. It addresses approvals, diverter configuration and testing, casing installation, cement placement, drilling-fluid management and monitoring. Further checks cover ventilation, gas detection, ignition prevention and retention of drilling and test records.
- 2026Jan
Decommissioning
A regulatory checklist for temporary and permanent well abandonment under Subpart Q. Questions cover prior approval, isolation of open-hole zones and perforated intervals, cement plugging, conditional pressure testing, plug integrity, residual fluid density and wellhead removal. It also checks installation of two independent wellbore barriers, including a mechanical barrier.
- 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.
- 202330 Nov
Yenkin-Majestic Resin Plant Vapor Cloud Explosion and Fire
Investigation of a fatal resin-plant explosion and fire following solvent vaporisation and release through an altered reactor manway. The report examines pressure-containment design, inadequate alteration assurance, agitator-dependent safeguards, alarm deficiencies and evacuation preparedness. Recommendations address low-pressure vessel guidance, safer process design and flame-resistant clothing.
- 202321 Nov
EI 158 Fatality Failure to Use Safety
An offshore worker died when surface casing failed during pressure testing supplied by a high-pressure well. The explosion involved pressure release without signs of ignition. BSEE identifies omitted pressure safeguards and deficiencies in planning and change management, and recommends operators consider equipment compatibility checks, gauge training and improved hazard assessment.
- 202330 Oct
Fire extinguisher fails during pressure testing
A 13-year-old, 5 kg CO2 fire extinguisher rated to 200 bar failed at 196 bar during a scheduled hydrostatic test intended to reach 300 bar. Nobody was harmed. The flash discusses ageing and integrity, alongside actions concerning maintenance reviews, age-sensitive testing plans, inspection records and personnel training.
- 202329 Aug
BSEE: Improper use and application of high-pressure hoses
An offshore inspection identified a hydraulic hose unsuitable for nitrogen during pressure safety valve testing. Injection of nitrogen at 2500 psi caused blistering and leakage. The flash summarises BSEE recommendations for operators and contractors to consider hose selection, fluid compatibility, inspection and replacement intervals, damaged-hose disposal, work permits and hazard communication.
- 202315 Aug
Caught between: Unplanned movement of equipment leads to severe injuries
A mechanic suffered severe injuries when moving hydraulic hoses tipped a three-tonne hose saddle towards a container door, trapping him. The flash examines instability, absent securing and shortcomings in change management and work coordination during maintenance. Actions address equipment stability, sea-fastening, work authorisation and toolbox participation.
- 202329 Jun
Improper Use High Pressure Hoses Leads to Injuries
An offshore inspection identified a hydraulic hose unsuitable for nitrogen service that blistered and leaked when pressurised to 2500 psi. The alert recommends considering hose selection, fluid compatibility, temperature, inspection and replacement intervals, alongside work permits, job safety analyses and communication of pressurised-hose hazards.
- 20234 Apr
Cut and bruise to right hand whilst pressure testing
A technician injured his right hand while removing a blanking flange after hydraulic hose pressure testing. Although the panel gauge indicated zero, a check valve trapped residual pressure. The flash recommends a ten-second delay after opening the main pressure valve, a second hose gauge, revised instructions and an updated task risk assessment.
- 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.
- 20239 Feb
Electrolytic corrosion: Failure of fire hose couplings
A fire hose coupling failed during annual pressure and leak testing aboard a vessel. Examination identified corrosion and seized floating flanges, with advanced deterioration also found at the opposite end. The flash recommends targeted coupling inspections, detailed planned maintenance and personnel briefings; brass may be preferred when replacement fittings are required.
- 202221 Dec
Dummy hot stab ejected during leak investigation
A pressure-test near miss involved an incompatible dummy hot stab ejecting from its receptacle while personnel stood nearby but outside the direct line of fire. The flash identifies missing retention, undocumented work controls and inadequate barriers, and recommends secure compatible fittings, safe-distance exclusion zones and depressurisation before investigating leaks.
- 20223 Oct
BSEE: Unsecured Pressurised Hoses Result in Hand Injuries
This safety flash summarises two hose incidents during coil tubing operations: valve impact injured a thumb during pressure release, and a failed nitrogen connection caused a whipping hose to injure two workers. Recommendations address glove selection, depressurisation, hose restraint, valve checks, job safety analysis and stop-work authority.
- 202229 Jul
Loy Lange Box Company Pressure Vessel Explosion
Investigation of a fatal steam-system pressure vessel explosion in St. Louis examines oxygen corrosion, incomplete repairs, water treatment and inspection failures. Metallurgical examination and thickness measurements underpin the findings. The report analyses regulatory oversight and process safety management, while noting that the pressure at rupture could not be determined.
- 20222 Jun
Unsecured Pressurized Hoses Result in Hand Injuries 442
BSEE describes two Gulf of Mexico coiled-tubing incidents involving hose backlash and a failed nitrogen hose fitting, with hand injuries and an additional arm injury. Operators and contractors are advised to consider hose restraint, reduced pressure before valve manipulation, suitable gloves, fuller job safety analyses and stop-work intervention.
- 202130 Apr
Blind Shear Door Blown Off BOP Body
A blind shear ram door blew off a blowout preventer during pressure testing at 109 bars, below the planned 570 bars. It was found on an adjacent equipment container. Earlier inspection and ram replacement involved opening the doors; anti-rotation bars were not engaged during reassembly.
- 202117 Mar
MSF: Air cylinder failure in lifeboat
A lifeboat air cylinder failed without warning, injuring three nearby crew members with blast debris. Investigation remained ongoing, with galvanic corrosion and prolonged submersion in bilge water identified as preliminary suspected causes. The correspondent recommends annual inspections for corrosion or wall damage and hydrostatic pressure testing at five-year intervals.
- 2021Feb
Failure of a road tanker pressure/vacuum relief valve
HSE safety alert describes a modified road-tanker relief valve that stuck open, releasing nitric acid vapour without injuries or property damage. A welded nut obstructed the valve stem. It calls for visual checks for unauthorised modifications, manufacturer-guided servicing and verification of both pressure and vacuum protection functions.
- 202119 Jan
Well Control - Issue 6
An offshore well-control inspection guide using questions, model answers and success criteria to assess operational arrangements. It examines conventional, high-pressure high-temperature and managed pressure drilling, including BOP assurance, kick detection, hydraulic modelling, fingerprinting, pressure relief, contingency procedures and crew training. Inspection scoring supports subsequent regulatory intervention planning.
- 202010 Dec
Entry to enclosed space on fishing vessel Sunbeam with loss of 1 life
Investigates a fatal tank entry aboard Sunbeam in Fraserburgh. Leaking refrigerant from corroded evaporator tubes displaced air in a refrigerated salt water tank. The report examines inadequate repairs, non-gastight isolation valves, normalised unsafe entry, absent atmospheric precautions, rescue arrangements and gaps in machinery survey oversight.
- 20209 Oct
Trapped Pressure Ejects Rod From Chamber and Strikes Subsea Technician in the Face
A subsea technician was injured when trapped pressure ejected a sheared indicator rod during blowout preventer pressure testing. Previously damaged rods had remained unrepaired, and a workaround omitted their hazard. BSEE recommends considering OEM maintenance, proper work procedures, avoiding out-of-service equipment and recognising trapped pressure in job safety analyses.
- 202028 Apr
Fire in engine room and subsequent collision with structure on transport barge
A tug suffered an engine-room fire after fuel oil escaped during pressure testing and ignited on hot engines. A blackout preceded collision with a structure protruding from the transport barge. The flash examines failed emergency and fire systems, permit shortcomings and recommendations for controlling non-standard work and improving crew familiarisation.
- 202019 Feb
UK HSE: Fatal injury following catastrophic failure of pressure test equipment
A worker suffered fatal shrapnel injuries when a test manifold failed during compressed-air leak testing of eight 1500-litre cylinders. HSE found that mineral oil-based corrosion inhibitor contaminated the manifold during venting and ignited under pressure. The flash highlights failure to identify additional risks when adapting work processes.
- 201918 Jun
High potential near miss: Person found unconscious in confined space
A commissioning engineer entered a gas valve unit during nitrogen pressure testing and collapsed. Entry proceeded without a confined-space permit, atmospheric test results or safety watch. Following rescue and CPR, the engineer recovered fully. The flash emphasises authorised entry, atmosphere testing, a safety watch, rescue planning and discussion with a supervisor.
- 201913 Feb
Enterprise Pascagoula Gas Plant Explosion and Fire
This case study examines the Pascagoula gas plant fires and explosions, identifying thermal fatigue in a brazed aluminium heat exchanger as the probable cause. It analyses repair history, blocked-layer venting, temperature monitoring and process safety management deficiencies, alongside emergency response and community notification. Two night-shift workers were uninjured.
- 201819 Sep
Well Integrity (Operate Phase)
Inspection guidance for assessing well integrity during operation through management-system document review and role-specific interviews. It examines barrier verification, annulus pressures, operating and load limits, maintenance, change management and end-of-life review. Optional risk-assessment scrutiny covers qualitative assessment, QRA and FMECA, while enforcement guidance links inspection findings to compliance scoring.
- 201811 Sep
Unintentional release of carbon dioxide from fixed fire-extinguishing systems on ro-ro vessels Eddystone and Red Eagle
Investigation of unintended carbon dioxide discharges on Eddystone and Red Eagle examines leaking cylinder valves, system activation arrangements and maintenance deficiencies. Neither incident harmed anyone. The report analyses leakage alarms, pressure protection, valve testing and servicing, and recommends design reviews and improved survey assurance of safety devices.
- 201823 Aug
High potential near miss: working on pressurised pipeline
A foam pig narrowly missed personnel after residual pressure ejected it during removal of a flexible jumper’s pull head. The flash identifies a closed vent valve, absent pressure confirmation and weaknesses in procedural sign-off and handover. Lessons emphasise verified ambient pressure, isolation, venting and supervision of safety-critical steps.
- 20182 Aug
Near-miss: Divers’ umbilical rupture during routine maintenance
A diver’s umbilical breathing hose ruptured at about 14 bar during scheduled pressure testing, before final test pressure was reached. Mechanical damage may have contributed. The flash highlights visual inspection before testing, designated test areas, personnel notification, appropriate PPE and careful umbilical handling.
- 20189 May
Corrosion cracking of strain-hardened type 304 stainless steel bolts
This flash describes stainless-steel bolt failure during pneumatic leak testing of offshore gas pipework, attributed to chloride-induced stress corrosion cracking at temperatures below 50°C. It explains strain-hardening susceptibility and recommends considering desktop identification, visual surveys, prioritised replacement and disposal of stored Type 304/304L fasteners.
- 2018May
Pipelines PINCs
Inspection questions for DOI-regulated offshore pipelines address pump protection, shutdown devices, pressure settings, riser protection and integrity testing. Items link checks to regulatory authorities and enforcement actions. The guide also covers conditional leak detection requirements and the isolation, preservation, removal and reporting of out-of-service pipelines.
- 20182 Mar
Loss of Containment (LoC) - Version 2 March 2018
Inspection guidance for assessing offshore oil and gas duty holders’ containment safeguards. It covers design, commissioning, operating limits, instrumented protection, relief, isolation, reinstatement and change management. Specialist sections address process hazards, FPSOs, tubing and hoses, alongside investigation, performance indicators, assurance and leadership.
- 201712 Dec
Worker suffers life changing injury after pressure test failure
During a boiler pressure test involving three companies, an overpressurised valve failed and a hose and metal fitting assembly struck a worker’s leg. Compound fractures led to amputation below the knee. The flash highlights absent pressure relief, an unsafe system of work and the importance of shared safety responsibilities.
- 201718 Oct
Safety Alert 325 - Bolt Failures
BSEE describes subsea connector bolt failures during a BOP high-pressure test, with leakage but no loss of well control or injury. Material suitability and heat treatment remained suspected causes under investigation. Recommendations address replacement of affected-lot bolts, material compliance, installation and maintenance procedures, and timely failure reporting.
- 201721 Mar
Near miss: Fire hazard arising from failed fuel pipe connection
A vessel in transit experienced smoke when a high-pressure fuel pipe coupling failed, releasing fuel onto hot engine components without a fire. The crew mustered, stopped the port engine and isolated its fuel supply. The flash discusses recurring piping failures and recommends checking similar systems, pressure testing and seal renewal during overhaul.
- 201628 Jun
Environmental Assessment
Final environmental assessment comparing regulatory alternatives for exploratory drilling in the Beaufort and Chukchi seas. It evaluates direct, indirect and cumulative effects of drilling-waste capture, well monitoring, source control, relief rigs and spill preparedness, balancing potential environmental benefits against additional operational disturbance and risks associated with more frequent BOP testing.
- 201620 Apr
Macondo Blowout and Explosion
Volume 3 examines human and organisational factors in the Macondo incident, including temporary abandonment, negative-test interpretation and riser gas handling. It analyses barrier assurance, change management, incident learning, process-safety indicators and corporate governance, contrasting written policies with operational practice and proposing improvements to major accident prevention.
- 201613 Apr
Fatality: Stored pressure release
A crewman suffered fatal injuries when a Techlok clamp released under high pressure during leak repair. The flash identifies incorrect removal methods, conflicting permit requirements, deficient mechanical isolation, procedural deviations and absent change management. It also highlights inexperienced personnel, inadequate shift handover and poor enforcement of earlier incident actions.
- 20167 Jan
High potential near-miss: Failure of both divers’ breathing air supply and dive stage recovery winch
A diving near miss involved entanglement with a submerged winch exhaust hose weight, restricting the diver’s breathing supply and stalling the recovery winch. Emergency gas and use of the clump weight winch enabled safe recovery. Corrective actions addressed hose positioning, weight attachment, umbilical testing and deck risk assessment.
- 201515 Dec
Hydraulic company sentenced after employee loses sight in one eye
A hydraulic pressure-testing incident left an employee blind in one eye after a connector failed and a pressurised hose struck his face. The flash reports prosecution and a fine, highlighting an unsegregated test zone, unsuitable and unmaintained test equipment, and failures in risk assessment and safe working arrangements.
- 20157 Oct
Fire on board ro-ro passenger ferry Dieppe Seaways resulting in 3 people injured
Investigation of a thermal oil heater fire aboard Dieppe Seaways at Dover. Weld-related stress caused coil failure, while a subsequent backdraught injured six crew and four firefighters, three seriously. The report examines inspection limitations, extinguishing systems, thermal imaging, joint firefighting command and cordon control.
- 201510 Feb
Environmental Assessment
Draft environmental assessment comparing proposed Arctic exploratory drilling rules with alternatives, including no action. It examines pollution prevention, blowout-preventer testing, well monitoring, containment equipment and relief-rig availability in the Beaufort and Chukchi Seas. Analysis considers potential spill consequences, marine wildlife, subsistence practices and additional operational effects.
- 201423 Sep
Hydraulic injection injury
An HSE safety alert describes a maintenance fitter’s fatal hydraulic injection injury during piling-rig track tensioning after a grease nipple detached. It explains pressure-driven tissue damage and fluid toxicity, recommends checking fittings and ensuring replacement compatibility, and stresses appropriate pressure-test precautions and immediate professional medical treatment.
- 20145 Jun
Macondo Volume 1 Final Report
Volume 1 examines the Macondo blowout during temporary abandonment aboard Deepwater Horizon. It explains deepwater drilling, cement barriers, drilling-fluid pressure and positive and negative pressure tests. The report describes inadequate barrier assurance, separator overload and drillpipe buckling that inhibited BOP sealing, followed by explosions, fire and fatal injuries.
- 2013Dec
Flooding incidents on twin rigged stern trawler Audacious and beam trawler Chloe T resulting in both vessels sinking
Combined investigation into the flooding and sinking of Audacious and Chloe T in 2012. Although precise causes remained unknown, seawater cooling pipework failure was considered likely. The report examines corrosion, survey records, bilge alarms, valve accessibility, pumping capacity, watertight closures, stability and contrasting crew abandonment responses.
- 20124 Sep
Near-miss: Cement tank hatch failure
A cement tank hatch failed during integrity testing at approximately 4 bar, rapidly releasing pressure. Nobody was in the cement room and no injuries occurred. Preliminary findings identified securing dogs replaced by oversized nuts, without proper documentation or management of change. A thorough investigation was continuing.
- 2012Apr
A guide to the Pipelines Safety Regulations 1996
Explains the Pipelines Safety Regulations 1996 across pipeline design, construction, operation, maintenance and decommissioning. Addresses operating limits, pressure testing, containment integrity and emergency shut-down valves, alongside additional duties for major accident hazard pipelines, including prevention documentation, notifications, safety management and emergency planning.
- 201217 Feb
Report - Montara investigation: Volume one
Volume one of an expert witness investigation into the Montara hydrocarbon release sets out the appointment, factual timeline and assessment framework. It examines well construction and suspension, cement isolation, barrier requirements, regulatory comparators and risk-management methods, introducing WAiT integrity assessment and documenting limitations in the supplied records.
- 201217 Feb
Report - Montara investigation: Volume two
The second volume of an expert witness investigation examines nine issues surrounding the Montara hydrocarbon release. It assesses cement volumes, slurry properties, over-displacement, casing-shoe testing and corrosion-cap handling. Documentary analysis considers well suspension, barrier adequacy and programme changes, with proposed improvements to verification, contingency procedures and risk assessment.
- 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.
- 2011Mar
OCE25 - Well servicing – chemical injection
This offshore COSHH sheet addresses chemical injection during well servicing and coiled tubing operations. It describes chemical exposure and nitrogen hazards, with guidance on planning, protective equipment, line testing, exposure monitoring and dermatitis surveillance. It also covers spill handling, waste disposal, decontamination, training and supervision.
- 2011Mar
OCE26 - Drilling waste treatment
This offshore information sheet addresses skin and respiratory exposure during drilling waste handling and treatment. It describes enclosed cuttings transport and storage, ventilation, skip shipment and injection-system checks, alongside cleaning, skin care, dermatitis surveillance, training and supervision. Recommendations support COSHH assessment and exposure reduction.
- 201024 Sep
Welding on a Truck Tire Rim Results in a Serious Injury
An alert describes welding repairs to a cracked truck wheel rim in a transport maintenance workshop. A newly mounted tyre was pressurised to 20–40 psi for weld testing, then leaking hub welds were repaired with pressure still inside. Minutes later, an explosion propelled the tyre to the roof, killing two people and injuring two.
- 200922 Dec
Fatality during pressure test
A nitrogen pressure test on a drilling rig caused a valve assembly to rotate as its relief valve vented, fatally striking a crew member checking an instrument. Lessons address exclusion zones, assessed access, remote monitoring and securing equipment against movement caused by escaping high-pressure gas.
- 200917 Aug
Pillar valve failure
A diver was injured when an emergency cylinder’s pillar valve separated under pressure and struck his helmet. Investigation identified incompatible imperial and metric threads, with valve mix-up after third-party hydrostatic testing considered the most likely cause. Actions addressed testing-agency processes, cylinder withdrawal, thread compatibility and hired-equipment acceptance.
- 2009May
Allied Terminals Fertilizer Tank Collapse — Allied Terminal Fertilizer Tank Collapse
Investigation of a fertiliser storage tank collapse at Allied Terminals that released about 2.1 million gallons and seriously injured two workers. The report examines defective welds, missing radiography, unsupported fill-level calculations, inspection practices and regulatory gaps, with recommendations for inspector training, verification and personnel exclusion during initial filling.
- 200928 Jan
Safety Alert 275 - Wellhead Damage Caused by Hurricane
Following Hurricane Ike, damaged flanged wellhead connections leaked, and one subsurface safety valve initially failed to isolate downhole pressure. The alert examines hurricane loading and failed supports, and recommends visual inspection before restarting wells, followed by isolation, repair and wellhead pressure testing where excessive loading is suspected.
- 20088 Dec
Safety Alert 274 - Wireline BOP and Lubricator Ejection into GOM
A wireline BOP and lubricator were ejected into the Gulf of Mexico during DX plug retrieval, severely injuring the operator’s face. The alert identifies omitted lubricator testing, inadequate pressure equalisation and an unsuitable pulling tool for a modified plug, alongside failures in job safety analysis, stop-work practice and management of change.
- 2008Nov
2008-054 Investigation of Loss of Well Control, South Pelto Block 10, Well No. 10, OCS-G02925, 14 February 2008, Gulf of Mexico off the Louisiana Coast..
Investigates natural-gas release during wireline scale removal and acid treatment at South Pelto Well No. 10. The panel identified ring-gasket corrosion, likely acceleration by acid treatment and an inoperable subsurface safety valve prolonging the event. It examines wellhead testing, integrity inspections and platform evacuation, recommending reviews of acid-operation policies and emergency plans.
- 2008Nov
2008-056 Investigation of Pipeline Leak, Pipeline Segment No. 4582, Main Pass Area Block 288, 23 June 2007, Gulf of Mexico, Off the Louisiana Coast
Investigates a crude-oil pipeline spill in the Gulf of Mexico on 23 June 2007, estimated at 187 barrels. Corrosion holes were attributed to inadequate cathodic protection and delayed corrective action. The report describes gas pressure testing, diver inspections, clamp repairs and decommissioning, recommending improved regulatory follow-up of overdue inspection submissions.
- 2008Oct
2008-049 Investigation of Blowout Eugene Island, Block 28 Well No. 4, OCS-G 05479, December 03, 2007, Gulf of Mexico, Off the Louisiana Coast.
Investigation of a workover blowout at Eugene Island Block 28, offshore Louisiana. Production tubing parted during pulling, allowing well pressure to eject tubing before preventers contained the annulus. Metallurgical examination identified fatigue cracking and flow-cut wall thinning. The report reviews barrier tests, work procedures and subsequent snubbing operations to kill the well.
- 2008Oct
2008-053 Investigation of Blowout, Main Pass Block 91 Platform A, OCS-G14576, August 23, 2007, Gulf of Mexico, Off the Louisiana Coast.
Investigation of a gas blowout at Main Pass Block 91 Platform A, followed by platform subsidence. The report examines sustained casing pressure, poor cement quality, diagnostic testing and procedural communication failures. It describes unsuccessful kill attempts and relief-well abandonment, while leaving the precise casing-failure mechanism unresolved and recommending abandonment of remaining wells.
- 200826 Mar
Dropped String – High Potential Incident Results from Pulling Against Closed BOP Pipe Rams
An alert describes drill pipe parting and dropping into a well while the final stands were being pulled against closed BOP top pipe rams. Following a leaking cement-plug and casing pressure test, the driller assisted with disconnecting cementing equipment before resuming pipe removal without opening the rams.
- 2007Oct
We Have Liftoff! — Process Safety Beacon, October 2007
A pneumatic pipe test pressurised a connected tank through a leaking block valve, causing bottom failure and lifting the tank onto the plant. The bulletin recommends positive isolation, adequate pressure relief, reviewing non-routine operations and keeping workers clear. Where possible, it favours hydrostatic testing because less energy can be released.
- 200724 Aug
Failure of welding on hyperbaric rescue chamber medical lock door assembly
A hyperbaric rescue chamber medical lock door displaced during pressure testing, seriously injuring an employee. Metallurgical examination identified corrosion and poor welding in the retaining bracket. The bracket had not been treated as load-bearing or critical and was excluded from routine inspection. The flash recommends thorough inspection of load-bearing dive-spread components.
- 20061 Oct
Release of Pressure Results in Laceration and Sutures
An alert describes a choke-manifold pressure test during which a test-hose leak was noticed at approximately 9,000 psi. A motorman disconnected quick-release couplings while the assistant driller was still opening a valve to bleed the line. Escaping pressurised water lacerated the left palm near the thumb, requiring four sutures.
- 2006Jun
Marcus Oil and Chemical Tank Explosion — Case Study
This case study examines the December 2004 explosion and fire at Marcus Oil’s Houston wax-processing facility. It analyses defective pressure-vessel alteration welds and oxygen contamination of the nitrogen system, alongside physical testing and regulatory gaps. Recommendations address vessel repair standards, overpressure protection and personnel training in inerting-system operation.
- 20061 Mar
Near Miss – Equipment Failure at 14,000 PSI
A near miss during pressure testing of a subsea stack’s choke and kill line caused property damage. Lock-ring threads stripped at 14,000 psi, transferring force to four studs, which failed and allowed a high-pressure hose to detach. Risk assessment had required barricading the hazard area before testing.
- 20061 Jan
Near-miss during connector pressure tests
A diver’s hydraulic fitting blew off during removal following a successful connector pressure test, despite a zero surface pressure reading. Trapped annulus pressure was reported; poppet failure was considered the most likely cause. The company proposed a tee and needle-valve check to confirm ambient pressure before hose disconnection.
- 2006
Testing regime for offshore TR-HVAC fire dampers & TR pressurisation requirements
Guidance for offshore duty holders on assuring temporary refuge HVAC fire-damper performance and maintaining protective pressurisation. It examines full-loop testing, closure indication and timing, detector arrangements, pressure-decay measurement and leakage inspection. Inspection findings inform recommendations on test frequency, access and maintenance records, with reference to relevant offshore regulations.
- 200531 May
Safety Alert 231 - Human Engineering Factors Result in Increasing Number of Riser Disconnects
This alert reviews accidental and emergency riser disconnects in deepwater operations, highlighting human error, hydraulic connection mistakes and station-keeping failures. It recommends reviewing existing requirements for deliberate sequential disconnection, protected controls and documented subsea function testing. An accompanying table summarises eleven events involving drilling and production risers.
- 20051 Apr
Starting air system incident
An explosion damaged a vessel’s starting-air system during management system trials. Investigation identified accumulated compressor lubricating oil and ignition through engine starting valves, with non-return valves and flame arrestors absent. The flash describes reinstatement testing and flushing, alongside longer-term commitments to filtration, maintenance review and protective-device design review.
- 20051 Mar
Transponder pressure relief system failure
Testing identified pressure-relief faults in two of three Kongsberg transponders. The attached manufacturer bulletin explains incorrect RPT valve assembly and provides dismantling, verification and repair procedures, including removal of an additional circlip. It addresses stored-pressure precautions and requires renewed pressure testing if the valve is moved.
- 20051 Jan
Personnel Hoisting Incident Results in a Fatality
A fatal personnel-hoisting incident occurred during pressure testing and adjustment of an upper Kelly cock. A floorhand wearing a fall-arrest harness was raised by winch to 12 metres above the rig floor. During lowering, he moved onto the derrick; he apparently disconnected, lost his grip and fell about 10 metres.
- 20041 Dec
Uncontrolled decompression of diving bell
A diving bell vented to surface from 175 fsw after the last man leaving accidentally kicked open an unsuitable quarter-turn valve. No injuries or equipment damage were reported. The flash discusses prior sealing problems, replacement with a small-bore needle valve, testing before vessel installation, familiarisation drills and cautious movement in confined spaces.
- 20043 Sep
Test Assembly Makeup Results in a Fatality
A fatal incident occurred during pressure testing on a rig. The top-drive connection was disconnected to align a torque tube key slot and close the lower IBOP. During reconnection, the tong bite broke, allowing the test assembly to rotate and strike the worker with its side outlet and lo-torque valve.
- 20037 May
Trapped Pressure Following Casing Test
A casing pressure test reached 1500 psi after cement and the float collar were drilled out using a mud motor. Pressure failed to bleed back through the motor. Opening the BOP subsequently expelled the rotary table’s inner bushings, despite an instruction to stand back. No injuries were reported.
- 20037 Mar
Failure of High Pressure Line Results in High Potential Serious Incident
During nitrogen pressure testing of a slick-line lubricator and connecting lines, a straight joint parted about one inch beyond a weld. Its safety chain slid off following the clean break. Personnel were clear and nobody was injured, although the alert identifies high injury potential.
- 200231 Oct
Safety Alert 205 - Blowout Results in Fatality and Injuries
An MMS alert describes a drilling blowout in which two men suffered hot-mud burns and one was lost during evacuation, presumed dead. Findings include a frozen safety valve, removed drill-pipe float and absent shear rams. Recommendations address backup valves, actuation and pressure testing, and reviews of pre-spud meetings and night-time illumination.
- 200116 Nov
Pressure Testing Fuel Hose Results in a Serious Injury
An alert describes serious head trauma to a crane operator struck by a fuel transfer hose during pressure testing before fuel transfer. Trapped air pressure escaped suddenly when a lock-type connector was unlatched to release pressure; no vent valve was used.
- 20005 May
Additional Serious Incidents with Mismatched Hammer Unions
This alert describes two drilling-industry incidents involving mismatched 1502 male and 602 female hammer-union components. One released a union and pressure sensor from a mud-pump discharge. During a surface-casing test, another union failed at 1300 psi, below the intended 1500 psi test pressure, striking and seriously injuring a service employee.
- 2000
MAIB Safety Digest 1/2000
A collection of marine accident accounts and lessons covering merchant vessels, fishing vessels and leisure craft. Cases examine passage planning, machinery failures, lifting, pressure testing, fatigue, flooding and stability. Discussions address communication, watertight closures, rest arrangements and casualty recovery, while retaining uncertainty where investigations could not establish mechanisms.
- 19991 Nov
Failure of a ½” BSP cap under pressure on well service work
A half-inch BSP cap apparently blew off a pressure-testing manifold on an offshore installation at approximately 1200psi water pressure. The missing cap left incomplete engagement and over-tightening as assumptions. Lessons emphasise fitting ratings, tightening procedures and limitations, and checking condition and thread cleanliness before use.
- 19991 May
Regen plumbing incident
A ten-year pressure test identified a cracked weld in regeneration plumbing aboard a vessel in dry dock. X-ray examination of the removed section showed unacceptable deterioration at the welded seam of stainless steel pipe. The contractor intended to replace all its regeneration plumbing with seamless tube.
- 1990Nov
The Public Inquiry into the Piper Alpha Disaster: Volume 1
Volume One of the public inquiry reconstructs the Piper Alpha disaster through witness testimony, experimental leak testing and explosion modelling. It attributes the initial condensate leak on a balance of probabilities to a non-leak-tight blind flange, and examines escalation, emergency systems, rescue, permit practices, management failures and regulatory inspections.
- 198919 Jul
Safety Alert 157 - Wireline Accident Involving the Formation of an Ice Plug in the Lubricator
An ice plug immobilised wireline tools in a lubricator. Bleeding pressure above the plug created a differential that propelled the plug and tools upwards, rupturing the lubricator. A subsurface safety valve shut in the well. The alert suggests retaining test pressure before opening the crown valve and using glycol in test fluid.
- 198511 Feb
Safety Alert 136 - Air Volume Tank Explosion
An offshore production-platform air volume tank failed when pressurised for sandblasting and painting, ejecting an end plate that struck a compressor. Inspection found incomplete weld penetration, flat rather than dished ends and extensive cracking. Despite earlier hydrostatic testing, failure occurred in service; the operator planned inspections and replacement of non-compliant vessels.
- 198415 Jun
Safety Alert 127 - Injury While Retesting Blowout Preventers
A threaded union connection failed at 4,800 psi during blowout preventer retesting after bonnet seal repair. The parted line struck a nearby employee, breaking his left shin. The operator cautioned personnel to keep away from test lines and was studying the feasibility of safety restraints.
- 197915 Nov
Safety Alert 89 - Blowout and Fire, 8 Fatalities
An offshore drilling blowout released gas through the mud system after drillpipe and standpipe valves could not be closed. Ignition killed eight men and destroyed the rig. The alert records prolonged well-control efforts and the operator’s planned expansion of pressure testing across mud-system equipment and piping.
- 19776 Dec
Safety Alert 69 - Blowout, Platform Loss
An offshore development well suffered a gas blowout during attempts to kill a deep saltwater flow. Gas jetting formed a seabed crater, undermining the platform legs; personnel evacuated safely before it toppled. The alert reviews drilling warning signs and planned casing-integrity checks, cement evaluation, well-control training and reassessment following operational deviations.
- 19775 May
Safety Alert 64 - Uncontrolled Gas Flow
An offshore drilling alert describes uncontrolled well gas flow after a safety-valve grease fitting failed during well-killing operations. A combustible atmosphere prompted evacuation; the well bridged two days later without injuries, fire or pollution. The operator replaced valve grease fittings with solid plugs and pressure-tested the valves.
- Undated
Emergency Disconnect During Completion Operations Releases Zinc Bromide
BSEE investigates a weather-related emergency disconnect during completion operations aboard Noble Stanley Lafosse in the Gulf of Mexico. A misaligned thruster compromised station keeping, while the well suspension procedure remained incomplete. Zinc bromide discharge was revised to approximately 420 barrels. The report examines failed barrier tests and subsequent thruster correction.
- Undated
Two Subsea Xylene Releases During Marco Polo Operations
BSEE investigates two subsea xylene releases associated with Marco Polo operations in January 2025. The first involved failed seals in an inline logic cap unsuitable for xylene service; the second followed an uncommunicated replacement delay caused by weather. Corrective actions included a suitably rated cap, revised isolation procedures and personnel retraining.
- Undated
Casing Weld Failure During Well Abandonment
Investigation of a casing weld failure during well abandonment. Reverse circulation following bit plugging led to casing rupture at recently welded seams. The report examines pressure testing, unchanged pump safety-device settings, inadequate job safety analysis and unapproved welding in place of cold cutting. No injuries or environmental spills occurred.
- Undated
02 - 17 - 2016 17:15 G14224 GB 216 Pollution
Investigates a zinc bromide release during permanent well abandonment at Garden Banks Block 216. Hess estimated 22 barrels entered offshore waters. Subsea vent safety valves left open were identified as the probable cause, with incomplete procedures and drawings possible contributors. An ROV required a different tool to close the valves fully.
- Undated
Crane Shock Loading During Tension-Packer Setting for Well Abandonment
BSEE investigates crane shock loading during tension-packer setting for well abandonment at Vermilion Block 371 platform A. Shear-ring failure reduced the crane load and stretched its boom cable. Findings address repeated shear-ring use, incorrect rating assumptions, an unsuitable job safety analysis and departure from crane operating requirements.
- Undated
Methanol and Well-Fluid Release from Valve During Well Flow-Back
Investigation of a methanol and well-fluid release from a compact valve on the Titan platform during Telemark well flow-back. Findings identify incorrect flange selection, uneven bolt torquing and failures to follow installation procedures. The report documents emergency shutdown, spill notification and subsequent valve inspection and pressure testing.
- Undated
Choke Hose Disconnection Released Synthetic-Base Mud During Testing and Flushing
An investigation examines a choke hose disconnection during testing and flushing on Ocean Star. A missing retaining pin allowed the main securing pin to disengage, releasing approximately 80 barrels of synthetic-base mud into the moon pool without recovery. The reason for the missing pin remained unknown; inspection frequency changed from weekly to daily.