Equipment
Pressure Vessel
Containers designed to hold fluids at pressure.
Newest 100 Documents
All 118 in search- 202627 May
Givaudan Sense Colour Explosion
Investigation of a fatal reactor explosion during caramel colouring manufacture in Louisville. A vent valve failed closed, accelerating sugar decomposition; cooling and emergency pressure relief capacity were inadequate. Calorimetry and component testing inform findings on reactive hazards, process safety implementation, operating limits, occupied-building siting and regulatory coverage gaps.
- 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.
- 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.
- 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.
- 202531 Jul
Dive chamber procedures and operations
A chamber operator began venting an outer lock while a diver remained inside following surface decompression diving. Recompression and treatment for omitted decompression followed; the diver remained asymptomatic. The flash examines assumptions, poor visibility and missing transfer checks, stressing diver signals and operator and supervisor verification before venting.
- 202527 May
Honeywell Geismar Chlorine and Hydrogen Fluoride Releases
Investigation of three releases at Honeywell Geismar’s HFC-245fa unit between 2021 and 2024, involving fatal HF exposure, a corrosion-driven reboiler explosion and serious injury during gasket replacement. The report examines mechanical integrity, startup procedures, protective equipment, organisational change and capital funding, recommending independent auditing and safer-technologies analysis.
- 20244 Sep
BSEE Safety Alert 488 - Flash Fires During Welding Operations
A flash fire and blast during nozzle tack welding on a fuel gas scrubber propelled a tied-off welder against a rail without injury. Subsequent flammability readings ranged from 0 to 70% LEL. BSEE recommends considering improved atmospheric checks, ventilation, hot-work protocols, supervision, training and protective equipment.
- 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.
- 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.
- 202327 Nov
Failure of proportional valve in saturation chamber control
A proportional valve feedback fault interrupted saturation diving, without injury or equipment damage. Automatic safeguards isolated the line and transferred control to a manual valve. Unauthorised dismantling obscured the origin of potentiometer damage; debris was also found. Lessons address manufacturer-led maintenance, critical spares, training and testing before diving resumes.
- 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.
- 20236 Jul
Optima Belle Explosion and Fire
An interim CSB investigation update describes a fatal dryer explosion during trial dehydration of sodium dichloroisocyanurate dihydrate at Optima Belle in West Virginia. It outlines vacuum drying, steam heating, sampling and temperature changes, alongside decomposition hazards. Explosion debris caused a neighbouring methanol pipeline fire; the initiating conditions remain under investigation.
- 202229 Dec
Husky Energy Superior Refinery Explosion and Fire
Investigation of the Superior refinery explosion during fluid catalytic cracking shutdown. It examines air entering hydrocarbon equipment, missing steam-barrier and purge safeguards, eroded slide valves, procedural and training deficiencies, and brittle vessel fragmentation. Debris punctured an asphalt tank, escalating the event into fire; recommendations address transient-operation safeguards and emergency preparedness.
- 202221 Dec
Kuraray Pasadena Release and Fire
Investigation of an ethylene release and fire during reactor startup at Kuraray’s Pasadena plant, injuring 23 workers. It examines unsafe atmospheric pressure-relief discharge, disabled interlocks, alarm flooding, conflicting operating instructions and restricted flare use. Recommendations address safe discharge design, worker exclusion, operating limits, training and independent process safety assessment.
- 202211 Oct
Philadelphia Energy Solutions (PES) Refinery Fire and Explosions
Investigates the PES refinery fire and explosions following corrosion-induced rupture of an elbow in its hydrofluoric acid alkylation unit. Examines material composition, inspection coverage, vessel failure, unavailable remote isolation and impaired water-spray mitigation. Contrasts successful rapid acid deinventory with failed safeguards and assesses alternative alkylation technologies and regulatory recommendations.
- 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.
- 202231 May
Surface decompression near-miss
A surface decompression near-miss involved an unintended chamber depth reduction from 12msw to 5msw following a SURDO2 dive. Divers remained symptom-free. The account identifies an incompletely closed exhaust valve and supervisor distraction, and describes revised operating responsibilities, venting and depth alarms, and camera monitoring.
- 20219 Jun
Fatality – explosive failure of corroded fire extinguisher
A condemned, corroded cartridge-type dry powder extinguisher ruptured during discharge, striking a person and causing fatal head injuries. The flash describes inadequate appreciation of the danger and job planning, and sets out inspection, moisture-reducing mounting, qualified disposal and handling measures. It also suggests considering stored-pressure alternatives.
- 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.
- 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.
- 201823 Aug
Near miss: unplanned release of 2″ blasting hose outlet from air receiver coupling clamp
A near miss during onshore blasting and painting involved a 2″ hose separating at an improperly tightened Chicago connector. Its restraint arrested the hose, but released energy overturned an air receiver standing unstably on sand. The flash recommends stable footings, connection inspections, restraints and assessment of safer connectors and protective barriers.
- 2018Aug
What if your agitator fails? — Process Safety Beacon, August 2018
This bulletin examines a German batch-reactor incident in which restarting agitation mixed accumulated reactants, rapidly raising temperature and releasing contents through a relief valve. It explains mixing and heat-transfer hazards, including in non-reacting vessels, and recommends obtaining technical assistance and reviewing operating history before restarting an agitator after loss of agitation.
- 2018Jul
Can overcooling a reactor cause a runaway reaction? — Process Safety Beacon, July 2018
This bulletin examines a British dye-factory reactor explosion following overheating, cooling below the required range and resumed reactant addition. It explains how low temperatures can allow reactants to accumulate, increasing vulnerability to runaway reactions. Laboratory studies and simulations suggested another heat source might also have been necessary in this incident.
- 201619 Oct
Williams Olefins Plant Explosion and Fire
CSB case study examines the fatal Williams Geismar reboiler rupture, BLEVE and fire. It analyses likely liquid thermal expansion in standby equipment lacking effective pressure relief, alongside shortcomings in change management, hazard analysis and operating procedures. Metallurgical testing, finite element analysis and process modelling inform the failure assessment and recommendations.
- 20166 May
Failure of fire extinguishers owing to corrosion
A safety flash describes a near miss found during mobilisation inspections of a relatively new fire extinguisher. Corrosion at the brass fitting and aluminium stem connection caused the stem to fall apart when touched. The cylinder showed no corrosion. The notice highlights dissimilar-metal corrosion in pressure vessels.
- 201628 Jan
West Fertilizer Explosion and Fire
Investigation of the West, Texas fertiliser facility fire and explosion, which killed 15 people and injured more than 260. The report examines ammonium nitrate detonation scenarios, storage construction, emergency planning, firefighter training, regulatory gaps and community siting. Laboratory analysis, damage surveys and seismic evidence inform findings while the precise detonation sequence remains uncertain.
- 20143 Oct
MSF: Near-miss incident involving dry bulk pressure system
This safety flash describes a near miss during live testing of a pressurised dry bulk cargo system aboard a vessel. A stop-work intervention occurred without injury or damage. Inadequate work control was identified as the root cause, with poor communication between engine-room and bridge staff contributing.
- 201416 Jun
Pressure vessel systems – response to fatal accident
This safety flash relays Australian maritime authority information about a fatal pressure-system accident aboard a ship. A compressed-air receiver drainage pot’s observation glass failed catastrophically while an engineer drained condensate from the main air reservoir. The brief account refers readers to the authority for further information.
- 20141 May
Tesoro Anacortes Refinery Fatal Explosion and Fire
Investigation of the Tesoro Anacortes refinery heat-exchanger rupture that killed seven employees. Metallurgical analysis identified high temperature hydrogen attack in carbon steel. Process modelling, inspection limitations and Nelson curves are examined alongside hazardous startup practices, ineffective safeguards, safety culture and regulatory gaps. Recommendations emphasise inherently safer materials and verified operating conditions.
- 2014May
Key Programme 4 (KP4) Report
HSE reports findings from its 2011–2013 ageing and life-extension inspection programme for offshore installations. It examines structural, process, marine and pipeline integrity, equipment obsolescence and organisational arrangements. Recommendations emphasise forward planning, performance-data trending and assurance, supported by dutyholder case studies covering structural monitoring, gap analysis and hydrocarbon leak reduction.
- 201421 Jan
Internal Explosion Ruptures Crown Mounted Compensator Piping
An alert describes ignition during pressure equalisation between composite air pressure vessels on a crown mounted compensator. Adiabatic compression heat or air-transfer static was identified as the ignition source. Rising pressure and temperature ruptured connecting pipework, leaving two employees with non-life-threatening injuries requiring shore-based treatment.
- 2014
Safety of pressure systems
Approved Code of Practice and guidance explaining duties under the Pressure Systems Safety Regulations 2000. It addresses stored-energy hazards, system design, safe operating limits, written examination schemes, competent-person examinations, protective-device testing, maintenance and records. Conditional exceptions and the distinction between examination and maintenance are also explained.
- 201314 Nov
NDK Crystal Inc. Explosion with Offsite Fatality
This investigation examines a crystal-production pressure-vessel rupture in Belvidere, Illinois, which killed a truck driver off site. It identifies stress corrosion cracking as the likely failure mechanism and considers possible embrittlement. The report analyses coating protection, missed internal inspections, vessel design, regulatory oversight and facility siting.
- 201330 Jan
Diving decompression chambers – not fit for purpose
This safety flash relays an OGP warning about air decompression chambers found to present serious safety hazards during verification audits. The supplied page gives no details of the defects, affected locations or corrective measures, and states that the underlying report is available from IOGP on request.
- 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.
- 2012Jul
Machinery failure on passenger/freight ro-ro ferry Pride of Calais resulting in contact with berth
Investigates Pride of Calais’s contact with a berth at Calais following propulsion loss on 22 October 2011. Compressor defects reduced control air pressure, disengaging the main engine clutches. The report examines fault diagnosis, maintenance, bridge–engine room communication and emergency check cards, recommending more realistic machinery breakdown drills.
- 201125 Nov
Person injured by parts ejected under pressure
This brief IMCA flash relays a BOEMRE account of a ruptured water pressure tank bladder. A fitting was expelled under pressure during removal, injuring an employee’s face. It directs readers to BOEMRE Safety Alert #297 for further information, without detailing preventive measures.
- 201129 Sep
Safety Alert 297 - Potable Water Pressure Tank Bladder Rupture
An employee suffered severe facial injuries when a fitting was ejected during troubleshooting of a platform’s potable-water pressure tank. Although the water lines had been depressurised, the internal bladder retained its manufacturer pre-charge. The alert recommends task-specific job safety analysis and access to manufacturer instructions before installation, operation or servicing.
- 2011Jul
OCE16 - Bulk sampling
Guidance for offshore personnel collecting process-fluid, well-fluid and fuel samples under COSHH. It describes pressure-rated sampling cylinders, valve sequences, safe venting, protective gloves and spill management. Maintenance, personal benzene monitoring to establish control effectiveness, dermatitis checks, training and supervision support the recommended exposure controls.
- 201120 Jan
Bayer CropScience Pesticide Waste Tank Explosion
Investigation of a fatal residue-treater explosion during restart of Bayer’s methomyl unit at Institute, West Virginia. It examines runaway decomposition, bypassed interlocks, deficient startup preparation, operator training and emergency coordination. Detailed modelling assesses the adjacent methyl isocyanate tank’s blast shield, distinguishing actual damage from hypothetical release scenarios.
- 2011
Stainless steels - chloride stress corrosion cracking report 2011
Research report examining chloride stress corrosion cracking in austenitic stainless steel through reactor assessments and a literature review. It proposes risk-based inspection refinements, compares penetrant, eddy current and ultrasonic techniques, and evaluates structural fitness for service. The report highlights uncertainty in crack initiation times and limitations of leakage as an indicator.
- 2009Nov
BLEVE! — Process Safety Beacon, November 2009
Explains boiling liquid expanding vapour explosions using the 1984 Mexico City LPG terminal disaster. Describes rapid vaporisation following vessel failure, projectile hazards and fire-induced weakening below design pressure. Highlights working water-spray protection, firefighting procedures and reporting defective safeguards, while noting that the accident’s initiating cause was not definitively established.
- 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.
- 20095 Mar
Crushed finger
A diver suffered crush injuries to two fingers when a chamber door swung against another during a rough-weather vessel transit. The flash identifies inadequate spring tension, securing arrangements and risk assessment, and asks members to consider assessing door movements, testing latches and following diving chamber transit procedures.
- 200826 Nov
Failure of Back Flow Valve During Nitrogen Foam Frac Results in a Fatality
This alert describes a fatal incident during a two-stage nitrogen foam fracturing treatment using four manifolded nitrogen pumps. During attempts to restore pump prime at the start of the second stage, gas backflow entered a storage vessel. Insufficient relief capacity led to catastrophic overpressurisation.
- 200823 Sep
Safety Alert 266 - Trouble Shooting Production Platform Upset Problems
A platform flash fire followed separator level-safety malfunction, condensate carry-over and wind-blown hydrocarbon mist reaching hot generator exhaust piping. The alert recommends troubleshooting upstream level set points, cleaning sight glasses, monitoring flare-scrubber accumulation and minimising disabled safety devices during restart. Flare-piping relocation may be required to avoid ignition sources.
- 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.
- 2008Jul
Valero McKee Refinery Propane Fire — Valero Refinery Propane Fire
Investigation of the propane fire at Valero’s McKee refinery in Sunray, Texas. It examines likely freeze-related failure of an unused piping dead-leg, subsequent release and fire escalation. Analysis covers management of change, hazard-analysis deficiencies, remote isolation, structural fireproofing and exposure of nearby chlorine containers and a butane sphere.
- 200830 Apr
Safety Alert 261 - Manually Operated Drains
An inadvertently opened heater-treater drain released approximately one barrel of oil into the Gulf of Mexico. Drain pipework bypassed water-treatment equipment following removal of a polishing unit from service. The alert recommends routing pressure-vessel drains through water/sand treatment and implementing management of change for offshore production-equipment modifications.
- 200819 Mar
DDC chamber viewport catastrophic failure
This safety flash describes a deck chamber viewport softened by radiant heat from a nearby droplight, allowing the chamber to vent to atmospheric pressure. It warns that fluorescent lamps can also overheat viewports and requires assessment of bulb heat and sufficient separation to prevent heat build-up.
- 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.
- 200714 Aug
Failure of chamber door spindles and seals
Two successive leaks at chamber-door spindle seals interrupted pressurisation on a diving support vessel following maintenance. Inspection found almost 70% of spindles unserviceable through sealing-area surface damage or bent shafts. The flash recommends identifying spindles and seals as critical components and including their inspection and replacement in planned maintenance.
- 200731 Jul
Synthron Chemical Explosion — Synthron Case Study
This case study examines a runaway acrylic polymerisation reaction and vapour cloud explosion at Synthron in North Carolina, killing one worker and injuring 14. It analyses recipe changes, inadequate reactor safeguards, condenser fouling, manway securing practices, training and corporate oversight, and identifies lessons for reactive hazard management and emergency evacuation.
- 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.
- 200622 Jun
Trapped pressure release incident
During saturation-system commissioning aboard a diving support vessel, a diver operated toilet valves out of sequence after assuming pressure was absent. A closed external valve left pressure trapped in the holding cylinder. Its release back-flushed raw sewage into the transfer chamber, covering the diver and fracturing the toilet seat.
- 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.
- 2005Sep
After Katrina: Special Precautions Needed During Oil and Chemical Facility Startup — In Wake of Hurricane Katrina, CSB Issues Safety Bulletin Urging Oil and Chemical Facilities to Take Special Safety Precautions During Startups
This CSB bulletin addresses safe restarting of refineries and chemical plants after Hurricane Katrina. It emphasises established startup procedures, management of change, staffing and training. Equipment checks cover flood and wind damage to tanks, pressure vessels, motors and instrumentation, including ground-fault testing and infrared scans when equipment is energised.
- 2005Aug
Honeywell Chemical Incidents — Final Investigation Report
Investigates three chemical incidents at Honeywell’s Baton Rouge plant involving chlorine, contaminated antimony pentachloride and hydrogen fluoride. Examines cooler inspection, control-room protection, shutdown isolation, cylinder identification and nonroutine draining. Findings address incomplete hazard analyses and departures from procedures, with recommendations on change management, testing, training and protective equipment.
- 20051 Jun
Dropped Accumulator Bottle Results in a Fatality
A rig manager collecting freight from a third-party distributor was fatally injured when an accumulator bottle exploded after striking a concrete pad edge. The bottle is believed to have fallen from a pallet as a forklift reversed away from a trailer. The manager stood approximately 25 feet (7.5 metres) from the trailer.
- 20058 Mar
Safety Alert 227 - Explosion and Fire on Platform Caused by Improper Welding and Burning Practice
An offshore platform maintenance alert describes switching from a cold-cut saw to a cutting torch without updating the job safety analysis. MMS attributed the resulting explosion and small fire to torch sparks igniting an air–hydrocarbon mixture. Recommendations address job preparation, revised task analysis, approved hot-work practices and protection or inerting of equipment.
- 20052 Mar
Incident involving Cameron high pressure accumulator (follow up to safety flash 03/05 item 7)
This interim safety flash follows an earlier notice concerning a Cameron high-pressure accumulator incident. The investigation remains ongoing, with a revision promised on completion. Pending that revision, maintenance involving accumulator disassembly must not proceed without prior contact with a Cameron representative or the named contact for further information.
- 2005Mar
Accidental release of vinyl chloride monomer from liquid gas carrier Coral Acropora exposing at least 33 people to vapours
MAIB investigates a vinyl chloride monomer release aboard Coral Acropora at Runcorn during preparation for cargo discharge. Pump-assisted sampling transferred cargo between tanks, with open valves and overridden safeguards contributing to over-pressurisation. The report examines segregation, alarm overrides, sampling precautions, ship–shore coordination and emergency arrangements.
- 20041 Oct
Uncontrolled decompression during gangway move
A gangway struck a hyperbaric chamber fitting during raising, causing uncontrolled decompression of a man-way trunk and adjacent entry lock. Four divers were in saturation; no injuries were reported. Initial findings identified an unprotected fitting and door misalignment. Recommendations address impact protection, door alignment and management of proposed modifications.
- 2004Mar
D.D. Williamson & Co. Catastrophic Vessel Failure — Final Investigation Report
CSB investigates a fatal spray dryer feed tank explosion and subsequent aqua ammonia release at DDW. The tank most likely failed through overheating and excessive pressure. Analysis examines missing pressure relief, vessel certification, equipment changes, inadequate hazard evaluation and operating guidance, with recommendations for safeguards and operator training.
- 2003Oct
First Chemical Corp. Reactive Chemical Explosion — Final Investigation Report
Investigates the First Chemical Corporation explosion in Pascagoula, where mononitrotoluene decomposed in an idle distillation column. Valve leakage sustained heating despite apparent isolation. Chemical testing and equipment examination informed findings on reactive hazard evaluation, alarms, overpressure protection, isolation practices, control-room vulnerability and community notification.
- 200315 Jul
Safety Alert 214 - Flash Fire and Explosion from Inadequately Vented Production Vessel
A confined-space sampling operation in a low-pressure separator resulted in a flash explosion, injuring four workers and blowing one off the platform into the water. The alert identifies inadequate ventilation and incomplete gas-detector deployment, and recommends procedural confirmation, hatchway hazard awareness, flotation-device readiness and review of guard barriers.
- 2002Jun
BP Amoco Thermal Decomposition Incident — Final Investigation Report
Investigates the fatal opening of a pressurised polymer catch tank at BP Amoco’s Augusta plastics facility. Retained molten polymer generated gas while solidified material obstructed venting. The report examines reactive-hazard evaluation, overfilling, unreliable isolation and indications, procedural changes and incident learning, supported by reconstruction and thermal testing.
- 200117 Dec
BOP Control System Uncontrolled Pressure Release Causes LTI
An alert describes an uncontrolled pressure release while three rig personnel removed a nitrogen accumulator bottle from a twelve-bottle manifold bank using a chain tong. The bottle blew upwards, and the tong apparently struck the driller’s face and head, causing severe injuries. The bottle then fell onto him.
- 19986 May
Stored Energy Hazards
A rig worker suffered serious injury when a top drive accumulator end cap blew off and struck him during removal. He was assisting another employee and did not know that the nitrogen pre-charge remained active. Pressure had not been bled off before the cap was removed.
- 198529 May
Safety Alert 139 - Pollution from Production Operations Due to Rupture Disc Failure
An offshore production alert describes a two-barrel oil spill after a fluid surge and downstream orifice restriction overpressurised a chem-electric heater treater. Its rupture disc failed before high-pressure shutdown activated. The operator subsequently disabled the disc outlet and resized two pressure safety valves to accommodate maximum emergency liquid discharge rates.
- 198521 Mar
Safety Alert 137 - Personal Injury During Well Test
A roustabout suffered severe facial injuries when a fire-water hose ruptured during test-separator cleaning on a gas-producing platform. Restoring pneumatic supply opened valves, admitting well flow and discharge back pressure. The alert describes job-specific safety meetings, checking isolation-valve settings and disconnecting pneumatic pressure lines under specified conditions.
- 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.
- 198431 Jul
Safety Alert 128 - Platform Fire
An OCS platform fire followed condensate carry-over through production equipment to an atmospheric tank, where spray reached a compressor exhaust. The alert describes an isolated separator shutdown sensor and a disconnected tank drain. It recommends relocating relief discharge, reinforcing out-of-service tagging and conducting thorough inspections at the start of each tour.
- 19833 Oct
Safety Alert 117 - Fatality While Testing Gas Turbine Meter
A production employee suffered fatal abdominal injuries when a gas turbine meter assembly blew off during preparations for a spin test. The alert reports an apparent failure to isolate and depressurise the test separator. The operator recommends upstream and downstream block valves with an intervening blowdown valve to simplify isolation and bleeding.
- 19828 Jun
Safety Alert 107 - Fire
A Gulf of Mexico platform fire followed bolt removal from a separator flange during sand flushing. The separator had been isolated but not depressurised; escaping natural gas ignited from an unknown source. One man was injured and buildings and equipment were damaged. The operator planned written precautions for production personnel.
- 198018 Jan
Safety Alert 94 - Pig Trap Ruptures
An offshore pipeline pig trap ruptured during dewatering after a second pig passed through a reopened riser valve, producing severe hydraulic hammer and gas escape. No personnel injuries or other property damage occurred. Future installations would incorporate a trap-side dewatering point and use only one non-metallic wiper pig.
- 19786 Oct
Safety Alert 76 - Injury, Glass Liquid Level Gauge Ruptures
A worker suffered severe injuries and lost an eye when a separator’s glass level gauge shattered during return to service after cleaning. The separator operated above the gauge’s rated pressure. The alert specifies suitable component ratings, side-on pressurisation, safety glasses, armoured gauges, protective guards and instruction on gauge construction.
- 19779 Nov
Safety Alert 68 - Explosion
Two service-company workers were injured when an engine air volume chamber exploded on an offshore production platform after gas well pressure was used instead of compressed air. The operator prohibited this starting method and stated that operations would stop until suitable engine-starting equipment was available.
- 197711 Mar
Safety Alert 59 - Compressor Explosion
An offshore compressor explosion followed rupture-disc failure and air entering a compressor that continued running. The alert identifies possible gas-surge causes, reports extensive compressor damage without injuries, fire or pollution, and describes changes to fuel shutdown, relief valves and isolation of out-of-service pressure vessels.
- 197222 Sep
Safety Alert 1 - Flash Fire from Liquid Phase Heat Transfer Unit
A platform restart led to a flash fire after heat-transfer fluid overheated while circulating pumps were stopped and the burner valve remained operating. Pressure expansion ruptured the expansion tank. The alert recommends secondary relief with monthly and pre-start testing, burner–pump controls, pressure-rated expansion vessels and continuously operating heat sensors.
- Undated
Platform Fire Following Oil Release from Heater Treater Sight Glass
Investigates a fire on Ship Shoal 266-A after oil escaped from a heater treater sight glass and ignited at a pipeline pump exhaust. Missing ball checks allowed continued discharge. The report describes unsuccessful firefighting, evacuation and rescue of four crew members, and recommendations concerning sight glass assemblies and facility design.
- Undated
Oil Spill from Heater-Treater Drain Valve During Cleaning
An investigation into an offshore oil spill found that a cleaning crew inadvertently opened a heater-treater drain valve, releasing approximately one barrel into the Gulf of Mexico. Drain rerouting bypassed water treatment after a polishing unit was removed from service. Recommendations address discharge treatment, process-flow review and management of change.
- Undated
Oil Discharge Through Produced-Water Outlet During Emulsion-Breaker Trial
BSEE investigates pollution at Na Kika during an emulsion-breaker trial. Foaming disrupted separation and level readings, allowing oil discharge through the submerged produced-water outlet. Estimates put the release at approximately 89 barrels of oil and grease. Findings address inadequate training and delayed detection; reverting to the original chemical ended the sheening.
- Undated
Reboiler Fire Following Glycol and Condensate Leakage
This investigation describes a reboiler fire discovered after employees responded to a filter-separator alarm. Internal corrosion was identified as the probable cause, with glycol and condensate leaking through a weld pinhole. Personnel extinguished the flame using a handheld extinguisher and potable-water hose; insulation was burnt or melted.
- Undated
Platform Heater-Treater Fire and Fire Tube Corrosion
Investigation of a heater-treater fire on South Pelto 23-D examines thermo-galvanic corrosion of fire tubes, acidic produced water and surface scales. Personnel extinguished the fire without injuries or evacuation. The report records planned cathodic protection, coating and chemical changes, reduced operating temperature, inspections and sharing of lessons.
- Undated
Platform Fire During Well Unloading
Investigation of a fire on Eugene Island 261 A platform during well unloading. Completion-fluid carry-over, a recurring header leak and compressor blowdown overloaded the vent system. Wind carried discharged hydrocarbons onto hot exhaust surfaces. Recommendations address scrubber design, automatic liquid drainage and restriction of compressor blowdown surges.
- Undated
Heater-Treater Fire Fed by Oil Through Pitted Fire Tube
Investigation of a heater-treater fire at Vermillion 369-A on 18 April 2014. Acid batch treatments caused or accelerated fire-tube pitting, allowing produced oil to feed the fire after burner gas isolation. The report identifies failure to inspect following earlier warnings and describes manual shutdown and successful extinguisher use.
- Undated
Heater-Treater Fire with Leaking Fire-Tube Weld
BSEE investigates a heater-treater fire at Ship Shoal Block 193, with no injuries reported. Inspection found a leaking fire-tube weld and subsequent magnetic particle testing identified another crack. The report examines production fluctuations, heat dissipation and weld failure, documenting emergency shutdown, repairs and daily temperature tracking.
- Undated
Fuel Gas Filter Fire During Restart After Shut-In
Investigation of a fuel-gas filter fire at EB 165A during restart after a shut-in. Overpressurisation expelled the vessel top, which struck a handrail and ignited escaping gas. Findings identify corroded securing tabs, malfunctioning pressure safety valves and vessel modifications. Operators extinguished the fire while other personnel mustered.
- Undated
Stored Pressure Propels Components into Mechanic During Pulsation Dampener Maintenance
Investigation of a mechanic’s injuries during pulsation dampener maintenance aboard Seadrill West Neptune. Removing the final retaining bolt released approximately 2,000 psi of stored pressure, propelling components into the mechanic. Findings address inadequate planning, unavailable manufacturer instructions, failures in pressure verification and hazard communication, and single-person handling beyond company limits.
- Undated
Platform Flash Fire Following Gas Blow-By Through Separator Dump Controller
Investigation of a production-platform flash fire following gas blow-by through a malfunctioning high-pressure separator dump controller. Gas reached the oil stock tank and escaped through secondary vents, accumulating near the generator building. Findings address building isolation, overlooked warnings, operator familiarity, supervision and failure to use stop-work authority.
- Undated
Hot Pressurised Crude Oil Released During Heater-Treater Controller Replacement
An offshore heater-treater controller replacement released hot, pressurised crude oil, burning an operator and polluting surrounding waters. The investigation found that the controller lacked a thermowell and was removed before depressurisation and oil-level reduction. Task hazard analysis missed this installation hazard and the necessary mitigations, including cooling.
- Undated
Stored Pressure Released During Potable-Water Tank Dismantling
Investigation of severe facial injuries during dismantling of a potable-water pressure tank. Removing a nozzle released stored bladder pressure, ejecting components and launching the tank. Findings identify failure to depressurise the bladder, unavailable manufacturer instructions, a job safety analysis covering filter changes rather than tank removal, and inadequate supervision.
- Undated
Oil Discharge Through Platform Produced-Water System
BSEE investigates an estimated three-barrel oil discharge through Thunder Horse’s produced-water system on 13 July 2020. The report links water-quality problems to inadequate flushing of subsea well workover fluids, discusses possible emulsion and foaming, examines delayed pollution notifications, and records corrective communication training and recommendations for agency coordination.
- Undated
Flash Fire During Preparation for Flare Scrubber Inspection
An investigation describes a flash fire during preparation to inspect Platform Irene’s flare scrubber vessel. A lead operator sustained minor burns and embedded debris in his hand. Findings identify failures in purging, isolation, lockout and ignition control, alongside permit compliance and communication deficiencies. Follow-up included permit checks and training.
- Undated
Glycol Reboiler Fire on Production Platform
An investigation examines a glycol reboiler fire on a production platform following process alarms. Dry chemical extinguishers proved ineffective, and operators evacuated before a vessel extinguished the fire using water. The probable cause remained unknown. Recommendations address inspection of concealed nipples and assessment of existing fire protection.
- Undated
Production Platform Fire During Restart Troubleshooting
An investigation of a production-platform fire during restart troubleshooting identifies fluid carry-over from a flare scrubber to hot generator piping. A malfunctioning separator level switch contributed. Personnel extinguished the fire with a handheld extinguisher. Recommendations address separator level-switch positioning, sight-glass checks and flare vent routing.
- Undated
Hydrogen Sulphide Release During Condensate Rerouting
Investigation of a hydrogen sulphide release on Hidalgo platform during condensate rerouting. Opening the wrong valve, combined with a check valve lacking a positive seal, allowed condensate into deck drains. Five workers received medical care and were evacuated. Corrective measures included locking the valve, documenting procedures and planned pipework alterations.
- Undated
Gas Release from Sight Glass Triggered Platform Shut-In and Muster
BSEE investigated a gas release at Stampede’s floating production platform. Four loose sight-glass bolts allowed vessel pressure to damage the gasket, triggering a platform shut-in and personnel muster. No injuries were reported. The operator isolated the sight glass for repair and decided to replace fourteen others with see-thru flanged sight flow indicators.
- Undated
Heater Treater Overheating on Offshore Platform
BSEE investigates heater treater overheating at Castex’s Vermilion 252-A platform on 9–10 September 2019. The report examines burner adjustment, restricted exhaust flow, ineffective temperature shutdowns, inadequate thermowell installation and delayed shut-in. It records equipment damage, inspection deficiencies and subsequent liquid-level corrections, while retaining uncertainty over several contributing mechanisms.