Equipment
Process Pipework and Pipelines
Pipework and pipelines conveying process fluids, including integrity and opening interfaces.
Newest 100 Documents
All 573 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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
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.
- 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
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.
- 202521 Nov
Emergency planning guidance note
Guidance on emergency planning and safety-case requirements for offshore petroleum facilities. It addresses command arrangements, team competence, medical provision, equipment assurance, communications, evacuation analysis and emergency shutdown. It distinguishes regulatory obligations from suggested approaches and explains performance standards, drills, review and management of planning changes.
- 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.
- 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.
- 2025Oct
Refinery Cooling Tower Explosion and Fire — Process Safety Beacon, October 2025
A refinery cooling tower incident in India illustrates how hydrocarbons leaking from a heat exchanger can accumulate in cooling water pipework and escape during commissioning. Ignition was likely associated with nearby hot work. The bulletin discusses exchanger vulnerability, start-up hazards and notifying nearby workers so they can suspend work.
- 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.
- 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.
- 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.
- 2025Aug
Thermal Expansion runs hot and cold! — Process Safety Beacon, August 2025
This bulletin explains how heating trapped liquids and freezing accumulated water can rupture process pipework. Two chemical-processing incidents illustrate releases, fires and injuries involving a burst strainer and cracked propane piping. It highlights pressure relief, established isolation and depressurisation procedures, accommodation of thermal movement and temperature-dependent freezeproofing.
- 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.
- 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.
- 202512 Jun
Design notification guidance note
Explains design notification requirements for new or significantly altered production facilities and new greenhouse gas facilities. Covers notification triggers, design options, major accident risks, pipeline materials, decommissioning and site conditions. Clarifies independent validation, subsequent safety-case demonstrations and NOPSEMA’s assessment process, which produces written comments rather than acceptance.
- 202510 Jun
BSEE Safety Alert 502 -Fatigue Cracking of Three-Quarter-Inch Pipe Nipple Results in Gas Release
An offshore gas release followed fatigue failure of a threaded ¾-inch pipe nipple on a compressor suction scrubber, prompting platform shut-in and personnel muster. The alert discusses possible installation stresses, vibration and unsupported bridle weight, and recommends considering structural support, proper tightening, regular inspection, vibration monitoring and maintained dampers.
- 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.
- 202513 Mar
Marathon Martinez Renewable Fuels Fire
Investigation of a renewable diesel startup fire at Martinez, California, following heater tube rupture. Low process flow and afterburning caused overheating, releasing diesel and hydrogen and seriously injuring an operator. The report examines valve alignment, instrumented safeguards, combustion monitoring, alarm responses, human factors and corporate oversight, with recommendations and comparisons to earlier incidents.
- 20256 Feb
Saturation diver exposed to chemicals from pipeline
A saturation diver suffered chemical burns after exposure to chemically treated seawater while disconnecting a pigging/flushing hose during decommissioning. The flash identifies uncertainty over flushing and absent engineered barriers. Lessons address understanding pipeline contents, hazard analysis, amended procedures, valve isolation and securing, and reducing exposure through local valves.
- 2025Feb
Communication is the key to safer operations — Process Safety Beacon, February 2025
A bulletin examines unclear torque instructions during pipefitting work that led to a hydrogen chloride release and workers falling while escaping. It contrasts equipment manuals with design drawings and promotes clear written instructions, field demonstrations of critical tasks, worksite permit reviews and radio message repeat-back.
- 2025
2 - Integrity management of FPSOs/FSUs
OMAR guidance addresses structural and maritime integrity of UKCS FPSOs and FSUs, drawing on regulatory interventions. It discusses inspection regimes, hull loading, watertight integrity, cargo systems and station keeping, alongside competence, independent verification and safety-case review. Ageing assets and formal life-extension assessments receive particular attention.
- 202412 Dec
Engine room fire on board ro-ro passenger ferry Stena Europe
Investigation of Stena Europe’s engine room fire while approaching Fishguard. Pressurised fuel escaped from a flange joint and ignited on exposed exhaust surfaces. The report examines recurring leaks, incomplete flange modifications, deficient insulation, maintenance and reporting weaknesses, firefighting response, and thermal imaging for detecting hazardous hot spots.
- 202412 Nov
Diver exposed to unplanned release of production gas
A saturation diver removing a blind stab from a subsea skid was pushed backwards by released production gas but remained unharmed. The flash identifies unverified isolation, deviation from procedures, inadequate review of task risks and unused ROV tooling. It highlights change management, procedural hold points and reinforcement of stop-work authority.
- 202414 Oct
Fire in engine room
A vessel engine-room fire was most likely caused by a fuel leak following pipe misalignment during reassembly. Blocked detection tubing and drains, unavailable water-mist suppression and delayed ventilation shutdown contributed to escalation. The flash highlights correct assembly, regular inspections, fire drills and checks of emergency procedures.
- 2024Oct
Some short-cuts may cut lives short — Process Safety Beacon, October 2024
This bulletin examines procedural shortcuts through a fatal polyethylene reactor incident in Pasadena, Texas. It describes inadequate isolation, unenforced permits and cross-connected valve air hoses. Guidance stresses operational discipline, functioning safeguards and authorised assessment of changes, warning against treating temporary safeguard bypasses as routine practice.
- 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.
- 20243 Jun
Diver’s umbilical trapped during a pipeline flooding operation
A saturation diver’s umbilical became trapped between pipelines when a newly laid line shifted during flooding, interrupting breathing gas. Another diver supplied pneumo gas and helped free the umbilical. The flash examines pipeline configuration, tidal current and umbilical routing, emphasising assessment of existing conditions and management of changing variables.
- 202416 Apr
BSEE Safety Alert - De-pressurizing Piping to Remove Hydrate Results in an Injury
An offshore platform operator suffered bruising and swelling when a ball valve assembly separated during depressurisation of gas lift piping containing a possible hydrate. Approximately 900 psi remained trapped behind the valve. The alert discusses inadequate isolation, missing task hazard analysis, and measures operators should consider for hydrate prevention and safe pressure bleeding.
- 202416 Apr
Improperly Depressurizing Piping to Remove a Hydrate Causes Injury
An offshore platform operator suffered bruising and swelling when a valve assembly detached during depressurisation of gas lift piping containing a possible hydrate. Approximately 900 psi was trapped behind the valve. The alert recommends considering energy isolation, balanced bleeding, task hazard analysis, management of change and gas dehydration.
- 202419 Mar
High potential: sea water inlet pipe leakage in engine room
A vessel crew discovered seawater leakage from corroded air-conditioning condenser pipework near the hull while offshore. A cement box contained the leak before emergency dry-docking for repairs. The flash identifies missing documented condition checks and recommends regular inspection of ship-side valves and piping within planned maintenance.
- 20249 Jan
Leak in hot water system for saturation divers
A saturation-diving hot-water unit leaked through locally corroded pipework inaccessible for visual inspection. Diving was suspended because the remaining unit lacked backup. Repairs involved welding a sleeve over the leak and inspecting the other unit. The flash suggests considering wall-thickness measurements of old pipes.
- 202321 Dec
KMCO LLC Fatal Fire and Explosion
Investigation of the fatal isobutylene explosion and fire at KMCO’s Crosby facility. Metallurgical testing established pressure-driven brittle fracture of a cast-iron y-strainer. The report examines thermal-expansion hazards, manual versus remote isolation, emergency-response roles and alarm use, identifying weaknesses in hazard evaluation and response that contributed to the incident and its severity.
- 202327 Nov
Case study: Saturation diver fatality due to hydrogen sulphide
This safety flash summarises a historical saturation-diving fatality during inspection of a leaking sour-crude pipeline in the Bombay High oilfield. Hydrogen sulphide in the bell caused collapse; the diver subsequently drowned. It discusses possible gas-entry routes, absent gas detection, bell-to-bell rescue and the potential use of ROVs for surveys.
- 202328 Sep
Safety Alert - Pipeline Loss of Containment
A gas export pipeline tie-in spool flange failed after severe corrosion of carbon steel lacking the specified corrosion-resistant cladding. The alert examines material traceability and quality-control failures, misinterpreted inline inspection data and incorrect defect location reporting. Lessons address preserved identification, consideration of positive material identification and diverse integrity inspection measures.
- 20233 Aug
Near miss with high pressure gas due to incorrect procedures
A crew preparing to pig high-pressure gas mains questioned a valve closure and identified that it would block the intended downstream flow. Work stopped and valves were restored to normal. Review found instructions based on an obsolete drawing; operations remained suspended pending correction, avoiding a compressor trip and possible downstream supply problems.
- 20236 Jul
Intercontinental Terminals Company (ITC) Tank Fire
Investigation of the March 2019 tank-farm fire at ITC’s Deer Park terminal, following a circulation-pump seal failure and butane-enriched naphtha release. The report examines pump maintenance, gas detection, emergency isolation, fire spread, containment failure and regulatory exemptions, with recommendations addressing mechanical integrity, tank-farm design and process safety management.
- 202329 Jun
Watson Grinding Fatal Explosion and Fire
Investigation of the Houston propylene explosion that killed two employees and a nearby resident. It examines a degraded, poorly crimped hose, inconsistent supply isolation and non-functional automated safeguards. Findings address process safety management, change assessment, emergency preparedness and regulatory exclusions; lighting activation is identified as the likely ignition event.
- 202315 Jun
Wacker Polysilicon Chemical Release
This investigation examines a hydrogen chloride release during heat-exchanger maintenance at Wacker Polysilicon. Excessive bolt torque fractured a graphite nozzle; three workers fell while escaping, with one fatality. The report analyses maintenance instructions, hazardous-energy control, simultaneous insulation work and restricted egress, recommending clearer procedures, coordinated operations and additional escape routes.
- 202325 May
LyondellBasell La Porte Fatal Chemical Release
This investigation examines the fatal chemical release during plug-valve actuator removal at LyondellBasell’s La Porte complex. Two workers died following exposure to acetic acid and methyl iodide. It compares similar incidents and examines valve design, pressure-retaining components, work procedures, training, isolation and pre-authorisation risk assessment.
- 202316 May
Differential pressure: Dummy choke ejected close to divers
A dummy choke insert was expelled by differential pressure during replacement work near two divers, who remained unharmed. The flash examines absent local venting, misunderstood pressure readings and unclear release expectations. It recommends explicit procedures and risk assessments, isolation training, confirmation of an open local vent and clarification of questionable instructions.
- 202312 May
Process Explosion Causes Medical Evacuation
Two offshore workers installing a skillet in pipework suffered smoke inhalation and burning sensations after opening a flange. The investigation identified absent purging or flushing and unrecognised potential pyrophoric materials. BSEE recommends considering fire and explosion management plans and procedures addressing ignition sources, oxygen ingress and fuel.
- 202320 Apr
Near Miss: Personnel nearly struck by rotating chain attached to flexible pipe
During a production flexible’s second-end transfer, residual torsion caused the pipe and an attached 16.5te chain to rotate, nearly striking two crew members. The flash identifies task inexperience, language barriers and procedural omissions, and discusses rigging removal, translated task documentation and restricted access to the pipelay system’s top module.
- 202313 Mar
Sudden and uncontrollable move of A&R head
During pipeline abandonment preparations aboard a vessel, an abandonment and recovery head was ejected from the pipe end while being aligned for welding. Crane support prevented it dropping, and nobody was injured. The flash identifies absent vent holes, unrecognised residual-water effects and unnecessary personnel exposure, encouraging reassessment of specifications and risks.
- 20237 Mar
Investigation of Subsea Leak Identifies the Use of Materials Susceptible to Hydrogen Embrittlement (update)
A subsea jumper leak released approximately 479 barrels of oil into the Gulf of Mexico. Investigation attributed fractured Inconel 718 flange studs to hydrogen embrittlement and identified procurement, quality assurance and change-management gaps. The alert recommends operators consider metallurgical evaluation, fastener torque documentation and improved subsea leak alarm monitoring.
- 202311 Jan
Umbilical management – near miss
A diver’s umbilical became trapped when a pipeline rolled during crane-assisted removal of sleeper supports beneath a repair spool. The diver freed it and was unharmed. The flash identifies missing removal procedures, unrecognised umbilical hazards and absent change management, recommending a removal procedure and crew review.
- 2023
Standards for offshore helicopter landing areas (Version 9.1, 7 January 2026; publisher status Current)
Sets criteria for offshore helicopter landing areas on installations and vessels, alongside wind-turbine winching arrangements. Covers structural loading, obstacle protection, surface friction testing, lighting, motion monitoring, meteorological reporting, rescue and fire-fighting, fuel-system design and maintenance, and passenger preparation. The January 2026 amendment introduces arrangements for temporary safety-critical equipment unserviceability.
- 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.
- 202219 Dec
TPC Port Neches Explosions and Fire
An investigation using AcciMap examines dead-leg management in high-purity butadiene service. Its causal analysis identifies an unimplemented process hazard analysis recommendation and a flushing procedure that was not carried out. It also records gaps in requirements for remotely operated emergency block valves on existing equipment.
- 202213 Dec
Fires During Decommissioning Cause Injuries
A contractor suffered facial burns when trapped hydrocarbons ignited during torch cutting of pipework being decommissioned. Earlier seawater flushing and draining had not removed the hydrocarbons. The alert identifies shortcomings in hazard analysis, planning and permitting, and recommends job-specific procedures, atmospheric verification, isolation safeguards and pre-job communication.
- 202230 Nov
MAIB: A scalding injury
An engineer aboard a cruise ship suffered severe facial scalding after opening an isolated economiser’s drain valve before cooling was complete. Hot water and steam discharged and deflected upwards from a tundish. The flash highlights discharge-path exposure, caution when opening pressurised drain lines, and controlled valve operation using a correctly sized wheel key.
- 20221 Nov
BSEE: Poor preparation prior to hot work leads to fires
This safety flash summarises three BSEE hot-work fires involving falling sparks, flammable condensate, a leaking gas riser and combustible building surfaces. Recommendations address spark shielding, sustained fire watches, extinguishers, continuous gas monitoring, detector checks, inerting nearby containers, and reviewing hot-work permits and job safety analyses.
- 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.
- 202228 Sep
Sunoco Logistics Partners Flash Fire
Investigation of a flash fire and explosion during flange welding at Sunoco’s Nederland terminal, injuring seven contractors. The report examines residual crude oil, pipe isolation tools, atmospheric testing, permits and procedure implementation. It discusses similar incidents and stresses ensuring a non-flammable internal atmosphere before hot work; the specific causal scenario remains unresolved.
- 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.
- 202226 Jul
Poor Preparation Prior to Hot Work Leads to Fires
Three hot-work fires illustrate hazards from flammable vapours at a water skimmer, a leaking gas riser and combustible building surfaces. The alert recommends considering spark shielding, drain sealing, inerting, permits, job safety analysis and continuous gas monitoring, alongside appropriately positioned fire watches and accessible extinguishers.
- 202220 Jun
Fire at sea – some timely reminders (Safety4Sea)
This safety flash reproduces Safety4Sea excerpts on shipboard fire risks involving fuel oil leakage, electrical devices, flammable cargo and hot work. It highlights hot-surface insulation above 220 °C, removal of defective equipment, package marking and labelling, and preparation of hot-work areas with an agreed written plan.
- 202228 Apr
Two catastrophic engine failures, one resulting in a fire, on board ro-ro passenger ferry Wight Sky
Investigation of Wight Sky’s August and December 2018 engine failures, extended to related fleet failures. It distinguishes lubrication loss from a factory bearing-cap assembly error and examines maintenance records, oil and coolant monitoring, contractor support, delayed declutching and missing engine protection. Effective crew response limited the consequences.
- 202228 Feb
UK HSE: Liquid petroleum gas (LPG) leak
This safety flash describes a release of around 15 tonnes of LPG at Fawley refinery, undetected for around four hours. HSE identified excessive pressure for the valve and absent flow-discrepancy detection. Emergency personnel reset the valve. The account stresses maintaining protective layers against major incidents; no fire or injury occurred.
- 202215 Feb
Crewmember burned while draining fluid from flare stack
A worker opened a ball valve to drain a flare stack without switching off its ignitor. Drainage allowed gas to reach the flare and ignite. Flammable liquid subsequently fell onto the worker, causing burns despite the fire-resistant clothing and hard hat being worn.
- 202124 Sep
Evergreen Packaging Paper Mill - Fire During Hot Work
Investigation of a fatal fire during paper-mill tower maintenance in Canton, North Carolina. A heat gun fell into flammable resin, and fire spread between connected bleaching towers, killing two workers. The report examines hot-work recognition, confined-space permits, contractor coordination, combustible fibreglass construction and emergency response, with recommendations for procedures and training.
- 202130 Mar
Engineer suffered burn injuries in engine room incident
An engineer aboard Mineral Temse sustained severe burns after opening a sludge discharge inspection plug shortly after switching off a fuel oil separator. The flash summarises findings concerning unrecognised heating and pressurisation during complete blockage, unaccompanied inspection and inadequate skin protection, alongside onboard first aid and subsequent hospital treatment.
- 202117 Mar
Offshore Pipeline Integrity Management (Issue 2)
Inspection guidance for assessing offshore hydrocarbon pipeline integrity management, compliance and performance. It addresses ageing and life extension, corrosion monitoring, pipeline and riser inspection, shutdown valve testing, pigging safeguards and emergency preparedness. Success criteria, sample inspection agendas and enforcement assessment guidance support examination of operators’ arrangements.
- 202121 Jan
Risk-Based Inspections of Subsea Leak Detection Technology Reveals Gaps in System Processes
BSEE reviews three subsea oil leaks and inspection findings showing weaknesses in leak-detection procedures and management processes. Operators and contractors are asked to consider clearer alarm response responsibilities, personnel training, system testing, configuration change control and ROV surveys. The alert emphasises investigating abnormal flow and learning from previous detection failures.
- 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.
- 202031 Dec
The Offshore Oil and Gas Exploration, Production, Unloading and Storage (Environmental Impact Assessment) Regulations 2020 – A Guide
Explains environmental assessment and consent procedures under the 2020 offshore EIA regulations. Covers screening, environmental statements, baseline surveys, alternatives, cumulative effects, mitigation and public consultation. Provides application requirements for drilling, pipelines and production changes, including PETS submissions, approval variations, reporting and enforcement.
- 202023 Oct
MSF: Grub screws and perished valves – trouble with methanol transfer
This flash describes unrecognised methanol discharge to sea during vessel cargo transfers. An incorrectly retained spool piece and passing valves allowed flow through the flushing line; a grub screw restricted one valve’s closure. Recommendations address recorded cargo receipt confirmation, transfer-system configuration checks and updating planned maintenance.
- 202016 Oct
Deficiencies in Process Piping Cause Gas Release Incidents
BSEE describes several Gulf of Mexico gas releases involving cracked welds, leaking gaskets and corrosion beneath insulation. The alert links incidents to quality assurance and mechanical integrity deficiencies, with vibration-related fatigue a possible contributor in one case. Recommendations address piping integrity programmes, leak detection, reporting, training and maintenance of compressors and pulsation dampeners.
- 20209 Oct
Oil production riser gas ignition
During recovery of an oil production riser at an FPSO, hot-work sparks ignited residual gas in the bore. A slit introduced to address another hazard allowed air ingress and a spark path. The flash highlights missed change-related risks in hazard assessments; no injuries or equipment damage were reported.
- 202015 Sep
UK HSE: Two workers suffer multiple burn injuries
Two workers, including an apprentice, suffered life-changing burns during reassembly of high-pressure steam pipework following maintenance of a steam turbine driven pump. Steam was released uncontrollably at around 250°C. The investigation identified safe-system-of-work failures, including incomplete checks and verifications required by the steam isolation procedure.
- 202028 Jul
Sudden Uncontrolled Pressure Release
Hazard alert addressing sudden pressure releases during commissioning, decommissioning, maintenance and repair in the oil and gas industry. It identifies equipment integrity problems, changing conditions and unsafe work practices, and outlines employer and worker responsibilities for assessments, isolation, controlled depressurisation, safe procedures and avoiding released-energy paths.
- 202013 Jul
MOB fatality from multi-cat
A chief engineer suffered a fatal man-overboard incident during pipeline recovery from a multi-cat in shallow inshore waters. After the plan changed from compressed-air refloating to crane lifting, an unsecured pontoon struck him. The flash identifies absent change management and risk assessment, inadequate supervision and operations during darkness contrary to instructions.
- 202012 Jun
MSF: Water-based mud spill on deck
A mud-transfer hose separated from a vessel manifold at an offshore installation, spilling approximately 2,500 litres onto deck. Incompatible threads allowed corrosion to weaken the connection. The crew contained and recovered the mud without environmental loss. Actions address thread compatibility, planned maintenance and visual pre-use inspections.
- 20201 Jun
UK HSE: Workers injured by unplanned release of mud slurry
Three contractors suffered multiple fractures when approximately 39 cubic metres of diluted slurry escaped during recirculation pump removal for maintenance. A blocked drain had prevented discharge of pressurised contents before work began. The flash reports inadequate risk assessment and failure to implement a safe system of work.
- 2020Apr
MAIB Safety Digest 1/2020
A collection of lessons from accidents involving merchant vessels, fishing boats and recreational craft. Cases examine distracted navigation, grounding, machinery fires, hazardous tank atmospheres, cargo handling and overboard emergencies. Discussions cover passage planning, maintenance, atmospheric testing, lifejacket performance and emergency drills, retaining uncertainty where accident causes remain unresolved.
- 202031 Mar
Safety Alert 380 - Subsea Jumper Failure Leads to Leak
BSEE describes a subsea jumper failure involving internal corrosion and mechanical stress from pipeline and PLET movement. The October 2017 leak released an estimated 16,000 barrels of oil and remained undetected for over 24 hours. Recommendations address operator training, improved leak detection, corrosion mitigation and verification of pipeline design tolerances.
- 202028 Feb
Safety Alert 379 - Broken Compressor Heat Exchanger Causes Fire
This alert describes a Gulf of Mexico platform fire after compressor heat-exchanger tubing detached and released gas that ignited at the engine exhaust, alongside a similar 2017 fire. It identifies inadequate inspection and maintenance, and recommends considering improved joint oversight and leak-detection methods, with exhaust routed outside classified areas.
- 2020
The safe approach, set-up and departure of jack-up rigs to fixed installations (REV 1)
Guidance for duty holders managing jack-up approach, positioning and departure beside fixed offshore installations. It examines collision and hydrocarbon-release risks, pipeline protection, human factors and personnel limits. Site-specific ALARP demonstrations underpin decisions on production shutdown, depressurisation and venting, with live approaches requiring justification of changed circumstances.
- 20194 Oct
Inadvertent Opening of Valve Under Pressure Causes Injury
An offshore worker inadvertently opened a ball valve while attempting to stop a leak. Released pressure dislodged drain tubing, which struck and fractured the worker’s nose. The alert examines redundant components, inadequate hazard analysis and weak tubing support, recommending consideration of valve selection, management of change and suitable tubing arrangements.
- 201930 Sep
For want of a watchman, the ship was lost
A winter-laid-up Great Lakes bulk carrier suffered a severe fire while unmanned, with no injuries. Frozen hydrants hindered firefighting; shore-power loss and freezing conditions subsequently contributed to machinery-space flooding. The flash relays USCG recommendations for continuous watches, written emergency duties and engineering expertise during lay-up preparations.
- 201930 Sep
UK HSE Investigation into Offshore Gas Explosion
This safety flash describes a methane release following corrosion under insulation and rupture of high-pressure pipework on Brae Alpha. Over two tonnes escaped almost instantaneously, causing widespread damage but no injuries or ignition. The HSE investigation identified inadequate inspection and required an effective pipework inspection and maintenance regime.
- 201924 Sep
Safety Alert 366 - Dangerous Levels Of H2S Detected At Offshore Facilities
BSEE describes three hydrogen sulphide releases during offshore pipeline flushing and well abandonment, including incidents at non-sour facilities. One worker experienced dizziness and nausea. The alert recommends considering gas monitoring, detector calibration and bump testing, job safety analysis, rescue preparedness and gas-buster safeguards during potentially hazardous operations.
- 201920 Aug
Catastrophic rupture of dead-leg pipe-work
This safety alert examines refinery pipework ruptures associated with highly localised internal corrosion in dead-legs. It explains how routine thickness checks missed deterioration and outlines inspection expectations, including risk assessment, wider wall-thickness testing and timely replacement. Operators should consider removing non-essential dead-legs and account for thermal gradients, liquid interfaces and condensation.
- 201912 Aug
Fire main dust cap blown away by pressure from the line
During checks of a firefighting water filling connection, trapped pressure propelled a steel dust cap into a wall approximately 10 metres away. Minor wall damage occurred without injuries. Work stopped and similar lines were checked and depressurised. The flash suggests considering a drain cock to release residual pressure before cap removal.
- 20197 Aug
Safety notice to act as a reminder of the phenomenon of condensate induced water hammer
HSE’s notice explains condensate-induced water hammer in existing steam systems following a steam release that injured three people. Early investigation findings suggest a pressure-boundary failure potentially caused by water hammer. It highlights drainage, steam-trap maintenance and statutory responsibilities, and recommends considering SAFed’s five-point action plan.
- 2019Aug
Hidden Hazards! — Process Safety Beacon, August 2019
This manufacturing safety bulletin addresses hidden chemical and energy hazards before opening process equipment. An employee injury involving undocumented piping containing sulphuric acid illustrates the problem. It recommends understanding equipment contents, verifying labels, reviewing service changes, following line-breaking and lockout procedures, and resolving uncertainties before proceeding.
- 201925 Jun
DuPont La Porte Facility Toxic Chemical Release
Investigation of a fatal methyl mercaptan release at DuPont’s La Porte insecticide unit. Four workers died inside the manufacturing building. The report examines hydrate-blocked pipework, drain valves, inadequate safeguards, alarm communication and emergency response, alongside management of change, audit effectiveness, process safety culture and misleading reliance on occupational injury metrics.
- 201913 Jun
Safety Alert 356 - Pipeline Pigs Inadvertently Launched in Close Proximity of Personnel into Gulf Waters
Three pigs were inadvertently ejected near two employees during pipeline pigging on a Gulf of Mexico platform, damaging structures and entering the sea. The alert identifies trapped valve-body pressure as the most likely cause and recommends considering revised hazard analyses, operating procedures, valve inspections, training and near-miss reporting.
- 201925 Apr
Oil spill during bunkering
A vessel bunkering alongside spilled around three litres of fuel after a hose coupling was loosened to investigate back pressure. The flash identifies failures to check drainage and residual pressure, describes containment and clean-up on deck and pier, and records a full review of bunkering procedures.
- 201928 Jan
Confined space entry: Worker died inside pump room
A worker died after losing consciousness while six workers dismantled valves in a vessel’s pump room and noticed fumes. The flash relays WSH precautions covering atmospheric ventilation, respiratory protection when adequate ventilation is impossible, and isolation, depressurisation and purging of hazardous-material pipelines before dismantling.