Equipment
Storage Tanks
Tanks for storing liquids, including atmospheric and process-fluid storage tanks.
Newest 100 Documents
All 228 in search- 202614 May
Shifting cargo and deck spill during heavy weather
During heavy-weather transit, a brine storage tank shifted approximately 0.5 m, struck a crash rail and damaged its manifold valve, spilling brine onto the deck. The flash identifies slackening lashing chains and inadequate securing, and recommends redundant lashings, impact protection for vulnerable fittings and review of weather risk assessments.
- 202617 Mar
Working in a confined space without a Permit to Work
A safety walk-round identified crew removing pipes inside a sewage tank without a confined-space entry permit. Work was stopped and treated as a near miss. The flash examines assumptions arising from the tank’s clean appearance, missing entry safeguards and inadequate hazard identification, and stresses following procedures and confirming confined-space work with supervisors.
- 2026Feb
CHIRP Superyacht FEEDBACK 11 (February 2026)
Six superyacht reports examine an unpermitted hull repair, a close-quarters encounter, grounding on uncharted coral, fuel-handling failure, hazardous acetone use in a bilge sump and premature anchor release. Commentary addresses reporting culture, collision avoidance, passage planning, fuel purification, respiratory protection limitations and confined-space precautions, emphasising communication and challenges to unsafe decisions.
- 202529 Apr
Hydrogen Sulphide (H2S) detected onboard vessel
A vessel-wide odour prompted crew to investigate with gas detectors but without respiratory protection. Hydrogen sulphide reached a measured 170 ppm in the Grease Trap room, entering through a dry drain trap. The flash examines sewage-system maintenance, incomplete procedures and risk assessment, and subsequent revisions to tank-flushing, drain-trap and emergency arrangements.
- 20253 Apr
BSEE Safety Alert 498 - Explosion and Fire Incident
A liftboat explosion during separator draining injured two workers with burns. Gas accumulated on deck and a generator surge triggered ignition. The alert examines tank sealing, unsuitable gas detectors, failed air-intake shutoff controls and delayed medical evacuation, recommending that operators consider improved procedures, inspections, testing and emergency arrangements.
- 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.
- 202425 Sep
Tampering with approved safety devices
A client inspection found a homemade clamp holding open a self-closing valve on a vessel’s lubricating oil storage tank. Installed to save time, the modification had escaped routine checks. The flash highlights safety-device integrity, adherence to procedures and proper approval or management of change for equipment modifications.
- 202427 Mar
Implosion of chemical tank
A chemical tank on a vessel imploded after pumping created a vacuum with its manual air inlet valve unopened. Around two cubic metres of monoethylene glycol spilled onto the deck and into the sea; nobody was injured. The flash examines unfamiliar replacement equipment, supplier assurance, documentation, familiarisation and management of change.
- 202427 Mar
LTI: person slipped climbing out of tank
A crew member fractured his right forearm after slipping while approaching a vessel’s fresh water tank exit hatch for a rest break. The investigation identified pooled cleaning water on smooth painted surfaces. Lessons include reviewing inspection frequency and assessing whether non-slip tank coatings are feasible.
- 202419 Feb
US BSEE: Confined space entry – tank cleaning
This safety flash summarises two tank-cleaning incidents requiring CPR, including unplanned entry while wearing an outside-use respirator. It reports rushing and non-compliance in the first case and a possible cardiac contribution in the second. BSEE recommends considering entry authorisation, task analysis, ventilation, communication, training and rescue arrangements where appropriate.
- 202313 Dec
BSEE Safety Alert 477 - Hazards of Working in Confined Spaces
BSEE describes two tank-cleaning incidents requiring CPR: an unplanned entry to free a vacuum nozzle and illness followed by collapse during exit. The alert examines procedural lapses and rushing in the first case, and recommends operators consider entry planning, communication, ventilation, appropriate respiratory protection, rescue arrangements and current training.
- 2023Dec
Overfill of vapour recovery units
HSE warns that a gasoline overfill exposed dependence between a vapour recovery unit’s process controls and overfill protection, resulting in loss of containment. The notice calls for risk assessment, physical verification, inspection, maintenance and testing of safety functions, with independent safeguards and control-system modifications where required, managed through change procedures.
- 20239 Nov
Safety Alert 472 - Tote Tank Drain Nozzles Pose Leak Hazard
Two Gulf of Mexico lifting incidents illustrate how protruding tote-tank drain nozzles can strike nearby objects, causing diesel spillage or a cracked weld and minor leak. BSEE recommends considering nozzle positioning, clear transport paths, protective guards, conditional drain securing or nozzle removal, conspicuous marking and spill-response provisions.
- 20232 Nov
H2S released during rig reactivation activities
During quayside rig reactivation, hydrogen sulphide escaped from a machinery-space bilge water tank after its top hatch was removed, threatening nearby personnel. The alert describes acute inhalation dangers, including immediate collapse at concentrations above 1,000 ppm, alongside steel corrosion and flammable or explosive concentration limits.
- 20236 Jul
Intercontinental Terminals Company (ITC) Tank Fire
Investigation of the March 2019 tank-farm fire at ITC’s Deer Park terminal, following a circulation-pump seal failure and butane-enriched naphtha release. The report examines pump maintenance, gas detection, emergency isolation, fire spread, containment failure and regulatory exemptions, with recommendations addressing mechanical integrity, tank-farm design and process safety management.
- 202322 May
Unexpected H2S Detection at Offshore Facilities
This alert summarises unexpected hydrogen sulphide detections at offshore facilities producing from fields classified as H2S absent. Cases involve production equipment, cargo tanks, defoamer transfer and ballast-tank cleaning. BSEE recommends considering atmospheric testing, stagnant-tank inspections, crew drills, routine sampling and risk assessments addressing bacterial generation of the gas.
- 2023Apr
High concentration of hydrogen sulfide (H2S) in cargo and slop tanks
This HSE safety notice addresses hydrogen sulphide in FPSO and FSU cargo and slop tank ullage spaces, including concentrations beyond standard portable instruments’ measuring limits. It discusses exposure during monitoring and releases, corrosion risks, suitable gas monitoring, revised risk assessments, integrity inspection and crew training.
- 2023
CHIRP Maritime FEEDBACK 71 (Summer 2023)
This maritime digest examines engine defects, misleading master–pilot exchanges, language barriers, a power shutdown, a yacht collision and repeated falls from a paint raft. Commentary addresses commercial pressure, communication and supervision. A separate article describes automated tank cleaning with high-pressure spinning nozzles and remote drone inspections to reduce enclosed-space entry.
- 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.
- 202213 Dec
Oil tank sight glass push buttons wired open
An engine-room visit identified oil-tank sight-glass push buttons deliberately held open with wire, defeating the gauge’s closing feature. The flash explains that accidental damage to the glass tube could allow tank contents to spill, creating slip and fire hazards and depriving equipment of its intended oil supply.
- 2022Aug
What’s an Acceptable LEL Detector Reading? — Process Safety Beacon, August 2022
This bulletin examines a fatal tank explosion during emptying by vacuum truck, where work continued after a reading of 67% of the lower explosive limit. It explains vapour accumulation and sludge hazards, emphasising calibrated gas testing, compliance with testing limits, bonding and grounding, and recognised tank-cleaning practices.
- 202212 May
Explosion – hot work in a flammable atmosphere (Transport Malta)
A tanker explosion followed angle-grinder use to remove stubborn ramp bolts during dry-docking preparations. Sparks travelled towards a fuel-oil tank vent; nobody was injured. The flash examines perceived time pressure and unawareness of nearby flammable gases, and records refresher webinars reinforcing stop-work authority and improved work planning.
- 202125 Nov
Hydrogen sulphide detected in a bilge tank
A vessel crew stopped bilge-water transfer after noticing a rotten-egg smell; a multi-gas meter detected 453 ppm hydrogen sulphide at the vent. The flash describes accumulated tank residue, delayed specialist cleaning, gas routing away from accommodation, continuous monitoring and respiratory protection, alongside lessons on machinery-space cleaning practices.
- 202120 Jul
Cargo tank explosion and fire on chemical tanker Stolt Groenland
Investigation of the Stolt Groenland explosion and fire at Ulsan examines runaway styrene polymerisation following heat transfer through an intermediate cargo tank. It analyses inhibitor depletion, stowage planning, unused temperature monitoring and alarms, and onboard remedial limitations. Fire response and missed learning from the separate Stolt Focus incident are also considered.
- 202123 Feb
Sludge accumulation in fresh water tank
An inspection revealed significant sludge in a fresh water tank, which the member attributed to water obtained from port. The flash highlights potential bacterial health hazards and describes inspection intervals, subsequent maintenance and hose disinfection using residual free chlorine, with a standing period of at least one hour.
- 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.
- 20206 Dec
Injury caused by closing fire flap
A crewman sustained a left-wrist wound when a fire damper closed during improvised filling of an expansion tank through ventilation trunking. The flash contrasts this method with the approved portable-pump arrangement and highlights non-routine risk assessment, adherence to procedures and management of change where approved systems are not functional.
- 202023 Oct
Firefighting (FiFi) Tank Outlet Blockage
A diving support vessel’s chamber firefighting tank outlet became blocked when a threaded endcap detached from its float and sank. The flash describes the plug assembly, potential loss of emergency water supply, permanent bonding of all six tank plugs, and recommended reviews for similar failure mechanisms.
- 2020Sep
Guidelines for Environmental Health for Offshore Installations
This addendum addresses potable-water management on offshore installations, including normally unmanned assets. It covers storage, bunkering, disinfection, Legionella control, sampling and emergency recovery. Chemical treatment, ultraviolet disinfection and pasteurisation are distinguished, alongside laboratory and field testing, written control schemes, competence assurance and management of change.
- 202014 Aug
Hull damage caused oil leakage from settling tank
A vessel’s fuel settling tank was punctured during berthing where protective fendering was missing, causing oil leakage. Port maintenance had not been communicated, while quayside access restrictions limited observation. Lessons address berthing risk assessment, decision-making information, possible shoreside support, alternative inboard tank arrangements and pollution emergency planning.
- 202013 May
Preventing Static Discharge
This alert describes static discharge contributing to offshore flash fires involving injuries and facility damage. It explains bonding and grounding, connection quality and the limitations of plastic containers. Recommendations address metal buckets, slow liquid discharge, grounded storage tanks, worker training and adherence to written procedures.
- 202030 Jan
Explosion and fire on-board the chemical tanker Stolt Groenland
This safety flash summarises preliminary MAIB findings on explosions and fire aboard Stolt Groenland during ship-to-ship styrene monomer transfer at Ulsan. Investigators considered deck rupture from over-pressurisation followed by vapour ignition the probable explosion mechanism. The incident caused extensive vessel damage and injuries to crew and firefighters.
- 201916 Dec
Explosion and fire on chemical tanker Stolt Groenland
This interim investigation examines explosions and fire aboard Stolt Groenland at Ulsan. Initial findings link probable tank rupture and vapour ignition to over-pressurisation during styrene monomer polymerisation. It describes inhibitor dosing, cargo conditions, firefighting and evacuation, alongside a separate Stolt Focus incident and reminders on monitoring and carriage instructions.
- 201930 Sep
UK HSE prosecution following 2011 fatal explosion in oil refinery
This safety flash reports HSE prosecution following a fatal refinery explosion in Pembrokeshire during tank emptying with a vacuum tanker. Four workers died and another was seriously injured. Investigators considered ignition of a highly flammable tank atmosphere the most likely initiator and identified longstanding safety-management failures.
- 201924 Sep
Safety Alert 366 - Dangerous Levels Of H2S Detected At Offshore Facilities
BSEE describes three hydrogen sulphide releases during offshore pipeline flushing and well abandonment, including incidents at non-sour facilities. One worker experienced dizziness and nausea. The alert recommends considering gas monitoring, detector calibration and bump testing, job safety analysis, rescue preparedness and gas-buster safeguards during potentially hazardous operations.
- 201929 May
Capsize and sinking of prawn trawler Nancy Glen with loss of 2 lives
Investigation of Nancy Glen’s fatal capsize in Lower Loch Fyne examines trawl loading during a turn and stability reduced by cumulative modifications, including a heavier crane and relocated tanks. Underwater surveys, laser scanning and inclining trials informed the analysis. Recommendations address regular, comparable stability checks for small fishing vessels.
- 201928 Jan
Confined space entry: Person overcome by fumes and rendered unconscious
A vessel crew member cleaning a faulty sewage-tank sensor was overcome by hydrogen sulphide, lost consciousness and fell from a fixed rack to the deck. The flash identifies failures in risk assessment, work authorisation, atmospheric checks and maintenance procedures, and reinforces safe systems of work and awareness of gas hazards.
- 201928 Jan
Confined space fatality on-board the fishing vessel Sunbeam
A second engineer died after entering a refrigerated saltwater tank aboard Sunbeam at Fraserburgh. Three crew members attempting resuscitation became unwell; recovery involved crew wearing breathing apparatus. Entry procedures had not been completed. The flash highlights robust confined-space procedures and practised rescue plans.
- 20186 Dec
Safety Alert 344 - Chemical Containment Release
BSEE describes an emulsion-breaker release from a cracked polyethylene tote on an unmanned platform. Xylene incompatibility was considered a contributing cause, while weather exposure may also have contributed. Rainwater compromised secondary containment. Recommendations address compatible containers, correct labelling, chemical training and inspection for continued service.
- 201819 Oct
Safety warning about working in enclosed spaces after the loss of 1 life on a fishing vessel
This bulletin presents initial findings from a fatal refrigerated salt water tank entry aboard Sunbeam at Fraserburgh. Testing found severe oxygen deficiency and Freon R22; refrigerant leakage through failed evaporator tubes was considered likely. It discusses hazardous rescue attempts and recommends tank-entry risk assessments, safe procedures and appropriate safety equipment.
- 201827 Sep
PSSR Rule Fact Sheet
This fact sheet outlines revisions to offshore oil and gas production safety regulations following review of the 2016 rule. It summarises updated standards, removal of third-party device certification, gas-lift shutdown valve classification, failure reporting, design documentation, atmospheric vessels, fire-tube inspection methods and approval before commencing production.
- 201824 Apr
Packaging Corporation of America Hot Work Explosion
Investigation of a foul condensate tank explosion at PCA’s DeRidder mill that killed three contractors and injured seven. Air ingress created an explosive atmosphere; nearby hot work was the probable ignition source. The report examines turpentine recovery, outage conditions, permit limitations, process safety boundaries and explosion safeguards, with comparisons to earlier incidents.
- 201811 Apr
Tank Gauging Hazard Alert
This alert explains how opening storage-tank thief hatches can release concentrated hydrocarbon vapours, creating oxygen-deficient, toxic and flammable conditions. It addresses tank gauging, sampling and fluid handling, outlining exposure assessment, gas monitoring, worker training, remote or closed gauging arrangements, ventilation and stopping unsafe work.
- 2018Apr
Measurements & Site Security
Inspection questions address liquid hydrocarbon and gas production measurement, royalty and allocation meters, sampling arrangements, proving and calibration. They cover run tickets, production commingling approvals, record retention and tank requirements. Site-security checks address theft, tamper-evident seals and meter bypasses, with regulatory authorities and enforcement actions listed alongside individual checks.
- 201819 Mar
Accidental Mixing of Different Fuel Oils
A vessel at anchorage experienced accidental mixing of ultra low sulphur and heavy fuel oils after transfer valves remained open overnight. Gravity transfer contaminated the fuel. The flash identifies inadequate oversight and procedural compliance, describes sampling for laboratory analysis, and records renewed reference to procedures and their display near the operating panel.
- 201819 Mar
Workboat Failed During Transfer Operations Due to Fuel Contamination
A workboat engine stopped during crew transfer and the craft was safely recovered. Condensation in its fuel tank promoted bacterial sediment that blocked the fine filter. Planned maintenance instructions had not been followed and spare filters were unavailable. Lessons address fuel inspections, tank levels and essential filter stocks.
- 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.
- 20183 Jan
MGPI Processing, Inc. Toxic Chemical Release
This case study investigates an incorrect sulfuric acid delivery connection to a sodium hypochlorite tank at MGPI in Atchison, Kansas, producing a chlorine-containing cloud. It examines unloading equipment design, pipe identification, procedure compliance, training, remote shutdown, control-room ventilation and escape respirator access, alongside community emergency planning and subsequent preventive changes.
- 201715 Dec
Bow thruster room flooded during fresh water transfer operation
Fresh-water transfer flooded a vessel’s bow thruster room through an unclosed sounding pipe after a cadet changed the tank filling sequence. The flash identifies inadequate risk assessment, absent crew discussion, neglected bilge alarm and failure to follow the emergency plan, with lessons on watch-keeping, handover and trainee supervision.
- 201715 Dec
Two cases of contaminated drinking water
Two incidents concern bacterial contamination in vessel fresh-water systems and office drinking water. Testing identified increased bacterial counts, while inspections and enquiries found neglected cleaning of tanks, dispensers and pumps. Actions included changing the drinking-water supplier, cleaning equipment, recommending scheduled cleaning and tank inspections, and avoiding reuse of drinking-water bottles.
- 20177 Dec
Environmental Alert 003/2017
An environmental alert describes a chemical release to sea during storage-tank commissioning. A design–construction discrepancy left the overflow lower than expected; filling above it and subsequent syphoning caused the release. Duty holders should verify overflow positions and may prudently consider water first fills with robust monitoring where possible.
- 201721 Sep
Failure of pipework in fuel tanks
Seawater leaking from pipework running through a vessel’s fuel tank raised the tank level. Subsequent fuel transfer was followed by a separator trip, and checks found water in the system. The flash identifies pipework failure and highlights visual inspection and ultrasonic baseline thickness measurements.
- 201730 Jun
Safety warning after explosion on container vessel Manhattan Bridge results in 1 fatality and 1 serious injury
MAIB bulletin describes a fatal auxiliary boiler explosion aboard Manhattan Bridge at Felixstowe and preliminary findings of wax restricting fuel flow. It explains marine gas oil cold-flow tests and recommends fuel selection, sample testing, filter inspection and temperature management, without establishing wax formation as the explosion’s cause.
- 20179 Jun
Huge leak discovered in fresh water system
Daily tank soundings revealed a vessel had lost 35 tonnes of fresh water over 24 hours. Checks traced continuous overboard discharge to bain-marie valves left open, without visible overflow. Inadequate supervision was considered the root cause. Valve-location and position signage was displayed, and valve operation explained to mess crew.
- 201711 May
Freedom Industries Chemical Release
Investigates the Freedom Industries chemical spill in Charleston, West Virginia, where internal tank-floor pitting corrosion released a mixture into the Elk River and public water supply. Examines deteriorated secondary containment, inspection deficiencies, treatment limitations, water testing, emergency communication and regulatory gaps, with recommendations for source-water protection and contamination response.
- 2017May
Corroded Tanks — Process Safety Beacon, May 2017
This bulletin describes two fatal refinery incidents involving corroded tanks: a hot-work ignition of flammable vapours and an operator falling through a weakened hot-oil tank roof during manual measurement. It highlights uncorrected defects, reporting and escalation of corrosion concerns, and avoiding access onto unsuitable or badly corroded equipment.
- 201720 Apr
AirGas Facility Fatal Explosion
CSB investigates the fatal nitrous oxide explosion at Airgas in Cantonment, Florida, on 28 August 2016. Probable initiation involved transfer-pump heating during trailer loading, although the initiating event remains uncertain. Analysis examines flame arrestors, interlock design, pump changes and process safety management, alongside earlier explosions and recommendations for inherently safer design.
- 201728 Mar
Vessel activities near platforms – two incidents
Two vessel incidents near fixed platforms illustrate failures in fuel-system restoration and steering control. An AHTS vessel blacked out and drifted away after generators tripped; another vessel struck a flare bridge during personnel transfer following rudder feedback-unit failure. Actions address bunkering procedures, handovers, emergency-generator checks and communications.
- 201612 Oct
Near-miss: Open hatches left without barriers
During contractor tank cleaning aboard a supply vessel, ten hatches remained open for ventilation without individual barriers, despite taped area barricading and a standby person. The flash describes an unchallenged fall hazard and subsequent work stoppage, risk assessment review, clarification of simultaneous-operation responsibilities, and ordering of barriers and vented grating.
- 201628 Sep
Hot Work Hazard Alert
This hazard alert addresses fire, explosion and toxic exposure during hot work on oilfield tanks and equipment containing hydrocarbon residues. It warns against treating empty equipment as safe and sets out employer and worker responsibilities for permits, atmospheric monitoring, tank cleaning, ignition control, protective equipment and hazard training.
- 20161 Sep
Confined space fatality – Sharp Lady
Following crude oil discharge and washing, two crew members entered a cargo tank to recover lost equipment and experienced hydrocarbon vapour effects. The Master entered to assist the collapsed Cadet and died. The flash highlights incomplete compliance with enclosed-space procedures, unappreciated atmospheric risk and missed opportunities to stop entry.
- 20164 Jul
Accidental discharge of bilge water in dry dock
This safety flash describes bilge water draining into a graving dock after personnel opened the wrong tank bottom plug. Findings identify inadequate communication and supervision. Preventative actions address docking-plan markings, confirmed plug identification, Chief Officer supervision, recorded risk assessment and toolbox talks. Absorbent sheets removed oil traces; no basin pollution was reported.
- 2016Mar
Safety Device or Control Device? — Process Safety Beacon, March 2016
This bulletin distinguishes routine process control from independent safety protection through a steam-locomotive example and a tank-overflow incident. It explains how reassigned operator duties turned a backup shutdown into primary control, and recommends clear procedures, training, calibration and scheduled testing of safety devices.
- 2016Feb
Mechrecovery Man
User manual for a browser-based calculator estimating advancing skimming systems’ oil recovery potential for planning, rather than actual spill performance. It explains encounter, recovery and storage inputs, decanting and offloading assumptions, continuous and batch spill scenarios, worked comparisons and equations, including limits imposed by maximum effective swath.
- 2016
Health and Safety Risks for Workers Involved in Manual Tank Gauging and Sampling at Oil and Gas Extraction Sites
Joint NIOSH–OSHA alert examines toxic hydrocarbon exposure, oxygen depletion and ignition hazards during manual gauging and sampling of production and flowback tanks. It reviews nine fatalities and field exposure measurements, explains filtering respirator limitations, and recommends closed sampling, atmospheric monitoring, exposure assessment, training and emergency arrangements.
- 2016
NIOSH-OSHA Hazard Alert: Health and Safety Risks for Workers Involved in Manual Tank Gauging and Sampling at Oil and Gas Extraction Sites
Joint NIOSH–OSHA alert examines hydrocarbon inhalation, oxygen deficiency and flammable atmospheres during manual tank gauging and sampling. It reviews nine fatalities and field exposure measurements, explains limitations of air-purifying respirators, and recommends closed sampling, exposure assessment, gas monitors, training and emergency arrangements.
- 201521 Oct
Caribbean Petroleum Corporation (CAPECO) Refinery Tank Explosion and Fire
Investigation of gasoline tank overfill at CAPECO’s petroleum terminal, followed by vapour-cloud ignition and multiple tank fires. It examines unreliable float-and-tape gauging, absent independent overfill safeguards, drainage valves, filling procedures and emergency preparedness. Comparisons with earlier incidents inform recommendations addressing regulatory gaps and automatic overfill protection.
- 201513 Oct
Spillage of methanol during cargo operations
An empty methanol tank being lowered onto a support vessel struck a full tank, damaging its valve and releasing approximately 1000 litres. The flash describes an unsuccessful removal attempt, the crew’s water-dousing response, failures to review cargo documentation, and lessons on certificate checks, stop-work policy and emergency preparedness.
- 20152 Jun
Near-miss: Hot work in no-weld zone
A vessel welder preparing to install steel shelves was stopped before welding onto a fuel tank beneath the deck. The flash identifies planning, communication, responsibility and signage failures despite an issued permit. Actions included marking prohibited welding areas, using general arrangement drawings for permit coordination, and clarifying permit issuers’ and area authorities’ responsibilities.
- 2015
Fatalities in Oil and Gas Extraction (FOG) Special Topic Report 2015
NIOSH summarises nine fatalities recorded during 2010–2014 involving crude oil tank gauging, sampling and fluid transfer at well sites. Case narratives examine possible petroleum vapour inhalation, oxygen displacement and reported medical findings. The report describes its surveillance sources and exclusions, while retaining uncertainty about contributing factors and unresolved causes of death.
- 2014Nov
2014-002 VR 200 Investigation of October 27, 2013, Fatality Vermilion Area Block 200 platform “A” Lease No. OCS-G 09500, Complex ID No. 24098-01
Investigation of a welder’s fatality during offshore platform decommissioning. A tank skid with attached vent booms rotated and fell into the sea during weld cutting, carrying the worker overboard. The panel examines ambiguous cutting instructions, omitted preparation planning, generic job safety analyses, inadequate oversight and failure to stop after unexpected movement.
- 20144 Jul
Storage tank external floating roof: the importance of inspection and maintenance to retain buoyancy of the roof structure
This alert addresses buoyancy and integrity of external floating roofs on hydrocarbon storage tanks. It explains pontoon flooding, rainwater accumulation, fluid specific gravity and repair defects, and recommends design calculations, in-service and out-of-service examinations, logged operator checks and, where reasonably practicable, roof–liquid deviation alarms.
- 201420 Jun
Improper Confined Space Entry Results in Multiple Fatalities
An employee became incapacitated after entering a tank containing a water–nitrogen mixture from a rigless coil tubing operation. Three colleagues entered in attempted rescue. The supervisor ordered drainage and further entry using a safety line. Three employees died; a fourth received first aid and hospital treatment.
- 201416 Apr
Pontoon compartment explosion on floating roof tanks
This safety flash describes a pontoon compartment explosion while two workers cut rim seal brackets near the pontoon on a tank’s floating roof. Released flammable residue caused a small fire, and the workers sustained moderate injuries. It notes more severe outcomes in previous similar incidents after tank clean-up.
- 201413 Mar
Loss of consciousness due to exposure to H₂S
Two mechanics lost consciousness and a third became dizzy after hydrogen sulphide escaped during high-pressure water cleaning of a sewage tank. All recovered. The flash identifies omitted toxic-gas hazards, absent gas detection and inadequate planning, and discusses permits, revised procedures, training and confined-space precautions.
- 201419 Feb
Tank Cable Strike Results in Injury to Employee
An alert describes loading a standing 400bbl tank onto a bed truck using a winch and tank bridle. The tank bottom slipped out and the bridle broke despite prior visual inspection. The recoiling line’s tail chain penetrated the rear cab window, injuring the driver’s head and face.
- 2014Feb
Are we reliving past incidents? — Process Safety Beacon, February 2014
This bulletin compares recurring storage-tank fires involving carbon adsorbers in Norway and Georgia, USA. Adsorption heat and the absence of flame arresters were shared design problems. It advocates retaining and sharing incident knowledge, reviewing events elsewhere, and evaluating new hazards introduced by environmental protection equipment through process hazard analysis and management of change.
- 201325 Nov
Safety Alert 305 - Explosion, Fire and Fatalities West Delta Block 32 Platform E
This alert describes fatal explosions and fires during piping installation on West Delta 32 E platform. Welding ignited hydrocarbon vapours from a wet oil tank, followed by explosions in three tanks. It identifies failures in hot-work authorisation, isolation, fire watching and supervision, and recommends improved contractor coordination, pre-work meetings and stop-work arrangements.
- 2013
Dangerous substances and explosive atmospheres
This consolidated Approved Code of Practice explains DSEAR duties for work involving dangerous substances. It addresses risk assessment, storage and containment, ventilation, ignition prevention and hazardous-area classification. Detailed guidance covers equipment suitability, hot work, tank cleaning and disposal, explosion-safety verification, emergency arrangements and employee training.
- 201220 Nov
Electrostatic Charge Results in Methanol Tank Explosion
This alert describes an explosion and flash fire involving a polyethylene methanol storage tank, attributed in its title to electrostatic charge. A worker checking the fluid level touched the inner tank cap; surrounding flammable vapour ignited. He received first aid for a second-degree arm burn.
- 201210 Jul
Confined space entry fatality
A crewman entered a vessel’s cargo tank without breathing apparatus to retrieve sampling equipment and died from oxygen deprivation despite rescue efforts. The flash summarises AIBN findings on the probable tank atmosphere, probable lack of motivation to comply with procedures, and wider non-compliance with confined space entry requirements aboard the vessel.
- 20122 Jul
Safety Alert 302 - Pressure beneath a Surface Bridge Plug Blows Work String out of Well
During well abandonment, pressure beneath a surface bridge plug expelled 385 feet of work string and the bottom-hole assembly before the BOP sealed the well. Debris struck a diesel tank, releasing approximately five gallons into the Gulf. BSEE recommends reviewing re-entry procedures and accounting for pressure beneath plugs.
- 201219 Apr
E. I. DuPont De Nemours Co. Fatal Hotwork Explosion
Investigation of a fatal hot-work explosion at DuPont’s Buffalo facility during repairs to slurry-tank agitator supports. Vinyl fluoride vapour reached the tank through interconnected pipework. The report examines missing isolation, omitted internal atmospheric testing, inadequate process knowledge in permit review and undocumented process changes, with comparisons to earlier tank-welding incidents.
- 20124 Apr
Bypassing of storage tanks safety features
This safety flash relays NOPSEMA’s alert about intentional defeat of safeguards on machinery-space oil and fuel storage tanks. Reported practices included holding spring-return valves open using zip ties and other means. The tanks contained hydrocarbons; no resulting release or injury is described.
- 2012Apr
What if you unload the wrong material into a tank? — Process Safety Beacon, April 2012
This bulletin describes a chemical delivery connected to the wrong storage tank, producing toxic gases and prompting evacuation and sheltering. It examines similar labels, identical connections, procedural changes and missing checks, and recommends clearer identification, connection verification, qualified workers and management of procedural changes.
- 201222 Feb
Bypassing of storage tank features
Inspections identified bypassed safety features on oil and fuel storage tanks, including sight-glass valves held open with zip ties or homemade clips. The alert explains potential inventory release if sight-glass integrity fails, outlines SOLAS requirements, and recommends safeguarding devices, meeting safety-case commitments and considering alternative level measurement arrangements.
- 2011Sep
Oil Tank Safety Study
This investigative study examines public exposure to explosions at oil and gas production storage sites, drawing on three investigations, a wider incident compilation and a community survey. It reviews regulatory and industry-standard gaps, unauthorised access, hazard signage and safer tank designs, including floating roofs, pressure-vacuum relief valves, flame arrestors and vapour recovery.
- 20114 Jul
Confined space – multiple fatalities
A bosun fell into a vessel’s slop tank for unknown reasons. Two colleagues entered to help, and all three became unconscious. Subsequent rescue used ventilation, atmospheric testing and breathing apparatus. The bosun died; both colleagues recovered after hospitalisation. Investigation noted impulsive rescue entries and inadequate understanding of hydrogen sulphide accumulation.
- 2011Jul
OCE15 - Potable water and legionella control
Guidance for offshore dutyholders on preventing potable-water contamination and legionella exposure. It addresses system design, temperature control, bunkering-hose hygiene, automated biocide dosing and scheduled water testing. Tank cleaning precautions, respiratory protection, chemical handling, maintenance records, dermatitis surveillance and worker training are also covered.
- 2011Mar
OCE10 - Chemical injection
Guidance for managing chemical exposure from offshore chemical injection systems. It addresses bunded storage, dedicated transfer lines, rated hoses, dry-release couplings and sequential calibration of pump heads. Operating procedures, maintenance, tank-level alarm checks, spill response and worker training are covered; breach of containment is outside its scope.
- 2011Mar
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.
- 2011Mar
OCM8 - Storing chemicals
Guidance for offshore dutyholders on chemical storage under COSHH. It addresses ventilated stores, segregation and bunding, leak checks, spill clean-up, emergency arrangements and permits for tank and silo work. Protective clothing, conditional respiratory protection, housekeeping, waste separation, training and supervision are also covered.
- 20119 Feb
Jacking of flat bottomed storage tanks
Following a storage tank slipping sideways on its jacks without injury, this alert examines planning and contractor assurance for tank jacking. It addresses ground stability, wind loading, structural stiffness, floor-weld stresses and additional support, with particular scrutiny of work beneath raised floors and consideration of finite element analysis.
- 201014 Oct
Safety Alert 290 - Plugged Flame Arrestor Results in Rupture of Oil Storage Tanks
Torch cutting near oil storage tanks preceded an explosion without fire that ruptured two tanks and spilled an estimated 29 barrels of crude oil overboard. The investigation identified probable ignition of escaping vapours, aggravated by a corrosion-plugged flame arrestor. Recommendations address periodic inspection, accessible positioning and protection of tanks during hot work.
- 201021 Jul
Veolia Environmental Services Flammable Vapor Explosion and Fire
This CSB case study examines a solvent-recovery explosion and fire at Veolia’s West Carrollton facility that injured four workers and damaged neighbouring properties. It analyses atmospheric relief arrangements, occupied-building siting and emergency response. The initiating overpressure cause remained uncertain; recommendations address closed relief systems, hazard analysis and safer building separation.
- 201030 Jun
Safety Alert to operators of "COMAH" oil/fuel storage sites & other storing hazardous substances in large tanks
HSE alerts bulk oil and hazardous-substance storage operators to installation and testing requirements for TAV high-level switches. Test levers or plates must be correctly returned and secured to avoid apparent test functionality masking inoperative protection. The June 2010 amendment extends applicability to some single-pole, single-throw switches, depending on magnet configuration.
- 201019 May
Assessment of the adequacy of venting arrangements for cargo oil tanks on FPSO and FSU installations
This HSE alert examines cargo oil tank venting on FPSO and FSU installations following a vapour ignition fire. It addresses changing hydrocarbon concentrations, dispersion during calm weather and nearby equipment effects. Duty holders should assess hazardous exposure and ignition risks, with possible controls including weather-related operational restrictions, re-inerting and vent modifications.
- 201031 Mar
The back-loading and carriage of hazardous oil contaminated bulk cargo on offshore supply vessels
This alert addresses hazardous oil-contaminated waste carried in offshore supply vessel mud tanks following reports of hydrogen sulphide and explosive atmospheres. It sets out pre-loading analysis, trained testing, hazard documentation and segregation measures, alongside restrictions on mud-tank use for fluids from wells with open perforations.
- 201021 Mar
Tank Welding – High Potential Incident
A senior mechanic stopped welding on a rig accumulator supply tank after recognising a potential explosive atmosphere. The tank remained closed, unpurged and uncleared of its contents. The alert describes deficiencies in permit completion, personnel involvement, pre-job checks, fire-watch coverage and the availability of firefighting equipment.