Topic
Hazardous Substances
Health or safety hazards from harmful substances.
Newest 100 Documents
All 318 in search- 202621 Jul
Bio-Lab Inc. Conyers Fire and Chemical Release
Investigation of the Conyers chemical-storage warehouse fire and release examines sprinkler corrosion, water-triggered decomposition and emergency response. It identifies sprinkler component failure as the most likely initiating water source, analyses storage and ventilation shortcomings, and recommends corporate safeguards and broader reactive-hazard coverage. Supporting work includes AcciMap analysis and chemical testing.
- 2026Apr
Emergency response systems save lives! — Process Safety Beacon, April 2026
This issue examines an ammonia release at a Virginia food processing facility where evacuees encountered the outdoor cloud and four employees were hospitalised. It highlights shortcomings in alarms, emergency shutdown use and release-specific planning, emphasising trained responders, regular drills, safe relief discharge locations and wind-dependent evacuation routes.
- 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.
- 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.
- 2026Feb
Inherently Safer Principles — Process Safety Beacon, February 2026
Explains inherently safer design through an alkylation reactor sampling case. Consistent quality-control results supported reducing routine sampling from twice daily to weekly, with additional samples under specified changes or upsets. Introduces minimisation, substitution, moderation and simplification, and calls for management-of-change review before implementing identified options.
- 202622 Jan
Petrol driven equipment left stored in an emergency generator room
A vessel safety round identified a petrol-containing snowblower stored in the emergency generator room, creating fire and explosion risks and obstructing access to critical equipment. The equipment was relocated. The flash recommends designated storage for flammables and keeping machinery spaces clear, with storage procedures and inspections identified for review.
- 2026
CHIRP Maritime FEEDBACK 82 (Spring 2026)
Maritime reports examine solvent use in bilges, navigation audit findings, refused fuel-tank entry, twin-lanyard misuse and obstructed pilot access. Further cases address partial power loss linked to an unannounced software update and pressure over navigation decisions. Commentary emphasises equipment limitations, safe attachment, supplier communication and supportive bridge leadership.
- 2025Nov
Control of Substances Hazardous to Health (COSHH)
An offshore inspection guide for assessing dutyholders’ COSHH arrangements and legal compliance. It uses a Plan, Do, Check, Act framework to examine risk assessments, engineering controls, respirator fit testing, exposure monitoring and health surveillance. Performance descriptors link inspection findings to enforcement expectations and help prioritise future regulatory interventions.
- 20252 Oct
USCG: Lithium-Ion battery system installations
Summarises USCG advice following a lithium-ion battery bank fire on a passenger vessel caused by overheated, loosely crimped lugs. Discusses thermal runaway, toxic off-gases and suppression difficulties, alongside engineering review, battery management, condition inspections, maintenance, crew competence and fire drills. No injuries and minimal vessel damage were reported.
- 202525 Sep
Cuisine Solutions Ammonia Release
CSB investigates an ammonia refrigeration release at Cuisine Solutions in Sterling, Virginia, which injured workers during evacuation. Relief-valve testing and dispersion modelling examine overpressure, liquid aerosol and unsafe discharge. The initiating upset remains undetermined. Recommendations address relief-system assessment, process-data retention, ammonia alarms and emergency preparedness.
- 2025Jul
CHIRP Superyacht FEEDBACK 10
Six superyacht reports examine dismissed safety concerns, inconsistent fall protection, unsafe pilot boarding, crew abandonment, a mooring-line injury and chemical burns. Commentary addresses leadership, reporting protection, procedural compliance and task risk assessment. An appended flag-state flyer reinforces safe working at height, equipment training and intervention in unsafe work.
- 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.
- 202529 Apr
Detergent chemical burn
An electrician and trainee suffered slight chemical burns from leaked detergent during dishwasher repairs aboard a vessel. Electrical isolation was addressed, but corrosive detergent hazards and labelling were overlooked. The flash highlights secondary hazards, stakeholder involvement, clear hazard identification and appropriate PPE for unidentified liquids.
- 20256 Mar
MSF: Cook got chemicals in eye
A vessel cook suffered eye irritation when sodium hydroxide oven cleaner fell from a cooker hood during galley cleaning, passing behind prescription glasses. The flash identifies inadequate eye protection and lack of situational awareness, and describes eye cleansing followed by medical evacuation to hospital.
- 20256 Feb
Confined space entry hot work fatality
A welder died after entering a pipe to check welding in a shipyard. The flash identifies shortcomings in entry restrictions, supervision, communication, procedures and assessment of argon-related risks. Actions included barriers and signage at specified pipe openings, revised restricted-space procedures, and additional inert-gas input to risk assessments and work permits.
- 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
CHIRP Maritime FEEDBACK 78 (Spring 2025)
This maritime digest examines pilot-ladder deficiencies, a caustic eye injury, unacceptable accommodation, charcoal cargo fire, corroded walkways, yacht fire, disabled carbon dioxide firefighting and rescue-craft capsize. Commentary emphasises time for post-maintenance checks, equipment handovers, crew training and risk assessment, alongside protective equipment and seafarers’ rights.
- 2025
CHIRP Maritime FEEDBACK 79 (Summer 2025)
Six confidential maritime reports examine heavy-weather fatalities, navigational audit findings, lifting entanglement, a pilot boarding fall, obstructed firefighting equipment and exposure to residual acid fumes. Commentary connects operational shortcomings with communication, supervision and safety culture, with separate lessons for seafarers, ship managers and regulators.
- 2025
CHIRP Maritime FEEDBACK 80 (Autumn 2025)
This maritime incident digest examines unsafe pilot transfers, an obstructed escape hatch, incorrect antenna labelling, pest infestation and unsafe fumigation, an unmanned survey vessel capsize, and an enclosed-space inspection injury. Commentary emphasises practical design validation, operational limits, crew welfare and confirmed communication between teams.
- 2024Nov
Risk of exposure of laboratory staff to biological agents due to missing clinical information
This safety notice addresses infection risks in clinical and veterinary diagnostic laboratories when specimen requests lack relevant clinical information. It describes exposures involving Hazard Group 3 agents and calls for better request forms, staff training, sample-processing procedures, linked patient specimens and IT systems that make updated clinical details accessible to laboratory staff.
- 202418 Jun
Carriage of methanol – dangerous goods – without proper certification
A workboat transported methanol for refuelling a LIDAR buoy at an offshore wind farm without the required dangerous-goods compliance document. The flash describes inadequate vessel suitability, omissions in contractor risk assessment and apparent lack of awareness. It explains certification requirements for methanol carriage and fully fuelled buoys.
- 202427 Mar
USCG: hazard from discarded munitions
This flash relays a US Coastguard alert about discarded munitions in coastal waters. A clamming-vessel deckhand suffered severe burns after a canister, likely containing mustard gas or another blistering agent, came aboard. Recommendations cover checking charts, avoiding marked dumping areas, recording encounters and reporting unexploded munitions.
- 202419 Mar
MSF: Chemical handling – eye burn
A biocide splash from a hose during pneumatic pump checks reached a person on the deck below, causing a small eye burn despite safety glasses. The flash identifies inadequate risk assessment and missing access safeguards, and calls for relocation of chemical transfer, review of assessment and renewed toolbox discussion.
- 2024
CHIRP Maritime FEEDBACK 74 (Spring 2024)
This maritime digest examines tug and barge safety, dry-ice asphyxiation, leaking bunker connections, sulphur-emission non-compliance, a fall during mast work, lift-maintenance hazards and open cargo hatches at sea. Commentary addresses leadership, familiarisation, ventilation, permits to work and verified isolation, alongside design shortcomings and protection for confidential reporters.
- 202314 Nov
Carbon Monoxide Exposure Risk in Offshore Environments
BSEE inspections identified elevated carbon monoxide exposure risks from gas-powered machinery on offshore facilities during calm weather. The alert examines accumulation in occupied spaces, delayed stationary detector alarms and occupational exposure limits. It recommends that operators and contractors consider portable detection, ventilation, exhaust integrity checks, machinery placement and personnel awareness measures.
- 20238 Sep
Welding Hazard Alert
This alert addresses welding fume exposure in the oil and gas industry, including respiratory and neurological harm from toxic metals. It presents open-air manganese exposure findings and outlines employer and worker responsibilities for air sampling, local exhaust ventilation, training, respiratory protection and chromium-related medical examinations.
- 202329 Aug
Paper shredder – explosion
An office paper shredder exploded after a sheet sprayed with WD-40 silicone lubricant was fed through its blades. Heat or a motor spark ignited accumulated vapours, destroying the plastic bin without injury. The flash discusses inadequate substance assessment and the purchase of proprietary lubrication sheets specified by the manufacturer.
- 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.
- 20231 Jul
Small boat crew exposed to FPSO process water discharge (fumes and aerosol)
Deck crews supporting diving at a live FPSO developed symptoms after exposure to process-water fumes and aerosols. Increased discharge and changing wind conditions were not adequately communicated or recognised. The flash describes stopping work, medical examination and follow-up, and calls for improved briefings, risk assessment and consideration of discharge diversion.
- 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.
- 202312 Jun
MAIB: Lithium-ion battery fire
This safety flash describes seawater contamination of a lithium-ion battery in subsea equipment stored aboard a vessel. Examination following deployment had identified a potential leak, but further investigation was delayed. A brief explosion occurred without injuries. The flash discusses battery hazards, secure storage of damaged batteries and appropriate extinguishing measures.
- 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.
- 202327 Apr
Carbon monoxide poisoning on board the sports cruiser Emma Louise with loss of 2 lives
Investigates two fatal carbon monoxide poisonings aboard Emma Louise at Port Hamble Marina. Gas measurements and optical gas imaging indicated that engine exhaust likely entered the poorly ventilated covered cockpit via a towable ski ring at the transom. The report discusses marine carbon monoxide alarms, ventilation and awareness among recreational boat users.
- 202324 Apr
Bio Lab Conyers Chemical Release
Investigation of Hurricane Laura damage, chemical decomposition, chlorine release and fire at Bio-Lab’s Louisiana facility. It examines hurricane preparedness, process hazard analysis, structural damage, fire-water reliability and regulatory coverage of reactive chemicals. Appendices analyse separate Conyers decomposition events and provide structural and fire-protection consultant reviews.
- 202324 Apr
Bio-Lab Lake Charles Chemical Fire and Release
Investigation of hurricane-related chemical decomposition, fire and chlorine release at Bio-Lab’s Louisiana manufacturing facility. It examines building resilience, process hazard analysis follow-through, deficient fire protection and emergency equipment readiness, alongside gaps in reactive-hazard regulation. Appendices include structural and fire-code assessments and separate Conyers decomposition incidents.
- 202316 Feb
Fluid Transfer Transport
Hazard alert addressing toxic and flammable vapours, hydrogen sulphide and oxygen displacement during vacuum loading and offloading of produced fluids. It assigns responsibilities to facilities, hauling companies and drivers, covering atmospheric monitoring, training, conductive hoses, bonding and grounding, safe vent discharge and prevention of diesel-engine runaway.
- 202316 Feb
LTI: Carbon Monoxide (CO) poisoning during Oxy-Acetylene brazing
A crew member suffered carbon monoxide poisoning while repairing a refrigeration valve using oxy-acetylene brazing. The flash identifies incomplete risk assessment, omitted exhaust ventilation and inconsistent mask requirements. Lessons address ventilation, exposure duration, air testing, conditional respirator use with personal CO monitoring, and further welding-hazard training.
- 2023Jan
Exposure to diacetyl vapour in food and drink manufacture
This safety alert addresses harmful diacetyl vapour exposure in food and drink manufacture, particularly coffee roasting and grinding and heated flavour mixtures. It sets out workplace exposure limits, risk assessment, sampling, substitution, temperature reduction, enclosure and extraction, with conditional respiratory protection and health surveillance. It also flags carbon monoxide in coffee processing.
- 2023
CHIRP Maritime FEEDBACK 72 (Autumn 2023)
This maritime digest examines an averted mooring-line failure, a lithium-ion battery cargo fire, contractor fatigue, a diver’s propeller injury, tanker engine-control difficulties and a fisher’s overboard rescue. It discusses mooring design, dangerous-goods packing, rest arrangements, diver visibility, emergency teamwork and personal rescue equipment, alongside two improper cargo-stowage reports.
- 202213 Dec
Accidental swallowing of paint thinners
A crew member accidentally drank paint thinners left in an unlabelled mineral-water bottle after stencil cleaning in an onboard workshop. Medical examination found no consequences. The flash identifies unsuitable containers and poor housekeeping, and recommends appropriate chemical containers, decanting in the chemical storage area and tidying away remaining substances.
- 202213 Dec
BSEE: Unsafe chemical use and disposal
This safety flash summarises three BSEE incidents involving mixed epoxy paint waste, a smouldering rag and incompatible drain-cleaning chemicals. It describes smoke, fire and gas inhalation, and presents recommendations on chemical handling procedures, safety data sheets, suitable protective gloves and the readiness and compatibility of firefighting equipment.
- 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.
- 20227 Sep
Unsafe Chemical Use and Disposal
Three incidents illustrate hazards from mixing expired epoxy products, disposing of a rag likely containing flammable thinner, and combining drain cleaner with bleach. BSEE recommends operators consider chemical-specific procedures, suitable protective equipment, firefighting readiness, specialist disposal contracts and lifecycle inventory management to address unsafe chemical use and disposal.
- 20225 Sep
Chemical burns to body
A recently joined vessel engineer suffered a severe chemical burn while decanting carbon remover for purifier maintenance. Posted instructions were not followed and chemical PPE was not worn; a less hazardous alternative was available. Lessons emphasise comprehensive familiarisation, supervised induction, competence assessment and confidence to stop unsafe work.
- 202222 Jul
Mixing of cleaning chemicals
A worker mixing bleach and toilet cleaner in a tug’s toilet area experienced chemical vapour exposure and was diagnosed with chemical bronchitis. The flash describes onboard treatment and assessment ashore, identifies limited domestic chemical awareness, and records training materials, revised risk assessments and a review of chemical stocks.
- 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.
- 20228 Apr
USCG: Lithium battery fire
This flash summarises a USCG alert about discarded lithium batteries burning in a freight container on a highway before planned shipment to China. It describes misleading cargo documentation, inadequate packaging and marking, and residual charge/full circuit as the determined cause. Recommendations address packaging, marking, short-circuit protection and storage.
- 2022Apr
Process Safety lessons from a ship fire — Process Safety Beacon, April 2022
This bulletin draws process-industry lessons from the USS Bonhomme Richard fire and a Navy review of earlier ship fires. It highlights improper storage of combustible and hazardous materials, ineffective inspections, deficient hot-work oversight and emergency preparedness, recommending adherence to permit procedures, designated storage and participation in emergency drills.
- 202220 Jan
Chemical reaction: person injured during grouting operations
A grouting worker suffered first-degree burns during high-pressure water-jet cleaning after work on an offshore wind transition piece. Water soaked his coveralls and combined with grout dust to form a corrosive solution. The member attributed the incident to missing safety data sheet information, leaving the risk assessment without mitigation measures.
- 202220 Jan
Hose management and chemicals: crew person felt ill
An engineer coughed and felt unwell while flushing a hose before filling a cooling-water system, with no long-term ill-effects. The member attributed the incident to poor hose management: residual cooling agent remained after previous use. Actions included separate hoses for cooling agent and non-potable water, plus flushing and drying before storage.
- 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.
- 202131 Aug
What are audits for? Some eCMID findings
This safety flash reviews findings from 769 eCMID vessel inspections over the 12 months to April 2021. It highlights shortcomings in confined-space entry arrangements, chemical handling procedures, firefighting equipment, watertight closures, navigation equipment, engine-room practices and lifting-equipment management, alongside links to related incidents.
- 202130 Jul
Acetylene quad fire on quayside
An acetylene cylinder quad caught fire on a quayside during vessel demobilisation involving removal of sea-fastenings by welders. No injuries were reported. The flash describes emergency response, cylinder puncturing, evacuation and cooling, and recommends pre-use inspections, appropriate quad storage and review of emergency procedures. Causes remained under investigation.
- 202122 Jul
HSE: Allergic reaction at work
An employee developed permanent allergic contact dermatitis after being splashed with metalworking fluid while cleaning a grinding machine. The flash reports inadequate exposure risk assessment and skin-contact controls despite a known history of dermatitis, highlighting the HSE inspector’s emphasis on suitable protective equipment, particularly gloves.
- 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.
- 20219 Jun
Inadvertently drinking hazardous substances
A crew member inadvertently ingested about 20 ml of paint thinners stored in a drinking-water bottle and later attended hospital after repeated vomiting. The flash emphasises appropriate chemical storage, suitable decanting containers and clear labelling, including product, manufacturer and safety data sheet details.
- 20219 Jun
MSF: Tank corrosion
A vessel’s routine tank sounding revealed rising liquid levels and a pinhole leak admitting salt water. Investigation found coating damage from the sounding weight and incorrectly discarded corrosive chemicals had degraded the striking plate and underlying steelwork. Repairs followed, with crew reminded about chemical handling, safety data sheets and authorised hazardous-waste disposal.
- 20212 Jun
Inhalation of toxic fumes during hot work
Two crew members suffered symptoms after heating a vessel’s thruster coupling released fumes from an anti-rust coating. The coating was unknown to the crew and no safety data sheet had been supplied. The flash examines cleaning instructions and ventilation used for cooling rather than extraction, highlighting assessment of toxic exposure risks.
- 20212 Jun
UK HSE: Worker fatally injured in oil drum explosion
An engineer suffered fatal injuries when a drum exploded while he cut its lid with a plasma torch. Drums labelled for motor oil had previously held gasoline without correct relabelling. The flash highlights residual vapour ignition and calls for adequate container information, labelling, cleaning and de-gassing before hot work.
- 202114 Apr
Carbon monoxide poisoning on motor cruiser Diversion with loss of 2 lives
This investigation examines two fatal carbon monoxide poisonings aboard Diversion at York. Exhaust leaked from an incompatible, non-marine cabin heater silencer and pipe connection, entering circulating air. Restricted ventilation and the absence of an alarm are analysed alongside installation checks, servicing and heater testing.
- 2021Feb
Failure of a road tanker pressure/vacuum relief valve
HSE safety alert describes a modified road-tanker relief valve that stuck open, releasing nitric acid vapour without injuries or property damage. A welded nut obstructed the valve stem. It calls for visual checks for unauthorised modifications, manufacturer-guided servicing and verification of both pressure and vacuum protection functions.
- 202015 Oct
Safety warning about carbon monoxide poisoning after the loss of 2 lives on the motor cruiser Diversion
This bulletin presents initial findings following two carbon monoxide deaths aboard Diversion, moored on the River Ouse in York. A non-gas-tight heater exhaust silencer and loose connection allowed fumes into the cabin. Safety lessons address marine-approved heater components, professional inspection, servicing, carbon monoxide alarm selection and testing, and suspected poisoning.
- 202010 Sep
Failure to detect dangerous gas/vapour due to incorrect specification of sample tube
This safety alert examines misleading readings from pumped gas detectors caused by vapour adsorption inside unsuitable sampling tubes. A fatal explosion followed hot work based on a false reading. It recommends checking detector–tube combinations with the substance of interest where practicable and assessing sampling-system response times.
- 202014 Aug
Positive: STOP WORK by Master challenging Sailing Order
A platform supply vessel Master challenged sailing orders that conflicted with local requirements for loading radioactive cargo last and dispatching it first. After initial rejection by client logistics, escalation secured company management support. The flash highlights stop-work authority and subsequent collaboration to change the sailing order.
- 202024 Jul
Cargo Ignited on Truck Bed During Transportation
A truck carrying materials from a warehouse to a vessel experienced a cargo fire, extinguished by the driver without injury or truck damage. The ignition source remained undetermined. Concerns included unsecured cargo, flammable hand sanitiser and inadequate segregation. Recommendations address packaging, securing, load integrity checks and eliminating potential ignition sources before travel.
- 2020Jul
Process interruptions: a threat to process safety — Process Safety Beacon, July 2020
This bulletin examines an explosion involving mononitrotoluene left in a shut-down vacuum distillation column. Leaking steam valves heated the material, leading to decomposition and a runaway reaction. It highlights shutdown isolation, detailed procedures, continued monitoring of process parameters and alarms, and repair or replacement of leaking block valves.
- 20201 Jun
Inadvertent activation of condensed aerosol fire extinguishing system leads to a fatality
An inadvertent partial discharge of a FirePro condensed aerosol extinguishing system during installation aboard Resurgam contributed to an apprentice’s death through inhalation of suppressant particles. The flash highlights underestimated exposure risks and MAIB recommendations for isolation during installation and maintenance, evacuation checks, warning alarms and enclosed-space rescue planning.
- 20205 May
Ignited hand sanitiser
This safety flash describes burns to a man’s hands after he touched a surface before alcohol-based sanitiser had dried. It attributes ignition of the fumes to static electricity, producing almost invisible flames. He extinguished them at a sink. The account highlights the sanitiser’s flammability and failure to identify all energy sources.
- 202010 Mar
Safety warning after inadvertent activation of condensed aerosol fire extinguishing system leads to a fatality
This bulletin addresses a fatal inadvertent discharge during installation of a FirePro condensed aerosol extinguishing system aboard Resurgam in Newlyn. Inhalation of concentrated suppressant particles significantly contributed to an apprentice’s death. Safety lessons cover isolation during installation and maintenance, discharge warnings, evacuation checks and enclosed-space rescue planning.
- 2020Mar
March, 2020 - Vacuum Trucks can Catch Fire and Explode! — Process Safety Beacon, March 2020
This bulletin describes a vacuum truck explosion at a Californian wastewater facility involving incompatible substances, followed by fires and evacuations. It explains flammable vapour and static electricity hazards during vacuum collection, and highlights permit completion, material compatibility checks, grounding and bonding, and separation of vent discharge from ignition sources.
- 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.
- 2020
Workplace exposure limits
EH40 sets out approved British workplace exposure limits and explains their application under COSHH. It covers time-weighted averages, short-term limits, personal and biological monitoring, dust and fibre measurement, and assessment of mixed exposures. Legally binding lists and calculation methods are distinguished from supporting guidance.
- 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.
- 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.
- 201922 Oct
Update to SF 11/19: Fatality and multiple injuries – flash fire onboard pipe-lay barge
This flash updates a pipe-lay barge incident involving repair of stuck polypropylene field-joint coating equipment. Vapour and droplets escaped during piston extraction and ignited, injuring fourteen people; one later died. It describes medical evacuation and recommends temperature control through the integrated system and manufacturer consultation on permissible repairs.
- 20192 Oct
Safety Alert 367 - Saturated Glycol Handling Leads to Fire
A production-platform fire followed unattended glycol reboiler start-up after an extended shut-in. BSEE attributed ignition to high water content and rapid heating, which flooded the still column and expelled fluids onto the stack. Recommendations for consideration address advanced training, attended start-up, circulation before heating and stack insulation.
- 201912 Aug
Near miss fire – epoxy overheating
Leftover mixed epoxy produced smoke in a freight container on a vessel’s deck. Closely stored cans prevented curing heat from dissipating, and the container was poorly ventilated. The flash recommends small quantities, ventilated storage on metal drip trays, frequent observation during cooling, separate storage risk assessments and available extinguishers.
- 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.
- 201910 Jun
Safety Alert 355 - Recent Safety Notices on Deficient Harnesses and Gloves
BSEE summarises two manufacturers’ notices concerning defective dorsal D-rings on specified DBI-SALA ExoFit NEX harnesses and potentially harmful benzidine in red Honeywell NF11/NF11X gloves. Identification depends on manufacturing dates and lot codes or receipt dates. Operators are advised to consider inventory searches, protective equipment during glove removal and manufacturer instructions.
- 201928 May
Oxygen service regulators
Regulators on several dive sites handling gas with greater than 25% oxygen were oxygen clean but contained incompatible materials. The flash distinguishes cleanliness from oxygen compatibility, discusses venting versus non-venting designs, and describes risk assessment and management of change for replacement, with limited retention of venting models under specified mitigations.
- 2019Feb
Change in Enforcement Expectations for Mild Steel Welding Fume
HSE strengthens enforcement expectations following evidence that mild steel welding fume can cause lung cancer and possibly kidney cancer. The alert requires suitable exposure controls regardless of welding duration, addressing local exhaust ventilation indoors, respiratory protection for residual fume and outdoor welding, training, maintenance and revised risk assessments.
- 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.
- 201928 Jan
Person felt unwell while working in confined space
A worker became dizzy and weak while cleaning a mud tank and was rescued by the tank watchman. The flash identifies deficiencies in permits, atmospheric checks, gas detector use, isolation and rescue arrangements. It highlights missing mud hazard information and checks of lockout kits, detectors and rescue equipment.
- 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.
- 20183 Dec
Glow sticks breaking open – chemical splash risk
Glow sticks from the same batch broke open during activation, releasing chemical dye. The flash discusses possible temperature-related brittleness and a manufacturing defect, without confirming either cause. Recommendations cover air-conditioned long-term storage, opening away from eyes, protective gloves, and checks on stock expiry or authenticity.
- 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.
- 201811 Sep
Unintentional release of carbon dioxide from fixed fire-extinguishing systems on ro-ro vessels Eddystone and Red Eagle
Investigation of unintended carbon dioxide discharges on Eddystone and Red Eagle examines leaking cylinder valves, system activation arrangements and maintenance deficiencies. Neither incident harmed anyone. The report analyses leakage alarms, pressure protection, valve testing and servicing, and recommends design reviews and improved survey assurance of safety devices.
- 201820 Jul
USCG: two alerts relating to gas releases
This flash summarises two US Coast Guard alerts: ethylene vapours triggering carbon monoxide alarms on an LNG carrier, and contaminated Gulf Coast bunker fuel causing fuel-system failures. It highlights gas-monitor cross-sensitivity, corrective action on alarms, and fuel contamination problems undetectable by standard ISO 8217 test methods.
- 201814 Jun
Accidental drinking of thinners stored in mineral water bottle
A trainee ETO swallowed thinners from a mineral water bottle kept by contractors in an engine room workshop. The flash identifies inadequate contractor briefing and unsafe chemical storage, and records reminders to use properly marked containers and recommendations for crew to carry their own drinking bottles.
- 201824 May
Arkema Inc. Chemical Plant Fire
Investigates organic peroxide fires at Arkema’s Crosby facility following Hurricane Harvey flooding. Examines loss of refrigeration and backup cooling, common-mode safeguard failures, flood-risk omissions in process hazard analysis, and evacuation decisions. Reviews extreme-weather guidance and recommends independent protection layers and improved emergency planning.
- 201811 May
Safety Alert 334 - Benzene Level Exceeds Exposure Limits
Two offshore production-platform inspections identified potential benzene exposure, inadequate emissions monitoring and shortcomings in worker information and safe work practices. The alert recommends considering improved procedures, exposure testing, communication and respiratory protection. It also presents exposure limits and acute and chronic health effects.
- 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.
- 2018Feb
Runaway Reactions Caused by Contamination — Process Safety Beacon, February 2018
This bulletin examines two explosions involving contaminated process materials: heated organic residue in pipework and crude methacrylic acid in a rail tank car. It explains reduced decomposition temperature, corrosion-related contamination and insufficient inhibitor, and recommends material identification, suitable construction materials, cleanliness and adherence to contamination-prevention procedures.
- 201831 Jan
Inadequate handling and storage of potentially hazardous substances
A vessel crew recovered two floating drums containing unidentified chemicals without considering the risks. Storage near a frequently accessed deck area lacked drip trays, and shore management was not informed. The flash recommends assessment before handling potentially hazardous unknown substances and immediate reporting to arrange collection and destination.
- 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.
- 2018
Fatalities in Oil and Gas Extraction (FOG) Special Topic Report 2018
NIOSH summarises eight fatalities and ten hospitalisations during 2015–2016 involving ignition, inhalation or suspected inhalation of hazardous gases and vapours during fluid handling at oil and gas sites. Tables distinguish exposures, fires and explosions, activities, fluids and reported outcomes, including cardiac deaths with possible work exposure.
- 2018
Manganese Exposures During Welding and Hot Work Tasks Presentation
Presentation examining manganese exposure during welding and hot work, neurological health effects and the basis for occupational exposure limits. It compares inhalable and respirable sampling results across working conditions, discusses local exhaust ventilation and worker positioning, and presents respiratory protection choices alongside welder engagement and implementation strategies.
- 201730 Nov
Limitations of Monitors Hazard Alert
This hazard alert explains multi-gas monitor selection and use in oil and gas operations. It highlights hydrogen sulphide monitor limitations, unreliable flammable-gas detection under some atmospheric conditions, and misleading alarm cessation. Guidance covers sensor selection, calibration, bump testing, breathing-zone positioning and immediate evacuation following any alarm.