Activity
Hot Work
Work producing flame, heat or sparks requiring ignition-risk controls.
Newest 100 Documents
All 255 in search- 202628 Apr
Diver entanglement – uncontrolled equipment in the water column
During shallow-water welding, a diver’s bail-out regulator became entangled in a rope supporting a rubber mat and welding rods. Swell moved the suspended items uncontrollably. A stand-by diver freed him within the planned diving time. The flash highlights loose-rope avoidance, tool positioning and possible use of lockable carabiners.
- 202627 Apr
Prevent Fires by Inspecting Cords, Plugs and Welding Leads Before Use
This alert reviews three incidents involving melting welding leads, flames at a cord connection and a tubing bender plug with a loose prong. It warns against applying water to potentially energised conductors and recommends that operators and contractors consider pre-use inspections, suitable electrical protection, hazard assessment and safety briefings.
- 202617 Mar
Unsafe handling of gas cylinders
A Chief Mate identified unsecured compressed gas cylinders on the quayside before planned gas cutting and welding during vessel maintenance. The flash discusses contractor awareness, perceived time pressure and unavailable securing arrangements, highlighting approved racks, restraint, contractor coordination and crew confidence to stop unsafe work.
- 2026Mar
Shared G-PINCs (Mar 2026) — General
General regulatory inspection questions address facility identification, operational safety, approvals, incident reporting, engine safeguards and equipment marking. Welding and burning checks cover equipment condition, authorisation outside approved areas, fire-watch arrangements, gas surveillance and precautions around wells. Entries identify regulatory authorities and enforcement actions.
- 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.
- 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.
- 202511 Sep
BSEE Safety Alert 507 - Improper Use of Equipment and Tools Increases Risk of Fires and Explosions Offshore
BSEE identifies recurring offshore tool misuse involving live electrical circuits, explosive atmospheres and high-pressure or high-temperature systems. Cases include unsuitable hand tools and a plumber’s plug used during welding. Recommendations address competence evaluation, tool ratings and tracking, maintenance, pre-work audits, qualified inspections and authority to halt unsafe work.
- 202516 May
Person injured when unsecured grating gave away
A worker securing sea-fastening lashings slipped through unfinished walkway grating beside a Multiple Reel Drive System, sustaining shoulder discomfort and leg abrasions. The hot-work subcontractor had been redirected before completing installation. Lessons address assessing risks from unfinished work, communicating its status, barricading access and checking worksite safety.
- 202519 Mar
Acetylene gas explosion
Two engineers setting up oxygen and acetylene cylinders experienced a small explosion and hose fire, leaving one with first-degree burns. The flash identifies inadequate flashback protection, bent hoses, faulty crimps, absent hot-work authorisation and unsuitable protective equipment. Lessons address arrestor placement and checking components after a flashback.
- 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.
- 202427 Nov
Hot work performed outside of Permit to Work (PTW) boundary limit
A contractor used a cutting torch and grinding disc to remove a metal trip hazard from a vessel deck outside the permitted work area. Sparks and slag fell onto scaffolding boards and an electrical cable below. The flash highlights failures in assessment, communication and supervision, recommending improved permit training and job preparation.
- 20244 Sep
BSEE Safety Alert 488 - Flash Fires During Welding Operations
A flash fire and blast during nozzle tack welding on a fuel gas scrubber propelled a tied-off welder against a rail without injury. Subsequent flammability readings ranged from 0 to 70% LEL. BSEE recommends considering improved atmospheric checks, ventilation, hot-work protocols, supervision, training and protective equipment.
- 20243 Sep
NTSB: Fire on vessel – stray electrical current during welding
This safety flash summarises a fire aboard Qualifier 105 during aluminium welding in winter yard storage. The probable ignition source was electrical but undetermined; stray welding current remained unconfirmed. Combustible accommodation materials increased damage. The lesson recommends placing the welding return clamp as close as possible to the weld.
- 202422 May
US BSEE: Welding and burning hazards
This flash summarises BSEE inspection findings on welding and burning hazards at Gulf of Mexico production and well-operation sites. It describes potential fires, including suspected slag penetration beneath living quarters, and highlights flammable materials, inadequate training and conflicting fire-watch duties. Recommendations address protective barriers, competence, supervision and pre-job discussions.
- 20244 Apr
BSEE Risk Based Inspection Identifies Welding and Burning Hazards
BSEE summarises targeted inspections of Gulf of Mexico production and well-operation facilities that identified welding and burning hazards. Findings include damaged or poorly positioned fire barriers, nearby flammables, deficient planning and training, and conflicting fire-watch duties. Operators and contractors are encouraged to consider improvements to protection, competence, procedures and supervision.
- 20244 Apr
Safety Alert - BSEE Risk Based Inspection Identifies Welding and Burning Hazards
BSEE reports targeted inspections of 22 Gulf of Mexico production and well-operation sites, identifying damaged or misplaced fire barriers, hot work near hydrocarbons, deficient planning and inconsistent training. The alert describes a living-quarters fire and recommends considering improved barrier inspection, task-specific planning, competence assurance, supervision and fire-watch arrangements.
- 202419 Feb
Hot work whilst working at height in a confined space – job was stopped
A contractor’s welder was observed flame-cutting inside a vessel’s ballast tank on a wooden platform over 1.80 m high, without fall protection. Work was stopped and a harness, inertia reel and tripod arrangement introduced temporarily. The flash identifies missing permits, an unreviewed risk assessment and inadequate supervision.
- 202419 Feb
Unauthorised entry into confined space
During barge repairs involving welding and grinding, subcontract personnel entered a confined space without authorisation. A stand-by person intervened and work stopped; nobody was harmed. The flash identifies inadequate barriers, hazard awareness and supervision, and describes strengthened access controls, contractor engagement, permits and training requirements.
- 202314 Nov
Flash Fire from Oxygen Regulator Leads to Burn Injury
A crew member suffered first- and second-degree wrist burns when an oxygen regulator burst during preparations for welding in platform decommissioning. The alert explains oxygen-system ignition hazards and recommends considering brass rather than aluminium fittings, controlled valve opening, contamination prevention, maintenance, training and protective clothing that keeps skin covered.
- 202313 Nov
Positive: Master stopped unsafe fuel transfer whilst vessel alongside rig
A supply vessel halted fuel transfer after its watch officer spotted welding on an adjacent semi-submersible rig. The flash highlights prompt bridge intervention, reporting and positive recognition by rig management. It identifies missing communication about hot work despite mandatory confirmation of simultaneous operations through the Safety Zone checklist.
- 202312 Sep
Fatality due to fire incident and fall from height
A rope access technician undertaking pipelay tower maintenance suffered a fatal fall from approximately 8.5 m after welding particles ignited solvent and fire melted the body harness. The flash examines independently authorised, conflicting work and highlights coordinated permits, shared planning, whole-operation supervision and effective stop-work authority.
- 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.
- 202327 Feb
Poor control of work in dry dock
This safety flash describes several cases of inadequately controlled contractor work on a vessel hull during dry-dock maintenance, including mesh cutting and pad-eye welding. Crew misunderstood vessel management’s responsibilities for external work. Contractors were unattended, task risk assessments were too generic, and company procedures and local safety requirements were not followed.
- 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.
- 202318 Jan
Small fire following hot work
A small fire followed contractor welding of jumper stands aboard a vessel alongside. A rag over the welded area was found smoking and extinguished with water; nobody was harmed. The flash identifies communication failures, absent joint inspection and no fire watch, and calls for contractor liaison, agreed work acceptance and fire watches.
- 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.
- 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.
- 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.
- 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.
- 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.
- 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.
- 20221 Apr
American P&I Club: Fire Started from cutting torch work
A cargo-hold fire occurred during oxy-acetylene cutting on a vessel in port. Sparks and molten slag passed through pontoon gaps and ignited plastic cargo covering; slag also burnt through a fire blanket. The flash highlights location-specific hot work permits, vigilant fire watches and effective shielding of nearby cargo.
- 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.
- 202210 Jan
UK HSE: uncontrolled movement of fabrication caused injury
An HSE prosecution followed life-changing injuries when a dolphin jacket weighing approximately 7.7 tonnes moved uncontrollably during fabrication and welding, crushing a worker’s feet. The flash describes a failed positioning and securing method using forklift trucks and temporary steel supports, alongside absent written risk assessments and work method statements.
- 2022
MAIB Safety Digest 1/2022
This multi-case marine digest examines collisions, groundings, machinery failures, fires and people entering the water across merchant, fishing and leisure vessels. Lessons address bridge teamwork, maintenance isolation, pilot-ladder securing, risk assessment and emergency preparedness. Reproduced bulletins and flyers discuss vehicle-deck crushing, collision avoidance and fishing-vessel survival.
- 202125 Nov
Use of damaged electrical equipment by dock workers
Third-party welders preparing anchor sea-fastening work aboard a vessel in port had damaged wiring connected without a plug. Vessel crew stopped the job, and the ETO repaired the wiring and fitted a suitable plug. The flash highlights omitted visual inspections and possible lessons for subcontractor oversight during busy port calls and mobilisations.
- 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 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.
- 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.
- 20218 Apr
SIMOPS – Smoke from hot work task enters confined space
During sewage-tank cleaning aboard a vessel in dry dock, a ventilation fan drew smoke from nearby oxy-propane cutting into the confined space. Workers evacuated without harm. The flash examines gas-detector placement, overdue calibration and missing bump tests, and identifies improvements to simultaneous operations planning and fume extraction.
- 20218 Feb
Safety Alert 410 - Damaged Electric Cord Results in Arc
An arc flash occurred during construction after a steel self-retracting lanyard cable wore through welding lead insulation and contacted exposed wires. Neither fire nor injury occurred. BSEE recommends considering cable separation, safe routing, pre-use inspections and inclusion of electrical hazard assessments in permit-to-work and job safety analysis reviews.
- 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.
- 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.
- 202023 Jun
Fall from a height into a ballast tank
A welder helper fell through a tween-deck opening while accessing work inside a vessel’s ballast tank. The flash identifies inadequate route assessment, job-specific permit shortcomings and a late team change. It describes safer access, revised confined-space risk assessments, retraining and renewed emphasis on stop-work authority; the cause of the fall remains unknown.
- 20206 Mar
Near miss: Failure of work procedures during hot work at height
A vessel Master spotted welding beside an unsecured edge during installation of access support plates in the port-side davit area. Despite a permit, risk assessment and toolbox talk, height hazards remained unaddressed. Welding was stopped and extra fall prevention installed; the account highlights inadequate assessment and acceptance of a supposedly quick task.
- 20196 Dec
Welder at work injured during close SIMOPS
A welder attaching lashing eyes to a deck sustained a slight neck injury from a wire while nearby crew secured reels. The flash identifies poorly managed simultaneous operations, inadequate supervision and preparation, and limited awareness of surroundings. Lessons emphasise understood toolbox talks, pre-task preparation and monitoring during hot work.
- 201928 Oct
Near Miss: Fire blanket caught fire during third-party hot work
A fire blanket ignited aboard a vessel in port after contractors paused sea-fastening work for lunch. A second mate extinguished the fire; no injuries occurred. Preliminary observations highlighted unrecognised ember hazards, inadequate fire-watch clearance and potentially poor blanket quality. Lessons address risk assessments, fire-watch responsibilities and contractor supervision.
- 201928 Oct
Ruptured acetylene hose: Fire
A subcontractor lighting an oxy-acetylene torch on a vessel experienced a small fire at a ruptured acetylene hose. The cause remained unestablished. The flash discusses flash-back prevention through equipment maintenance, arrestors, correct connections and separate hose purging, alongside contractor compliance and conditional emergency actions.
- 201916 Jul
Near miss: Dropped magnet during dry docking
During dry docking, a magnet securing fire protection fell 32 m from scaffolding while the protection was adjusted during hot work. No injuries or damage occurred. The flash identifies absent secondary retention and barriers below the worksite, and calls for identifying equipment used at height and suitable dropped-object controls.
- 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.
- 2018Aug
Life-Saving Rules (IOGP Report 459)
Introduces nine revised Life-Saving Rules for oil and gas workers, supported by analysis of reported fatalities from 2008–2017. Explains organisational conditions for implementation, leadership commitment, ongoing engagement and integration with existing management systems. Provides guidance on hazardous activities, work authorisation, energy isolation and personal safeguards.
- 20189 May
Incorrectly selected oxygen welding gas hose bursts & catches fire
A shipboard oxygen hose exploded and caught fire when a cylinder valve was opened for cutting work. The replacement was a hydraulic oil hose, unsuitable despite its pressure rating. Adiabatic compression and residual oil were suggested as the cause. Lessons address hose specifications, oxygen-service cleanliness and slow valve opening.
- 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.
- 2018Apr
MAIB Safety Digest 1/2018
A collection of marine accident lessons covering merchant, fishing and recreational vessels. Cases examine collisions, groundings, flooding, fires and personnel injuries, with attention to navigation, towing, maintenance and emergency readiness. Equipment-specific discussions include pilot-ladder deterioration, bilge-pump blockage, carbon monoxide alarms and safety-tether hook deformation under lateral loading.
- 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.
- 201711 Aug
Oxygen and acetylene hose caught fire
An oxygen/acetylene hose fire was stopped by interrupting the gas supply, with no injuries and slight material damage. The flash identifies oil contamination, sharp edges and potentially inadequate ventilation as possible contributors. It explains oxygen-enrichment hazards and outlines isolation, ignition-source removal, ventilation and leak repair when enrichment is suspected.
- 201727 Jun
LTI: Crewman burnt in fire following release of flammable gas from hand rail
A mechanic suffered burns while drilling a rescue craft access handrail, releasing an unidentified flammable gas that ignited. The flash examines gas accumulation in enclosed hollow structures, inadequate hazard assessment and unsecured PPE fastenings. Actions address handrail design, procedures for penetrating enclosed structures and correct PPE use.
- 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.
- 20166 Dec
Fatalities – pipe fell from skids
Two employees undertaking a construction weld repair were killed when a curved gas export pipe fell approximately 60 cm from temporary wooden supports. The flash highlights unrecognised dropped-object hazards and lateral movement associated with thermal expansion, differential heating and residual pre-stress, despite rigorous application of permits to known risks.
- 2016Dec
Ignition Sources – Once More — Process Safety Beacon, December 2016
This bulletin explains obvious and less visible ignition sources, including delayed fires after hot work, unstable or incompatible chemicals, enhanced oxidation and pyrophoric materials. It emphasises hazardous-area procedures, combustible spill containment, checking insulation for leaks, chemical storage requirements and management of change when introducing new materials.
- 201622 Nov
Diver loss of consciousness during underwater burning activities
A diver lost consciousness during underwater burning while removing a subsea structure after cold cutting proved problematic. A suspected blow back was believed responsible, with gas accumulation a possible immediate cause. The flash examines unrecognised task changes, risk assessment and procedural shortcomings, and competence assurance while the investigation remained ongoing.
- 20163 Oct
High potential near-miss incident: 440v cable damaged by grinder
During vessel mobilisation, a rigger/welder damaged a live 440 V cable while grinding aluminium protection covers in place over cables on the aft deck. The investigation identified inadequate task planning, permit coverage, risk assessment and toolbox communication, with no electrical isolation during work and delayed isolation afterwards.
- 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.
- 201620 Sep
Fatal engine room fire on suction dredger Arco Avon
This flash summarises MAIB findings on a fatal engine-room fire aboard Arco Avon during sand loading. An engineer attempting fuel-pipe repair used a portable angle grinder before pressurised fuel ignited. Missing risk assessment and permit authorisation were identified as possible contributors to his underestimation of risk.
- 201620 Sep
Near-miss: Welding in ‘no hot work’ zone
This safety flash describes a near miss identified during main-deck checks before sailing. The Chief Officer found dogging plate welds securing a half-height container in an area where hot work was prohibited. Initial findings indicated inadequate task planning and supervision had allowed the sea-fastenings to be welded there.
- 20161 Sep
Fire in the engine room on the suction dredger Arco Avon with loss of 1 life
Investigation of a fatal engine-room fire aboard Arco Avon during an attempted fuel-pipe repair. It identifies portable angle-grinder sparks as the probable ignition source and examines pipe fretting, hot-work controls, lone working, protective clothing, CO2 system operation and medical response. Recommendations address maintenance inspections and safety-management implementation.
- 201610 Aug
Proper care of oxy-acetylene cutting and welding equipment
This safety flash addresses fires involving deteriorated hoses and flashbacks in oxy-acetylene equipment. It explains reverse-flow hazards and distinguishes non-return valves from flashback arresters. Precautions cover lighting, purging, gas pressures, leak detection, hose fittings and pre-use inspection, including checks on third-party equipment and cylinder storage.
- 20162 Aug
Tesoro Martinez Sulfuric Acid Spill
CSB case study examines two sulfuric acid releases at the Martinez refinery in February and March 2014, injuring four workers. It analyses sampling-system integrity, protective equipment, pipe preparation and isolation, alongside process safety culture and missed incident learning. Comparisons with other refineries inform discussion of safer sampling arrangements.
- 201515 Dec
Confined space entry incidents – a reminder
This safety flash describes confined-space incidents during a vessel’s class renewal docking, involving subcontractors and a company-personnel near miss. Cases include obstructed access, absent attendants, untested gas detectors, missing harnesses and hot work without ventilation. Crew interventions prevented harm, with lessons stressing procedural compliance, contractor vigilance, training and safety leadership.
- 201523 Jun
‘Routine’ task, non-routine result: Finger injury during welding
A welder injured his left index finger while clearing loose slag by hand after cutting. A hole was found in his glove, but its timing was uncertain. The flash recommends using a broom, checking and replacing damaged PPE, and maintaining attention during routine tasks; welding risks were reassessed.
- 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.
- 201418 Dec
Confined space entry fatality
This safety flash summarises an IOGP alert concerning two shipyard workers who entered a confined space following welding with argon shielding. One died and the other required medical treatment. It highlights the seriousness of confined-space entry risks and points readers to the original alert and an IMCA video.
- 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.
- 2014Aug
Ignition Sources — Process Safety Beacon, August 2014
This bulletin explains why preventing flammable mixtures must be complemented by ignition-source control when equipment or procedures fail. It emphasises work permits, emergency actions during releases, hazardous-area classification and restrictions on portable electronics. It also highlights hot surfaces as potential ignition sources, particularly for materials with low autoignition temperatures.
- 201414 Jul
Punctured welding hose flash fire
An offshore vessel flash fire involved acetylene escaping from a damaged welding hose during air-operated grinding. No injuries occurred, and damage was limited to the hose. The account identifies poor hose protection and inadequate inspections, and describes suggested spark containment, maintenance inspections and a hose checklist incorporated into the permit-to-work process.
- 20144 Jun
Crewman suffered first aid injury during cutting operations
A crewman injured his right inner thigh when a hand grinder slipped during pipe bevel cutting. The investigation identified unsuitable scaffold adjustment and unstable positioning, despite fitted safeguards and correct PPE. Corrective actions addressed equipment and personnel positioning through training, toolbox talks and provision of a suitable working platform.
- 20144 Jun
Cutting torch hose separates from flame arrestor
An oxy-acetylene cutting hose detached during modification work inside a pile-driving hammer, producing a flashback. An improvised taped connection joined mismatched components and slipped off when warmed. The fire watch extinguished the flames; nobody was harmed. Corrective actions included hose inspections, crew training and renewed emphasis on pre-job checks.
- 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.
- 201420 Feb
Hose fire caused by flashback in oxygen and acetylene hoses
An oxygen–acetylene cutting hose burst and burned during torch ignition, without injuries. Inspection found brittle, perished hoses; an inoperative non-return valve was suspected, and connections had not been leak checked. The flash explains flashback hazards and recommends suitable leak detection, equipment inspection, correct lighting procedures and flashback arresters.
- 2014
MAIB Safety Digest 1/2014
This marine accident digest presents lessons from merchant vessels, fishing boats and small craft, including republished articles on kill cords. Cases examine navigation, lifeboat access, equipment failures, fires, flooding and overboard emergencies. Recommendations address maintenance, testing, communication and emergency preparation; appendices list investigations and reproduce safety bulletins.
- 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.
- 201321 May
Fire caused by hot work
A safety flash describes a chair fire beneath a forecastle plate repair using oxy-acetylene cutting. Glowing slag ignited the chair; nobody was injured. Findings highlight poorly planned fire watching, failed permit planning and workplace checks. Corrective measures address adjoining spaces, heat-transfer risks, responsibilities and functional fire detection.
- 20134 Apr
Explosion causing fatal injury during maintenance of Metocean buoy
A crewman suffered fatal injuries when grinder sparks ignited hydrogen inside a recovered metocean buoy, projecting instrument components outwards. Investigation identified corrosion, cracked battery cases, inadequate maintenance and unfulfilled purging procedures. The flash describes pressure equalisation, air or nitrogen purging, ignition restrictions and precautions against exposure to the compartment lid.
- 201320 Mar
Hot Work Operations Results in Dropped Object
During removal of derrick crown platform grating, a construction contractor used a pulley system and retaining wire before cutting a section free for lowering. A 5.7 kg section detached and fell 52 m, striking accommodation, breaking into three pieces and landing on the rig’s port-side box girder.
- 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.
- 201211 Dec
Fire in engine room workshop
This safety flash describes a small fire in a vessel’s engine-room workshop when engineering personnel undertook welding without notifying anyone. An alarm prompted mobilisation of the vessel’s emergency response team, which extinguished the fire safely. No injuries were reported.
- 201214 Nov
High potential near-miss: Dropped object
During tensioner platform removal, a worker inadvertently kicked a cut angle bar from scaffolding. It fell 11 m, landing approximately 1.5 m from four crew members. The flash identifies inadequate competence, unsecured material and absent barricading, and describes corrective measures for securing loose materials, restricting access and assuring worker competence.
- 201220 Sep
Exploding Ball Valve Results in Near Miss
A near-miss alert describes a rig welder cutting a mild steel fitting from a brass ball valve using an oxy-acetylene torch. After cutting finished, an explosion propelled a threaded valve section across the lease. It struck the ground approximately 8 m from the bench, then travelled another 12 m and dented a cargo container.
- 201210 Jul
Small fire and minor injury during gas cutting
A welder suffered minor thigh burns during oxyacetylene cutting on a vessel after an oxygen hose detached. Investigation identified damage to an acetylene fitting and assumed similar oxygen fitting damage. Visual inspection had missed concealed fittings. Actions addressed fitting replacement during hose re-termination, suitable protective overalls and welder training.
- 201230 Apr
Near-miss during subsea cutting operations
A flashback during subsea gas flame cutting with a PVL torch ruptured an oxygen hose underwater and on deck, causing a small fire without injuries. Investigation identified missing flashback arrestors, incorrect bottle-change procedures and an improperly closed torch valve. Changes included arrestors, non-return valves, gas quads and revised instructions.
- 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.
- 201229 Feb
Near-miss: Serious subsea burning incident
A saturation diver triggered an explosion while burning holes in a toppled submerged quarters building. Air flushing failed to remove trapped explosive gases from its complex interior. Lessons distinguish vent holes from drain holes, address communication and verification, and recommend alternative cutting methods where the absence of explosive gases cannot be assured throughout the job.
- 201120 Jun
Welding Operation Results in a Fire in the Store Room
This alert describes welding to trim a guidepost on a rig storeroom roof. Insulation beneath the hot-work area ignited and smouldered, producing substantial toxic smoke. The storeroom suffered extensive smoke damage, with potential loss of equipment, materials and life reported.
- 201119 Apr
Hot work conducted within the 500 metres safety zone
A crew member resumed grinding on a vessel 20 m from a platform, bypassing work-control formalities within its 500 m safety zone. The flash describes procedural violation and incorrect judgement, warns of possible flammable-gas ignition, and recommends permit-to-work control and briefing crew before zone entry.
- 2011Jan
Vapor Cloud Explosions — Process Safety Beacon, January 2011
This manufacturing safety bulletin explains how released flammable materials can form vapour clouds and explode following ignition. It describes blast and fireball consequences, including increased danger in congested or confined areas. Recommendations emphasise containment, inspection and preventive maintenance, safe hot work, immediate leak reporting and preparation for emergency procedures.
- 201015 Dec
Subsea oxy-arc cutting – risk of explosion
This safety flash addresses explosion risk during subsea oxy-arc cutting. It recommends dependable double isolation that breaks both circuit poles between the surface generator and diver. Referenced diving guidance advises mounting the knife switch against accidental activation, ideally using a double-pole switch enclosed in a protective wooden or plastic box.
- 201015 Dec
Welding of shackles
This flash describes routine welding modifications to shackles and hooks despite contrary work instructions. It explains that welding alters material properties, invalidates manufacturer certification and increases unpredictable brittle failure risks that inspection cannot prevent. The member recommends removing modified items from service and instructing suppliers not to provide them.
- 201018 Nov
Deadly explosions during cutting of drums and containers
Following two fatal drum-cutting accidents in North East Scotland, this alert explains how residues in apparently empty containers can create explosive vapours during hot work. It calls for urgent review of working and training procedures, considers cold alternatives, and identifies specialist services, cleaning, gas-freeing and inerting where hot work is necessary.