Control
Ignition Source Control
Control of sources capable of igniting hazardous atmospheres.
Newest 100 Documents
All 187 in search- 202612 Aug
Control Portable Electronic Device Use to Prevent Ignition Hazards Offshore
This alert describes inspection findings involving unauthorised cellphone use during offshore wireline operations and unrated electronic devices in a hazardous area without a hot work permit. It recommends that operators and contractors consider intrinsic-safety certification, conditional permit requirements, policy reviews and reinforcement of device restrictions during orientations.
- 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.
- 2026Jan
D-PINCs (Operators Version - Jan 2026) — Drilling
A regulatory checklist for oil and gas drilling, linking numbered compliance questions to statutory authorities and enforcement actions. It addresses approvals, diverter configuration and testing, casing installation, cement placement, drilling-fluid management and monitoring. Further checks cover ventilation, gas detection, ignition prevention and retention of drilling and test records.
- 202522 Dec
Vessel facilities subject to external hydrocarbon hazards guidance note
Guidance on safety cases for vessel facilities exposed to external hydrocarbon hazards. It addresses facility descriptions, formal safety assessment, ignition prevention, gas detection, emergency shutdown and evacuation arrangements. Supporting analyses examine fire, explosion and emergency-system survivability, while the Montara case illustrates shortcomings in preparedness and external-hazard assessment.
- 20254 Dec
Fire in the engine room – fuel spray fire
Fuel sprayed onto hot surfaces of a starboard main engine after maintenance left return-pipe bolts missing and protective barriers absent. Crew extinguished the fire without injuries or pollution, but water mist failed and shutdown actions were delayed. Lessons emphasise post-maintenance checks, splash protection and familiarity with emergency equipment.
- 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.
- 202518 Jun
MAIB: Is your Lead-Acid battery safe?
A barge crew member escaped injury when four lead-acid batteries exploded during generator starting. The steel locker contained the explosion. Investigation identified batteries unsuitable for continuous float charging. The flash highlights documented maintenance and replacement records, ventilated battery stowage and corrosion-resistant, flame/explosion-proof compartment lighting.
- 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.
- 202412 Dec
Engine room fire on board ro-ro passenger ferry Stena Europe
Investigation of Stena Europe’s engine room fire while approaching Fishguard. Pressurised fuel escaped from a flange joint and ignited on exposed exhaust surfaces. The report examines recurring leaks, incomplete flange modifications, deficient insulation, maintenance and reporting weaknesses, firefighting response, and thermal imaging for detecting hazardous hot spots.
- 202326 Dec
Wendland 1H Well Fatal Explosion
CSB investigates a fatal blowout and fire during tubing-head replacement at a Texas oil and gas well. It analyses inadequate well-control planning, ineffective hydrostatic and valve barriers, and ignition-source management. Recommendations address workover methods for underpressured reservoirs, well-history review and gaps in industry guidance and federal regulation.
- 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.
- 202312 May
Process Explosion Causes Medical Evacuation
Two offshore workers installing a skillet in pipework suffered smoke inhalation and burning sensations after opening a flange. The investigation identified absent purging or flushing and unrecognised potential pyrophoric materials. BSEE recommends considering fire and explosion management plans and procedures addressing ignition sources, oxygen ingress and fuel.
- 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.
- 20227 Sep
Temporary Equipment as a Potential Source of Ignition on Offshore Facilities
BSEE describes three examples of temporary equipment unsuitable for hazardous areas on offshore facilities: a diesel air compressor, hydraulic power pack and portable fan. The alert recommends considering equipment checks, ignition controls, management of change, pre-startup review and documented risk assessment throughout installation, use and removal.
- 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.
- 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.
- 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.
- 20224 Apr
Improper Fan and Other Equipment Used in Hazardous (Classified) Locations During Coiled Tubing Operations
BSEE inspectors found an unsuitable fan and extension cord beside a gas buster during coiled tubing operations. Changing the plug had not changed the fan’s rating. The alert recommends considering classification drawings, equipment approval markings, applicable standards and checks for damage or improper electrical modifications.
- 202215 Feb
Crewmember burned while draining fluid from flare stack
A worker opened a ball valve to drain a flare stack without switching off its ignitor. Drainage allowed gas to reach the flare and ignite. Flammable liquid subsequently fell onto the worker, causing burns despite the fire-resistant clothing and hard hat being worn.
- 202121 Oct
Management of Hot Surfaces information paper
This information paper examines hot-surface ignition risks from non-electrical equipment in open process areas. It distinguishes hazardous area classification from assessment of large hydrocarbon releases, explains auto-ignition temperature and operating temperature limits, and discusses dispersion modelling, inspection assurance and evaluation of temperature exceedances against facility-specific standards.
- 20202 Oct
Fire Tube Hazards Increase Risk of Flame Migration
BSEE inspectors found warped flame-arrestor flanges and gaps after heater-treater and glycol-reboiler fire tubes were reinstalled using incompatible non-OEM fasteners. These defects created potential paths for flame migration. The alert recommends considering pre-startup reviews, OEM-recommended parts, more frequent visual inspections and checks of connections disturbed during maintenance.
- 2020Oct
Process Safety Fundamentals (IOGP Report 638)
Guidance introduces ten Process Safety Fundamentals for upstream operations, with downstream applicability also proposed. It addresses procedures, barriers, operating limits, isolation, ignition sources, change and unexpected conditions. Implementation guidance emphasises organisational engagement and coaching, supported by analysis of fatal and non-fatal process safety events and discussion of performance indicators.
- 202028 Sep
US Coast Guard: Addressing hazardous area electrical issues
This flash summarises US Coast Guard findings concerning certified electrical installations in vessel hazardous areas. Incorrect installation, missing or degraded components and unfamiliarity with standards compromised protection. The alert strongly recommends IEC-aligned training, periodic inspection and maintenance by competent personnel, competent repairs and regulatory approval of system modifications.
- 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.
- 202018 May
Turbo and Exhaust Manifold Fires Related to Engines
This alert reviews more than 20 compressor and generator fires involving hot turbocharger and exhaust components. Common factors include defective components, hose failures, loose electrical connections and oil entering exhaust or compressor systems. Recommendations for consideration address shielding, insulation, leak checks, temperature shutdowns, fire detection, pressure protection and operator competence.
- 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.
- 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.
- 202028 Feb
Safety Alert 379 - Broken Compressor Heat Exchanger Causes Fire
This alert describes a Gulf of Mexico platform fire after compressor heat-exchanger tubing detached and released gas that ignited at the engine exhaust, alongside a similar 2017 fire. It identifies inadequate inspection and maintenance, and recommends considering improved joint oversight and leak-detection methods, with exhaust routed outside classified areas.
- 20198 Nov
Safety Alert 370 Overcharged Battery in Non-Ventilated Box
An RTU panel exploded after an overcharged 12-volt battery generated hydrogen in an unventilated enclosure. An unsuitable electrical component was the likely ignition source. No injuries or nearby equipment damage occurred. BSEE recommends operators consider compliant battery enclosures, installation arrangements preventing hazardous hydrogen accumulation, and electrical components rated for their area classification.
- 201923 Oct
Use of gas-fired oven cleaning equipment inside vehicles
HSE alerts suppliers, installers and users to hazards of LPG-fired oven cleaning equipment inside vehicles following a van explosion. It sets expected standards for cylinder storage, ventilation, driver separation, ignition control, gas isolation and training, and recommends substitution where reasonably practicable to eliminate or reduce risk.
- 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.
- 20193 May
Safety Alert 350 - Fires on Facilities Caused by Use of Outdoor Grills
Two facility fires involved hot barbecue debris reaching a waste bag and used charcoal being discarded into a trash compactor. Neither caused injury or equipment damage. BSEE recommends operators consider debris containment, safe charcoal disposal, checks before cooking and communication of disposal policies and smoking-area requirements.
- 201912 Mar
Sparks from funnel caused small fire
Funnel sparks ignited stored cardboard on a diving support vessel during diving operations. Crew extinguished the fire with foam extinguishers, mustered personnel and recalled divers to the bell. The flash identifies exhaust soot accumulation and missing maintenance routines, and records improved drain-plug access, spark arrestors and revised soot-removal maintenance.
- 201820 Jul
Fuel spray fire
A vessel’s cracked fuel-system isolating valve released approximately 1 m³ of fuel. Engine vibration and assembly weight caused the failure following a pipework alteration. The flash describes replacement with a stainless-steel fitting, installation of a spray deflector and lessons on assessing short- and long-term consequences through management of change.
- 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.
- 2018Feb
Electrical PINCs
A platform electrical-system compliance checklist links inspection questions to federal regulatory authorities, API recommended practices and enforcement actions. It covers hazardous-area classification, battery installation, lighting and portable devices, wiring and grounding, explosionproof and pressurised equipment, electrical lockout/tagout procedures and transformer nameplate information.
- 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
Fuel spray fire – Déjà vu: Prepare and prevent it from happening to you!
A ruptured flexible fuel hose sprayed diesel onto a turbocharger in an offshore supply vessel’s unmanned engine room. The resulting fire caused significant damage but no injuries. The flash describes the crew’s response and USCG recommendations for machinery-space inspections, examination of heat sources and reduced use of non-metallic flexible hoses.
- 201731 May
Mobile Engine Hazard Alert
This hazard alert addresses ignition of flammable vapours by mobile engines and auxiliary motors during oil and gas operations. It outlines fire risk assessment, equipment positioning, atmospheric monitoring and access controls, and suggests protective engine systems. Workers are instructed to evacuate immediately when an engine over-revs or runs away.
- 20173 May
ExxonMobil Torrance Refinery Explosion
CSB investigates the Torrance refinery electrostatic precipitator explosion during FCC Safe Park operation and expander isolation. It examines failed catalyst and steam barriers, slide-valve erosion, hydrocarbon backflow, inadequate procedures and detection, and ignition within the energised precipitator. Recommendations address isolation, safeguard assurance, maintenance, operating modes and equipment siting.
- 201710 Jan
A-Belco Group, Hadar range of ATEX Lighting products
HSE alerts users to compliance and safety concerns affecting four Hadar ATEX luminaire series manufactured during 2006–2016. Sample testing identified inadequate impact resistance and ingress protection, with potential ignition risks in flammable atmospheres. It recommends inspection, replacement of defective units with compliant products, and continued inspection and maintenance of non-defective luminaires.
- 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.
- 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 Feb
Use of Barrier Glands in Potentially Explosive Atmospheres to meet IEC 60079:14_2013 (Edition 5)
HSE warns that revised cable-gland selection provisions may allow fire propagation through cable sheaths after multiple ignitions. The notice compares IEC and British Standards and directs duty holders to use the British Standard’s informative National Annex as relevant good practice when assessing barrier-gland requirements in potentially explosive atmospheres.
- 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.
- 201516 Jan
Disposal of flammable substances with ignition sources
Vessel waste was offloaded with flammable paint thinners and potential ignition sources mixed in opaque bags, despite promised segregation. A contractor’s chemist had to open and sort the waste. The flash identifies failures in waste procedures and communication, and records actions on transparent bags, labelling, segregation and crew awareness.
- 2014Oct
Dust Explosions - Clean up this Hazard! — Process Safety Beacon, October 2014
This bulletin describes a fatal zirconium powder explosion involving a damaged blender, subsequent fire spread and a secondary dust explosion. It also references other combustible dust incidents. Worker guidance emphasises recognising dust hazards, ensuring proper operation of protective systems, preventing dust accumulation and withholding operation of equipment with sparking or overheating concerns until repaired.
- 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.
- 201416 Jul
AL Solutions Fatal Dust Explosion
Investigates the fatal December 2010 metal dust explosion at AL Solutions in West Virginia, probably originating in defective zirconium blending equipment. Examines dust testing, earlier incidents, ignition hazards, water-based cleaning and suppression, and regulatory oversight. Recommendations address combustible-metal safeguards, process hazard analysis and employee and contractor training.
- 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.
- 201430 Jun
Serious engine room fire whilst divers in saturation
An engine-room fire aboard an offshore vessel alongside prompted transfer of saturation divers to a hyperbaric rescue craft. Investigation linked diesel spray ignition to fatigue failure of an insufficiently tightened fuel-filter stud. The flash discusses water-mist suppression, fuel shut-off shortcomings, torque information and separation of filters from hot exhaust surfaces. Nobody was injured.
- 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.
- 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.
- 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.
- 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.
- 20119 Dec
Use of mobile phone "Expert XP-Ex-1" in potentially explosive atmospheres
HSE alerts suppliers and users to ignition risks associated with the Expert XP-Ex-1 mobile phone in potentially explosive atmospheres. The phone fails essential ATEX safety requirements and can generate hazardous sparks under fault conditions. The alert calls for UK suppliers to cease supply immediately and users to avoid use in explosive atmospheres.
- 2011Aug
Flammable Vapor Release Hazards in Congested Areas — Process Safety Beacon, August 2011
This bulletin examines a fatal natural gas explosion during pipe cleaning at a Connecticut power plant under construction. It explains how congestion can intensify vapour cloud explosions, including outdoors, and recommends hazard analysis, ignition control and safe venting arrangements when flammable releases are unavoidable.
- 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.
- 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.
- 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.
- 201025 Aug
Xcel Energy Company Hydroelectric Tunnel Fire
Investigates the fatal Cabin Creek penstock fire during epoxy sprayer cleaning with methyl ethyl ketone. Static discharge was the most likely ignition source. The report examines confined-space monitoring, contractor selection, training and rescue arrangements, with recommendations on solvent substitution, ignition prevention and escape, supported by comparative incident research.
- 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.
- 20106 May
Safety Alert 287 - Hot Bolting Fire
During hot bolting on a contact tower inlet valve flange, a hammer broke a grease fitting, releasing high-pressure gas towards a nearby line heater. The gas ignited; no injuries occurred. The alert identifies missed JSA hazards and recommends isolation and depressurisation as a safer option, non-sparking tools and contingency planning.
- 2009Oct
Overflow + Ignition = Tank Farm Fire! (Part 2) — Process Safety Beacon, October 2009
This bulletin examines a tank overflow followed by an explosion and spreading fires, with a responding truck believed to have supplied ignition. It explains how internal combustion engines can ignite flammable atmospheres or accelerate on vapour intake, and highlights vehicle restrictions, conditional hot-work permits and plant-specific air-shut-off requirements.
- 2009Sep
ConAgra Natural Gas Explosion and Ammonia Release — Safety Bulletin - Dangers of Purging Gas Piping Into Buildings
This safety bulletin examines the ConAgra factory explosion and similar incidents involving indoor fuel-gas purging. It explains direct displacement of air, hazardous gas accumulation and unreliable odour detection. Recommendations favour outdoor venting wherever practicable, with gas monitoring, ignition control, ventilation, removal of nonessential personnel and training addressing odour fade.
- 2009Sep
Imperial Sugar Company Dust Explosion and Fire — Final Investigation Report
Investigation of the fatal sugar-dust explosions and fires at Imperial Sugar’s Port Wentworth refinery. It examines enclosed conveyor dust accumulation, secondary explosions, deficient housekeeping and dust collection, ignition possibilities, evacuation arrangements and management responses to known hazards. Recommendations address combustible-dust training and stronger inspection and audit practices.
- 200919 Jun
Poor maintenance and subsequent failure of welding equipment
This safety flash describes poorly maintained welding equipment aboard a vessel, including an acetylene regulator fire, smouldering and arcing cable connections, and a detached torch nozzle. A separate incident involved a welder’s burnt hand, oil contamination and an oxygen leak. It warns against organic contamination of pressurised oxygen.
- 2009Jan
Fire while filling portable container! — Process Safety Beacon, January 2009
This bulletin revisits a fire during ethyl acetate filling into a portable steel tote. It explains how free-falling liquid can generate static charge and recommends bottom filling or dip pipes, with initially restricted velocity. Further measures include bonding, earthing and hoses designed for flammable liquids.
- 2008Dec
Static Electric Discharge Causes Fire — Process Safety Beacon, December 2008
Describes a fire during ethyl acetate filling at a chemical distribution facility. Isolated metal nozzle components likely accumulated static charge and sparked to the tote, igniting vapour. Explains bonding and grounding, regular ground-connection checks and minimising liquid free fall when filling containers with flammable liquids.
- 2008Nov
Laboratory Refrigerator Explosions – Electrical Classification — Process Safety Beacon, November 2008
This bulletin describes explosions damaging two laboratories where flammable materials were improperly stored in household refrigerators. It explains how accumulated vapours can be ignited by internal electrical components, and emphasises hazardous-area electrical classification, suitable sample storage, appropriate portable equipment and inspection and maintenance of electrical installations.
- 200823 Sep
Safety Alert 266 - Trouble Shooting Production Platform Upset Problems
A platform flash fire followed separator level-safety malfunction, condensate carry-over and wind-blown hydrocarbon mist reaching hot generator exhaust piping. The alert recommends troubleshooting upstream level set points, cleaning sight glasses, monitoring flare-scrubber accumulation and minimising disabled safety devices during restart. Flare-piping relocation may be required to avoid ignition sources.
- 2008Sep
Barton Solvents Flammable Liquid Explosion and Fire — Case Study
This case study examines a fire and explosions during ethyl acetate filling at Barton Solvents in Des Moines. Static discharge from unbonded metal components likely ignited vapour near a portable tank opening. It analyses nozzle and hose suitability, bonding and grounding, dip-pipe filling, and inadequate fire separation and suppression.
- 20085 May
Safety Alert 263 - Pipeline Pump Fire
Oil escaping around a pipeline pump rod ignited on another pump engine’s hot exhaust, causing approximately $350,000 damage and four weeks’ downtime without injury. The alert identifies a loosened packing nut, unsecured inspection cover and degraded exhaust insulation, and recommends inspections, secure covers and insulation maintenance.
- 2008May
CAI / Arnel Chemical Plant Explosion — Final Investigation Report
Investigation of the CAI/Arnel explosion in Danvers, Massachusetts, examines solvent boiling in an unsealed heated mix tank and vapour accumulation after ventilation shutdown. It analyses operating safeguards, procedures and regulatory oversight, using laboratory testing and blast reconstruction. The ignition source remained unidentified; recommendations address safer indoor heating and hazard review.
- 2008May
Is sugar an explosion hazard? — Process Safety Beacon, May 2008
This bulletin explains combustible dust explosion conditions using a sugar refinery explosion whose detailed causes remained under investigation. It describes the dust explosion pentagon, secondary explosions and dust accumulation indicators, emphasising housekeeping, grounding and bonding, electrical area classification and suitable equipment selection.
- 2007Dec
Oil Tank Fire Caused by Static Discharge — Process Safety Beacon, December 2007
A floating-roof tank exploded and burned during diesel filling after previously containing petrol. The bulletin describes NTSB findings linking unsafe filling and content-change procedures to static ignition in a flammable vapour space. It highlights operating procedures, change review and filling-velocity limits until the fill pipe is sufficiently submerged.
- 2007Jul
Fire Caused by Hose Repaired with Duct Tape! — Process Safety Beacon, July 2007
A methanol transfer on an offshore oil platform led to fires on two decks after leakage from a split hose previously repaired with duct tape. One man sustained second-degree burns. The bulletin emphasises management of change for temporary repairs, equipment inspection before use and separation from ignition sources.
- 20069 Nov
Safety Alert 245 - Serious Fire Caused by Methanol Sprayed from Duct-Tape Repaired Hose
Methanol escaping from a split, duct-tape-repaired hose during gravity transfer ignited on two decks, causing one worker second-degree burns. Sunlight and barely visible combustion delayed recognition. The alert recommends checking transfer components, avoiding transfer above ignition sources, and establishing written procedures supported by pre-operation job safety analysis.
- 200630 Apr
Flash fire in field joint coating station
A pipelay vessel experienced a flash fire when escaped fusion bonded epoxy powder met a naked flame, burning a nearby crew member. The investigation identified inadequate machine extraction and sealing. Recommendations address powder release reporting, ignition sources, explosion-proof vacuum cleaning, approved spraying equipment and prompt housekeeping.
- 20062 Mar
Safety Alert 239 - Casing Bleed-down into Plastic Drum Results in Fire on Platform
An offshore platform fire began during casing-fluid bleed-down into a plastic drum. Investigators identified static electricity as a possible ignition source. The alert contrasts the drum with required grounded metal containers, describes fire-system failures and containment, and recommends reviewing relevant policies and stressing strict adherence.
- 2006Jan
Acetylene Service Company Gas Explosion — Safety Bulletin: Explosion at ASCO - Dangers of Flammable Gas Accumulation
This bulletin analyses a fatal acetylene explosion at ASCO in Perth Amboy. Gas backflow through the recycled-water system accumulated in an unventilated shed; the heater was the most likely ignition source. It examines valve failure, operating sequence and building design, recommending positive isolation, reliable procedures, training and valve inspection.
- 200530 Nov
Engine room fires – Appropriate use of insulating material on hot surfaces
This safety flash follows up an engine-room fire attributed probably to hydraulic oil spraying onto an inadequately insulated exhaust flange. It explains how absorbent lagging can retain leaking oil and increase ignition risk, contrasts oil-resistant silver-faced lagging, and notes the SOLAS insulation requirement for surfaces above 220 °C.
- 200531 Oct
Engine room fire
An engine room fire was probably caused by leaking hydraulic oil spraying onto an inadequately insulated exhaust flange. Carbon dioxide brought the fire under control, but the ship lost power and was towed to port. The flash highlights hot-spot identification, insulation reinstatement after maintenance and relevant SOLAS requirements.
- 200518 Feb
Safety Alert 18 - Well-Control Equipment Circumvention
An MMS alert describes loss of well control during workover/completion after completion-fluid pumping stopped and a tubing hanger lockdown pin was removed, bypassing blowout prevention. Seawater and hydrocarbons escaped. It distinguishes direct from possible contributing causes and recommends improved hanger-landing procedures, well-control training and job safety analyses.
- 20051 Feb
Fire at sea
A vessel fire originating in a rubbish basket destroyed diving equipment and was extinguished within 15 minutes. A welding rod or cigarette butt was suspected, but ignition remained uncertain. The flash highlights overflowing waste, strong winds, an exposed air cylinder and nearby oil drums, alongside recommendations for housekeeping and electrode disposal.
- 2003Sep
BLSR Operating Ltd. Vapor Cloud Fire — Final Investigation Report
This investigation examines a fatal vapour-cloud deflagration during oilfield waste unloading near Rosharon, Texas. It analyses waste flammability, tank withdrawal methods and diesel-engine ignition, identifying backfire as the most likely ignition source. Recommendations address hazard information, closed-piping transfer, grounding, training and overspeed emergency procedures.
- 20037 Mar
Decanting Synthetic Based Mud Can Results in a Flash Fire
This alert highlights fire and explosion hazards when decanting low-flash-point synthetic-based mud additives. It describes delivery in tote tanks and gravity feeding through flexible hoses into mud pits, identifies a flammable-liquid classification, and links explosion potential to absent bonding or grounding. It also directs readers to check additive safety data for flammability.
- 20021 Apr
Caution advised on cellphone use due to ignition fears
A contracted specialist suffered burns when a flash fire occurred as he opened a ringing cellphone while working on an instrumentation-gas panel. The company subsequently prohibited cellphone use in the field concerned and reiterated the ignition danger posed by electronic devices outside safe locations or without a gas detector.
- 2002Jan
Bethlehem Steel Corporation Gas Condensate Fire — Final Investigation Report
Investigation of a fatal condensate fire during valve removal at Burns Harbor steel mill. The report examines deadleg accumulation, probable freezing damage, isolation and drainage deficiencies, potential ignition sources and demolition-related escape obstructions. Recommendations address written maintenance preparation, condensate monitoring, winterisation and communication of hazards and incident findings.
- 20011 Jul
Explosion caused by ignition of paint vapour
A barge water tank exploded after solvent vapours from curing epoxy paint accumulated without mechanical ventilation. Escaping vapours reached a non-ex-rated electric fan ventilating an adjacent tank and flashed back. Nobody was injured, but structural damage occurred. The flash highlights unassessed curing hazards, unavailable safety information and recommendations for formal risk assessment.
- 20011 Jul
Oxy-arc cutting
A safety flash describes a diver fatality during subsea oxy-arc cutting, with spark ignition of trapped gas identified as the most likely explosion cause. Company instructions address alternatives, task approval, risk assessment, training and cavity venting, alongside oxygen flow through the Broco rod to prevent electrolytic hydrogen accumulation.
- 20001 Oct
Transponder/beacon explosion
A mini transponder exploded on activation after charging, ejecting an end piece and injuring an employee’s face. With the cause unresolved, the flash includes the manufacturer’s interim dismantling procedure for AAE 91x beacons, covering controlled end-cap removal, possible internal pressure, ignition avoidance and protection against ejected components.
- 200025 Jan
Safety Alert 15 - Electrical Cable Testing
A Pacific OCS platform fire followed insulation testing of a submersible pump power cable when grounding produced a spark that ignited escaping well-annulus gas. The alert recommends avoiding rig-floor testing, using purged rooms where feasible, requiring permits and continuous flammable-gas monitoring in non-purged environments, and reducing sparking through suitable instruments and capacitance discharge.
- 199916 Nov
Safety Alert 183 - Electrical Shock Hazard
MMS inspections identified incorrectly wired portable electrical steam pressure-washing units. The alert describes shock risks in three-phase, 440-volt units lacking a separate external earth connection. It advises reviewing installation and manufacturer operating procedures, and considering equipment location because the units may be unsuitable ignition sources in classified areas.
- 1999Jul
Safety warning after liquid petroleum gas causes explosion on vessel with 4 people injured
This safety bulletin follows an explosion aboard a sail training vessel berthed in Poole Harbour, injuring four people. LPG leakage appeared to be a crucial factor, pending confirmation. Recommendations address bottle connections, locker ventilation, gas-tight pipe penetrations, detector positioning and maintenance, appliance instructions and avoiding naked lights when locating leaks.
- 1996
MAIB Safety Digest 2/1996
A marine accident digest examining merchant shipping and fishing casualties, including machinery failures, collisions, unsecured cargo, fires, tank hazards and crew injuries. Case commentary addresses radar watchkeeping, cargo lashings, safety lamps, rescue arrangements, fall protection, pre-departure checks and accessible machinery controls.
- 199023 Aug
Safety Alert 158 - Water-Treating Facility Upset Leads to Fire on Production Platform
A production-platform fire followed separator gas blowby, an inadequately rated shutdown valve and flotation-cell overflow onto a transformer. Emergency vent gas subsequently ignited, briefly engulfing the platform. The alert describes deluge protection, firefighting and corrective changes to equipment, shutdown arrangements and vent routing; no injuries and minimal damage were reported.
- 19886 Jul
Safety Alert 156 - Fire on the Water Beneath Facilities
Describes two fires beneath offshore platforms during welding, one without injuries and another involving three deaths and eight burn injuries. The second fire was believed to involve welding slag igniting escaped production fluids. Recommendations address bypass coordination, monitoring water for hydrocarbons and enhanced approval and supervision for night welding.
- 198814 Jun
Safety Alert 155 - Fire on Glycol Reboiler Due to Carry-over and Uninsulated Compressor Exhaust
Two fires on a production platform’s glycol reboiler involved leakage from a loose flange and, after restart, flashing cold glycol vented through the reflux column. Both were ignited by uninsulated compressor exhaust. The alert records suppression, no injuries, and corrective changes to vent location, flange bolts, dump-valve adjustment and exhaust insulation.
- 198818 Mar
Safety Alert 154 - Flash Fire During Portable Well Testing Operations
An alert describes a flash fire during portable well testing when propane leaking from synthetic tubing ignited as the heater burner lit. One operator suffered burns, with no equipment damage. It recommends hoses designed for liquid petroleum gas service and insulation of specified heater components to prevent ignition.