Control
Non-Destructive Testing
Inspection methods evaluating integrity without damaging the component.
Documents
- 2026May
GEC Type VMX High Voltage Switchgear (including GEC Alsthom, Alstom or Areva T&D)
HSE safety notice addresses partial discharge and vacuum interrupter integrity in legacy GEC VMX high-voltage switchgear. Following a disruptive circuit-breaker failure involving arcing and fire, it recommends checking applicable design modifications, maintenance records and substation environmental conditions, alongside discharge surveys, integrity testing and revised access risk assessments.
- 202615 Apr
BSEE: Exterior Walkway separates from temporary living quarters, putting workers at risk
An offshore accommodation walkway detached while three workers stood outside their room; all remained safe. Temporary quarters had served for 23 years, with inadequate inspections and degraded tab welds. The flash presents BSEE recommendations for operators to consider long-term design needs, revised inspection programmes and non-destructive weld testing.
- 20265 Feb
BSEE Safety Alert 513 - Exterior Walkway Separates from Temporary Living Quarters, Putting Workers at Risk
Three workers escaped harm when an offshore platform’s third-floor walkway detached from temporary living quarters used for 23 years. The alert examines inadequate welded support, corrosion, material fatigue and inspection weaknesses. BSEE recommends considering long-term use in design, revised inspection programmes and non-destructive testing alongside visual checks.
- 202615 Jan
Fatal injury to a deckhand following a chain failure on the scallop dredger Honeybourne III (PD905)
Investigation of a deckhand’s fatal injury aboard Honeybourne III after a quick-release chain failed and a towing block fell during fishing-gear retrieval. The report examines chain bending, wear, material properties, inspection competence and suspended-load exposure, supported by laboratory testing and finite element analysis. It records company actions and regulatory oversight deficiencies.
- 20252 Oct
Crane cab access platform collapsed
A vessel crane’s cab access platform collapsed as the operator climbed the ladder, causing a fall partially mitigated by its enclosure without injury. Hidden weld cracking and corrosion caused the failure. The flash questions inspection access, alternative testing and contractor oversight, and stresses surface preparation before repainting.
- 202519 Jun
Fatal accident on the beam trawler Cornishman with loss of 1 life
Investigation material examines the fatal failure of Cornishman’s trawl quick-release chain, including corrosion, side loading and material properties. Technical annexes document magnetic particle inspection, metallography, hardness and break-load testing. Recommendations address inspection, fabrication quality and consideration of alternative release designs; an annex discusses the separate Honeybourne III accident.
- 202430 May
2024-01 64 Investigation of March 25, 2022, Hydraulic Workover Unit Failure Fatality
BSEE investigates a fatal hydraulic workover unit collapse at Main Pass Block 64 Platform #19. Severely corroded structural casing buckled after crane support was removed, and a worker tied to the unit was pulled into the water. Findings examine load assessment, Anchor Spool stabilisation, oversized equipment and unclear operator–contractor responsibilities.
- 20249 Jan
Leak in hot water system for saturation divers
A saturation-diving hot-water unit leaked through locally corroded pipework inaccessible for visual inspection. Diving was suspended because the remaining unit lacked backup. Repairs involved welding a sleeve over the leak and inspecting the other unit. The flash suggests considering wall-thickness measurements of old pipes.
- 2023Oct
Radiograph duplication and falsification
This safety alert examines falsified weld radiographs, including duplicated boiler weld images and cropped tank negatives concealing defects. It explains how post-exposure identification and film double loading can enable substitution, and addresses competence, ethical obligations and procedural controls needed to assure non-destructive testing and structural integrity.
- 202328 Sep
Safety Alert - Pipeline Loss of Containment
A gas export pipeline tie-in spool flange failed after severe corrosion of carbon steel lacking the specified corrosion-resistant cladding. The alert examines material traceability and quality-control failures, misinterpreted inline inspection data and incorrect defect location reporting. Lessons address preserved identification, consideration of positive material identification and diverse integrity inspection measures.
- 202210 Nov
USCG: Hidden corrosion on deck fittings can cause dangerous failures
This flash describes corroded D-ring securing straps failing during hatch-cover positioning aboard a vessel, with sling snap-back causing a severe head injury. It highlights missing testing and replacement records, concealed corrosion and ageing fittings. USCG recommendations address high-risk lifting-point identification, inspection, possible gauging or testing, safe lifting limits and scheduled maintenance.
- 202229 Jul
Loy Lange Box Company Pressure Vessel Explosion
Investigation of a fatal steam-system pressure vessel explosion in St. Louis examines oxygen corrosion, incomplete repairs, water treatment and inspection failures. Metallurgical examination and thickness measurements underpin the findings. The report analyses regulatory oversight and process safety management, while noting that the pressure at rupture could not be determined.
- 20224 May
Maintenance and painting – two incidents
Two maintenance-related incidents involved a lifeboat brake mechanism and a crane high-hook alarm. Paint restricted moving components; a broken shackle affected lifeboat braking, while the crane hook block struck sheaves. Neither incident caused injury. Actions include post-maintenance operational checks, alarm testing, crane movement monitoring and dye penetration inspection.
- 202210 Mar
Safety warning issued after discovery of blocked fixed CO2 fire extinguishing system pilot hoses
This bulletin examines blocked pilot hoses discovered after Finnmaster’s engine-room fire in Hull. Incompletely bored couplings prevented gas passage, while servicing tests missed blockages and leaks. It describes radiographic examination, revised pneumatic flow testing and recommendations to rectify affected assemblies and improve purchasing and quality control.
- 202116 Jun
Failure of EGS valve stem on dive helmet
A diving helmet’s emergency gas valve handle broke during pre-dive inspection on deck. Laboratory analysis attributed the failure to pitting and chloride-induced stress corrosion cracking. After replacement and testing, the helmet returned to service. The company introduced scheduled dye penetrant testing and identified three further stems with stress-like indications.
- 20218 Apr
Flooding and sinking of trawler Ocean Quest
Investigation of Ocean Quest’s loss following uncontrolled engine-room flooding. The source remained undetermined, but shell plating or weld failure beneath the main engine was considered almost certain. Analysis examines hull survey limitations, reduced bilge-pump effectiveness with partly open sea suctions, unusable borrowed pumps and successful crew abandonment following regular drills.
- 202117 Mar
Crane wire parted during offshore operations
A vessel crane wire failed while overboarding a concrete mattress for a pipeline crossing, dropping the load before it entered the water. The flash examines unresolved magnetic rope testing results, misunderstood operational limits and absent change management, and calls for better shore–vessel communication and lift routing away from existing pipelines.
- 202125 Feb
Engine failure and subsequent fire on ro-ro cargo vessel Finlandia Seaways with 1 person injured
Investigation annexes examine a vessel’s main-engine failure and engine-room fire through connecting-rod fracture analysis, microscopy and material testing. Fatigue was identified, but consequential damage limited precise initiation-site identification. Supporting documents address connecting-rod ovality, recommended replacement intervals and machinery survey examinations credited through Chief Engineers.
- 202111 Feb
Crane whip line parted during hook stop testing
During auxiliary winch hook-stop testing, uncontrolled hoisting caused a headache ball to strike the crane jib, snap the wire and fall with the rigging to deck. Corroded speed encoders and poor wire condition were identified. The flash addresses rope examination, encoder maintenance, management of change and start-up risk assessment.
- 202028 Apr
Lifting operations: Wire hoist rope failure
A crane wire hoist rope failed during a standard lift, dropping the load, main block and wire approximately 3 m onto a wharf without injury. Examination identified ductile overload following internal corrosion. The flash recommends rope-specific maintenance informed by manufacturer input and risk assessment, and criteria for magnetic rope testing.
- 201920 Aug
Catastrophic rupture of dead-leg pipe-work
This safety alert examines refinery pipework ruptures associated with highly localised internal corrosion in dead-legs. It explains how routine thickness checks missed deterioration and outlines inspection expectations, including risk assessment, wider wall-thickness testing and timely replacement. Operators should consider removing non-essential dead-legs and account for thermal gradients, liquid interfaces and condensation.
- 201918 Apr
Near miss: Cargo shifted on deck in heavy weather
A platform supply vessel experienced casing movement of approximately 3 m to starboard after securing stanchions sheared during heavy rolling. Nobody was on deck. The flash identifies securing and back-load planning shortcomings, and describes pin replacement, non-destructive weld examination, lifespan reassessment and risk assessment for additional pins during winter loading.
- 2018Dec
High Temperature Hydrogen Attack: Safe use of carbon steel
HSE alerts operators to carbon steel degradation through high temperature hydrogen attack. It distinguishes safer metallurgy for new or replacement equipment from cautious use of Nelson curves for existing plant. Recommendations address operating histories, temperature and hydrogen partial pressure limits, validated complementary non-destructive testing, examination intervals and specialist inspector competence.
- 20186 Jul
Personnel certification in non-destructive testing (PCN) scheme fraud
HSE alerts duty holders to fraudulent PCN certification involving NDT International PTE Ltd and uncertain technician proficiency. It explains potential implications for equipment integrity, including imported equipment and in-service examinations, reviews relevant regulations, and advises assurance in consultation with competent persons, with options for checking technician details and certificate validity.
- 201822 Mar
Aircraft Accident Report 1/2018, G-WNSR High resolution
Investigation of G-WNSR’s loss of yaw control during landing at West Franklin. A failed tail rotor pitch change shaft bearing damaged the control servo; the initiating reason remained undetermined. The report examines missed HUMS warnings, software interfaces, maintenance review and crew decisions, documenting safety actions and recommendations. No injuries occurred.
- 201822 Mar
Sustained load cracking in aluminium cylinders manufactured from aluminium alloys HE30/AA6082 and AA6351
This flash examines sustained load cracking in older aluminium breathing-gas cylinders made from HE30/AA6082 and AA6351 alloys. It summarises New Zealand approval withdrawals and UK inspection requirements, including eddy-current testing. IMCA recommends excluding these cylinders from member worksites and provides identification markings and disposal guidance.
- 20188 Mar
Cylinders manufactured from aluminium alloys HE30/AA6082 and AA6351 and used primarily for gases for underwater breathing apparatus
HSE warns of catastrophic failures in HE30/AA6082 and AA6351 aluminium cylinders used for diving gases, highlighting susceptibility to sustained-load cracking. The alert requires visual inspection and eddy-current testing by competent inspectors, explains alloy identification, and specifies withdrawal or condemnation where identification or satisfactory testing cannot be established.
- 201715 Nov
Changes from dry gas to wet gas operation: guidance for HSE inspectors
Inspector guidance examines offshore installations converting from dry to wet gas operation. It addresses corrosion inhibition and monitoring, pipeline pigging and inspection, altered liquid flow, valve performance, detection and blowdown arrangements. It also covers maintenance, staffing, training, health hazards and management of change, including implications for onshore processing.
- 201721 Sep
Failure of pipework in fuel tanks
Seawater leaking from pipework running through a vessel’s fuel tank raised the tank level. Subsequent fuel transfer was followed by a separator trip, and checks found water in the system. The flash identifies pipework failure and highlights visual inspection and ultrasonic baseline thickness measurements.
- 201722 May
Dropped object: Lay tower adjuster leg pin
A 600 kg securing pin fell 16 m to deck after keeper plate bolts loosened; nobody was injured. The flash identifies unclear maintenance and inspection arrangements and possible movement and lubrication issues. Actions included structural NDT, stronger anti-rotation bolts, bolt locking, revised inspection criteria and survival-mode positioning during transits.
- 201724 Apr
Catastrophic failure of silo – bolted conical bottom section
This alert examines catastrophic separation of a silo’s bolted conical bottom, releasing approximately 600 tonnes of wheat grain. It links failure to manufacturing-induced micro-cracks at sharp cold-formed folds and subsequent fatigue cracking. Recommended measures include penetrant inspection of both fold surfaces, repeated inspections, attention to warning signs and exclusion zones.
- 201629 Feb
Safety Alert 319 - Chemical Injection Point Corrosion Causes Production Header Failure
A Gulf of Mexico production header ruptured after acidic demulsifier injection caused localised corrosion beneath the injection point. Production fluid sprayed three workers and the platform was evacuated. BSEE recommends procedures for chemical injection equipment and visual and non-destructive inspection, highlighting injection quills to direct chemicals away from pipe walls.
- 20157 Dec
Near-miss: Corrosion caused crane boom failure during heavy lifting
A crane boom buckled during a 37T lift from a jetty towards a vessel; the load dropped approximately 30 cm without injury. Investigation identified apparent old fatigue cracking and internal corrosion missed by recent testing. Lessons recommend a more thorough NDE maintenance and inspection plan, including spot-check magnetic particle inspection or similar after-load testing.
- 201518 Sep
Catastrophic failure of a pipework clamp connector
This safety alert examines brittle failure of small pipework clamp connectors associated with improper heat treatment, excessive hardness and hydrogen cracking. It describes an offshore gas release and other failures, and calls for checking pre-2010 Techlok and Destec connectors of 2 inches or below through certification, appropriate non-destructive inspection and hardness testing.
- 201529 Apr
Keel detachment and capsize of sailing yacht Cheeki Rafiki with loss of 4 lives
Investigation of Cheeki Rafiki’s keel detachment and capsize during an Atlantic passage, after which four crew remained missing. It examines bonded hull–matrix integrity, grounding inspections, certification, passage planning, flooding response, beacon performance and liferaft accessibility. The report explicitly acknowledges uncertainty about the accident’s causes.
- 201514 Apr
External chloride stress corrosion cracking of stainless steel lokring pipe connectors
This alert examines chloride stress corrosion cracking in stainless steel Lokring connector driver rings and the resulting containment risk. It explains limitations of surface inspection, contrasts radiographic detection of internal cracks, and advises identifying affected connectors and removing those whose failure could pose safety risks, with removal prioritised by consequence, service time and corrosive conditions.
- 20152 Apr
Lifting equipment failure: Objects dropped into moonpool
A chain hoist failed while crew positioned moonpool frames during mobilisation of multibeam echosounder equipment. The falling frame and carriage damaged stopper bars and brackets without injuries. Investigation identified obstruction by a bracket stopper and chain overstress. Corrective actions included dye penetration testing and revised procedures and job safety analysis.
- 201528 Jan
Chevron Richmond Refinery Fire
Final investigation of the Richmond refinery pipe rupture and fire examines sulfidation corrosion in low-silicon carbon steel, incomplete component inspection and rejected material upgrades. It analyses leak response, shutdown decisions, stop-work authority and safety culture, recommending stronger inspection requirements, corrosion-resistant materials and site-specific leak response protocols.
- 201410 Dec
Sikorsky S-76C Restricted Yaw Control During Approach
Investigation of restricted yaw control during a Sikorsky S-76C approach to Denham Aerodrome. The crew completed an uneventful running landing. Computed tomography and hydraulic bench checks identified a split solenoid valve ball causing internal leakage in the pedal damper trim actuator. Manufacturer advisory and flight manual changes were being prepared.
- 201414 Jul
Lost time injury (LTI): Winch base plate failure
During pipeline offloading from a vessel to shore, winch base-plate welds failed, throwing the operator and seriously injuring his knee and lower leg. The flash examines replacement of a constant-tension winch, unresolved deflection and tension-measurement limitations, with corrective actions addressing change management, weld testing, procedures and load-cell calibration.
- 20141 May
Tesoro Anacortes Refinery Fatal Explosion and Fire
Investigation of the Tesoro Anacortes refinery heat-exchanger rupture that killed seven employees. Metallurgical analysis identified high temperature hydrogen attack in carbon steel. Process modelling, inspection limitations and Nelson curves are examined alongside hazardous startup practices, ineffective safeguards, safety culture and regulatory gaps. Recommendations emphasise inherently safer materials and verified operating conditions.
- 201414 Apr
Silver Eagle Refinery Flash Fire and Explosion and Catastrophic Pipe Explosion
Metallurgical investigation of a refinery discharge-pipe rupture during hot hydrogen catalyst regeneration in Woods Cross, Utah. Ultrasonic thickness measurements, chemical analysis, metallography and fracture alignment document internal wall thinning. The findings are consistent with sulfidation corrosion as the primary cause; gas-release calculations and security-video analysis examine the subsequent explosion.
- 201314 Nov
NDK Crystal Inc. Explosion with Offsite Fatality
This investigation examines a crystal-production pressure-vessel rupture in Belvidere, Illinois, which killed a truck driver off site. It identifies stress corrosion cracking as the likely failure mechanism and considers possible embrittlement. The report analyses coating protection, missed internal inspections, vessel design, regulatory oversight and facility siting.
- 20111 Nov
Offshore tank container rigging failure
Two offshore tank-container rigging incidents involved cold fractures of master links, with damage noticed before lifting. Certification was in order and loads remained within safe working limits. A forging defect was initially considered most likely; subsequent batch similarities prompted replacement of 32 rigging sets pending laboratory results.
- 2011Oct
MAIB Safety Digest 2/2011
This marine accident digest presents separate cases involving navigation, propulsion failures, cargo handling, flooding, fishing hazards and passenger safety. Lessons examine bridge teamwork, training, emergency drills and equipment checks. Reproduced Tombarra bulletins analyse rescue-boat weight, water retention and davit overload protection; hull cases discuss ultrasonic thickness measurement and visual inspection.
- 201116 Sep
Lifeboat drill – near casualty
A lifeboat fell into the sea during a drill after its forward and aft chains parted. Nobody was aboard and no injuries occurred, but the craft was considered a total loss. The flash discusses possible corrosion or weld damage, periodic chain replacement or non-destructive testing, maintenance and conditional recommendations for boarding after lowering.
- 201112 May
Safety Alert 296 - Catastrophic Failures in Mooring Systems Possibly Put Floating Structures at Risk
This alert examines tether-chain failure in a Gulf of Mexico hybrid riser system and earlier mooring shackle and socket failures. It discusses prohibited post-heat-treatment weld repairs, material toughness and inadequate specifications or testing. Recommendations address manufacturing inspection, qualified inspectors, representative test coupons and restrictions above buoyancy air cans.
- 2011
Stainless steels - chloride stress corrosion cracking report 2011
Research report examining chloride stress corrosion cracking in austenitic stainless steel through reactor assessments and a literature review. It proposes risk-based inspection refinements, compares penetrant, eddy current and ultrasonic techniques, and evaluates structural fitness for service. The report highlights uncertainty in crack initiation times and limitations of leakage as an indicator.
- 201024 Jun
Manitowoc Cranes, Potain Tower Cranes - MD, MDT and MR series - Potentially faulty spigots on K600 and K800 mast sections
This safety alert addresses potentially defective spigots connecting K600 and K800 mast sections on Potain MD, MDT and MR tower cranes following two mast failures. It specifies identification ranges, immediate withdrawal and quarantine, or manufacturer-specified welded reinforcement, with inspection and non-destructive testing requirements for the reinforcement.
- 20108 Apr
Failure of hose reel bearing housing
A rented hydraulic winch suffered bearing-housing failure during seabed load recovery, with no injuries. Investigation identified repetitive overload damage, inadequate braking and design calculations not updated after a spooling-device modification. The flash recommends routine non-destructive testing, revised design verification and a proper drum disc brake, while suggesting failure-mode analysis.
- 200911 May
Safety Alert 19 - Pump Can Pollution Incident
External corrosion perforated a platform pipeline pump can, releasing between 20 and 30 barrels of crude oil into the Santa Barbara Channel. The alert identifies inspection and containment limitations and recommends preventive inspection procedures, risk assessment of uncontained equipment and consideration of guards against potential vessel damage.
- 2009May
Allied Terminals Fertilizer Tank Collapse — Allied Terminal Fertilizer Tank Collapse
Investigation of a fertiliser storage tank collapse at Allied Terminals that released about 2.1 million gallons and seriously injured two workers. The report examines defective welds, missing radiography, unsupported fill-level calculations, inspection practices and regulatory gaps, with recommendations for inspector training, verification and personnel exclusion during initial filling.
- 200816 Jan
Safety Alert 259 - Catastrophic Failures in Mooring Systems Possibly Put Floating Structures at Risk
Joint MMS and US Coast Guard alert examines catastrophic failures of mooring shackles and sockets affecting floating facilities. Suspected manufacturing deficiencies, inadequate or outdated specifications and shortcomings in material testing prompted recommendations to review specifications, Charpy toughness testing, destructive and non-destructive testing, representative coupons, and equipment inspection and handling.
- 2007
Technical guidance on the safe use of lifting equipment offshore
HSE technical guidance addresses lifting equipment on fixed and mobile offshore installations under LOLER and PUWER. It covers crane selection, sea-state derating, lift planning, examination and maintenance, wire ropes, personnel carriers and drilling hoists. Recommendations also address competence, protective systems, load retention and emergency controlled lowering.
- 200621 Nov
Flash fire in gas supply equipment onboard dive support vessel
An oxygen-decanting incident aboard a dive support vessel produced an explosion and flash fire, causing superficial burns and equipment damage. Investigation identified three equally likely possible causes without establishing a direct cause. Reported measures included replacement pipework and valves, a dedicated oxygen line, non-destructive testing, valve-opening signs and regular oxygen cleaning.
- 200612 Oct
BP America (Texas City) Refinery Explosion — Safety Bulletin: Positive Material Verification
This bulletin examines the July 2005 hydrogen-fed fire at BP’s Texas City refinery. A carbon steel elbow substituted during maintenance failed through high-temperature hydrogen attack. It discusses interchangeable piping components, material verification using x-ray fluorescence, component tracking and maintenance quality controls to prevent incompatible material substitutions.
- 20052 Sep
Near Miss – Dropped Objects – Unsecured Marine Riser Inserts
Two marine riser inserts fell about 15 to 20 feet onto the drill floor while a top drive lifted a pup joint from a raised catwalk. Nobody was injured. The alert describes recent MPI inspection involving insert and circlip removal, and subsequent discovery of four other inserts without retaining circlips.
- 2005Aug
Honeywell Chemical Incidents — Final Investigation Report
Investigates three chemical incidents at Honeywell’s Baton Rouge plant involving chlorine, contaminated antimony pentachloride and hydrogen fluoride. Examines cooler inspection, control-room protection, shutdown isolation, cylinder identification and nonroutine draining. Findings address incomplete hazard analyses and departures from procedures, with recommendations on change management, testing, training and protective equipment.
- 2003May
DPC Enterprises Festus Chlorine Release — Final Investigation Report
Investigation of a chlorine release during tank car unloading near Festus, Missouri. It examines inappropriate hose braid material, corrosion-impaired emergency shutdown valves, material verification and mechanical integrity deficiencies. Facility and community emergency arrangements, notification delays and cleanup exposures are analysed, with recommendations for equipment assurance and response planning.
- 2002Oct
Motiva Enterprises Sulfuric Acid Tank Explosion — Final Investigation Report
Investigation of a fatal sulphuric acid tank explosion at Delaware City refinery during catwalk repairs. The report examines corrosion, deferred inspections, inadequate carbon dioxide inerting, hot-work authorisation and changes to cutting methods. It analyses tank failure and containment limitations, compares earlier incidents, and recommends improvements to integrity management and change review.
- 20005 Dec
Block Hanging Line Load Path
An annual MPI inspection revealed overloading of the top clevis on a rig’s 500-ton travelling block. The rating plate specified a maximum hanging weight of 13 tons, whereas the combined block and top drive weighed 17.5 tons, exceeding that limit by 4.5 tons.
- 200010 Jul
Safety Alert 16 - Rupture Of Sour Gas Piping
An offshore sour-gas piping rupture released natural gas containing hydrogen sulphide without injury. Earlier ultrasonic testing had identified serious corrosion near the failed elbow, but no corrective action followed. The alert recommends detector testing and breathing-equipment familiarity during drills, and asks operators to consider periodic ultrasonic inspection, prompt results review and predetermined wall-thickness limits.
- 19991 Dec
Crane whip line incident
A crane whip line parted while lifting a 4.5-tonne concrete mat from a vessel deck, without injury or damage. Investigation attributed failure to internal corrosion and inadequate lubrication. Approximately 25 m had escaped inspection. Actions addressed complete non-destructive testing, high-pressure lubrication and review of planned maintenance.
- 19991 May
Regen plumbing incident
A ten-year pressure test identified a cracked weld in regeneration plumbing aboard a vessel in dry dock. X-ray examination of the removed section showed unacceptable deterioration at the welded seam of stainless steel pipe. The contractor intended to replace all its regeneration plumbing with seamless tube.
- 197929 Dec
Safety Alert 93 - Flowline Parts, Injury
A pumper suffered head injuries while restarting offshore well production. Pressure against a closed header valve ruptured a flowline weakened by carbon dioxide corrosion; flying debris or impact against an object was reported. The operator’s measures included X-ray, density-meter and visual inspections, corrosion inhibitor injection and replacement with corrosion-resistant alloy steel.
- 19776 Dec
Safety Alert 69 - Blowout, Platform Loss
An offshore development well suffered a gas blowout during attempts to kill a deep saltwater flow. Gas jetting formed a seabed crater, undermining the platform legs; personnel evacuated safely before it toppled. The alert reviews drilling warning signs and planned casing-integrity checks, cement evaluation, well-control training and reassessment following operational deviations.
- 197518 Aug
Safety Alert 28 - Weld Fails, Derrick Collapses
An offshore workover rig derrick collapsed during pipe fishing after skid welds failed. Falling equipment caused minor injuries to one crewman, and an overturned diesel tank caused minor pollution. The alert records weld radiography and modifications to the skid joint, drawworks position and connections intended to prevent recurrence.
- 19759 Jul
Safety Alert 26 - Crown Block on Workover Rig Fails, Fatality
An offshore workover rig suffered crown-block support weld failure while jarring stuck drill pipe. Falling equipment struck two men, killing one and seriously injuring the other. The operator recommends radiographic examination of all crucial derrick welds after manufacture and before the first job.
- Undated
Hydrogen Sulphide Released from Ruptured Glycol Vessel Piping
This investigation records a hydrogen sulphide gas release from ruptured three-quarter-inch piping attached to a glycol vessel on Platform Hidalgo’s production deck. The vessel operated at approximately 1285 psi with approximately 19,500 ppm H2S. Gas detection initiated an alarm and emergency shutdown; similar piping was undergoing ultrasonic non-destructive inspection.
- Undated
Offshore Oil Discharge During Wet Oil Tank Drainage
BSEE investigates an offshore oil discharge during draining of produced water from a wet oil tank. Findings identify an unattended valve, unsuitable drainage routing and a sand-blocked micro-filter exposing piping leaks. The report records ultrasonic inspection, planned repairs and valve blinding, while finding no evidence that reports were falsified.
- Undated
Drill Pipe and Bottom Hole Assembly Dropped During Well Abandonment
Investigation of drill pipe and a bottom hole assembly dropped during well abandonment from the Helix Q-4000. Weight-indicator records placed separation on 31 March, before discovery on 1 April 2022. The report identifies inadequate connection torque, describes ROV surveys and ultrasonic inspection, and reports no subsea infrastructure damage.
- Undated
Two Hydraulic Boom Cylinder Failures on a Crane
An investigation examines two hydraulic boom cylinder failures on a crane at Vermilion 252-A. Inferior refurbished welds and mismatched working strokes were identified as causes. Dye penetrant testing had not detected the weld defects. Operators should consider paired replacement when one cylinder needs repair, or verify matching cylinder dimensions.
- Undated
Oil Spill from Worn Centrifugal Pump Housing
Investigation of an oil spill from SP 67 A platform on 6 May 2005. Produced sand wore through a centrifugal pump housing and blocked deck drains, allowing oil to escape overboard. The report records revised spill estimates, platform shut-in, ultrasonic testing and proposed monitoring of sand production using a shake-out flask.
- Undated
Heater-Treater Fire with Leaking Fire-Tube Weld
BSEE investigates a heater-treater fire at Ship Shoal Block 193, with no injuries reported. Inspection found a leaking fire-tube weld and subsequent magnetic particle testing identified another crack. The report examines production fluctuations, heat dissipation and weld failure, documenting emergency shutdown, repairs and daily temperature tracking.
- Undated
Drilling Riser Failure on Discoverer Enterprise
Investigation of a drilling riser failure on Discoverer Enterprise examines connector insert cracking, hydrogen embrittlement and progressive connection failure. It documents wellbore sealing, subsea recovery and potential synthetic-mud discharge. Recommendations address insert and bolt redesign, hardness limits, coating removal and more frequent magnetic particle inspection.
- Undated
Nitrogen Cylinder Rupture During Workover Operations
BSEE investigates a nitrogen-cylinder rupture aboard Helix Q5000 during workover operations. Three personnel sustained minor shrapnel injuries. The report identifies corrosion-related wall loss, inadequate coating protection, incomplete visual inspections and poor rack drainage. It describes muster and cylinder venting, alongside planned nitrogen generation, protective barriers and changes to vendor selection and inspection.
- Undated
Partial Separation of Temporary Living Quarters Walkway
BSEE investigates partial separation of a temporary living quarters walkway at Devils Tower, with three workers present and no injuries or dropped objects. Findings identify insufficient weld support, corrosion, fatigue and inadequate visual inspections after prolonged use. The report describes immediate securing, access restrictions, repairs and planned non-destructive testing.
- Undated
Telescopic Joint Dropped After Running-Tool Pin Failure
An investigation into a telescopic joint dropping approximately 15 feet on a spar rig identifies failure of four running-tool j-pins. Investigators attributed the failure to loading beyond design limits, probably during crane handoff and righting. The report discusses missing manufacturer operating parameters and limitations of routine visual inspection; nobody was injured.
- Undated
Drill-Line Failure Dropped Travelling Block and Top Drive
Investigation of a drill-line failure on Rowan Gorilla IV that dropped the travelling block and top drive, trapping a roughneck’s foot. The report attributes line damage to impact loading while running casing, with defective manufacture a possible contributor. It documents inspections, repairs and Rowan’s recommendations for inspection and maintenance.
- Undated
Well Toppled During Hurricane Isaac
Investigation of a well toppled during Hurricane Isaac at MP 116 beneath Ensco 81. Sonar identified the well resting on the seabed; failure appeared near a weld above the mud line. Findings discuss hurricane preparations, absent ultrasonic weld inspection and possible welding and drive-pipe design deficiencies. No recommendations were made.
- Undated
Low-Pressure Pipe Rupture During Front Runner Spar Restart
Investigation of a low-pressure pipe rupture during restart of the Front Runner spar. The release prompted shutdown and evacuation. Internal corrosion was identified as the likely cause, with absent chemical injection quills and inadequately located non-destructive testing contributing. Subsequent inspections led to repairs or replacement of separator inlet piping.
- Undated
Crane Pad-Eye Failure During Casing Removal for Well Abandonment
Investigation of a crane pad-eye failure during casing removal for well abandonment on VR-226A. Incorrect installation caused the attachment to pull from the boom; hoist equipment fell and remained suspended from the casing. The report also identifies inadequate inspections and earlier use of static rather than dynamic load limits. No injuries were reported.
- Undated
Casing Failure Released Drilling Mud During Deepwater Well Operations
This investigation examines casing failure and drilling-mud pollution during deepwater well operations. Drill-pipe wear at a buckled liner connection caused leakage, with synthetic-base mud reaching the seabed. It describes diagnostic logging, cement plugging and leak squeezing, alongside proposed improvements to casing design, wear monitoring, change management and engineering training.
- Undated
Cargo Box Fell Following Crane Winch Failure During Offloading
BSEE investigates an auxiliary crane winch failure during cargo offloading at Front Runner. A cargo box fell approximately 20–30 feet before striking a supply vessel and entering offshore waters. The report examines ring-gear fatigue, overloading, shock-loading, incorrect manifested weight, inspection records and alarm-triggered shutdown behaviour. No injuries occurred.
- Undated
Gas Pipeline Riser Ruptured During Production Shutdown
An investigation examines a gas pipeline riser rupture at WC-45-A during production shutdown. Rising pressure and external corrosion were identified as causes. Findings address inadequate maintenance, inspection and reactivation testing, delayed valve closure and deficient tracking records. Two operators evacuated by boat; ultrasonic testing confirmed extensive metal loss.
- Undated
Subsea Condensate Leak from Sea Robin Pipeline
Investigation of a subsea condensate leak from Sea Robin pipeline segment 3334 near South Marsh Island Block 27. Diver inspection, ultrasonic testing and cathodic protection readings found no evidence of corrosion or third-party damage. An isolated pit or manufacturing defect was suspected; the final estimated release was 0.7 barrels.
- Undated
Crane Wire-Rope Failure During Compressor Offloading
BSEE investigates an auxiliary crane wire-rope failure during compressor offloading at Ship Shoal 72 OF. The load fell into offshore waters without injuries. Records and bending examinations identified corrosion, inadequate maintenance and unresolved inspection deficiencies. The report examines overdue winch testing, infrequent-use inspection requirements and failures to restrict crane service.
- Undated
Oil Release from Permanently Abandoned Subsea Well
Investigation of an oil release from a permanently abandoned subsea well in the Gulf of Mexico examines drilling, cement placement, plug verification and delayed well-control response. The specific cause remained unresolved because deeper plugs could not be reached. Findings identify possible contributing factors and propose research and regulatory changes.
- Undated
2012-104 Investigation of February 23, 2012, H2S Gas Release Platform Hidalgo, OCS-P 0450 Pacific OCS Region
Investigates a hydrogen sulphide release at Platform Hidalgo offshore California, with no reported injuries. Examines failed pipework, oxygen contamination and elemental sulphur formation, alongside limitations of point-specific ultrasonic inspection. Includes radiographic follow-up, thickness-monitoring arrangements and five-year inspection recommendations, plus historical Hermosa findings and emergency-response recommendations.
- Undated
Engineered Safety and Environmental Aspects of Well Construction and Fracturing Design
Presentation on engineering well construction and hydraulic fracturing for pressure containment and groundwater protection. It covers casing and liner design, cement evaluation, treating-line ratings and testing, staged pump shutdowns, relief arrangements and wellhead valves. Surface planning addresses fluid storage, spill berms and logistics, alongside examples of fracturing-fluid ingredients.
- Undated
Equinor - Johan Castberg - investigation of the reasons for the challenges faced in constructing hull and equipment
Investigation into weld-quality problems and fatigue-analysis errors during construction of the Johan Castberg hull and integrated living quarters. It examines contractor oversight, inspection competence, non-destructive testing and verification independence. Findings identify inadequate welding expertise and quality assurance, persistent unresolved risks, strained multi-yard follow-up and delayed communication to licensees.
- Undated
Equinor – Troll C – investigation of incident with gas cooler cracks
The PSA investigates externally initiated chloride stress corrosion cracking in Troll C’s second-stage gas coolers. Through-wall cracks compromised pressure containment, with potential for a major gas leak. Findings address coating inspection, preventive maintenance, consequence classification and passive fire protection. Penetrant testing revealed shell cracking; no harm to people or the environment was identified.
- Undated
Failure of lifeboat suspension link on ro-ro passenger ferry Pride of Hampshire with 16 people injured
Investigates a lifeboat collapse during an emergency drill aboard Pride of Hampshire alongside in Cherbourg. The aft suspension link failed through pre-existing cracks and stress corrosion; forward davit weld failure followed. Six occupants entered the water and 16 people were taken to hospital. Recommendations address testing, certification, inspection competence and embarkation procedures.
- Undated
Failure of starboard outer bow door on ro-ro passenger ferry Pride of Provence before departure from port
Investigation of Pride of Provence’s starboard bow door failure while closing at Calais. The synopsis examines previously identified hinge cracks, continued operation without detailed examination or weather limitations, omitted non-destructive testing during refit, earlier structural cracking and contact with the cowcatcher framework, and removed hydraulic locking wedges.
- Undated
Post-Hurricane Inspection and Reporting
BSEE guidance addresses hurricane damage assessment for Gulf of America OCS platforms, moored drilling units and pipelines. It describes tiered structural surveys, mooring inspections, pipeline leak testing, reporting deadlines and repair arrangements, alongside restrictions on manning and conditions for restarting production and safety-device testing.
- Undated
Statoil - Mongstad - Investigation into steam leak
This investigation examines the Mongstad steam leak of November 2012, linking pipe fracture to corrosion-related wall thinning. It identifies weaknesses in corrosion monitoring, operational data, inspection follow-up, contractor oversight and repair risk assessment. Valve isolation stopped the leak after 12 minutes; nobody was seriously injured.
- Undated
Tie-Downs on OCS Production Platforms
MMS guidance addresses hurricane tie-down assurance for rigs and permanent equipment on OCS production platforms. It specifies seasonal visual inspections, bolt and weld checks, fail-safe verification, evacuation procedure integration and post-evacuation inspections. Engineering reviews use updated site-specific environmental and dynamic loads, with conditional non-destructive testing for permanent-equipment tie-downs.