Control
Pressure Relief
Devices and measures preventing harmful excess pressure.
Newest 100 Documents
All 114 in search- 202610 Aug
United States Steel Corporation Clairton Plant Coke Oven Explosion
Investigates the fatal Clairton coke works explosion during high-pressure water washing of a cast-iron isolation valve. Overpressurisation caused valve failure and a coke oven gas release. The report examines maintenance procedures, hazard assessment, occupied-building siting and process safety governance, supported by valve examination and causal analysis.
- 202627 May
Givaudan Sense Colour Explosion
Investigation of a fatal reactor explosion during caramel colouring manufacture in Louisville. A vent valve failed closed, accelerating sugar decomposition; cooling and emergency pressure relief capacity were inadequate. Calorimetry and component testing inform findings on reactive hazards, process safety implementation, operating limits, occupied-building siting and regulatory coverage gaps.
- 202628 Apr
BSEE Safety Alert 516 - BSEE Identifies Compressed Gas Cylinder Hazards During Risk-Based Inspections
Following reported cylinder-failure explosions, BSEE inspected 20 Gulf assets and identified gaps in cylinder marking knowledge, inspection programmes, maintenance and contractor assurance. The alert presents findings on storage, corrosion and recharging, and asks operators and contractors, where appropriate, to consider improved labelling, documented inspections, overpressure protection and training.
- 2026Mar
Production PINCs
Numbered regulatory inspection questions address production safety systems, well barriers and casing-pressure diagnostics. Checks cover shutdown valve operation, gas and fire detection calibration, firewater pumps, pressure relief and protective devices on process equipment. Conditional approval requirements and specified testing intervals support inspection of production facilities and subsea components.
- 202626 Feb
Dow Louisiana Operations Explosions
Investigation of the Dow Plaquemine explosion examines work lights left inside a reflux drum during turnaround. Degraded light debris punctured a rupture disc, admitting ethylene oxide into air-containing relief piping. The report analyses vessel closure practices, loss of nitrogen inerting, inadequate monitoring and relief routing that enabled propagation into the drum.
- 202525 Sep
Cuisine Solutions Ammonia Release
CSB investigates an ammonia refrigeration release at Cuisine Solutions in Sterling, Virginia, which injured workers during evacuation. Relief-valve testing and dispersion modelling examine overpressure, liquid aerosol and unsafe discharge. The initiating upset remains undetermined. Recommendations address relief-system assessment, process-data retention, ammonia alarms and emergency preparedness.
- 20254 Sep
MSF: Grease gun hand injury
A crew member suffered a grease injection injury through a glove while disconnecting a battery-powered grease gun hose during tensioner maintenance. The flash reports a malfunctioning pressure release valve and possible handling and training shortcomings. Lessons emphasise manufacturer instructions, pre-use hose and nipple inspections, suitable gloves and consideration of safer tools.
- 2025Aug
Thermal Expansion runs hot and cold! — Process Safety Beacon, August 2025
This bulletin explains how heating trapped liquids and freezing accumulated water can rupture process pipework. Two chemical-processing incidents illustrate releases, fires and injuries involving a burst strainer and cracked propane piping. It highlights pressure relief, established isolation and depressurisation procedures, accommodation of thermal movement and temperature-dependent freezeproofing.
- 202430 Apr
Near miss – lid on ash trash barrel blown off due to hot ash
A vessel waste-container lid was expelled by pressure from hot incinerator ash while a crew member attempted to release the compression ring. The lid fell 11 m to the main deck. The flash identifies unrecognised disposal risks and records installation of a goose neck vent and revisions to waste-management procedures.
- 202422 Jan
MSF: LTI – Engineer scalded
An engineer aboard a platform supply vessel suffered scalding burns when a cooling-water compensator burst during refilling after repair. The flash discusses sudden pressure increase, unsuitable temperature rating, likely material degradation and potentially inadequate pressure relief. Corrective measures address compensator suitability, installation checks, cooling before refilling and planned inspection and maintenance.
- 202321 Dec
KMCO LLC Fatal Fire and Explosion
Investigation of the fatal isobutylene explosion and fire at KMCO’s Crosby facility. Metallurgical testing established pressure-driven brittle fracture of a cast-iron y-strainer. The report examines thermal-expansion hazards, manual versus remote isolation, emergency-response roles and alarm use, identifying weaknesses in hazard evaluation and response that contributed to the incident and its severity.
- 20236 Dec
Didion Milling Company Explosion and Fire
CSB investigates fatal combustible corn dust explosions at Didion’s Cambria mill. It examines propagation through interconnected dust collectors and pneumatic conveying systems, secondary explosions and building collapses. Comparative mill teardown, dust testing and explosion modelling support analysis of deficient safeguards, change management, housekeeping, emergency preparedness and regulatory oversight.
- 202330 Nov
Yenkin-Majestic Resin Plant Vapor Cloud Explosion and Fire
Investigation of a fatal resin-plant explosion and fire following solvent vaporisation and release through an altered reactor manway. The report examines pressure-containment design, inadequate alteration assurance, agitator-dependent safeguards, alarm deficiencies and evacuation preparedness. Recommendations address low-pressure vessel guidance, safer process design and flame-resistant clothing.
- 202321 Nov
EI 158 Fatality Failure to Use Safety
An offshore worker died when surface casing failed during pressure testing supplied by a high-pressure well. The explosion involved pressure release without signs of ignition. BSEE identifies omitted pressure safeguards and deficiencies in planning and change management, and recommends operators consider equipment compatibility checks, gauge training and improved hazard assessment.
- 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.
- 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.
- 2021Feb
Failure of a road tanker pressure/vacuum relief valve
HSE safety alert describes a modified road-tanker relief valve that stuck open, releasing nitric acid vapour without injuries or property damage. A welded nut obstructed the valve stem. It calls for visual checks for unauthorised modifications, manufacturer-guided servicing and verification of both pressure and vacuum protection functions.
- 202119 Jan
Well Control - Issue 6
An offshore well-control inspection guide using questions, model answers and success criteria to assess operational arrangements. It examines conventional, high-pressure high-temperature and managed pressure drilling, including BOP assurance, kick detection, hydraulic modelling, fingerprinting, pressure relief, contingency procedures and crew training. Inspection scoring supports subsequent regulatory intervention planning.
- 20204 Sep
High potential DROPS near miss: Failed crane component
A crane’s man-riding brake casing failed during preparation, dropping components to the deck without injury. Investigation identified hydraulic overpressure and incorrectly set relief valves, with commissioning changes insufficiently evaluated. The flash describes isolation by blanking and recommends valve adjustment checks and reviews of change management, commissioning, competence and maintenance procedures.
- 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.
- 201917 Dec
Midland Resource Recovery Explosion
This investigation examines two fatal explosions during draining of chemically treated gas odorizers at Midland Resource Recovery in West Virginia. It identifies failures to characterise vessel contents and manage reactive chemistry hazards, while leaving the exact reactions unresolved. The report discusses operating procedures, overpressure protection and gaps in regulatory coverage.
- 201913 Feb
Enterprise Pascagoula Gas Plant Explosion and Fire
This case study examines the Pascagoula gas plant fires and explosions, identifying thermal fatigue in a brazed aluminium heat exchanger as the probable cause. It analyses repair history, blocked-layer venting, temperature monitoring and process safety management deficiencies, alongside emergency response and community notification. Two night-shift workers were uninjured.
- 201811 Sep
Unintentional release of carbon dioxide from fixed fire-extinguishing systems on ro-ro vessels Eddystone and Red Eagle
Investigation of unintended carbon dioxide discharges on Eddystone and Red Eagle examines leaking cylinder valves, system activation arrangements and maintenance deficiencies. Neither incident harmed anyone. The report analyses leakage alarms, pressure protection, valve testing and servicing, and recommends design reviews and improved survey assurance of safety devices.
- 2018May
Pipelines PINCs
Inspection questions for DOI-regulated offshore pipelines address pump protection, shutdown devices, pressure settings, riser protection and integrity testing. Items link checks to regulatory authorities and enforcement actions. The guide also covers conditional leak detection requirements and the isolation, preservation, removal and reporting of out-of-service pipelines.
- 20182 Mar
Loss of Containment (LoC) - Version 2 March 2018
Inspection guidance for assessing offshore oil and gas duty holders’ containment safeguards. It covers design, commissioning, operating limits, instrumented protection, relief, isolation, reinstatement and change management. Specialist sections address process hazards, FPSOs, tubing and hoses, alongside investigation, performance indicators, assurance and leadership.
- 201712 Dec
Worker suffers life changing injury after pressure test failure
During a boiler pressure test involving three companies, an overpressurised valve failed and a hose and metal fitting assembly struck a worker’s leg. Compound fractures led to amputation below the knee. The flash highlights absent pressure relief, an unsafe system of work and the importance of shared safety responsibilities.
- 20175 Oct
Fatality: Overpressure of an explosion-proof enclosure
An engineer suffered fatal head injuries when trapped pressure propelled an explosion-proof enclosure cover during removal. Leaking sample gas or instrument air components had pressurised the enclosure, which lacked pressure indication and relief. Lessons address identifying susceptible enclosures and developing mitigation with manufacturers while preserving electrical certification.
- 201724 Jul
Track Tensioning incident
This safety alert examines a fatal hydraulic injection injury during piling-rig track tensioning and reports separate component failures without injury. It discusses possible over-pressurisation, weakened grease-nipple connections and retained grease pressure. Required precautions address component replacement, protective covers, operator positioning, training and manufacturer-specified track tension.
- 201625 Nov
Electrolytic Chlorination Units (Electrolysis) in Marine Ballast Treatment Systems
Safety alert following catastrophic failure of an electrolytic ballast-water treatment unit on a UKCS semi-submersible installation. It describes projectile damage and potential overpressure or hydrogen explosion hazards, including continued electrode operation during low or absent flow. Operators should assess risks, with attention to pressure relief and instrumented protection assurance.
- 201619 Oct
Williams Olefins Plant Explosion and Fire
CSB case study examines the fatal Williams Geismar reboiler rupture, BLEVE and fire. It analyses likely liquid thermal expansion in standby equipment lacking effective pressure relief, alongside shortcomings in change management, hazard analysis and operating procedures. Metallurgical testing, finite element analysis and process modelling inform the failure assessment and recommendations.
- 20166 Oct
Near-miss: Release of trapped pressure after ROV dive
An incorrectly oriented ROV tooling frame released trapped pressure when a crew loosened an Allen bolt during dismantling. The supervisor evacuated and cordoned off the area while pressure bled down naturally. Subsequent measures included reassessing risks, drilling cross-member holes, checking similar systems and marking correct frame orientation.
- 201529 Oct
Fire in engine room on ro-ro passenger ferry Pride of Canterbury
Investigation of Pride of Canterbury’s engine room fire while berthing in Calais. A jammed back pressure valve caused hydraulic overpressure and joint rupture, releasing oil onto hot exhaust uptakes. The report examines valve testing, joint shielding, pressure safeguards and hi-fog firefighting. The engine room sustained significant damage, but nobody was injured.
- 201510 Aug
Lost time injury (LTI) and restricted workday case (RWC) following failure of diving bell door system
A diving bell door fell after its hydraulic ram failed, trapping one diver’s feet. A second diver injured his hand during the attempted release using recovery equipment. The flash examines hydraulic pressure, missing maintenance and door securing arrangements, and highlights secondary closure-prevention systems and planned maintenance.
- 201413 May
First aid injury: Thermos cup exploded after being in hyperbaric environment
A thermal cup returned from saturation through a medical airlock separated violently from its plastic base at surface pressure, causing minor bruising to an assistant life support technician. The flash records the diver’s assumption about pressure differential and recommends drilling such vessels or prohibiting non-venting thermal vessels in saturation chambers.
- 2014
Safety of pressure systems
Approved Code of Practice and guidance explaining duties under the Pressure Systems Safety Regulations 2000. It addresses stored-energy hazards, system design, safe operating limits, written examination schemes, competent-person examinations, protective-device testing, maintenance and records. Conditional exceptions and the distinction between examination and maintenance are also explained.
- 201120 Dec
Pressure Relief Valve Sprays Dilute Acid Across Location on a Frac Job
During hydraulic fracturing, a hydraulically activated pressure relief valve opened unexpectedly, spraying about six barrels of a diluted mixture of 15% HCL and gel across equipment. No injuries occurred. The alert describes acid neutralisation with soda ash, recovery from the cellar and a subsequent safety stand-down and investigation.
- 201127 Oct
Failure of pressure washer
A portable Karcher pressure washer failed during post-maintenance testing, injuring a technician. A corroded, unserviceable pressure relief valve and defective boiler-regulating switch allowed overpressure to rupture the heating coil, ejecting the boiler hatch. The flash recommends inspection of similar devices and their inclusion in planned maintenance.
- 2011Sep
Oil Tank Safety Study
This investigative study examines public exposure to explosions at oil and gas production storage sites, drawing on three investigations, a wider incident compilation and a community survey. It reviews regulatory and industry-standard gaps, unauthorised access, hazard signage and safer tank designs, including floating roofs, pressure-vacuum relief valves, flame arrestors and vapour recovery.
- 2010Nov
Two valve actuator rupture incidents! — Process Safety Beacon, November 2010
Two valve operator failures expelled components without striking anyone. In the first, process gas entered a gear operator whose relief vent had been painted over; the second actuator’s failure cause remained uncertain. The bulletin emphasises understanding overpressure protection, maintaining documentation, training maintenance workers and inspecting their work before equipment returns to service.
- 201021 Jul
Veolia Environmental Services Flammable Vapor Explosion and Fire
This CSB case study examines a solvent-recovery explosion and fire at Veolia’s West Carrollton facility that injured four workers and damaged neighbouring properties. It analyses atmospheric relief arrangements, occupied-building siting and emergency response. The initiating overpressure cause remained uncertain; recommendations address closed relief systems, hazard analysis and safer building separation.
- 2009Dec
The Bhopal Tragedy – 25 Years Ago — Process Safety Beacon, December 2009
This anniversary bulletin revisits the Bhopal methyl isocyanate release, with an accompanying 2004 Beacon. It describes water contamination, an exothermic reaction and inadequate safety systems, while retaining uncertainty over the water source. Lessons address reactive hazards, safe relief discharge, maintenance, change evaluation and emergency procedures.
- 200826 Nov
Failure of Back Flow Valve During Nitrogen Foam Frac Results in a Fatality
This alert describes a fatal incident during a two-stage nitrogen foam fracturing treatment using four manifolded nitrogen pumps. During attempts to restore pump prime at the start of the second stage, gas backflow entered a storage vessel. Insufficient relief capacity led to catastrophic overpressurisation.
- 200826 Jan
Standpipe Pressure Gauge Thread Nipple Failure (Under Pressure)
During reaming after a connection, mud pump pressure spiked as the crew aligned the table and kelly bushings. The pressure-relief valve blew and a standpipe pressure gauge was expelled. It deflected off the A-leg and struck a worker cleaning breakout tong dies, causing head and torso injuries.
- 200724 Nov
Safety Alert 255 - Compressor Explosion
Two contract employees suffered hot-oil burns following a compressor explosion during start-up. The explosion displaced a crankcase door, and oil was redirected onto the operators by the building wall and window. The alert recommends correctly sized flame-arresting explosion relief valves and access covers capable of withstanding the specified internal pressure.
- 2007Oct
We Have Liftoff! — Process Safety Beacon, October 2007
A pneumatic pipe test pressurised a connected tank through a leaking block valve, causing bottom failure and lifting the tank onto the plant. The bulletin recommends positive isolation, adequate pressure relief, reviewing non-routine operations and keeping workers clear. Where possible, it favours hydrostatic testing because less energy can be released.
- 20074 Apr
Near-miss: Hyperbaric fire extinguisher incident
A hyperbaric extinguisher’s safety valve assembly blew off during six-monthly functional checks at a shore-base workshop, without injury. A faulty first-stage regulator and non-functioning burst disc were identified. Actions included phasing out twin-cylinder extinguishers, annual burst-disc replacement and improved equipment traceability.
- 200720 Mar
BP Texas City Final Investigation Report
Investigation of the Texas City refinery explosion during raffinate splitter startup examines tower overfilling, atmospheric blowdown discharge and occupied trailer siting. It analyses instrumentation, operator displays, procedures, training and fatigue alongside organisational culture, resource decisions and regulatory oversight. Process reconstruction and blast modelling inform recommendations for stronger process safety management.
- 2007Jan
BP America (Texas City) Refinery Explosion — Report of the BP Independent Refineries Safety Review Panel (Baker Panel Report)
An independent panel assesses corporate oversight, safety culture and process safety management across BP’s five US refineries, rather than investigating the Texas City accident itself. Interviews, workforce surveys, document examination and sampled technical reviews underpin findings on leadership, competence, hazard analysis, inspection backlogs, performance indicators and incident learning, with recommendations for sustained improvement.
- 200628 Dec
Safety Alert 248 - Stainless Steel Tubing-Related Fires
This alert describes two fires following stainless steel tubing separations. Pump vibration caused one failure; unexplained overpressure and possible weather damage were considered in the other. Locally piped pressure safety valves complicated firefighting. MMS recommends reviewing tubing policies, maintenance and inspections, including potentially undetected hurricane damage.
- 20066 Dec
Safety Alert 246 - Stainless Steel Tubing-Related Fires
Two stainless steel tubing failures caused fires. Pump-induced vibration was identified in the glycol-system incident; overpressure and weather damage were possible contributors in the gas-scrubber incident. The alert recommends reviewing tubing procedures and considering undetected hurricane damage, and records difficulty extinguishing the glycol fire associated with locally piped pressure safety valves.
- 2006Jun
Marcus Oil and Chemical Tank Explosion — Case Study
This case study examines the December 2004 explosion and fire at Marcus Oil’s Houston wax-processing facility. It analyses defective pressure-vessel alteration welds and oxygen contamination of the nitrogen system, alongside physical testing and regulatory gaps. Recommendations address vessel repair standards, overpressure protection and personnel training in inerting-system operation.
- 20052 Nov
Near Miss – Mud Pump Relief Line
This alert describes a mud pump near miss after a module repair and return to circulation. The relief valve operated at approximately 4,900 psi, while bolts securing an anchor clamp on the mud tank failed. Nobody was present in the area, and no personnel were injured.
- 2005Sep
Hayes Lemmerz Dust Explosions and Fire — Final Investigation Report
CSB investigates the fatal aluminium dust explosion at Hayes Lemmerz in Huntington, Indiana. The report examines dry-chip processing, dust collection, deflagration propagation and possible ignition sources using laboratory testing and fault-tree analysis. Findings address collector design, housekeeping, maintenance, protective clothing and incident learning, with recommendations for training, procedures and improved explosion protection.
- 20051 Apr
Starting air system incident
An explosion damaged a vessel’s starting-air system during management system trials. Investigation identified accumulated compressor lubricating oil and ignition through engine starting valves, with non-return valves and flame arrestors absent. The flash describes reinstatement testing and flushing, alongside longer-term commitments to filtration, maintenance review and protective-device design review.
- 20051 Mar
Transponder pressure relief system failure
Testing identified pressure-relief faults in two of three Kongsberg transponders. The attached manufacturer bulletin explains incorrect RPT valve assembly and provides dismantling, verification and repair procedures, including removal of an additional circlip. It addresses stored-pressure precautions and requires renewed pressure testing if the valve is moved.
- 2004Dec
Bhopal - a tragic event — Process Safety Beacon, December 2004
This bulletin revisits the Bhopal methyl isocyanate release twenty years later. It describes water entering storage, rising temperature and pressure, and inadequate safety systems, while noting uncertainty over the water source. It emphasises chemical reactivity, emergency procedures and understanding worst-case scenarios and protective layers.
- 2004Mar
D.D. Williamson & Co. Catastrophic Vessel Failure — Final Investigation Report
CSB investigates a fatal spray dryer feed tank explosion and subsequent aqua ammonia release at DDW. The tank most likely failed through overheating and excessive pressure. Analysis examines missing pressure relief, vessel certification, equipment changes, inadequate hazard evaluation and operating guidance, with recommendations for safeguards and operator training.
- 2003Oct
First Chemical Corp. Reactive Chemical Explosion — Final Investigation Report
Investigates the First Chemical Corporation explosion in Pascagoula, where mononitrotoluene decomposed in an idle distillation column. Valve leakage sustained heating despite apparent isolation. Chemical testing and equipment examination informed findings on reactive hazard evaluation, alarms, overpressure protection, isolation practices, control-room vulnerability and community notification.
- 20033 Jul
Fatality: Pressure build-up leading to sudden release of mechanical plug
A welder died when pressure behind a non-pressure-containing mechanical plug ejected it during welding on produced-water pipework. Freezing water vapour blocked the nitrogen purge vent. The flash examines inadequate vent monitoring, hazard analysis and incorporation of earlier near-miss lessons, and describes revised isolation, purging and pressure-control procedures.
- 2003Mar
Third Coast Industries Petroleum Products Facility Fire — Final Investigation Report
Investigation of the fire that destroyed Third Coast Industries’ lubricant blending and packaging facility in Friendswood, Texas. The report examines fire spread, tank failures, inadequate suppression water, containment and fire-code gaps. The initiating event remained undetermined; no employees or firefighters were injured.
- 200219 Dec
Safety Alert 208 - Loss of Well Control
An MMS alert describes a kick during gravel-pack wash-over and a release through a mud-pump pressure safety valve during bull-heading. Investigators identified possible shear-pin deformation following repeated near-set-pressure exposures. Recommendations address visual inspection after such exposures, maintenance to manufacturers’ recommendations and routing valve discharges to a safe location.
- 20021 Sep
Failure of bail-out regulator
Routine maintenance aboard a dive support vessel revealed corroded mild steel washers preventing a bail-out regulator’s relief valve from operating. The flash explains potential exposure of low-pressure equipment to full bail-out pressure and records instructions to check correct relief-valve components in both operational and stored standby regulators.
- 20021 Jul
Toxic gas emission from transponder
A recovered underwater transponder vented whitish material believed to be toxic, with leaking battery chemicals contacting water identified as the most likely explanation. The flash describes deck evacuation, increased accommodation airflow, quarantine, specialist dismantling and neutralisation of deck contamination. It urges users to obtain battery safety data and recognise venting or suspected water ingress.
- 20021 Apr
Explosion of hose-ball valve assembly
During onshore drilling, mud-pump activation pressurised a filling hose after its ball valve had been closed, injuring a roustabout’s right arm and hand. The investigation identified an unsuitable hose, shared pump controls, absent pressure relief and inadequate training. Corrective actions included separate pump controls, a relief valve, toolbox meetings, JSA and suitable training.
- 20001 Apr
Emergency communications system incident
Flooding of an external battery pack damaged through-water communications electronics aboard a vessel, allowing smoke into the diving bell and requiring divers to use BIBS and masks. Investigation identified an incorrectly fitted pressure-relief screw after charging. The manufacturer supplied modification information, revised manufacturing procedures and manuals, and issued a field service bulletin.
- 19991 Jan
Structural failure of a transponder housing
A transponder end blew off during storage in an onshore workshop. Seawater ingress during subsea operation reacted with battery electrolyte, generating gas whose pressure failed the plastic retaining ring. The vent bleed valve was closed. Recommendations include fitting a suitable vent valve where practicable, cautious opening and venting before shipment.
- 199726 Nov
Safety Alert 174 - Accumulation of Gas in Living Quarters Results in Explosion, Fire, and Injuries
An explosion and fire in platform living quarters severely burned three workers during well unloading. The alert examines probable gas blowby, drain connections, disabled equipment and repeated gas alarms. Recommendations address equipment repair, piping arrangements, detector placement and testing, flare-line design and consideration of emergency beacons.
- 199728 Aug
Safety Alert 173 - Pig Launcher Explosion Results in Two Fatalities
Two operators died while opening a pig launcher during an attempted gas pipeline blowdown on a production platform. Trapped gas at 1,020 psi tore the lid from its hinge assembly. The alert recommends pressure relief valves and gauges, restricting lid-based blowdown to cases without practical alternatives, and analysing and documenting such operations.
- 1994
MAIB Safety Digest 2/1994
This marine accident digest presents lessons from collisions, groundings, machinery failures, shipboard fires and injuries during fishing and access operations. Case commentaries examine lookout and radar use, tank pressure relief, hatch-cover securing, shaft guarding and first aid. An appendix lists investigations commenced between April and July 1994.
- 198529 May
Safety Alert 139 - Pollution from Production Operations Due to Rupture Disc Failure
An offshore production alert describes a two-barrel oil spill after a fluid surge and downstream orifice restriction overpressurised a chem-electric heater treater. Its rupture disc failed before high-pressure shutdown activated. The operator subsequently disabled the disc outlet and resized two pressure safety valves to accommodate maximum emergency liquid discharge rates.
- 198431 Jul
Safety Alert 128 - Platform Fire
An OCS platform fire followed condensate carry-over through production equipment to an atmospheric tank, where spray reached a compressor exhaust. The alert describes an isolated separator shutdown sensor and a disconnected tank drain. It recommends relocating relief discharge, reinforcing out-of-service tagging and conducting thorough inspections at the start of each tour.
- 198316 May
Safety Alert 112 - Fire
An offshore platform fire followed line-heater start-up with a flow-line block valve left closed. Well pressure ruptured the fuel gas supply pot, and ignited gas burnt the adjacent workboat’s captain. The alert records supply-pot relocation, installation of a self-relieving regulator, planned piping upgrades and restrictions on locking SSVs open.
- 197726 Oct
Safety Alert 67 - Fatality
An offshore drilling rig accident caused one fatality and one minor injury when a mud pump cylinder head was expelled under pressure. The discharge valve remained closed after repairs and the relief valve failed. The alert records pump restart communication requirements and fortnightly relief-valve inspections with shearing-nail replacement.
- 197711 Mar
Safety Alert 59 - Compressor Explosion
An offshore compressor explosion followed rupture-disc failure and air entering a compressor that continued running. The alert identifies possible gas-surge causes, reports extensive compressor damage without injuries, fire or pollution, and describes changes to fuel shutdown, relief valves and isolation of out-of-service pressure vessels.
- 197713 Jan
Safety Alert 53 - Compressor Explosion
An offshore production platform suffered a compressor crankcase explosion after gas leaked through prematurely worn packing associated with an excessively worn crosshead pin. Ignition was considered probable at the power cylinders. Relief-valve venting led to secondary fires, extinguished by automatic CO2 protection. The operator initiated overhaul and component inspection and replacement.
- 197625 May
Safety Alert 42 - Hydraulic Pump Reservoir Ruptures, Minor Injury
An offshore platform serviceman suffered minor hand injuries when a hydraulic pump reservoir ruptured during high-pressure safety-pilot testing. Leaking discharge and suction check valves admitted pressure beyond the reservoir’s low-pressure capability. The operator instructed personnel to install a vent or relief valve before reusing these pumps.
- 197315 Jun
Safety Alert 5 - Flash Fires/Explosions
This alert reviews flash fires and explosions reported by Gulf of Mexico OCS oil operators in early 1973. Cases involve gas engines, glycol reboilers and engine exhausts. It discusses leaking fuel, backfires and hot surfaces, recommending preventive maintenance, combustible-gas leak checks, reinforced intake hoses, pressure relief and insulation integrity.
- 197222 Sep
Safety Alert 1 - Flash Fire from Liquid Phase Heat Transfer Unit
A platform restart led to a flash fire after heat-transfer fluid overheated while circulating pumps were stopped and the burner valve remained operating. Pressure expansion ruptured the expansion tank. The alert recommends secondary relief with monthly and pre-start testing, burner–pump controls, pressure-rated expansion vessels and continuously operating heat sensors.
- Undated
Manifold Assembly Ejected During Well Flowline Pressure Bleeding
An investigation examines a severe right-hand injury during bleeding of approximately 1100 psi from a well flowline. A poorly designed manifold rotated, disconnected and ejected its upper assembly. Recommendations address discharge forces, manifold construction, controllable valves and use of the platform vent scrubber where designed for pressure relief.
- Undated
Casing Weld Failure During Well Abandonment
Investigation of a casing weld failure during well abandonment. Reverse circulation following bit plugging led to casing rupture at recently welded seams. The report examines pressure testing, unchanged pump safety-device settings, inadequate job safety analysis and unapproved welding in place of cold cutting. No injuries or environmental spills occurred.
- Undated
Uncontrolled Crane Boom Movement During Tote-Tank Lifting
An investigation examines uncontrolled crane boom movement during tote-tank lifting aboard the Superior Champion. It identifies adjustment beyond safe operating limits as the probable cause and discusses possible hydraulic-control problems, crane placement and an earlier event not reported to office staff. Recommendations address communication, pressure relief and engine kill-switch accessibility.
- Undated
Gas Release and Water Hammer Following Compressor Shutdown
Investigation of a gas release at Mad Dog following compressor shutdown. Flare backpressure caused tandem rupture discs to fail, allowing gas into seawater cooling pipework and causing water hammer and damage. The report examines earlier failures and recommends check valves, revised pressure protection, flare modifications and delayed seawater pump shutdown.
- Undated
Synthetic-Based Mud Spilled Following Premature Pump Relief Valve Opening
A drilling mud pump’s faulty relief valve opened prematurely, overwhelming a 15-barrel tank. Approximately nine barrels of synthetic-based mud spilled, including six barrels overboard. The investigation identified inadequate containment capacity and absent pre-service pressure testing. Corrective actions included a tested replacement valve, larger discharge tank and level alarm.
- Undated
Rig Generator-Engine Fire Following Blower Seizure
Investigation of a rig generator-engine fire following blower seizure and quill-shaft failure. The report links pressure and temperature build-up to displacement of the air-box cover and subsequent ignition. It discusses ageing components, extinguisher response and possible increased maintenance or replacement. No injuries or environmental pollution were reported.
- Undated
Synthetic Oil-Based Mud Discharge During Drilling After Mud Pump Replacement
This investigation examines a synthetic oil-based mud discharge during drilling after a replacement mud pump retained a lower relief-pressure setting. Findings identify an unsecured overflow-tank hatch, closed pneumatic-pump air valves and failure to follow documented alignment procedures. The report recommends a thorough valve-alignment walkdown.
- Undated
Well Gas Release During Wireline Retrieval
BSEE investigates a small well-gas release during wireline retrieval at Ewing Banks Block 305. Broken wire escaped through the stuffing box, and gas ruptured the grease seal oil reservoir. Findings identify inadequate vent capacity and lubricator check-valve failure. Blow-out preventers and the crown valve secured the well; no injuries or environmental damage occurred.
- Undated
Nitrogen Cylinder Explosion During Refilling aboard FPSO
BSEE investigates a nitrogen cylinder explosion during refilling aboard the BW Pioneer FPSO. Misidentification of the cylinder’s pressure rating and an incorrectly rated relief device resulted in over-pressurisation. The report examines booster pumping, metallurgical failure analysis, inadequate training and procedures, equipment damage and injuries to a nearby worker during helicopter refuelling.
- Undated
Fuel Gas Filter Fire During Restart After Shut-In
Investigation of a fuel-gas filter fire at EB 165A during restart after a shut-in. Overpressurisation expelled the vessel top, which struck a handrail and ignited escaping gas. Findings identify corroded securing tabs, malfunctioning pressure safety valves and vessel modifications. Operators extinguished the fire while other personnel mustered.
- Undated
Hydrogen Sulphide Vented into Platform Wellbay Following Gas Blow-By
An investigation describes hydrogen sulphide venting into the wellbay on platform Gail following gas blow-by to a slop tank. Failure of separator level controls to close a valve was identified as the probable cause, with polymer deposits contributing. The report recommends keeping the drain pot valve closed.
- Undated
Platform Flash Fire Following Gas Blow-By Through Separator Dump Controller
Investigation of a production-platform flash fire following gas blow-by through a malfunctioning high-pressure separator dump controller. Gas reached the oil stock tank and escaped through secondary vents, accumulating near the generator building. Findings address building isolation, overlooked warnings, operator familiarity, supervision and failure to use stop-work authority.
- Undated
Gas Release Following Braided Steel Hose Rupture
Investigation of a gas release on the MC 280 A platform following an apparent pressure safety valve malfunction and braided steel hose rupture. Venting persisted after shutdown and isolation. Personnel mustered, and subsequent closure of the well production casing valve stopped the release. No injuries were reported.
- Undated
Mud-Pump Pressure-Relief Valve Housing Failed and Ejected End Cap
Investigation of a shoulder injury aboard the Noble Globetrotter drillship when a mud-pump pressure-relief valve housing failed and ejected its end cap. Findings identify incorrect pump alignment, pumping into a closed system and absent valve maintenance. The report discusses manufacturer requirements for disassembly, functional checks and calibration.
- Undated
Compressor Crankcase Explosion Burns Operators During Restart
Investigates a compressor crankcase explosion during restart that burnt two operators with redirected hot oil. The report identifies leaking piston-rod packing, engine backfire and a failed pneumatic relay among the causes. Recommendations address crankcase relief doors, flame arrestors, downward oil deflection, control-station positioning and crew safety discussions.
- Undated
Pipeline Leak Released Hydrocarbons at Offshore Platform
BSEE investigated a pipeline leak at Grand Isle 76-A releasing an estimated 8.35 barrels of hydrocarbons. The report examines inadequate high-pressure trip and safety-valve settings as possible contributing causes, unauthorised conversion to bulk oil service, spill reporting and monitoring, and diver-observed pressure testing of a split-sleeve repair.
- Undated
Flash Fire During Well Abandonment Cutting Operations
Investigation of a flash fire during well abandonment on Eugene Island Platform F. Gas and condensate travelled through shared pressure-relief piping to an unblinded flowline and ignited at a cutting torch, injuring a welder. Findings address a leaking wing valve, inadequate isolation and joint job safety analysis.
- Undated
Condensate Discharge Through Platform Vent During Vessel Overpressure
Investigation of an approximately one-gallon condensate discharge from West Delta 41 A Platform into the Gulf of Mexico. A failed blanket-gas pressure regulator caused vessel overpressure and safety-valve relief. The vent discharged trapped rainwater and residual oil; debris obstructing the vent-boom drain allowed fluid to enter the sea.
- Undated
Gas Release Following Sand Damage to Well Equipment
Investigation of sand damage and a subsequent gas release from well A-15 at HI-A571. Sand damaged the choke and pressure-relief discharge piping, blocked pressure-sensing lines and impeded safety-valve closure. Manual wing-valve closure stopped the leak. Investigators also found a gas-detection shutdown relay bypassed and identified inadequate monitoring for continued sand production.
- Undated
Gas Compressor Discharge Pipe Explosion During Restart
BSEE investigates a gas-compressor discharge-pipe explosion during restart at Main Pass 64 A. Leaking suction valve-cover gaskets were identified as the probable cause of oxygen intrusion; ignition was likely associated with hot compressed gas. The report records integrity and leakage testing, localised piping damage and no injuries.
- Undated
Reboiler Line Rupture and Liquid Release Resulted in Flash Fire
The investigation describes a ruptured line inside a reboiler that caused overpressure, dislodged a pressure safety valve and released liquids, resulting in a flash fire. Improper valve sizing was considered the likely reason for detachment. Emergency shutdown and isolation followed; no personnel were injured. Two noncompliance notices were issued.
- Undated
Hot Sewage Burns During Marine Sanitation Pump Troubleshooting
Investigation of burns sustained while troubleshooting a marine sanitation pump aboard Seadrill West Auriga. Scale blocked discharge piping, causing overpressure and sight-glass failure that released hot sewage. Findings address absent overpressure protection, hazardous viewing position and missing troubleshooting procedures. Medical evacuation was delayed by weather.