Topic
Corrosion
Material degradation through chemical or electrochemical processes.
Newest 100 Documents
All 342 in search- 202612 Aug
Crane Failure Highlights Crane Inspection Gaps
Two platform crane incidents involved failed sheave bearings, a falling boom and a dropped cable and load block. Inspection gaps included omitted pin removal and inadequate lubrication checks. The alert recommends considering revised inspection criteria, scheduled inspections, training to recognise mechanical distress and lift planning around vessel interfaces.
- 202621 Jul
Bio-Lab Inc. Conyers Fire and Chemical Release
Investigation of the Conyers chemical-storage warehouse fire and release examines sprinkler corrosion, water-triggered decomposition and emergency response. It identifies sprinkler component failure as the most likely initiating water source, analyses storage and ventilation shortcomings, and recommends corporate safeguards and broader reactive-hazard coverage. Supporting work includes AcciMap analysis and chemical testing.
- 20261 Jul
Inspect A2B Systems and Wire Rope Terminations to Prevent Crane Hazards
A lift boat crane incident involved a detached anti–two-block weight, corroded wire rope and falling components. Recoiling rope struck a nearby diver, causing minor injuries. The alert recommends considering termination maintenance, pre-use and periodic inspections, adjusted replacement intervals in corrosive environments, and competence assurance under API RP 2D.
- 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.
- 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.
- 202615 Apr
Death of seafarer due to fall from crane cabin
A seafarer cleaning a cargo crane cabin on an anchored vessel fell 12 m to the deck and died. The investigation identified probable window seal failure following removal of protective grating. Possible corrosion and glass weakening are discussed, alongside lessons on barrier integrity, structural inspection, routine-task risk assessment and warning signage.
- 202617 Mar
Failure of A-frame fold-down platform
A hinged A-frame platform failed during sheave-block load checks aboard a vessel alongside for mobilisation, leaving a crew member suspended in their harness with minor injuries. The flash identifies missing cotter pins, hinge design flaws and galvanic corrosion, alongside omitted change management, scheduled maintenance and platform inspections.
- 20263 Mar
BSEE: Falling corroded crane component results in near miss
A corroded crane boom cable runner fell approximately 16 m during maintenance on an offshore platform, landing approximately 6 m from personnel. The flash describes outstanding inspection repairs, incomplete hazard identification and absent barricades, with lessons on inactive equipment, dropped-object controls and workforce involvement in pre-job planning.
- 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.
- 20255 Dec
Falling Corroded Crane Component Results in Near Miss
A corroded crane boom cable runner fell approximately 50 feet during maintenance on an offshore platform, landing approximately 20 feet from personnel. The alert identifies uncompleted inspection repairs, incomplete hazard identification and absent barricading, and recommends considering improved job safety analysis, supervision and maintenance follow-through.
- 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.
- 2025Oct
Refinery Cooling Tower Explosion and Fire — Process Safety Beacon, October 2025
A refinery cooling tower incident in India illustrates how hydrocarbons leaking from a heat exchanger can accumulate in cooling water pipework and escape during commissioning. Ignition was likely associated with nearby hot work. The bulletin discusses exchanger vulnerability, start-up hazards and notifying nearby workers so they can suspend work.
- 202517 Sep
SWL plate dropped from crane block
A safety flash describes a 0.9 kg SWL plate falling from an auxiliary hook block onto a vessel’s main deck, with its fall height unconfirmed. Suspected galvanic corrosion caused rivet failure. It highlights missed inspection hazards, undocumented fittings, checks of other plates and a brought-forward third-party DROPS inspection.
- 2025Jul
Hydrocarbon Active Fire Protection
An inspection guide for offshore hydrocarbon fire protection, setting out regulatory expectations, success criteria and dutyholder scoring. It examines firewater pumps, ring mains, deluge coverage and chemical dosing, with emphasis on corrosion, marine growth, system availability, as-found testing and investigation of recurring blockages.
- 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.
- 20254 Jun
BSEE: Failure to identify and restrict access to faulty gratings
A worker installing a pump supported himself on nearby piping when corroded grating beneath scaffolding boards failed. Previously installed barricades had been removed to allow work. The flash highlights checks on surface integrity, protection of openings and clear expectations for rigid barricades restricting access to unsafe areas.
- 202527 May
Honeywell Geismar Chlorine and Hydrogen Fluoride Releases
Investigation of three releases at Honeywell Geismar’s HFC-245fa unit between 2021 and 2024, involving fatal HF exposure, a corrosion-driven reboiler explosion and serious injury during gasket replacement. The report examines mechanical integrity, startup procedures, protective equipment, organisational change and capital funding, recommending independent auditing and safer-technologies analysis.
- 202529 Apr
BSEE: Nitrogen cylinder rupture causing worker injuries and equipment damage
A nitrogen cylinder ruptured at its base during preparations to pre-charge accumulator cylinders, dispersing cylinders and debris and causing minor shrapnel injuries to three rig personnel. BSEE attributed the failure to corrosive wall loss aggravated by environmental and structural conditions. Recommendations address recertification, filling pressure, training, inspection and corrosion-preventive maintenance.
- 20256 Mar
BSEE Safety Alert - 496 - Misidentification of Corrosion Hazard Results in High Potential Event
A worker installing a pump at a Gulf production facility supported himself on nearby piping when corroded grating gave way beneath scaffold boards. Previously installed barricades had been removed. The alert recommends facility walkthroughs, secure restriction of unsafe areas and review of safe work practices governing barricades.
- 202524 Jan
BSEE Safety Alert 494 - Ruptured Nitrogen Cylinders
A nitrogen cylinder ruptured during preparations to pre-charge an accumulator system, causing three minor shrapnel injuries and equipment damage. BSEE attributes the failure to corrosive wall loss, aggravated by crevices, moisture and deteriorated rack coating. Recommendations address cylinder recertification, filling records, training, inspection and corrosion-preventive maintenance.
- 2025
2 - Integrity management of FPSOs/FSUs
OMAR guidance addresses structural and maritime integrity of UKCS FPSOs and FSUs, drawing on regulatory interventions. It discusses inspection regimes, hull loading, watertight integrity, cargo systems and station keeping, alongside competence, independent verification and safety-case review. Ageing assets and formal life-extension assessments receive particular attention.
- 2025
CHIRP Maritime FEEDBACK 78 (Spring 2025)
This maritime digest examines pilot-ladder deficiencies, a caustic eye injury, unacceptable accommodation, charcoal cargo fire, corroded walkways, yacht fire, disabled carbon dioxide firefighting and rescue-craft capsize. Commentary emphasises time for post-maintenance checks, equipment handovers, crew training and risk assessment, alongside protective equipment and seafarers’ rights.
- 202427 Nov
NTSB: Crane wire failure
This safety flash recounts a crane wire failure during offloading of a 69-tonne wind turbine nacelle into a cargo vessel’s hold. Undetected corrosion and strand-wire wear were the probable cause. It explains how grease concealed corrosion despite routine inspections and maintenance, and highlights inspection requirements and condition-dependent wire replacement intervals.
- 202424 Oct
AC vent unit cover dislodged and fell 1.7m
An air-conditioning vent cover detached from a capstan electrical cabinet on a pipelay tower and fell approximately 1.7 metres, without injury. Initial investigations identified galvanic corrosion of securing rivets. The flash calls for compatible fixings, checks of primary and secondary retention, and updates to dropped-object checklists and planned maintenance.
- 20243 Sep
Nitrogen cylinder ruptured
A nitrogen cylinder ruptured on a drill rig floor, destroying its rack and propelling other cylinders up to 15 metres away. Severe base corrosion had escaped inspection. The flash highlights inspection access within cylinder quads and asks readers to check certification, condition, drainage and supplier inspection standards.
- 202429 Aug
Lifeboat air cylinder explosion on an empty installation
A lifeboat air bottle explosion was discovered on an uncrewed, shut-in offshore platform, with no injuries or known incident date. Inspection revealed corrosion beneath bottles seated in saddles. The flash discusses restricted inspection access, possible galvanic effects, depressurisation, improved bottle positioning and insulation between dissimilar materials.
- 202419 Jun
Safety Bulletin - Helideck Structural Integrity
This bulletin discusses corrosion-related impairment of offshore helidecks and the risks introduced by alternative personnel transfers. It highlights difficult access for inspection and repair, galvanic corrosion, protective coatings and maintenance regimes, alongside statutory duties to maintain structures throughout facility life, including infrastructure needed for future decommissioning.
- 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.
- 202419 Mar
High potential: sea water inlet pipe leakage in engine room
A vessel crew discovered seawater leakage from corroded air-conditioning condenser pipework near the hull while offshore. A cement box contained the leak before emergency dry-docking for repairs. The flash identifies missing documented condition checks and recommends regular inspection of ship-side valves and piping within planned maintenance.
- 202419 Feb
USCG: wire rope hazard management – dropped turbine nacelle
A vessel crane’s wire rope failed during offloading, dropping a 69-ton wind turbine nacelle 2.2 m onto the deck near personnel. Corrosion, wear and monotonic ductile overload were identified. The flash relays USCG recommendations on load testing, lubrication, maintenance tracking, earlier rope renewal, visual inspection and crane-operator training.
- 202412 Feb
Failure of self-righting frame on Fast Rescue Craft (FRC)
A fast rescue craft lost its self-righting frame during a rescue drill while travelling at approximately 15 knots. Securing arrangements showed stress and galvanic corrosion despite a recent visual inspection. The flash highlights periodic integrity inspections, potentially involving frame removal, and records recovery communication and repairs to manufacturer specifications.
- 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.
- 20232 Nov
H2S released during rig reactivation activities
During quayside rig reactivation, hydrogen sulphide escaped from a machinery-space bilge water tank after its top hatch was removed, threatening nearby personnel. The alert describes acute inhalation dangers, including immediate collapse at concentrations above 1,000 ppm, alongside steel corrosion and flammable or explosive concentration limits.
- 20232 Nov
Lifeboat davit failure on polar research vessel RRS Sir David Attenborough
Investigates a lifeboat launch accident aboard RRS Sir David Attenborough that caused minor injuries to three crew. The report examines an interlock that failed to reset, likely corrosion-induced piston-rod seizure, omitted checks and maintenance, incomplete davit installation, and shortcomings in operating procedures and crew familiarisation.
- 202330 Oct
Fire-fighting equipment in poor condition
A vessel audit identified several 50 kg wheeled dry powder extinguishers with low pressure and extensive corrosion, despite monthly inspections. The flash highlights gaps in crew understanding of inspection quality and calls for defective equipment to be quarantined, repairs or replacements arranged, regular servicing and crew awareness sessions.
- 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.
- 202321 Jun
Lifting chains parted – hydrogen embrittlement
Three lifting chains failed during a vessel demobilisation lift, leaving grillage suspended approximately 4 m above deck. It was lowered without injury. Analysis attributed failure to hydrogen embrittlement and corrosion cracking under tensile load. Replacement of the four-way bridle with slings and shackles enabled safe completion.
- 20235 May
Environmental Alert 001/2023
An environmental alert describes inadvertent discharge of over 400 kg of fluorinated fire suppressant following routine testing. Water ingress affected an ATEX activation microswitch, causing delayed operation. Examination also found corrosion at switch interfaces. Duty holders should consider reviewing inspection and maintenance schedules to minimise seal failure and water ingress.
- 2023May
Hydrogen Sulfide
Regulatory inspection questions address areas classified as hydrogen sulphide present or unknown. They cover contingency plans, training, drills, gas detection, respiratory protection, ventilation and medical equipment. Further checks address soluble sulphide testing, well-control fluid treatment, flaring, detector testing intervals and corrosion-resistant materials during well and production operations.
- 202320 Apr
BSEE: Person injured when safety mechanisms failed
An offshore sandblasting worker sustained head and shoulder injuries when a T-connection detached and a whip check failed. The flash discusses improper cable crimping, slightly corroded baling wire and stresses from horizontal hose positioning. Recommendations address additional securing, fitting orientation, pre-job inspection and depressurisation before valve adjustment where practical.
- 2023Apr
High concentration of hydrogen sulfide (H2S) in cargo and slop tanks
This HSE safety notice addresses hydrogen sulphide in FPSO and FSU cargo and slop tank ullage spaces, including concentrations beyond standard portable instruments’ measuring limits. It discusses exposure during monitoring and releases, corrosion risks, suitable gas monitoring, revised risk assessments, integrity inspection and crew training.
- 20239 Feb
Electrolytic corrosion: Failure of fire hose couplings
A fire hose coupling failed during annual pressure and leak testing aboard a vessel. Examination identified corrosion and seized floating flanges, with advanced deterioration also found at the opposite end. The flash recommends targeted coupling inspections, detailed planned maintenance and personnel briefings; brass may be preferred when replacement fittings are required.
- 202210 Nov
BSEE: Hazards associated with cranes on idle facilities
This flash summarises BSEE observations of deteriorated cranes on idle Gulf of Mexico facilities. Corroded cables, degraded slings and leaking reservoirs present dropped-object and pollution hazards. Recommendations address removing or temporarily securing blocks and balls, inspecting cranes before return to service, storing or discarding slings, and clearing reservoirs and hoses.
- 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.
- 202211 Oct
Philadelphia Energy Solutions (PES) Refinery Fire and Explosions
Investigates the PES refinery fire and explosions following corrosion-induced rupture of an elbow in its hydrofluoric acid alkylation unit. Examines material composition, inspection coverage, vessel failure, unavailable remote isolation and impaired water-spray mitigation. Contrasts successful rapid acid deinventory with failed safeguards and assesses alternative alkylation technologies and regulatory recommendations.
- 202210 Aug
Hazards Associated with Cranes on Idle Facilities Pose Safety and Environmental Risks
BSEE reports deteriorated crane cables, missing components and pollution hazards on idle Gulf of Mexico facilities. Corroded cables and weather-exposed slings create dropped-object risks. Operators are advised to consider removing or securing blocks and balls, inspecting cranes before returning them to service, and clearing diesel and hydraulic reservoirs and hoses.
- 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.
- 202226 Jul
Accidental release of free-fall lifeboat
A free-fall lifeboat fell approximately 14 m during a drill on an anchored bulk carrier, seriously injuring two crew members. The flash summarises findings on stress-corrosion cracking of sling crimp sleeves, uneven loading, unsecured occupants and absent additional restraint, alongside risks concerning sling inspection and divided supervisory attention.
- 202226 Jul
Third-party truck not in appropriate or safe condition
Joint inspections before pipe transport identified unsafe third-party trucks, including tyre defects, corroded trailer beds and worn bolster padding. Rejected vehicles were withdrawn pending rectification. The flash recommends defining supplier requirements and considering an inspection checklist, and separately describes a low-loader hydraulic hose failure that leaked approximately 10 litres.
- 202220 Jul
Bailout manifold failure
A diving bell bailout manifold failed under pressure with no divers inside. Forensic testing supported likely lateral loading from inappropriate securing, followed by stress corrosion cracking and internal corrosion. The flash describes suspended diving, bailout inspections, replacement with more robust assemblies and familiarity with planned maintenance tasks.
- 202231 May
MSF: Corrosion in fire-fighting equipment
A vessel’s monthly inspection identified significant corrosion in its fixed CO2 firefighting system, preventing insertion of the cylinder isolation safety pin for maintenance. Corrective repair restored alignment. The flash stresses regular care and checks in accordance with manufacturers’ recommendations to keep critical firefighting systems ready for activation or isolation.
- 20224 May
MAIB: Loss of containers overboard – task seen as routine
This safety flash summarises MAIB’s preliminary assessment of Francisca’s loss of 34 containers in heavy weather near Duncansby Head. Green sea forces collapsed container stacks. Findings highlight reduced crew appreciation of weather risks, the absence of a bow breakwater and corrosion that may have increased the loss. No injuries occurred.
- 202228 Apr
Two catastrophic engine failures, one resulting in a fire, on board ro-ro passenger ferry Wight Sky
Investigation of Wight Sky’s August and December 2018 engine failures, extended to related fleet failures. It distinguishes lubrication loss from a factory bearing-cap assembly error and examines maintenance records, oil and coolant monitoring, contractor support, delayed declutching and missing engine protection. Effective crew response limited the consequences.
- 202221 Apr
Subsea transponder wire parted
A positioning transponder’s tripod wire parted during vessel repositioning. The 4 mm wire failed approximately 1 m from the lifting eye, with corrosion and insufficient replacement identified. Divers and a crane recovered the tripod. Actions included performance testing, visual checks before launch and during recovery, and six-monthly wire replacement.
- 202218 Apr
Barricades and Fall Protection Will Help Prevent Injuries Even Without Open Holes Visible
This alert describes two incidents involving deteriorated deck grating: a contractor fell into water and another worker partially fell through grating. BSEE recommends that operators and contractors consider barricading suspect areas even without visible holes, using fall arrest equipment, preparing job safety analyses, communicating hazards and invoking stop-work authority.
- 20221 Apr
UK HSE: worker falls from height during oil platform decommissioning
An IMCA safety flash describes a worker’s 15-metre fall during dismantling of the Brent Bravo platform. Corroded attachment bolts and an unrecognised separate platform affected structural integrity. The HSE investigation identified a missing full structural appraisal before demolition, with implications for risk assessment and the cutting method.
- 202211 Mar
Fatal fall from collapsing scaffolding on a merchant vessel
A sailor died after scaffolding and a crane maintenance platform collapsed aboard a merchant vessel. Seriously corroded securing bolts failed under load, while his harness lanyard snapped. The flash identifies shortcomings in risk assessment, supervision, scaffold configuration, work instructions, harness maintenance and training.
- 202210 Mar
BSEE Identifies Maintenance and Certification Issues of Rental Generators
BSEE reviews rental generator incidents during start-up and commissioning on the US Outer Continental Shelf in 2021. Failures involved fires, arc flashes and work stoppages. The alert discusses degraded windings, moisture ingress and corrosion, and recommends operators consider certification checks, commissioning assurance, insulation resistance testing and personnel competence measures.
- 202128 Oct
USCG: Corrosion causing structural failure on accommodation ladders
This flash summarises a USCG alert about corrosion of accommodation ladder turntable pins. A pin failed during ladder stowage, causing a crew member to fall approximately 30 feet and suffer serious injuries. The Coast Guard strongly recommends pin maintenance, periodic inspection, replacement when necessary and inclusion in ladder maintenance plans.
- 202122 Sep
Failure of in-service saturation bailout bottle
A saturation diver’s bailout bottle lost pressure through wall defects associated with internal corrosion. Similar bottles were quarantined and operations suspended. Moisture was identified as the primary factor, while third-party testing or unsuitable storage was suspected. The flash calls for improved servicing specifications, procedural assurance, receipt inspection, drying and sealing.
- 202122 Sep
Stuck emergency hatch freed
An onboard inspection found a rusted emergency escape hatch that could not be opened. The flash identifies poor maintenance culture, neglected safety responsibility and crew unfamiliarity with the hatch’s importance. Actions include keeping escape routes unobstructed, adding hatch inspections to planned maintenance and maintaining greased hinges.
- 202131 Aug
Condition of fire-fighting installation and equipment
This safety flash describes obstructed fire-main nozzles in paint and chemical storage facilities and a corroded CO2 release station with illegible instructions. It suggests members may wish to inspect fire-fighting equipment, especially sprinklers and nozzles in poorly lit or infrequently visited vessel spaces, and check rarely inspected equipment for usability.
- 202130 Jul
COBRA bailout system – guidance note
This safety flash summarises JFD’s investigation of lacquer blistering and excessive aluminium-neck corrosion in COBRA’s 2L composite cylinders. It distinguishes manufacturer assurances about lacquer defects from unresolved batch concerns, and advises external-condition checks whenever sets leave the dive system, with replacement and IDEST inspection before re-use where condition is questionable.
- 202122 Jul
Failure of dive chamber overhead door centre pin
A diving bell overhead-door hinge pin failed after the dive team left the entry lock. The pin fell into the unoccupied lock, without pressure loss. The door was lowered under control and divers transferred. Investigation remained ongoing; suspected factors included design, corrosion and cyclic fatigue. Similar doors should receive prompt crack checks.
- 202122 Jul
HSE: Catastrophic failure of marine loading arm
This flash summarises an HSE alert about a marine loading arm collapsing during positioning for connection to a ship. Bearing corrosion and inadequate inspection and maintenance were identified, with inaccessible servicing points left unlubricated. It outlines a structured programme for reviewing maintenance needs, inspecting structural components and verifying completed work.
- 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.
- 20219 Jun
Fatality – explosive failure of corroded fire extinguisher
A condemned, corroded cartridge-type dry powder extinguisher ruptured during discharge, striking a person and causing fatal head injuries. The flash describes inadequate appreciation of the danger and job planning, and sets out inspection, moisture-reducing mounting, qualified disposal and handling measures. It also suggests considering stored-pressure alternatives.
- 20219 Jun
MSF: Tank corrosion
A vessel’s routine tank sounding revealed rising liquid levels and a pinhole leak admitting salt water. Investigation found coating damage from the sounding weight and incorrectly discarded corrosive chemicals had degraded the striking plate and underlying steelwork. Repairs followed, with crew reminded about chemical handling, safety data sheets and authorised hazardous-waste disposal.
- 202124 May
Fatality Caused by Explosion of Corroded Fire Extinguisher
A person discharged a corroded cartridge-type dry chemical powder extinguisher previously condemned during an annual third-party inspection. Activation of its internal carbon dioxide cylinder was followed by rupture at the corroded base and an explosion. The unit struck the injured person, causing critical head injuries.
- 202120 May
Floodlight dropped to deck – corrosion
A floodlight weighing about 6 kg fell 4.5 m to the deck after its mounting frame corroded. Paint concealed the deterioration, and secondary retention was absent. No personnel were nearby. The flash recommends dropped-object surveys, consideration of cross-departmental hazard hunts, clear inspection responsibilities and secondary retention where appropriate.
- 2021May
Catastrophic failure of marine loading arm
This safety alert describes a marine loading arm collapse following failure of a pantograph pivot pin. Inaccessible servicing points contributed to missed lubrication and corrosion. It calls for structured inspection and maintenance planning, prompt checks of structural components, verification of completed work and periodic review of maintenance arrangements.
- 202116 Apr
BSEE: Crewman fell to his death through faulty grating
This safety flash summarises BSEE findings on a fatal platform fall in the Gulf of Mexico in 2019. A production operator fell through corroded grating into the sea. It highlights deficient walking surfaces, hazard communication and barricading, alongside failures in operator–contractor safety-management bridging arrangements.
- 202130 Mar
Dropped object – Steel deck plate falls from pipelay tower
A steel deck plate fell 9 m during pipelay tower inspection on a vessel in dry dock. Corroded, incorrectly specified bolts and inadequate support were identified in an undocumented modification. Nobody was hurt; barriers protected the drop zone. The flash recommends routine inspection of elevated plates and fixings, and controlled equipment modifications.
- 202130 Mar
Dropped object during crane operations
A vessel crane shed a 7.6 kg timber board from approximately 10 metres while preparing for lifting. Corroded screws in a temporary boom-rest repair allowed the board to loosen. The flash examines missed inspection findings and premature repair closure, and calls for boom-rest inspections and planned maintenance.
- 202117 Mar
MSF: Air cylinder failure in lifeboat
A lifeboat air cylinder failed without warning, injuring three nearby crew members with blast debris. Investigation remained ongoing, with galvanic corrosion and prolonged submersion in bilge water identified as preliminary suspected causes. The correspondent recommends annual inspections for corrosion or wall damage and hydrostatic pressure testing at five-year intervals.
- 202117 Mar
Offshore Pipeline Integrity Management (Issue 2)
Inspection guidance for assessing offshore hydrocarbon pipeline integrity management, compliance and performance. It addresses ageing and life extension, corrosion monitoring, pipeline and riser inspection, shutdown valve testing, pigging safeguards and emergency preparedness. Success criteria, sample inspection agendas and enforcement assessment guidance support examination of operators’ arrangements.
- 202124 Feb
Hazards Identified in Level I Surveys not Communicated to Affected Personnel
BSEE describes platform inspections revealing structural deterioration already recorded in Level I Surveys but not communicated to visiting personnel. Cases include collapsed helideck skirting and unsecured well-deck grating. Operators are urged to consider disseminating findings, tracking structural issues to closure, marking compromised access areas out of service and barricading hazards pending repairs.
- 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.
- 202010 Dec
Entry to enclosed space on fishing vessel Sunbeam with loss of 1 life
Investigates a fatal tank entry aboard Sunbeam in Fraserburgh. Leaking refrigerant from corroded evaporator tubes displaced air in a refrigerated salt water tank. The report examines inadequate repairs, non-gastight isolation valves, normalised unsafe entry, absent atmospheric precautions, rescue arrangements and gaps in machinery survey oversight.
- 202016 Oct
Deficiencies in Process Piping Cause Gas Release Incidents
BSEE describes several Gulf of Mexico gas releases involving cracked welds, leaking gaskets and corrosion beneath insulation. The alert links incidents to quality assurance and mechanical integrity deficiencies, with vibration-related fatigue a possible contributor in one case. Recommendations address piping integrity programmes, leak detection, reporting, training and maintenance of compressors and pulsation dampeners.
- 20206 Jul
High potential incident: gantry hoist failure
A gantry hoist failed while lifting palletised provisions onto a vessel, dropping cargo and a chain box onto the deck without injury. Previously unidentified internal corrosion caused securing bolts to fail. The flash describes changes to procurement, mechanical lifting procedures and maintenance and inspection record management.
- 202012 Jun
MSF: Water-based mud spill on deck
A mud-transfer hose separated from a vessel manifold at an offshore installation, spilling approximately 2,500 litres onto deck. Incompatible threads allowed corrosion to weaken the connection. The crew contained and recovered the mud without environmental loss. Actions address thread compatibility, planned maintenance and visual pre-use inspections.
- 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.
- 202015 Apr
Vessel flooding incident
Seawater entered a vessel’s engine room through a hole in a box cooler bulkhead. Hand pumps controlled flooding before an emergency return to port. Dry-dock inspection identified extensive corrosion; a link to the marine growth protection system malfunction remained unverified. Repairs included additional sacrificial anodes, with regular condition and performance verification recommended.
- 202031 Mar
Chain hoist failure resulting in a serious near miss
An electric chain hoist failed while lifting a 400 kg charge air cooler during vessel engine maintenance, dropping the load two metres. Internal brake corrosion impaired load holding despite current inspection records. The flash describes inadequate unloaded testing, personnel remaining in safe zones, expanded maintenance scopes and annual overload-device checks.
- 202031 Mar
Safety Alert 380 - Subsea Jumper Failure Leads to Leak
BSEE describes a subsea jumper failure involving internal corrosion and mechanical stress from pipeline and PLET movement. The October 2017 leak released an estimated 16,000 barrels of oil and remained undetected for over 24 hours. Recommendations address operator training, improved leak detection, corrosion mitigation and verification of pipeline design tolerances.
- 202013 Feb
Dropped object from crane
A crane’s composite end-stop block fell 20 m to deck while the crane was being secured for sea after a Suez Canal transit. Crew were within 4 m; nobody was injured. Investigation found adhesive-only attachment and rust-induced loosening. Fleet-wide actions included crane checks, consideration of engineered solutions and a renewed dropped-object survey.
- 202013 Feb
Dropped object near miss – Crane boom bumper stop falls off
A vessel crane bumper stop fell onto the cab during preparations for reactivation after warm stacking, without injury. Deteriorated rubber detached and a corroded secondary securing wire parted. The flash examines inspection access limitations and recommends corrosion-resistant retention, reviewing inspection arrangements and investigating materials less vulnerable to sunlight.
- 202030 Jan
Poor condition of on-board equipment
Vessel safety walk-arounds identified a used galley fire blanket returned to storage and damaged step ladders still in service. The flash describes missed inspections and procedural failures, calling for thorough checklist checks, immediate incident reporting, monthly ladder inspection and labelling, removal of damaged ladders and renewed emphasis on pre-start checks.
- 202030 Jan
Sea King Accident During Hover Check
AAIB investigation of a Sea King accident during a hover check at Marchwood. Corrosion seized the swashplate spherical bearing following prolonged inactivity during sea transport. Maintenance and pre-flight checks failed to detect the restriction. Recorder analysis, CCTV and component examinations informed findings and changes to daily inspections.
- 201917 Dec
Failed shackle on vessel life raft
Two stainless steel D shackles failed in a vessel’s life raft release assembly, allowing the container to fall into the water. Recovery using the painter inflated the raft. Possible crevice corrosion prompted replacement of remaining shackles, corrosion inspections, weekly condition checks and improvements to scheduled preventive maintenance.
- 20196 Dec
Raising awareness on safety barriers such as railings and gratings
This safety flash summarises two fatal falls on container ships and TSIB advice on inspecting railings, gratings and concealed metallic surfaces. It discusses corrosion and structural deterioration, recommending timely repairs, preventive maintenance, and practicable warning signs and cordoning where corroded barriers could compromise personnel safety.
- 20195 Dec
Safety Alert 371 - Conductor Failures Put Workers' Safety and the Environment at Risk
BSEE highlights well conductor failures observed during inspections and in industry incident reports. It describes internal corrosion associated with water and air entering the annulus, alongside inadequate structural support. Recommendations for operators to consider address water ingress, lateral support, cathodic protection and recurring ultrasonic or laser inspection for metal loss.
- 201930 Sep
UK HSE Investigation into Offshore Gas Explosion
This safety flash describes a methane release following corrosion under insulation and rupture of high-pressure pipework on Brae Alpha. Over two tonnes escaped almost instantaneously, causing widespread damage but no injuries or ignition. The HSE investigation identified inadequate inspection and required an effective pipework inspection and maintenance regime.
- 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.
- 201925 Jul
Important safety notice for users of Crosby S-1326 18/20mm Shur-Loc Hook with 16t WLL – PN 100434
Crosby warns that selected 18/20mm S-1326 Shur-Loc hooks may have thread defects aggravated by corrosion, reducing ultimate load capacity despite factory proof testing. The notice identifies affected latch codes, requests nut removal and thread inspection, and requires withdrawal and return of non-conforming hooks; conforming hooks may be reassembled.
- 201911 Jul
Safety Alert 360 - Collision Leads to Significant Near Miss
A vessel collision during preparations for a swing-rope personnel transfer dislodged a load block from an out-of-service crane into nearby water. Inspection revealed a broken load line and severe corrosion. BSEE recommends considering visual inspections, securing or removing blocks and headache balls, and lubricating wire ropes during prolonged inactivity.
- 20199 Jul
Safety Alert 358 - Dislodged Boom Pawl Pin Unnoticed by Crane Operator during Pre-use Inspection
BSEE inspectors identified a dislodged, corroded crane boom pawl pin missed during a pre-use inspection, alongside shortcomings in operator knowledge and job safety analysis participation. The alert discusses reinstatement and redesigned retention, and recommends considering improved component checks, competence verification and review of the JSA process.
- 20195 Jul
Two incidents relating to life-rafts/life boats
Two vessel incidents concern accidental liferaft deployment during monthly inspection and hydraulic davit failure while lowering an occupied lifeboat for testing. The first highlights unfamiliarity with the release system and recommends familiarisation and an easily broken locking-clip seal. The second identifies worn, rusted threads and a broken bearing; no injuries occurred.
- 201927 Feb
Corrosion: Failure of bolts on a cargo barge bollard
A cargo barge’s centre bow bollard toppled while an additional mooring line was taken up during pipelay operations. Corroded securing bolts no longer connected it to the deck, and the bollard was not intended for mooring. The flash recommends engineered mooring arrangements and detailed inspection of bolted load-bearing connections.