Topic
Explosion
Rapid energy release, overpressure or explosive atmosphere hazards.
Newest 100 Documents
All 359 in search- 2026Sep
Shell Polymers Furnace Explosion and Fire — Furnace Explosion and Fire at Shell Polymers
Investigates the June 2025 furnace explosion and fire at Shell Polymers Monaca following coke-trap cleaning. Inadvertent opening of isolation valves allowed cracked gas to enter the firebox and ignite. The report examines reliance on administrative safeguards, safety instrumented system bypasses, alarm suppression and confusing valve interfaces, recommending engineered protection and improved interface design.
- 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.
- 202617 Mar
Battery power bank explodes in cabin
A power bank exploded during overnight charging in a vessel cabin. Its owner extinguished the fire with a wet towel, with minor damage to cabin fittings and furniture reported. The flash highlights restrictions on unattended charging and recommends certified charging equipment from reputable suppliers.
- 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.
- 202622 Jan
Petrol driven equipment left stored in an emergency generator room
A vessel safety round identified a petrol-containing snowblower stored in the emergency generator room, creating fire and explosion risks and obstructing access to critical equipment. The equipment was relocated. The flash recommends designated storage for flammables and keeping machinery spaces clear, with storage procedures and inspections identified for review.
- 202612 Jan
Spontaneous explosion of a plastic ruler
A plastic ruler spontaneously fractured in a vessel’s office drawer, ejecting fragments across the floor without injury. The flash discusses likely stored tension and brittle material behaviour, highlighting potential eye injuries and cuts. Recommendations include replacing acrylic rulers, discarding damaged ones and avoiding tightly packed drawers or solvent exposure.
- 202522 Dec
Vessel facilities subject to external hydrocarbon hazards guidance note
Guidance on safety cases for vessel facilities exposed to external hydrocarbon hazards. It addresses facility descriptions, formal safety assessment, ignition prevention, gas detection, emergency shutdown and evacuation arrangements. Supporting analyses examine fire, explosion and emergency-system survivability, while the Montara case illustrates shortcomings in preparedness and external-hazard assessment.
- 2025Dec
CHIRP Superyacht FEEDBACK 8 (December 2025)
Superyacht incident reports examine a failed mooring attachment, captain harassment, generator starter battery explosions, collision at anchor, unsafe pilot boarding arrangements, unprotected work aloft and defective life rafts. Commentary discusses battery capacity and ventilation, engineering handovers, equipment servicing and testing, reporting concerns and organisational safety culture.
- 202530 Oct
Supporting safety studies guidance note
Guidance explains supporting studies for facility safety cases, covering fire and explosion risk analysis, smoke and gas impairment, evacuation, escape and rescue, and emergency-system survivability. It distinguishes regulatory requirements from recommendations and discusses systematic assessment, modelling assumptions, control performance and evidence that risks are reduced as low as reasonably practicable.
- 20252 Oct
USCG: Lithium-Ion battery system installations
Summarises USCG advice following a lithium-ion battery bank fire on a passenger vessel caused by overheated, loosely crimped lugs. Discusses thermal runaway, toxic off-gases and suppression difficulties, alongside engineering review, battery management, condition inspections, maintenance, crew competence and fire drills. No injuries and minimal vessel damage were reported.
- 2025Oct
Refinery Cooling Tower Explosion and Fire — Process Safety Beacon, October 2025
A refinery cooling tower incident in India illustrates how hydrocarbons leaking from a heat exchanger can accumulate in cooling water pipework and escape during commissioning. Ignition was likely associated with nearby hot work. The bulletin discusses exchanger vulnerability, start-up hazards and notifying nearby workers so they can suspend work.
- 202511 Sep
BSEE Safety Alert 507 - Improper Use of Equipment and Tools Increases Risk of Fires and Explosions Offshore
BSEE identifies recurring offshore tool misuse involving live electrical circuits, explosive atmospheres and high-pressure or high-temperature systems. Cases include unsuitable hand tools and a plumber’s plug used during welding. Recommendations address competence evaluation, tool ratings and tracking, maintenance, pre-work audits, qualified inspections and authority to halt unsafe work.
- 2025Sep
Several errors lead to a hydrogen leak & fire — Process Safety Beacon, September 2025
This bulletin examines a hydrogen filling incident in Santa Clara in which a trainee inadvertently restarted filling while piping was dismantled for repair. Escaping hydrogen ignited, producing a deflagration and jet fire. It emphasises isolation procedures, authorised repairs, understandable controls and clear instructions for newer employees.
- 202518 Jun
MAIB: Is your Lead-Acid battery safe?
A barge crew member escaped injury when four lead-acid batteries exploded during generator starting. The steel locker contained the explosion. Investigation identified batteries unsuitable for continuous float charging. The flash highlights documented maintenance and replacement records, ventilated battery stowage and corrosion-resistant, flame/explosion-proof compartment lighting.
- 20253 Jun
TS USA Molten Salt Eruption
Investigates the fatal molten-salt eruption at TS USA’s Chattanooga facility on 30 May 2024. Retained water in a plugged roller generated pressure before entering the oxidising bath and producing a steam explosion. Examines drainage hazards, reprocessing procedures, training, protective barriers and failures to share learning from earlier incidents.
- 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.
- 20253 Apr
BSEE Safety Alert 498 - Explosion and Fire Incident
A liftboat explosion during separator draining injured two workers with burns. Gas accumulated on deck and a generator surge triggered ignition. The alert examines tank sealing, unsuitable gas detectors, failed air-intake shutoff controls and delayed medical evacuation, recommending that operators consider improved procedures, inspections, testing and emergency arrangements.
- 202519 Mar
Acetylene gas explosion
Two engineers setting up oxygen and acetylene cylinders experienced a small explosion and hose fire, leaving one with first-degree burns. The flash identifies inadequate flashback protection, bent hoses, faulty crimps, absent hot-work authorisation and unsuitable protective equipment. Lessons address arrestor placement and checking components after a flashback.
- 2024Oct
Some short-cuts may cut lives short — Process Safety Beacon, October 2024
This bulletin examines procedural shortcuts through a fatal polyethylene reactor incident in Pasadena, Texas. It describes inadequate isolation, unenforced permits and cross-connected valve air hoses. Guidance stresses operational discipline, functioning safeguards and authorised assessment of changes, warning against treating temporary safeguard bypasses as routine practice.
- 20244 Sep
BSEE Safety Alert 488 - Flash Fires During Welding Operations
A flash fire and blast during nozzle tack welding on a fuel gas scrubber propelled a tied-off welder against a rail without injury. Subsequent flammability readings ranged from 0 to 70% LEL. BSEE recommends considering improved atmospheric checks, ventilation, hot-work protocols, supervision, training and protective equipment.
- 20243 Sep
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.
- 2024May
CHIRP Superyacht FEEDBACK 6 (Summer 2024)
This superyacht incident digest examines watertight door failures, a starting battery explosion, a galley fire, unprotected window cleaning and steering loss. Commentary addresses alarm visibility, towing checks, battery maintenance, heat lamp safeguards, crew numbers and the independence of the designated person ashore.
- 202427 Mar
USCG: hazard from discarded munitions
This flash relays a US Coastguard alert about discarded munitions in coastal waters. A clamming-vessel deckhand suffered severe burns after a canister, likely containing mustard gas or another blistering agent, came aboard. Recommendations cover checking charts, avoiding marked dumping areas, recording encounters and reporting unexploded munitions.
- 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.
- 20236 Dec
UK MAIB: Electrician injured in explosion
An electrician suffered serious burns aboard a ship after a spanner bridged live switchboard conductors, causing a short-circuit and arc flash. The flash highlights unfamiliarity with the circuit-breaker assembly, disregarded instructions, unplanned work without a permit or lockout/tagout, and unsuitable tools and protective equipment.
- 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.
- 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.
- 202329 Aug
Paper shredder – explosion
An office paper shredder exploded after a sheet sprayed with WD-40 silicone lubricant was fed through its blades. Heat or a motor spark ignited accumulated vapours, destroying the plastic bin without injury. The flash discusses inadequate substance assessment and the purchase of proprietary lubrication sheets specified by the manufacturer.
- 20236 Jul
Optima Belle Explosion and Fire
An interim CSB investigation update describes a fatal dryer explosion during trial dehydration of sodium dichloroisocyanurate dihydrate at Optima Belle in West Virginia. It outlines vacuum drying, steam heating, sampling and temperature changes, alongside decomposition hazards. Explosion debris caused a neighbouring methanol pipeline fire; the initiating conditions remain under investigation.
- 202329 Jun
Watson Grinding Fatal Explosion and Fire
Investigation of the Houston propylene explosion that killed two employees and a nearby resident. It examines a degraded, poorly crimped hose, inconsistent supply isolation and non-functional automated safeguards. Findings address process safety management, change assessment, emergency preparedness and regulatory exclusions; lighting activation is identified as the likely ignition event.
- 202312 Jun
MAIB: Lithium-ion battery fire
This safety flash describes seawater contamination of a lithium-ion battery in subsea equipment stored aboard a vessel. Examination following deployment had identified a potential leak, but further investigation was delayed. A brief explosion occurred without injuries. The flash discusses battery hazards, secure storage of damaged batteries and appropriate extinguishing measures.
- 202312 May
Process Explosion Causes Medical Evacuation
Two offshore workers installing a skillet in pipework suffered smoke inhalation and burning sensations after opening a flange. The investigation identified absent purging or flushing and unrecognised potential pyrophoric materials. BSEE recommends considering fire and explosion management plans and procedures addressing ignition sources, oxygen ingress and fuel.
- 202327 Feb
Battery explosion during routine maintenance
A harbour tug’s Chief Engineer sustained minor injuries when a spanner inadvertently short-circuited a battery during preparations to replace a failed disconnect switch. The flash discusses electrical isolation, terminal protection, suitable tools and protective equipment, alongside increased maintenance inspection and consideration of chargers with temperature sensors.
- 202316 Feb
Fluid Transfer Transport
Hazard alert addressing toxic and flammable vapours, hydrogen sulphide and oxygen displacement during vacuum loading and offloading of produced fluids. It assigns responsibilities to facilities, hauling companies and drivers, covering atmospheric monitoring, training, conductive hoses, bonding and grounding, safe vent discharge and prevention of diesel-engine runaway.
- 2023
CHIRP Fisher Feedback Autumn 2023
CHIRP’s first commercial fishing newsletter examines pot-line propeller fouling, a conveyor fingertip injury, a lone fisher falling overboard, failed trawl hoisting, a ferry collision and recovered unexploded ordnance. Case commentary discusses maintenance isolation, work communication, wire-rope inspection, harbour navigation and personal emergency signalling and self-rescue arrangements.
- 202229 Dec
Husky Energy Superior Refinery Explosion and Fire
Investigation of the Superior refinery explosion during fluid catalytic cracking shutdown. It examines air entering hydrocarbon equipment, missing steam-barrier and purge safeguards, eroded slide valves, procedural and training deficiencies, and brittle vessel fragmentation. Debris punctured an asphalt tank, escalating the event into fire; recommendations address transient-operation safeguards and emergency preparedness.
- 20221 Nov
Failure to plan properly: electrician sustains serious burns (UK HSE)
An electrician suffered serious burns at a supermarket warehouse when his metal spanner contacted a live busbar, causing an electrical explosion. Generator connection work alongside high-voltage maintenance lacked adequate planning and contractor coordination. The flash highlights failures to stop the circuit supply and appoint a competent person to organise the work.
- 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.
- 202228 Sep
Sunoco Logistics Partners Flash Fire
Investigation of a flash fire and explosion during flange welding at Sunoco’s Nederland terminal, injuring seven contractors. The report examines residual crude oil, pipe isolation tools, atmospheric testing, permits and procedure implementation. It discusses similar incidents and stresses ensuring a non-flammable internal atmosphere before hot work; the specific causal scenario remains unresolved.
- 20227 Sep
Temporary Equipment as a Potential Source of Ignition on Offshore Facilities
BSEE describes three examples of temporary equipment unsuitable for hazardous areas on offshore facilities: a diesel air compressor, hydraulic power pack and portable fan. The alert recommends considering equipment checks, ignition controls, management of change, pre-startup review and documented risk assessment throughout installation, use and removal.
- 2022Aug
What’s an Acceptable LEL Detector Reading? — Process Safety Beacon, August 2022
This bulletin examines a fatal tank explosion during emptying by vacuum truck, where work continued after a reading of 67% of the lower explosive limit. It explains vapour accumulation and sludge hazards, emphasising calibrated gas testing, compliance with testing limits, bonding and grounding, and recognised tank-cleaning practices.
- 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.
- 202222 Jul
Flash fire on Oxygen gas quad hose
An oxygen supply change aboard a DSV was followed by a hose burst, explosion and flash fire. The technician closed valves after hearing an unfamiliar regulator noise. Investigation identified missing inlet filtration and accumulated rust particles contributing to ignition. A deck foreman extinguished the fire using dry powder.
- 202212 May
Explosion – hot work in a flammable atmosphere (Transport Malta)
A tanker explosion followed angle-grinder use to remove stubborn ramp bolts during dry-docking preparations. Sparks travelled towards a fuel-oil tank vent; nobody was injured. The flash examines perceived time pressure and unawareness of nearby flammable gases, and records refresher webinars reinforcing stop-work authority and improved work planning.
- 2022May
“ What happens if ?” An important question for hazard reviews — Process Safety Beacon, May 2022
A fatal batch-mixing explosion and an earlier near-miss illustrate the importance of considering material misidentification and unintended reactions during hazard reviews. The bulletin recommends examining human error traps, using reactivity compatibility matrices, rigorously checking materials and keeping operating tanks closed, sealed and vented to a safe location.
- 20224 Apr
Improper Fan and Other Equipment Used in Hazardous (Classified) Locations During Coiled Tubing Operations
BSEE inspectors found an unsuitable fan and extension cord beside a gas buster during coiled tubing operations. Changing the plug had not changed the fan’s rating. The alert recommends considering classification drawings, equipment approval markings, applicable standards and checks for damage or improper electrical modifications.
- 202222 Mar
MAIB: Unexploded ordnance – subsea explosion causes injury and damage
This safety flash summarises a seabed bomb explosion during crab-pot hauling by Galwad-Y-Mor in the North Sea. Five crew members suffered significant injuries, while the vessel sustained major damage and flooding. It highlights effective distress communication, evacuation, rescue and casualty triage, alongside the hull’s resistance to the blast.
- 202220 Jan
Subsea explosion resulting in damage to crab potting vessel Galwad-Y-Mor and injuries to crew
Investigation of a seabed bomb explosion during crab-pot recovery by Galwad-Y-Mor, causing vessel damage, flooding and significant crew injuries. The report assesses potting-gear disturbance of likely wartime ordnance, fragment examination and explosive traces, alongside watertight subdivision, crew preparedness, rescue and casualty triage.
- 202210 Jan
Lifejacket battery caught fire
An inspection of a laid-up vessel revealed burnt lifejackets beneath a wheelhouse bench. An expired lithium battery in a lifejacket light had exploded; the closed compartment limited fire spread and contained smoke. The flash recommends suitable storage, expiry checks, scheduled inspections and proper disposal of damaged or expired batteries.
- 202128 Oct
UK HSE: Lubrication of circuit breakers – safety notice
This flash summarises an HSE notice following an HV circuit breaker explosion and fire. It examines unsuitable cleaning and lubrication products, possible stiction and solvent evaporation, and calls for maintenance procedures to be reviewed against manufacturers’ instructions for product selection, application and servicing intervals.
- 202121 Oct
Management of Hot Surfaces information paper
This information paper examines hot-surface ignition risks from non-electrical equipment in open process areas. It distinguishes hazardous area classification from assessment of large hydrocarbon releases, explains auto-ignition temperature and operating temperature limits, and discusses dispersion modelling, inspection assurance and evaluation of temperature exceedances against facility-specific standards.
- 202124 Sep
AB Specialty Silicones, LLC
Investigation of a fatal hydrogen explosion during silicone-emulsion batch manufacture in Waukegan, Illinois. Reactivity experiments linked unintended potassium hydroxide addition to hydrogen generation. The report examines similar chemical drums, atmospheric batch tanks, ventilation, failed detector trials, evacuation preparedness and procedural checks, alongside process safety culture and regulatory gaps for reactive chemicals.
- 2021Sep
Lubrication of circuit breakers
HSE warns that unsuitable lubricants can impair high- and low-voltage circuit breaker mechanisms. An investigated failure may have involved lubricant-related stiction. The notice calls for maintenance procedures to follow manufacturers’ instructions, distinguishing cleaning products from lubricants and selecting compatible products at appropriate intervals. LV MCCBs and MCBs are excluded.
- 202120 Jul
Cargo tank explosion and fire on chemical tanker Stolt Groenland
Investigation of the Stolt Groenland explosion and fire at Ulsan examines runaway styrene polymerisation following heat transfer through an intermediate cargo tank. It analyses inhibitor depletion, stowage planning, unused temperature monitoring and alarms, and onboard remedial limitations. Fire response and missed learning from the separate Stolt Focus incident are also considered.
- 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.
- 20212 Jun
UK HSE: Worker fatally injured in oil drum explosion
An engineer suffered fatal injuries when a drum exploded while he cut its lid with a plasma torch. Drums labelled for motor oil had previously held gasoline without correct relabelling. The flash highlights residual vapour ignition and calls for adequate container information, labelling, cleaning and de-gassing before hot work.
- 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.
- 202124 May
Measurement While Drilling (MWD) Lithium Thionyl Chloride Cell Battery Explosion
An explosion occurred during the second attempt to lower a measurement while drilling tool into a drill collar. A discharged vent plug shattered the driller’s cabin glass, sending glass and chemicals inside. The driller was struck in the face and neck; other rig-floor employees sustained minor injuries from concussion and gas release.
- 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.
- 202123 Feb
Lead-acid battery explosion
A generator starting incident destroyed the top of a lead-acid battery case. The flash identifies a hot negative-terminal connection that would have ignited any excess hydrogen accumulated in the battery box. Actions include checking connections, following installation instructions and considering batteries that do not release hydrogen during charging.
- 202114 Jan
Structural response to fire and explosion
Guidance sets out expectations for demonstrating offshore installations’ structural resilience to fire and explosion. It addresses accidental loading, critical elements, temporary refuges, fire partitions, post-explosion door performance and escape tunnels. Particular considerations include floating structures, safety gaps, scaffolding congestion, passive fire protection and combined-operation safety cases.
- 202016 Dec
LTI: Person injured by a battery explosion on vessel deck
A charged battery for portable subsea magnetic particle inspection equipment exploded during deck checks, projecting its housing lid and injuring a worker. Inadequate post-charge venting allowed an explosive atmosphere to develop; the precise ignition cause remained inconclusive. Lessons address venting times, charging instructions, toolbox talks, protective equipment and emergency response.
- 202010 Nov
Confined space entry fatality
An explosion during spray painting in a fresh-water tank aboard a vessel in a shipyard killed one worker and injured another. The worker assisting outside the tank was rescued conscious; the worker inside was found unconscious and later declared dead at hospital. The ignition source remained under investigation.
- 202028 Sep
US Coast Guard: Addressing hazardous area electrical issues
This flash summarises US Coast Guard findings concerning certified electrical installations in vessel hazardous areas. Incorrect installation, missing or degraded components and unfamiliarity with standards compromised protection. The alert strongly recommends IEC-aligned training, periodic inspection and maintenance by competent personnel, competent repairs and regulatory approval of system modifications.
- 202010 Sep
Failure to detect dangerous gas/vapour due to incorrect specification of sample tube
This safety alert examines misleading readings from pumped gas detectors caused by vapour adsorption inside unsuitable sampling tubes. A fatal explosion followed hot work based on a false reading. It recommends checking detector–tube combinations with the substance of interest where practicable and assessing sampling-system response times.
- 202025 Aug
Emergency lithium battery failed catastrophically in a diving bell
A diving bell’s emergency lithium battery failed with an explosion and small fire after its pod flooded through an incorrectly fitted replacement check valve. No injuries occurred. The flash highlights interchangeable valve connections, absent management of change and crew uncertainty about immediate battery-fire response.
- 2020Jul
Process interruptions: a threat to process safety — Process Safety Beacon, July 2020
This bulletin examines an explosion involving mononitrotoluene left in a shut-down vacuum distillation column. Leaking steam valves heated the material, leading to decomposition and a runaway reaction. It highlights shutdown isolation, detailed procedures, continued monitoring of process parameters and alarms, and repair or replacement of leaking block valves.
- 20203 Jun
Safety Alert 388 - Malfunctioning Storage Batteries Cause Fires and Explosions
This alert describes several lead-acid battery fires and explosions involving internal shorts, ageing circuitry and heat accumulation. BSEE recommends that operators and contractors consider battery dating, inspection and replacement policies, enclosure ventilation, suitable storage, correct battery selection and charger settings. It also highlights hydrogen generation during charging and related UPS hazards.
- 2020Mar
March, 2020 - Vacuum Trucks can Catch Fire and Explode! — Process Safety Beacon, March 2020
This bulletin describes a vacuum truck explosion at a Californian wastewater facility involving incompatible substances, followed by fires and evacuations. It explains flammable vapour and static electricity hazards during vacuum collection, and highlights permit completion, material compatibility checks, grounding and bonding, and separation of vent discharge from ignition sources.
- 202019 Feb
Two electrical incidents – UK HSE
This flash summarises two HSE prosecutions involving live electricity. Workers suffered serious hand burns after a fixing penetrated a live cable during cable-tray repairs. In a separate container delivery, a crane arm contacted an overhead power line, causing an electric shock to a helper. Both investigations identified shortcomings in assessing the work.
- 202030 Jan
Explosion and fire on-board the chemical tanker Stolt Groenland
This safety flash summarises preliminary MAIB findings on explosions and fire aboard Stolt Groenland during ship-to-ship styrene monomer transfer at Ulsan. Investigators considered deck rupture from over-pressurisation followed by vapour ignition the probable explosion mechanism. The incident caused extensive vessel damage and injuries to crew and firefighters.
- 201917 Dec
Exploding television recovered from sea
A workboat crew attempted to recover a floating television to prevent potential damage to passing boats. Before landing, the set exploded, scattering glass across the aft deck. Both crew members remained protected in the wheelhouse. The flash recommends appropriate PPE and extreme caution when handling objects recovered from the sea.
- 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.
- 201916 Dec
Explosion and fire on chemical tanker Stolt Groenland
This interim investigation examines explosions and fire aboard Stolt Groenland at Ulsan. Initial findings link probable tank rupture and vapour ignition to over-pressurisation during styrene monomer polymerisation. It describes inhibitor dosing, cargo conditions, firefighting and evacuation, alongside a separate Stolt Focus incident and reminders on monitoring and carriage instructions.
- 20196 Dec
Safety Alert 372 - Improper Use of Equipment Causes Blasting Cap Misfire
An offshore operator was injured when a blasting cap ignited during continuity testing with a megohmmeter before tubing cutting. The alert identifies unsuitable testing equipment and omission of a safety loading tube, outlines detonator test-current limits, and recommends procedures, training and equipment labelling while the investigation remains ongoing.
- 20198 Nov
Safety Alert 370 Overcharged Battery in Non-Ventilated Box
An RTU panel exploded after an overcharged 12-volt battery generated hydrogen in an unventilated enclosure. An unsuitable electrical component was the likely ignition source. No injuries or nearby equipment damage occurred. BSEE recommends operators consider compliant battery enclosures, installation arrangements preventing hazardous hydrogen accumulation, and electrical components rated for their area classification.
- 201928 Oct
Battery fire with subsequent gas explosion: Warning about lithium-ion power following ferry fire
A passenger ferry battery-room fire was followed by an explosion below deck, in or near the battery room, after safe evacuation. The flash relays Norwegian Maritime Authority recommendations on battery-system risk assessment, emergency procedures and drills, and stresses communication between energy management and battery packs. The cause remained unidentified.
- 201928 Oct
Ruptured acetylene hose: Fire
A subcontractor lighting an oxy-acetylene torch on a vessel experienced a small fire at a ruptured acetylene hose. The cause remained unestablished. The flash discusses flash-back prevention through equipment maintenance, arrestors, correct connections and separate hose purging, alongside contractor compliance and conditional emergency actions.
- 201923 Oct
Use of gas-fired oven cleaning equipment inside vehicles
HSE alerts suppliers, installers and users to hazards of LPG-fired oven cleaning equipment inside vehicles following a van explosion. It sets expected standards for cylinder storage, ventilation, driver separation, ignition control, gas isolation and training, and recommends substitution where reasonably practicable to eliminate or reduce risk.
- 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.
- 201930 Sep
UK HSE prosecution following 2011 fatal explosion in oil refinery
This safety flash reports HSE prosecution following a fatal refinery explosion in Pembrokeshire during tank emptying with a vacuum tanker. Four workers died and another was seriously injured. Investigators considered ignition of a highly flammable tank atmosphere the most likely initiator and identified longstanding safety-management failures.
- 201912 Aug
Near miss: Fire/explosion thermal runaway – lead acid battery
This safety flash describes an overheated, swollen lead acid battery found aboard a vessel. Charging heat accelerated the internal reaction, and the battery was at the end of its design life. Lessons address periodic maintenance, possible infrared inspection, suitable chargers and procedures, ventilation, fire protection and faulty-battery removal planning.
- 201928 May
Two battery issues – Step Change
Two battery incidents illustrate different hazards: a lifeboat lead-acid starter battery exploded after repeated overcharging, while a lithium-ion battery caught fire following water exposure and short-circuiting of inspection equipment. Lessons address equipment suitability, clear charging instructions, workforce competence, protection against water ingress and care when drying equipment.
- 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.
- 201818 Dec
LTI: Severe burn from short circuited Li-Ion battery
A crew member sustained severe burns after a loose lithium-ion vaporiser battery short-circuited with keys in his pocket, triggering thermal runaway and fire. The precise initiating mechanism remained inconclusive. The flash describes medical treatment, a prohibition on carrying loose batteries at work, and recommendations for information on charging, handling and storage.
- 201823 Aug
Safety Alert 340 - Caisson Well Surface Safety Valve Actuator Explodes
An offshore caisson well’s surface safety valve actuator exploded during cold-weather start-up after a tubing jumper admitted unregulated well gas. The alert describes overpressure, failed fasteners and a removed pressure relief device, with no reported injuries or pollution. BSEE recommends considering measures addressing start-up procedures, management of change and stopping unsafe operations.
- 20183 Aug
High potential near miss: unplanned handling of unexploded ordnance
A high-potential near miss involved recovering and handling wartime munitions during subsea debris clearance. ROV operations continued after ammunition emerged, and crew handled recovered items before specialist advice prompted their return to the seabed. The flash identifies information, identification and management failures, calling for reinforced stop-work authority, change management and revised procedures.
- 201818 Jul
Catastrophic engine failure and fire on board ro-ro passenger ferry Wight Sky
This investigation examines Wight Sky’s rebuilt propulsion engine failure, explosion and fire near Yarmouth, which seriously burned the engineer. It analyses probable debris-related bearing failure, engine assembly arrangements, oil and filter tests, and loss of essential electrical services. Actions address rebuild cleanliness and load testing; the recommendation asks Volvo to consider wear particle detection.
- 2018Jul
Can overcooling a reactor cause a runaway reaction? — Process Safety Beacon, July 2018
This bulletin examines a British dye-factory reactor explosion following overheating, cooling below the required range and resumed reactant addition. It explains how low temperatures can allow reactants to accumulate, increasing vulnerability to runaway reactions. Laboratory studies and simulations suggested another heat source might also have been necessary in this incident.
- 20189 May
Incorrectly selected oxygen welding gas hose bursts & catches fire
A shipboard oxygen hose exploded and caught fire when a cylinder valve was opened for cutting work. The replacement was a hydraulic oil hose, unsuitable despite its pressure rating. Adiabatic compression and residual oil were suggested as the cause. Lessons address hose specifications, oxygen-service cleanliness and slow valve opening.
- 201824 Apr
Packaging Corporation of America Hot Work Explosion
Investigation of a foul condensate tank explosion at PCA’s DeRidder mill that killed three contractors and injured seven. Air ingress created an explosive atmosphere; nearby hot work was the probable ignition source. The report examines turpentine recovery, outage conditions, permit limitations, process safety boundaries and explosion safeguards, with comparisons to earlier incidents.
- 2018Feb
Runaway Reactions Caused by Contamination — Process Safety Beacon, February 2018
This bulletin examines two explosions involving contaminated process materials: heated organic residue in pipework and crude methacrylic acid in a rail tank car. It explains reduced decomposition temperature, corrosion-related contamination and insufficient inhibitor, and recommends material identification, suitable construction materials, cleanliness and adherence to contamination-prevention procedures.
- 2018
Fatalities in Oil and Gas Extraction (FOG) Special Topic Report 2018
NIOSH summarises eight fatalities and ten hospitalisations during 2015–2016 involving ignition, inhalation or suspected inhalation of hazardous gases and vapours during fluid handling at oil and gas sites. Tables distinguish exposures, fires and explosions, activities, fluids and reported outcomes, including cardiac deaths with possible work exposure.
- 20178 Dec
Safety Alert 327 - Failure to Properly Purge Compressors Leads to Explosions
This alert describes two compressor start-up explosions involving inadequate purging. One injured a mechanic with flying debris; the other damaged a cooler and piping. Preliminary findings discuss panel logic, purging knowledge and job safety analysis. Recommendations address procedures, training, start-up permissives and manufacturer-directed maintenance.
- 20177 Dec
Gas explosions on general cargo ship Nortrader with 1 person injured
Investigation of two explosions aboard Nortrader at anchor in Plymouth Sound, injuring the chief engineer. Hydrogen generated by unprocessed incinerator bottom ash accumulated in the unventilated hold and entered the forecastle store. The report examines probable switchgear ignition, inadequate cargo testing and shortcomings in applying bulk-cargo carriage requirements.