Offshore safety inspections lead to warnings about welding and burning work

Washington – Recent performance-related risk inspections by the Bureau of Safety and Environmental Enforcement uncovered “several critical issues” related to welding and burning operations, the agency said in a safety alert.

BSEE examined compliance and incident data since 2022 and found “multiple high-risk fires” caused by welding and burning. These fires triggered targeted on-site inspections at 13 manufacturing facilities and nine drilling rigs in the Gulf of Mexico.

In many cases, fire barriers such as tarps, curtains and blankets were either incorrectly installed or damaged, posing a safety risk. In one case, evidence showed that hot slag from a cutting torch had penetrated the underside of a residential building’s fire blanket. The residual heat likely triggered an ignition of the wood subfloor.

Further findings:

• Workers did not follow welding and hot work safety procedures. Hot work was performed in areas within 35 feet of equipment containing hydrocarbons. Additionally, hot work permits and job safety analyses listed the same person for fire watch and hot work.
• Inadequate cleanliness practices were identified, such as storing flammable materials (e.g. cardboard boxes) within 10.7 meters of hot work areas.
• The need for prevention tools such as fire extinguishers and portable gas detectors was not sufficiently recognized.
• The work was carried out without an approved welding safety plan, suggesting that comprehensive safety measures, planning and training are required.

The BSEE recommendations include:

• Take all necessary precautions to control, remove, or otherwise remedy dangerous accumulations of oil and gas or other hazards.
• Ensure that workers understand their work and can carry it out in a safe and environmentally sound manner.
• Require attendance and participation in a JSA meeting before work begins and ensure that supervisors at all work phases know and understand the full scope of the work.