UK HSE: Fatal injury following catastrophic failure of pressure test equipment
- Safety Flash
- Published on 19 February 2020
- Generated on 9 May 2025
- IMCA SF 06/20
- 1 minute read
A 64-year-old worker was fatally wounded by shrapnel ejected from testing equipment
What happened?
The man was leak testing eight 1500 litre cylinders, by applying compressed air inside to create pressure.
Whilst in the process of venting the air through the test manifold, it catastrophically failed and fatally injured the worker.
What was the cause?
The UK HSE's investigation found that prior to installing the fittings, 1.5 litres of a mineral oil-based corrosion inhibitor had been placed into each of the cylinders. The incident occurred because the inhibitor contaminated the leak test manifold during venting of cylinders and was subjected to enough pressure inside the manifold to ignite and cause the test equipment to fail.
The company was fined £700,000 with full costs of £169,498.82.
The HSE inspector noted: “This was a tragic and wholly avoidable incident, caused by the failure of the company to identify any additional risks that arise when work processes are adapted.” [IMCA bold for emphasis]
IMCA Safety Flashes summarise key safety matters and incidents, allowing lessons to be more easily learnt for the benefit of the entire offshore industry.
The effectiveness of the IMCA Safety Flash system depends on the industry sharing information and so avoiding repeat incidents. Incidents are classified according to IOGP's Life Saving Rules.
All information is anonymised or sanitised, as appropriate, and warnings for graphic content included where possible.
IMCA makes every effort to ensure both the accuracy and reliability of the information shared, but is not be liable for any guidance and/or recommendation and/or statement herein contained.
The information contained in this document does not fulfil or replace any individual's or Member's legal, regulatory or other duties or obligations in respect of their operations. Individuals and Members remain solely responsible for the safe, lawful and proper conduct of their operations.
Share your safety incidents with IMCA online. Sign-up to receive Safety Flashes straight to your email.