Following offshore worker’s injury in Gulf of Mexico, BSEE sets forth five recommendations

After looking into circumstances surrounding an injury at an offshore installation in the Gulf of Mexico, the U.S. Bureau of Safety and Environmental Enforcement (BSEE) has come up with five recommendations for oil and gas operators, which can assist in avoiding potential incidents on the Outer Continental Shelf (OCS).

In a safety alert published on 17 February 2023, BSEE pointed out that a third-party contract operator, sandblasting on an offshore facility in the Gulf of Mexico, was injured when a temporary air dryer used for sandblasting operations recoiled and broke the safety cable.

Following an inspection at the facility, BSEE inspectors discovered that a worker was refilling the sand pot with an abrasive material to continue sandblasting operations.

After confirming the air supply valve (shown in the right circle on the image) from the temporary air dryer to the sand pot was shut-in, the worker attempted to disconnect the air supply valve from the air dryer.

As the worker tried to access this coupling, he loosened the T-connection, which blew off and broke the braided steel cable – whip check or safety cable – designed to suppress the hose recoil when a pressurized release occurs.

The whip check ends were looped between the hose and the coupling connection (left circle on the image). BSEE says that the T-connection and broken whip check caused multiple cuts and abrasions to the worker’s head and shoulders.

Furthermore, BSEE inspectors identified several contributing factors during their investigation. In line with this, the baling wire involved in the incident was slightly corroded, potentially diminishing its overall integrity.

As explained by BSEE, the baling wire, which is often used in place of a cotter pin on crowfoot couplings, is used as an additional safety measure to ensure couplings are securely connected.

The U.S. regulator highlighted that the failed whip check cable was improperly crimped, elaborating that crimping the whip check cable before placing it into service allows it to function correctly at its full rated capacity.

In addition, the bull hose configuration on the air inlet valve from the platform air compressor was installed in a horizontal position. According to BSEE, the added weight caused the T-connection to be off-centre at the time of operation, adding stress on the associated couplings and baling wire.

Therefore, the added weight, combined with the worker’s force when manipulating the air supply valve to the sand pot, resulted in air escaping the inlet valve from the platform compressor, likely causing the connection to come loose, concluded the regulator.

Taking into consideration its findings, BSEE recommends that operators and contractors conduct a pre-job hazard assessment with all affected personnel, including facility leadership, to confirm all aspects and associated mitigations of the task are understood.

Moreover, operators and contractors are advised to install stainless steel tie wires in addition to whip checks on bull hoses to reduce the risk of disconnection; and install 90-degree fittings to eliminate the horizontal orientation of the supply hose, reducing the stress at each connection.

Additionally, BSEE points out that operators and contractors should depressurize equipment prior to adjusting valves when practical; and inspect all equipment and parts pre-job to ensure they are in adequate condition.