Offshore alert: Use safety devices with temporary test equipment

Washington — The death of an offshore worker conducting a pressure test on a well surface casing has prompted the Bureau of Safety and Environmental Enforcement to issue a safety alert.

The agency’s investigation into the May 2021 incident found that the victim and a co-worker were using a high-pressure well to supply pressure to the well casing. They installed temporary test equipment that included a high-pressure hose and a digital pressure gauge, but didn’t use the pressure regulating device and pressure safety valve.

The workers were unaware of the casing pressure rating during the test. The well casing exploded as pressure built, resulting in a fluid release in an opening between the drive pipe and wellhead base plate.

BSEE recommendations to operators and contractors include:

• Ensure the pressure rating for all temporary equipment is verified to be compatible to a specific application before use.
• Use a pressure regulating device and a pressure safety valve to protect against overpressure anytime temporary equipment is used where the source pressure is greater than any downstream components’ existing pressure rating.
• Establish training and raise awareness to enhance workers’ proficiency in using, interpreting and accurately reading units of measurement recorded by all gauges and measurement devices.
• Ensure workers thoroughly evaluate a hazard analysis as pressure testing procedures are developed.
• Create comprehensive hazard and risk assessment procedures for inactive wells to prioritize the abandonment procedures.
• Ensure pre-job reviews and discussions of the job safety analysis.