BSEE Warns of Offshore Cylinder Explosion Risks

A recent safety review by the Bureau of Safety and Environmental Enforcement (BSEE) is raising serious concerns about compressed gas cylinders at offshore facilities throughout the Gulf of America. According to the BSEE, offshore cylinder explosion risks may be higher than safety officials were aware of.

The BSEE safety review identified multiple compressed gas cylinder explosions across the Outer Continental Shelf during 2024 and 2025. Several of these incidents reportedly caused injuries and significant damage to offshore facilities.

In response to these incidents, the BSEE conducted inspections of 20 offshore assets operated by 13 different companies. The investigation revealed concerns about various training, safety, and maintenance programs.

The BSEE report serves as an important reminder: offshore employers have a responsibility to provide workers with a reasonably safe place to work. When they fail to meet these responsibilities and workers are injured, they must be held accountable. Below, the offshore injury attorneys at Kherkher Garcia discuss the BSEE report and what maritime workers and families need to be aware of.

Multiple Explosions Prompt Federal Review

The BSEE’s investigation into the cylinders was prompted by several failures that resulted in explosions on offshore facilities.

Compressed gas cylinders are used throughout the offshore industry for many different reasons. When they are properly maintained and handled, they are generally safe. However, damage, corrosion, improper storage, or improperly charged cylinders pose significant risks. Particularly the risk of cylinder explosion, which can be catastrophic.

Although the BSEE’s inspection involved only a sample of offshore facilities, inspectors identified several recurring concerns, including:

Overreliance on Third-Party Contractors

The report suggested that many offshore operators rely almost entirely on outside vendors to manage cylinder inspections and maintenance. Third-party contractors play an important role in offshore operations. However, outsourcing maintenance does not eliminate an employer’s obligation to maintain safe working conditions.

Lack of Inspection Programs

Inspectors found that some offshore facilities completely lacked compressed gas cylinder inspection programs. Others lacked documentation proving that inspections were complete, or that corrective actions had been taken, as necessary.

Limited Worker Training

According to the BSEE, many offshore personnel they surveyed were unfamiliar with important elements of cylinder use, storage, and safety. Personal reported unfamiliarity with:

• Cylinder markings
• Recertification dates
• Storage requirements
• Inspection requirements
• Applicable federal regulations

Inspectors also reported that workers were often unable to identify potential hazards associated with compressed gas cylinders, and many had no training at all.

A 2025 BSEE investigation previously found that many offshore workers did not have adequate training or supervision when using certain equipment. Improper tool use was linked to a variety of hazards and injuries.

Corrosion and Storage Concerns

The investigation revealed several storage concerns. Some cylinders in storage had no markings whatsoever. Others showed signs of corrosion. Inspectors also identified storage practices that could increase the risk of explosion. For example, cylinders stored with different pressure ratings in the same area without adequate safeguards.

Why Offshore Employers Cannot Ignore These Risks

The offshore industry depends on rigorous safety practices in order to protect workers and property. Workers in offshore jobs are routinely exposed to:

• Heavy machinery
• Flammable materials
• Elevated workspaces
• Hazardous chemicals
• Confined environments
• High-pressure equipment

Because the risks are so significant, employers must take steps to identify hazards before incidents occur. Safety cannot be delegated to a third party and be forgotten by those responsible for workers’ lives.

Maritime Employers Have a Duty to Protect Workers

Offshore workers perform physically demanding jobs under some of the most complex and challenging conditions. Whether working on production platforms, support vessels, or drilling operations, workers depend on employers to maintain safe environments, provide safety equipment, and provide adequate training. When safety programs break down, the consequences can be devastating.

That’s why federal safety investigations are so important. They examine:

• Employee training
• Contractor oversight
• Inspection procedures
• Hazard communication
• Emergency response planning
• Equipment maintenance practices

These investigations can help determine whether preventable failures contributed to an incident causing injuries or loss of life.

Common Injuries Following Offshore Explosions

Even relatively small offshore cylinder explosions can cause severe injuries and disrupt victims’ lives. Some of the injuries often reported in offshore incidents include:

• Burn Injuries: Burns may result from explosions, fires, heat, or steam. Exposure to toxic substances can also cause chemical burns. Severe burn injuries often require ongoing medical care, surgeries, and skin grafts.
• Blast Injuries: Pressure waves generated by offshore explosions can cause damage to internal tissue and organs, lungs, and hearing. These can occur even when workers are not directly struck by debris.
• Traumatic Brain Injuries: Workers who are close to an explosion may suffer concussions or more serious brain injuries due to blast forces or impact with objects.
• Orthopedic Injuries: Flying debris and contact with structures can cause fractures, crush injuries, and other serious trauma.
• Wrongful Death: Unfortunately, offshore explosions and equipment failures sometimes result in fatal injuries. In cases of wrongful death, families are left searching for answers and accountability.

How Kherkher Garcia Helps Injured Offshore Workers

For more than three decades, Kherkher Garcia has represented maritime workers, offshore employees, and families battling the aftermath of catastrophic workplace accidents. Our attorneys understand the unique challenges involved in offshore injury litigation, including incidents involving major offshore companies.  These cases require extensive investigation, expert analysis, and a thorough understanding of maritime law.

When serious offshore accidents occur, workers and their families deserve answers about what happened and if the incident was preventable. That’s where Kherkher Garcia can help. Our oil and gas injury lawyers know how to break down the complexities of these cases and pursue justice for victims.

Find Out How Kherkher Garcia Can Work for You

The BSEE’s findings highlight an important reality for offshore workers. Safety requires more than policies put on paper. It requires a delicate balance of inspection programs, maintenance procedures, employee training, contractor oversight, and hazard awareness. These elements all play critical roles in protecting workers.

If you or a loved one has been injured in an offshore incident and you believe that negligence contributed to your injuries, Kherkher Garcia can help. We have recovered millions of dollars on behalf of our clients injured in offshore explosions and other maritime incidents. Find out how we can help you by contacting our team for a free and confidential consultation. Start now by calling 713-333-1030. You can also learn more about your rights and legal options by completing our online contact form.

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