(Working Together for Safety)
BEST PRACTICE IN PREVENTION OF
FALLING OBJECTS
Revision 2
19.11.2007
This best practice guidance is intended to address all phases from the design to the removal
of equipment, i.e. the design, manufacture, packing, transport, installation, operation,
maintenance and removal of equipment. Samarbeid for Sikkerhet (SfS) (Working together for
Safety) recommends that each company incorporates this practice into its management
systems.
List of Contents
1. DEFINITIONS
2.
FALLING OBJECTS (FO), MANAGEMENT SYSTEMS AND FOLLOW - UP
3. DESIGN AND DEVELOPMENT
4. MANUFACTURE
5. TRANSPOR AND PREPARING FOR TRANSPORT
6. EQUIPMENT AT HEIGHTS, SECURING PERMANENTLY MOUNTED, MOVABLE AND LOOSE
EQUIPMENT
7. TIDINESS AND CLEANING
8. WORK SITUATIONS THAT MAY LEAD TO FALLING OBJECTS
9. PREPARATION, IMPLEMENTATION AND COMPLETION OF WORK AT HEIGHTS
10. INSPECTIONS
11. REPORTING
12. TRAINING
1.
Definitions
Falling object (FO):
An object that moves uncontrollably from one level to a lower level. An incident involving
falling objects should be reported when the energy in the fall is equivalent to or exceeds 40
joules.
2. Falling objects (FO), management systems and followup
By means of management systems established in their companies, all actors (operators,
drilling contractors, shipowners, service contractors, manufacturers, suppliers, carriers and
base operators) shall implement measures to ensure a reduction in the number of incidents
involving falling objects and prevent such incidents occurring in the future. Management
systems shall address: compliance with own procedures; routines for following up incidents
involving falling objects; and the measurement of results. The system should be included in
the company’s supervision plan. The management system should be incorporated into the
company’s steering documentation for preventative HSE work and should reflect the actors’
overall goals with respect to injuries and accidents. Goals for continual improvements should
be established.
•
Follow-up work on FOs should include: goals, strategy, plans, action list, operation
and system maintenance and follow-up of suppliers and third parties.
Requirements to prevent FOs in the entire value chain (see Best Practice Dropped
Object Management, page 3) should be included in contracts.
3.
Design and development
General
Risk assessments/analyses of design in respect of FOs should be implemented on all
equipment which is planned for use at heights. To the extent to which it is possible, any
findings from such analyses should result in redesigns being undertaken before the
manufacture of equipment is initiated. It must be possible to track all decisions/choices
relating to solutions back to such risk assessments. Any weaknesses in equipment which
cannot be prevented by means of design or redesign should be reported to the client so that
compensatory measures can be evaluated and implemented.
For new installations or installation of safety devices on existing equipment, user
manuals/maintenance instructions should be made available or prepared.
Permanently mounted equipment (static, moveable and temporary)
Based on the results of risk analyses and experience with equipment, safety devices should
be designed and installed on equipment which represents a potential FO and on equipment
where slinging parts can pose a hazard.
Barriers to protect against FOs should be integrated into the equipment itself. Where this is
not possible, safety devices should be installed by the supplier.
The equipment should be designed in such a way that inspections and maintenance work
can easily be carried out without any risk from FOs. Fastening systems for equipment should
be able to withstand the maximum load to which the equipment may be exposed.
To ensure continual improvements, a system for experience transfer between owner/user
and manufacturer should be established. This system must ensure that other users are
provided with the necessary experiences and information about deficiencies in the equipment
within a reasonable period of time.
Suppliers of assembled equipment (cranes, top drives, pipe handling equipment, etc) should
provide image-based inspection and maintenance manuals (see Functional Requirements in
enclosure) which identify potential FOs, including descriptions of how barriers should be
inspected and maintained.
Tools
All tools should be designed so that they can be properly secured.
Hand tools
Suppliers should provide documentation that fastening points for hand tools are dimensioned
in line with the maximum fall energy for tools up to 5 kg. It should be ensured that provisions
for weakling couplings are made.
Heavy tools
Suppliers should provide documentation that fastening points for safety devices are
dimensioned in line with the maximum fall energy for tools up to 5 kg.
4.
Manufacture
Manufacturing should be performed in accordance with recognised standards and
specifications.
Any design changes which are made during the manufacturing phase should be assessed
for risk in respect of FOs. It must be possible to track all decisions/choices relating to
solutions back to such risk assessments.
The risk analyses that are carried out should be documented and should be made available
on request.
Before the finished product leaves the place of manufacture, it should be inspected for
potential FOs. Such inspections should be documented.
5.
Transport and preparing for transport
This means preparation work performed at the place of dispatch, transport to the quay,
reloading at the base, seagoing transport, lifting of loads onto installations, internal transport
on board, and return loads to base/land. Ref. NORSOK-R003, Section 7.11.
This also includes preparation at the place of dispatch, transport to the installation, reloading
onto the installation, internal transport on the installation and return loads, where appropriate.
Ref. NORSOK-R005, Section 7.12.
Suppliers
Suppliers should pack and prepare equipment for transport and should use the correct loadbearing equipment for the equipment involved. The load-bearing equipment should be
approved; ref. DNV 2.7.1. Furthermore, suppliers should ensure that the personnel involved
have sufficient competence in packing work.
Dispatches should be checked for loose objects before being transported and such
inspections should be documented.
Bases
Load-bearing equipment should be checked at the base/installation for loose objects before
cargo is loaded on board boats. All types of pipes and risers should be checked for loose
objects inside the pipes and for any loose thread protectors or covers.
Installations
Load-bearing equipment should be checked for loose objects before loads proceed on
internal transport for installation.
Offshore internal transport and return loads
The above-mentioned activities should also be performed on installations before loadbearing equipment is returned.
Sea transport
Captains should notify installations/bases if cargo has been exposed to abnormal stress or
possible damage during transport.
6. Equipment at heights, securing permanently mounted,
movable and loose equipment
For equipment which represents a hazard due to FOs, securing measures above and beyond
normal fastenings should be established. Such secondary securing measures should be
prepared during the design and construction phases. Secondary securing measures should
withstand the maximum loads that may arise should normal fastenings fail. All equipment
should be secured according to movement, vibration, load in use, temperature, corrosion,
weather conditions (e.g. safe sea transport).
Securing measures should be incorporated into inspection and maintenance programmes.
For new installations or installation of securing devices on existing equipment, user
manuals/maintenance instructions should be made available or prepared by the
manufacturers.
7.
Tidiness and cleaning
High levels of tidiness and cleanliness should be maintained at all times.
Responsible companies should set standards for which levels of tidiness and cleanliness are
acceptable. Standards of tidiness and cleanliness in areas should be made visible.
Guidelines should be established for how all equipment should be positioned.
8.
Work situations that may lead to falling objects
When performing work at heights, personnel should at all times have full control of their own
equipment and tools as well as of any activity going on at lower levels.
For work situations that may lead to FOs, the following safeguard should be taken:
lower levels should be cordoned off. When cordoning off areas, consideration must be given
to the possibility that FOs can hit obstacles, change direction and thereby land outside the
anticipated landing area.
Safety nets cannot replace these barriers, but can be used as additional ones.
Workplaces shall be secured when they are left unmanned, even if only temporarily.
All tools, parts and equipment should be secured. Weaklink couplings should be used in
safety devices for tools and equipment. This is so as to prevent personal injury in situations
where tools or equipment get caught up or stuck. Use of tool bags with suitable anchorage
points is recommended. Securing of tools directly to body parts should not occur.
When using manriders, tools/equipment should be fastened by safety wires to the manrider
wire. It is recommended that bags be used if several components are to be used at height.
Safety equipment should be regularly maintained to ensure that it works as intended. The
parties involved should carry out assessments of risk associated with FOs and implement
any necessary measures, both during the planning stage and throughout the entire work
process.
The time and resources required for checking for potential falling objects and safeguarding
tidiness and cleanliness should be taken into account when planning operations.
A control system for everything that is brought up to heights should be established.
For example, a separate locker for tools to be used for work at heights could be designated,
with a list of its contents. Should such a system be introduced, someone should be
designated responsibility for the locker. Lockers and their contents should be clearly marked
with both area of application and contents.
A separate log book for equipment that is brought up to heights should also be established.
Someone should be designated responsibility for following up the log book.
The locker for equipment to be used at heights should be inspected at the end of each shift
and the log book should be updated.
9. Preparation, implementation and completion of work
at heights
Preparation
A supervisor should be appointed for this task.
Before work commences, a risk assessment/safe job analysis should be carried out in which
both the supervisor and the operatives participate. The risk of FOs in particular should be
discussed at such meetings.
The supervisor should:
• Establish plans for cordoning of the work area and safeguarding it against potential
FOs (the work area should also be checked for tools/equipment left behind from
previous work/operations).
• Plan requirements for access and necessary tools/equipment.
• Familiarise himself/herself with special procedures and coordinate simultaneous
operations. Delegate responsibility for tools in the work team.
Implementation
Operatives should:
• Assess their own activities in relation to any other activities that may be going on at
the same time.
• Safeguard tidiness, cleanliness and control over all loose components during the
course of the activity.
• Stop an operation in the event of changes and assess the need for new,
compensatory measures.
• Check that safety equipment for work at heights is correct and in good condition.
Completion
• The work area should be checked for tools/equipment left behind and then tidied up.
This should be verified by a person who is not involved in the activity. Verification
can be done by keeping account of what is taken up to and what is brought down
from heights.
• Record feedback regarding possible design improvements, requirements, best
practices, procedures and instances of non-compliance, where appropriate.
10.
Inspections
Programmes
Permanently and temporarily mounted equipment at heights which pose potential risks due
to FOs should be identified and made visible. Periodic inspections should be included,
recorded and followed up as part of the maintenance programme.
Such inspections should safeguard equipment which is mounted at heights and which is not
in use. Removal of such equipment should be considered. Periodic inspections should be
carried out, focusing on FOs according to the visual inspection systems.
Periodic inspections which focus on falling objects in all other zones/areas should also be
undertaken.
Completion
Inspections should be carried out by personnel who have been trained in observation
techniques.
It is recommended that personnel from other divisions participate in such inspection teams. It
is particularly important that new/inexperienced personnel participate so that they can learn
about good observation techniques.
Use of individual checklists/inspection guides for the different areas is recommended. These
should be updated in conjunction with the installation of new equipment (preferably with
descriptive illustrations).
Plans
An annual inspection plan should be drawn up and should include:
• Designated responsibility for and intervals of inspections and updates of plans and
revisions.
• Inspection of inaccessible areas with the help of access techniques.
Required standards should be documented with written and pictorial material.
Time should be allocated to inspecting equipment that is in continual use or is difficult to
access due to operation or location.
Non-compliances/findings should be documented with the help of photographic and written
material and should include proposals for corrective measures.
In addition to the regular inspections, others should also be conducted to check for signs of
heavy stress on equipment (bad weather, jarring, etc).
The status of inspection plans should be followed up and regularly reviewed at management
meetings. In accordance with the company’s internal requirements, outstanding items should
be treated as non-compliances.
11.
Reporting
Falling and potential falling objects (damage/potential/condition) should be registered and
processed in the company’s incident recording system. Such reports should state whether
there were personnel in the area, weight, fall height, joule calculation and whether the area
was cordoned off. Descriptions should also be made of other barriers (those that worked and
those that did not).
Reports should also contain other important conditions which may help to prevent future
incidents. Where relevant, reports and, where appropriate, inspection reports should be sent
to equipment suppliers for experience transfer. Important experiences must be shared with
other users.
It is important to shed light on underlying causes.
12.
Training
It is recommended that training in inspection and observation techniques which focus on
potential falling objects is incorporated into training programmes for all relevant personnel.
Enclosures:
• Functional requirements for establishing visual inspection systems.
• Best Practice Dropped Object Management