What causes dropped objects? - Lloyd`s Register Energy Blog

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Lloyd’s Register Energy - Drilling
DROPS… who is responsible?
Luther Lonidier
Regional Technical Lead – Drilling Systems
October 9, 2013
Integrating ModuSpec and WEST Engineering Services
to advance excellence in drilling safety, integrity and performance
Lloyd’s Register Energy - Drilling
Agenda
•
What are dropped objects?
•
What causes dropped objects?
•
Through the supply chain
•
Examples
•
What can you do?
•
Resources
Lloyd’s Register Energy - Drilling
At home and at leisure
The top three causes of fatal accidents are…
falls from height…
being struck by moving vehicles…
and being struck by falling objects.
Lloyd’s Register Energy - Drilling
There are two types of dropped objects:
Static - any object that falls from its previous static
position under its own weight.
Dynamic – any object that falls from its previous static
position due to applied force from
equipment/machinery or moving object.
Lloyd’s Register Energy - Drilling
Lloyd’s Register Energy - Drilling
Lloyd’s Register Energy - Drilling
What causes dropped objects?
•
Poor hazard and risk assessment
•
Inadequate design (not addressing dropped object potential)
•
Poor behaviors (people walking by unsafe acts/conditions)
•
Inadequate or improper inspection, repair and maintenance
•
Redundant/neglected/homemade tools and equipment
•
Failed fixtures and fittings/corrosion/vibration
•
Inappropriate procedures/not following procedures
•
Inadequately stored/secured tools and equipment
•
Poor housekeeping
•
Environment (weather, sea motion)
•
Planning and operational miscalculations
Lloyd’s Register Energy - Drilling
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Design - Bolt fell from upper racking arm to drill floor – 3.5 lbs. x 82 ft.
• A bolt attaching the gripper head to the upper racking
arm came loose and fell to the drill floor during a
tripping operation
• All personnel were outside the danger area.
Causes:
1. Incorrect material in manufacture
2. Bolt had the incorrect part number
3. Faulty design - should not have been with welded head
4. New design bolt in 2000 - not changed out.
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Manufacture - Bar fell 100 ft. to cargo deck
• Bar holding skid rubber in
place fell 100 ft. to cargo
deck.
Causes:
1. Poor design
2. Poor manufacture
3. Poor maintenance.
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Packaging - Unsuitably packaged equipment
• Unsuitably packaged equipment
transported to offshore destination
Box shown without warning labels/markings of
heavy contents
• Cardboard box weighed approximately 70
lbs.
• Contents fell out during transit.
Causes:
1. Unsuitable packaging process
2. Failure to check loads prior to dispatch.
Hydraulic pump approximate weight 70 lbs was inside
cardboard box
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Transport - Items found on the top of container
• Hammer and chisel found on
the top of container prior to
lifting.
Causes:
1. Carelessness of persons
using tools
2. Failure to check loads prior to
dispatch.
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Quayside - Debris found in the forklift pockets
• Debris found in the
forklift pockets.
Causes:
1. Poor storage facility
2. Failure to check loads prior
to dispatch.
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Transport by Sea - Item left on top of a unit
• A temperature gauge used to
check exhaust temperature was
left on top of a unit
• The gauge weighed
approximately 0.5 lbs.
Causes:
1. Lack of awareness of
maintenance staff
2. Failure to check loads prior to
dispatch.
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Installation / Commission - Item not designed for use at height
•
Air regulator fitted to wireline hoist.
•
Not designed for use at height
•
Securing dogs not engaged
•
When energized, cover and
internals (0.5 lbs.) blew off and fell
35 ft. to drill floor
•
No injuries were sustained.
Cause:
1. Equipment unsuitable for use at
height.
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Operations - Broken tool handle (15 lbs.) fell 25 ft.
•
During cleaning of the drill floor the grating over a drain
hole was removed. The grating was bent and a sledge
hammer was used to straighten it. While hitting the
grating, the handle broke and the sledge hammer
bounced over the edge of the floor landing on the cat
walk. The area below was not fenced off however no
personnel were in the vicinity.
Recommended actions:
1. Secure tools when there is a possibility of dropping to lower levels
2. Fence off areas below when working at height
3. Replace sledge hammer handles from wood to composite material.
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Maintenance / Repair - Hammer fell 100 ft.
• Hammer (1 lbs.) fell 100 ft. from
work platform following
maintenance operations.
• No personnel were working in the
vicinity.
Causes:
1. Insufficient Risk Assessment
2. No securing of tools at height.
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Decommission / Dismantle - Spike fell 7 - 8 feet
• Spike, hidden inside scaffolding tube fell
7 - 8 feet to the deck narrowly missing
Scaffolder.
Causes:
1. Insufficient Risk Assessment
2. No securing of tools at height
3. Bad habits.
Recommendations:
1. Cap tube ends
2. Secure tools at height.
Dropped Objects Who’s Responsible
Responsibilities Through the Supply Chain
Packing - Access Door fell off during backloading
•
Diesel power pack being back loaded. Access
door opened and fell off.
•
Further investigation revealed door hinges had
failed and were repaired with Ty-wraps.
Causes:
1.
Poor maintenance and fabrication of
containers
2.
Poor standards of inspection prior to
dispatch
3.
Insufficient repair methods.
Lloyd’s Register Energy - Drilling
Preventive and Mitigating Controls
Preventive Controls
Mitigating Controls
Good planning (Site inspection, PTW)
Safety securing systems
ols
Effective use of barriers
Primary fixings / secondary retention /
maintenance
Restricted access areas (Red Zones / No Go
Zones)
Surveys and inspections
Tools and equipment aloft registers and log
books
Collision checklist
Management of distractions
DROP
Use of approved drops tools kits
PPE (Personal Protective Equipment)
Communications, standby persons and PA
warnings
Observation, STOP, individual awareness and
vigilance
DROPS training
PREVENTING AN INCIDENT BY REDUCING THE
LIKELIHOOD THAT AN INCIDENT WILL OCCUR
REDUCING THE CONSEQUENCES OF AN INCIDENT
IF PREVENTIVE CONTROLS FAIL OR ARE NOT
EFFECTIVE
Lloyd’s Register Energy - Drilling
How can I personally prevent dropped
Implement a Dropped Objects program, if not already in place.
objects?
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Actively support the Dropped Objects program.
Take responsibility for my actions.
Look after my colleagues.
Maintain good housekeeping.
Stop unsafe activities by using Stop Work Authority.
Make observations and report incidents.
Review and follow procedures.
Recognize known hazards, and follow the controls in place.
Consider dropped objects in all Toolbox Talks.
Consider dropped objects in all JSAs.
Check areas after all work is completed, even if work was permit
controlled.
Participate in Hazard Hunts.
Investigate all incidents, including and especially near misses.
Secure all tools and equipment when working at height.
Lloyd’s Register Energy - Drilling
Dropped objects can
occur anywhere…
Lloyd’s Register Energy - Drilling
Dropped objects can
occur anywhere…
Lloyd’s Register Energy - Drilling
Dropped Objects –
EVERYONE is
responsible!
For more information visit:
WWW.DROPSONLINE.ORG
Lloyd’s Register Energy - Drilling
Any questions?
Lloyd’s Register Energy - Drilling
For more information, please contact:
Luther Lonidier
Regional Technical Lead – Drilling Systems
Lloyd’s Register Drilling Integrity Services, Inc.
1330 Enclave Parkway, Suite 200
Houston, Texas 77077 USA
D +1 281 649 2219 M +1 985 212 1375 T +1 281 398 3998
[email protected]
http://www.lrenergy.org/drilling
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