Dropped objects -_drops

Dropped ObjectsWho’s Responsible

Dropped Objects Who’s Responsible

Introduction:

Since the introduction of the Dropped Objects Forum one of the biggest challenges to its development has been the perception that DROPS is entirely a Drilling Issue.

This presentation has been developed by the DROPS Forum for the industry. Many thanks are given to those who contributed and if the information given helps to prevent one incident this effort can be considered well spent.

While the presentation is aimed at the UKCS operations it is intended that the lessons learned can be transferred to other theatres of the industry.


The purpose of this presentation is to:

• Show that a Dropped Object can manifest itself anywhere in the working environment.

• Everybody; Employers, Workers, Drivers, Suppliers, Designers, Maintainers etc. have a moral and legal responsibility to carry out their activities in a safe manner.

• Provide sufficient material to be communicated to relevant personnel for both training and awareness purposes.


Responsibilities Through the Supply Chain


Health and Safety at Work - Duties of Employer

HSE at Work

HSAW Act Duties of Employer s.2(2)

So far as is reasonably practicable:

1. Provide and maintain plant and systems of work that are safe and without risk to health.

2. Ensure that the use, handling, storage and transport of articles is safe and without risk.

3. Provide such Information, Instruction, training and supervision to ensure that employees can carry out their jobs safely.

4. Ensure that any workshop under their control is safe and healthy and that proper means of access and egress are maintained, particularly in respect of high standards of housekeeping, cleanliness, disposal of rubbish and the stacking of goods in the proper place.

5. Keep the workplace environment safe and healthy so that the atmosphere is such as not to give rise to poisoning, gassing, or the encouragement of the development of disease. Adequate welfare facilities should be provided.



HSE at Work

HSAW Act Duties of Employer s.3

So far as is reasonably practicable:

To conduct his undertaking in such a way to ensure that persons not in his employment who may be affected thereby are not exposed to risks to health and safety.



HSE at Work

HSAW Act Duties of Employer s.6

Legislation: HSAW s(6) Places duties on every one in the supply chain from the designer, manufacturer, importer to the supplier to:

• Ensure that the article is safe and without risks to health at all times when it is being set, used, cleaned or maintained

• Carry out any necessary testing and examination to ensure that it will be safe

• Provide adequate Information about its safe setting, use, cleaning, maintenance, dismantling and disposal.



Design

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s(6)

Designers

Dropped objects due to poor design

Competent persons, Procedures, Provision of Information, Instruction, Training and Supervision, Quality Control

Vibration, Corrosion, Transit shock, Shock Loading, Contact with fixed / moving objects



• 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.

Design - Bolt fell from URA to Drillfloor - 1.6kg x 25m



Manufacture

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s(6)

Manufacturers

Loose articles, Scrap material, Overlooked tools

Competent Persons, Procedures, Quality Control, Information, Instruction, Training and Supervision

Loose materials following build, final checks



• Bar holding skid rubber in place fell 30m to cargo deck.

Manufacture - Bar fell 30m to Cargo Deck

Causes:

1. Poor design

2. Poor manufacture

3. Poor maintenance.



Packaging

Legislation

Responsibility

Hazard

Controls

Consider

HSAW 1974 ss(6), 2(2), 2, 3

Packaging Manager

Loose packaging, damage to equipment, loose articles

Competent Persons, Quality Control, Procedures, UKOOA Cargo Handling Guidelines

Secure stowage of all assembly / packaging equipment. Ensure packaging equipment can be used for return.



Packaging - Unsuitably Packaged Equipment

Box shown without warning labels/markings of heavy contents

Causes:

1. Unsuitable packaging process

2. Failure to check loads prior to despatch.

Hydraulic pump approx weight 30kg was inside cardboard box

• Unsuitably packaged equipment transported to offshore destination

• Cardboard box weighed approximately 40kg

• Contents fell out during transit.



• Compressor delivered with broken Weco coupling inside skid

• Coupling was external to frame and had been sheared off during transit.

Packaging - Coupling sheared off during transit

Causes:

1. Poor design

2. Poor packaging

3. Lack of awareness.



Transport by Road

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s(6)

Driver

Loose articles, Poorly secured cargo

Competent Person, Procedures, Information, Instruction, Training and Supervision, Quality Control

Debris, Tools, Loose Articles, Forklift Pockets.



• Hammer and Chisel found on the top of container prior to lifting.

Transport - Items found on the top of container

Causes:

1. Carelessness of persons using tools




• Piece of Wood found on the top of container prior to lifting.

Transport - Items found on the top of container

Causes:

1. Carelessness




Quayside

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s2(2)2, 3, s(3)1

Quayside Manager

Load damaged during lift, Dislodged objects, Loose articles, Poorly secured cargo

Competent Person, Procedures, Quality Control, UKOOA Cargo Handling Guidelines, Information, Instruction, Training and Supervision, Quality Control, LOLER 98

Debris, Tools, Loose Articles, Forklift Pockets.



• Rubble found in the Forklift Pockets.

Quayside - Rubble found in the Forklift Pockets

Causes:

1. Poor storage facility




Transport by Sea

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s2(2)2, s(6)

Ships Master

Load damaged during lift / transit, Dislodged objects, Loose articles, Poorly secured cargo

Competent Person, Design of Equipment, Procedures, Quality Control, UKOOA Cargo Handling Guidelines, Information, Instruction, Training and Supervision, Quality Control, LOLER 98

Debris, Tools, Loose Articles, Forklift Pockets, Secure / Controlled Areas.



Transport by Sea - Item left on top of a unit

Causes:

1. Lack of awareness of maintenance staff


• A temperature gauge used to check exhaust temperature was left on top of a unit

• The gauge weighed approximately 0.25kg.



Installation / Commission

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s2(2)1-5

Offshore Installation Manager

Dropped objects during installation, Incorrect installation, Equipment ejected during operation / test, Dislodged objects, Loose articles, Poorly secured cargo

Competent Person, TRA, Safe Working Practices, Competent Persons, Design of Equipment, Information, Instruction, Training and Supervision

Debris, Tools, Loose Articles, At Height Toolkit,Secure / Controlled Areas.



• Air regulator fitted to wireline hoist.

• Not designed for use at height

• Securing dogs not engaged

• When energised cover and internals (230gm) blew off and fell 10m to drill floor

• No injuries were sustained.

Installation / Commission - Item not designed for use at height

Cause:

1. Equipment unsuitable for use at height.


• During a connection, a piece of the chain (0.4kg) on the compensator link broke and fell (33m) to the drill floor

• No personnel in the vicinity.

Causes:

1. The chain was corroded with an old crack

2. Only visual inspection performed

3. The compensator link was not de-activated before lifting the string.

Installation / Commission - Chain fell to Drillfloor



• While running riser a 1m long (2kg) piece of wood fell to the drill floor. The height is not known as nobody observed the piece of wood on the riser

• Several persons were working at the drill floor, no one was injured.

Causes:

1. Carelessness

2. Failure to check loads prior to lifting.

Installation / Commission - Item fell from Riser to Drillfloor




Operations

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s2(2)1,3,4,5


Dropped objects during operation, Incorrect installation, Equipment ejected during operation, Vibration dislodged objects


Barriers, Signs, Maintenance, Debris, Tools, Loose Articles, Secure / Controlled Areas.


• A bolt was observed laying on drill floor 3m from personnel

• Investigation showed that a bolt for a roller on pipe handler had come loose, the nut and bolt had disassembled. Roller (750gr) was found loose on roller gripper head.

Causes:

1. Failure of lock washer

2. Poor design.

Operations - Bolt fell 24m to Drill floor




• Pin fell 6m from Bail Retainer to Drill floor, the pin weighed 0.5kg.

Operations - Pin fell 6m to Drill floor

Causes:

1. Poor design of cotter pin security

2. Cotter pin safety spring was flicked-up and fell out.

Considerations:

1. Secure pins with ty-wraps

2. Re-design pin security.


• 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.

Operations - Broken tool handle (7kg) fell 7m



• While running riser a flange on the riser knocked loose a part of the grating on a work platform.

• The grating fell to a lower level landing 2m from a person.

• There were people on all levels observing to make sure the riser was not hitting obstructions.

Causes:

1. Roughneck changes level without notifying the Driller and has his focus on the guide lines

2. Failure to follow procedures - Work platform was not fully retracted

3. Person was inside closed area.

Operations - Grating (20kg) fell 8m




Maintenance / Repair

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s2(2)1, 3, 4, 5


Dropped objects during Maintenance / Repair, Incorrect installation, Equipment ejected during test, Dislodged objects, Loose articles Competent Person, Design of equipment, Procedures

Competent Person, TRA, Safe Working Practices, Competent Persons, Design of equipment, Information, Instruction, Training and Supervision

Debris, Tools, Loose Articles, At Height Toolkit, Secure / Controlled Areas.


• Hammer (0.4kg) fell 33m from work platform following maintenance operations.

• No personnel were working in the vicinity.

Maintenance / Repair - Hammer fell 30m

Causes:

1. Insufficient Risk Assessment

2. No securing of tools at height.




Decommission / Dismantle

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s2(2)1-5


Dropped objects during dismantling, Incorrect installation, Dislodged objects, Loose articles


Debris, Tools, Loose Articles, At Height Toolkit, Secure / Controlled Areas.



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.



Packing

Legislation

Responsibility

Hazard

Controls

Consider

HSAW s2(2)2, s(6)


Dropped objects during packaging, Damage to equipment, lack of suitable packaging, Dislodged objects, Loose articles

Competent Person, Safe Working Practices, Design of Equipment, Information, Instruction, Training and Supervision

QA Procedures, Debris, Tools, Loose Articles, At Height Toolkit, Secure / Controlled Areas.



• 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.

Packing - Access Door fell off during backloading

Causes:

1. Poor maintenance and fabrication of containers

2. Poor standards of inspection prior to despatch

3. Insufficient repair methods.



• Container back loaded from offshore. Door opened and fell off.

• Further investigation revealed door hinges were unsatisfactory and container had made substantial contact with solid object.

Packing - Door fell off during backloading

Causes:

1. Poor maintenance and fabrication of containers

2. Poor standards of inspection

3. Poor handling of loads.



• Whilst fork lifting a large crate from a 20 feet height back loaded from offshore the crate collapsed.

• Within the crate were unsecured Drill Collars.

Packing - Crate collapsed during backloading

Causes:

1. Poor understanding of strength of container

2. Poor standards of inspection prior to despatch

3. Insufficient securing methods.

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