Applying DROPS approach to preventing dropped object incidents In the Singapore construction industry

Leong Weng Fei

M.Sc, B.Eng(Hons), CMIOSH, ACMA

Asia Pacific HSE Director, Baker Hughes Inc. DROPS Asia Chairman

Dropped Object Awareness and Prevention

Working to make our industry a safer place

 To raise awareness of potential dropped objects

To explore methods for the control and prevention of dropped objects To recognise your personal responsibilities for the prevention of dropped objects Eliminate injury to people and damage sustained to equipment due to dropped objects throughout Industry. Ultimately to deliver a second-nature dropped objects prevention strategy

DROPS Asia Objectives

WHAT IS A DROPPED OBJECT?

Any object that falls from its previous static position under its own weight

Dropped Object Awareness and Prevention

HOW BAD IS THE PROBLEM?

AT WORK :

Objects are among the Top 10 Dropped causes of Fatality and Serious Injury in the Oil and Gas Industry
AT HOME AND AT LEISURE :

top three causes of fatal accidents are The falls from heightbeing struck by moving vehiclesand being struck by falling objects (RoSPA)

Dropped Object Awareness and Prevention

NIOSH 2003 2006

Fatalities among US Oil and Gas Workers

Its Still HappeningReal Incidents

Its Still HappeningReal Incidents

 Over 70 companies all sharing commitment and enthusiasm for dropped object prevention. Basic remit to consider and review all avenues available for improving the industrys dropped object prevention performance.
Distil and identify key learnings and deliver these to industry effectively as awareness, best practice, recommendations, lessons, tools and techniques.

DROPS Worldwide

 Happened in 2006, Petaling Jaya, Malaysia Corporate figured killed when 2 tonne (3m X 3m) formwork fell on his vehicle Raised many questions about standards, compliance, enforcement, culture in the industry that could have led to this incident.

This is what we all aim to prevent!

Even small objects can kill!!!

 Awareness and appreciation of DROPS Inspection and Surveys

Control Measures:
Static and dynamic dropped object risk

DROPS systems / procedures Enforcement and industry self regulation

DROPS Approach to Preventing Dropped Object Incidents

 Poor awareness and appreciation on DROPS in construction industry Controls and regulations do cover DROPS but awareness and appreciation of criticality of DROPS is missing Approach in the oil and gas industry:
All DROPS incident are considered hi-po incidents Massive awareness blitz on DROPS in the industry through: Posters Training Videos sample language free video on Tools at Height to be shown at the end Campaigns etc.

Sustained DROPS specific awareness and appreciation campaign in Singapore is needed

Awareness and Appreciation of DROPS

Awareness and Appreciation of DROPS

Awareness and Appreciation of DROPS

 Survey and inspection key to preventing dropped object risk

Dropped Object Survey Criteria (ensures consistency in surveys)
Inspection Areas The Survey What to look out for Required survey tasks Deliverables Dropped Objects Survey Report Failed Item List Dropped Objects Inspection Book

Survey and Inspection

 Survey tasks:
Document equipment location by Inspection Area Photograph each item surveyed Include unique identification number to each item (tag numbers) Describe each item surveyed Inspect and document Primary Securing method(s) Inspect and document Secondary Retention method(s) Record equipment condition as Pass or Fail, including comments (ie Satisfactory or Reason for Failure) Record inspection frequency (ie weekly, monthly) as recorded in the Equipment Family Inspection Criteria Generate a Failed Items List

Survey and Inspection

Survey and Inspection

Survey and Inspection

Survey and Inspection

Example Equipment Family Inspection Criteria

AREA 1 : Derrick/Mast and Traveling Equipment Derrick Equipment Zone 1 (A-Frame / Crown / Water Table)
Item Family Frequency Possible Fastening method How to inspect

Active heave cylinder hydraulic control lines, support wires Valve block, flex hoses & accumulator bottle

180 days

Hydraulic

control

lines

pipe Check beam clamps and bolts are

clamped together and secured to secure and for any signs of corrosion, Active Heave Compensator with check all bolted connections and hoses bolted flanges. Other control lines are in good condition. Check support beam clamped to gin pole wires, turnbuckles and shackles,

structure with turnbuckles and 4 ensure shackles are fitted with split
part shackles Accumulator bottle pins. pipe and support wires clamped to framework & beam clamped to gin pole structure. Valve block

secured with bolted flanges. 2 Cable trays, Cable conduit pipe runs & cable clamps 180 days Cable trays with beam clamps to Check cable tray/conduit runs are derrick structure. Cables secured secure, ensure all brackets are tight with stainless steel tie wraps. and check for signs of corrosion. Other cables fed through pipe work which is beam clamped to derrick & gin pole structure.

Survey and Inspection

 Survey and inspection for construction industry:

Recommendation to conduct survey/inspection on a routine basis Eg. survey should be done upon installation of tower crane, formwork, scaffold etc. which have drop potential Initial survey helps to produce inventory of equipment used at height Initial survey output can be basis for determining frequency for subsequent surveys/inspection Maintenance of critical equipment can also be determined through survey and inspection output Essential to have inspectors/surveyors to have sufficient knowledge and experience in DROPS for survey/inspections to be effective

Survey and Inspection

 Static and Dynamic Dropped Objects

Dropped Object Management System (DOMS) effective in reducing frequency of static dropped object incidents
STATIC DROPPED OBJECTS Preventive Controls
Preventive Maintenance Tasks (ref DROPS Campaign Workpack) Calendar-based Dropped Objects Inspections (ref DROPS Campaign Workpack) Primary Securing Devices (ref DROPS Reliable Securing Booklet) Independent Dropped Object Surveys (ref DROPS Campaign Workpack) Dropped Object Inspection (Picture) Books (ref DROPS Campaign Workpack)

Mitigating Measures
Secondary Retention (ref DROPS Reliable Securing Booklet) Effective Use of Barriers (ref DROPS Campaign Workpack) Restricted Access Areas (ref DROPS Guidelines for Restricted Access Areas)

Control Measures : Static and Dynamic Dropped Objects

 Behavioral factors more dominant in controlling dynamic dropped objects

DYNAMIC DROPPED OBJECTS Preventive Controls
Individual Awareness Effective Task Planning (incl Lift Plans) Collision Checklists Pre-task Assessment and Checks (ref DROPS Prompt Card)

Observation and Vigilance (ref DROPS Training and Hazard Hunts)

Management of Change Time Out For Safety (TOFS) Management of Distractions Tools Aloft Log Book (ref DROPS Guidelines for Tools at Height) Subcontractor Equipment Inspections

Mitigating Measures
Individual Awareness Use of Approved Tools for Working at Height (ref DROPS Guidelines for Tools at Height)) PA Announcements / Warnings (eg overhead operations, crane operations, work in derrick, etc)

Effective Use of Barriers (ref DROPS Campaign Workpack)

Restricted Access Areas (ref DROPS Guidelines for Restricted Access Areas)

Static and Dynamic Dropped Object

 Examples of static dropped objects in a work site:

Scaffold and its parts Formwork Tower crane etc.

Compared to offshore environment, risk of static dropped object in construction worksite is lower but less precautions are taken What is done in the oil and gas industry:
Secondary retention system on objects placed at height Designing equipment at height with consideration for DROPS Minimizing need to place objects at height Pre-commissioning/installation inspection Periodic inspection through use of picture book

Managing Static Dropped Objects

 Managing static dropped object in construction industry:

Ensuring objects at height come with primary and secondary retention devices Inventory of parts that has potential to drop Produce picture book and use that as a mean to inspect after installation and periodic inspection Use of equipment that has lower DROPS risk eg. clamp free scaffolds, bolts and nuts with locknut/pin Commisioning/post installation checklist that includes DROPS check items Zoning/Baricading of danger/high risk zone

Managing Static Dropped Objects

Primary and Secondary Retention

PRIMARY SECURING DEVICES Nuts, bolts, screws Clamps, Brackets Turnbuckles Welding

SECONDARY RETENTION

Wire slings Encasement Lock Nuts Lock Wire

Split pins, roll pins, spring clips Lock Washers, tab washers Clamp and safety chains

Managing Static Dropped Objects

Secondary Retention

Managing Static Dropped Objects

 Example of dynamic dropped objects:

Hand tools Material on crane etc.

What is done in the oil and gas industry:

Work at height tools Red zones / No-go zones Trained and competent lifting personnel PTW for lifting operation

Managing dynamic dropped object in construction industry:

Promote use of work at height tools Use concept of zoning Improve competency and DROPS awareness of lifting personnel

Managing Dynamic Dropped Object Risk

Managing Dynamic Dropped Object Risk

 Management system approach towards DROPS in oil and gas industry Commitment of operators and contractors towards DROPS DROPS focal person in every rig is appointed. Similar concept can be done for all worksites DROPS survey is done before a rig is commissioned. Results of survey compiled in the form of picture book and used for routine inspection of high risk equipment.
Similar initiative can be done for erection of tower cranes, formwork, scaffolds etc.

Zoning system used in oil and gas industry Managing contractors ensuring that equipment used by contractors are also controlled against dropped object risk

DROPS System and Procedures

DROPS Guidance: Restricted Access Areas (Red Zones)

 Green Zone: where the layout and activities of the area present little likelihood of personnel being exposed to potential dropped objects under normal circumstances.
Yellow Zone: where the layout and activities of the area do present some risk of personnel being exposed to potential dropped objects under normal circumstances. Red Zone: where the layout and activities of the area present significant risk of personnel being exposed to potential dropped objects under normal circumstances.

DROPS Guidance: Restricted Access Areas (Red Zones)

 Green Zones- anyone may enter as long as no additional barriers are in place.
Yellow Zones- only personnel with specific tasks in that zone may enter. All others require the Area Authoritys permission to enter or work in that zone. Red Zones- personnel may be more exposed to falling objects, the movement of remotely operated equipment, high pressure, and/or other hazards as determined by risk assessment. Personnel in Red Zone must be required for the current operation and must be authorized by the Area Authority. Area Authority must ensure an appropriate plan is in place for specific operations in a Red or Yellow Zone

DROPS Guidance: Restricted Access Areas (Red Zones)

 Every effort should be made to identify and define an access route to the Area Authoritys common workplace location within the Green Zone to allow personnel access to Area Authority to request authorization into the Yellow and Red Zones.
Personnel not required for current operations must not be permitted into Yellow or Red Zones. For any activities that require entry to a Red Zone, and for non-routine activities within a Yellow Zone, a documented risk assessment must be performed before permission is given.

DROPS Guidance: Restricted Access Areas (Red Zones)

 Access to Red or Yellow Zones must be controlled at all times.

All access points should be identified and equipped with a physical barrier marking the point at which personnel cannot proceed without approval from the Area Authority. The physical barrier may be a chain, gate, door etc. (Emergency egress must not be impeded.) The barrier shall always be in place at all access points leading directly to Yellow and Red Zones, and at any other access points determined by the Area Authority. The physical barrier should also include a sign (in both English and the predominant local language) that communicates the zone is a hazardous area and access requires the Area Authoritys authorization

DROPS Guidance: Restricted Access Areas (Red Zones)

 Dropped object incidents dropped considerably when the UK HSE focused extensively on offshore safety Key to use 2-pronged approach to promote DROPS (Enforcement & Self regulation)

Enforcement & Industry Self Regulation