Reliable Securing
Contents
1. Ch li Ar e i set screw is installed E through the nut and into the bearing 82 Reliable Securing Previously snatch blocks had a securing wire as a secondary barrier This is not a satisfactory way of securing blocks as the wire used for this purpose will be unable to prevent the equipment from falling ifthe shaft or the suspension were to come loose Blocks must have two barriers in the suspension and two barriers in the shaft A maintenance programme must be established in accordance with the instructions where there is a requirement a competent person of blocks shackles and lifting lugs Blocks must be dismantled at the request of the competent person or in accordance with the manufacturer s recommendations or in any case at least every fifth year A competence matrix must be drawn up for personnel who are to maintain and operate snatch blocks JPS Reliable Securing 83 Umbilical roller sheaves DROPS As a result of inadequate securing of rollers in umbilical roller sheaves there have been several serious incidents where rollers have worked loose and fallen onto the deck Rollers must be secured with two independent barriers The preferred solution is to use through bolts with lock nuts and split pins The umbilical must be installed on deck and the support rollers reinstalled An umbilical roller sheave must be used exclusively for the purpose for whic2. ROPS Reliable Securing 13 2 m ion ONG 14 Reliable Securing The following methods are recommended for locking bolted connections NOTE Dual nuts are not recommended for locking screw bolted connections arl E Nord Lock Bol www nordlock com When correctly mounted the Nord Lock Bolt securing system provides a guaranteed secure screw bolt lock It works by means of wedge locking ensuring that the squeeze force is maintained in the screw bolted connection Areas of use Particularly suitable for connections exposed to vibrations eg grating loudspeakers guide rails etc Safe Lock spiralo www spiralock com Safe lock is an all metal lock nut The nut has a specially designed threaded profile that locks when tightened and distributes the tension over the whole length of the thread This provides better load distribution which in turn helps to improve the locking of the screw connection Areas of use Used for fastening cable support systems DROPS Reliable Securing 15 16 Reliable Securing Castle nuts provide a visual and reliable method for locking bolted connections The nut has radial slots and is locked by non corrosive split pins that are inserted through a hole in the bolt Generally used for bolted connections exposed to shear forces rather than tensile stresses Areas of use Critical connections or components that are disconnected frequently
3. DROPPED OBJECTS AWARENESS AND PREVENTION Reliable Securing DROPPED OBJECTS STILL HARMING KILLING We thank StatoilHydro for their kind assistance in the publication of this document In our ongoing efforts to prevent dropped objects investigations have shown that our greatest challenges relate to behaviour work processes and inadequate securing of equipment As part of our continued efforts we have updated this handbook which collates relevant requirements for securing both fixed and freestanding equipment Developed by StatoilHydro SfS after much research and consultation the handbook is an excellent guide to Best Securing Practice DROPS highly recommend these guidelines as a point of reference to all on a global basis The handbook has been compiled in close collaboration between equipment suppliers and users The objective has been to improve safety by providing guidance and illustrations of the most important factors in the prevention of falling objects We thank StatoilHydro for allowing us to publish the handbook to the benefit of all involved in our ongoing fight against dropped objects The DROPS Workgroup October 2009 DROPS Reliable Securing 1 Purpose of the handbook 4 DROPS responsibilities through the value chain 5 DROPS calculator 6 Barriers 8 Galvanic corrosion 10 Bolted connections 12 Correct use of lock pins 22 Correct use of eye bolts eye nuts 24 Securing devices wire
4. personnel must have documented training The user manual instructions must also provide guidelines for necessarymaintenance and inspection of the hose securing system Reliable Securing 87 Typical landing sites for potential dropped objects Forklift pockets and roof Forklift pockets frame tank and tank top Forklift pockets frame and tank top 88 Reliable Securing Several serious incidents have been discovered relating to the use and dispatch of carriers containers baskets tanks etc Chain slings must have the necessary certification be intact without twists and shackles and equipped with nuts and split pins Carriers must have the necessary identification and certified lifting lugs Lifting lugs doors hinges and locks must not be deformed or damaged Permitted loads in containers and baskets must be well distributed and adequately secured by stamping use of lashing rings lashing and nets baskets Lashing rings must not come into contact with sharp edges and padding should be used where appropriate Heavy objects must be placed at the bottom Tanks must have secured and sealed manholes valves All attached equipment grids covers plates etc must be adequately secured The permitted load must not be exceeded On carriers with attached equipment such as pumps tanks winches etc check to ensure no equipment protrudes from the frame It must be ensured that there are no loose objects in t
5. secondary retention Attachment brackets must have holes for fastening safety wires Covers must be hinged or have internal safety wires Hatch covers for electrical connections must not be completely removable Calculations must be made for attachment points and securing devices relating to the relevant fall energies Navigation lights with sliding grooves for bolt attachment are not recommended User manuals instructions must provide guidelines for the correct mounting of securing devices User manuals instructions must also provide guidelines for necessary maintenance and inspection of securing devices Reliable Securing 59 60 Reliable Securing Within the industry it is identified that CCTV cameras have been inadequately secured CCTV camera location must be evaluated to prevent risk of contact with moving equipment loads In areas where there is crane activity cameras should be shielded by protective cages The camera casing must be fastened to the bracket and structure with adequate locking of attachment bolts The attachment point for securing devices should form an integrated part of the camera casing and bracket Strength of attachment points and securing devices related to the relevant fall energies must be evaluated For new installation or when installing securing devices on existing equipment a user manual maintenance instructions should be available The instructions should also cove
6. secured against falling Wires and connectors must be used between the tools and belt or bag There must be a weak link between the snap hook on the belt or bag and the wire Swivels with set screws shall not be used Wrist straps must not be used because of potential personal injury If there is a need for more tools a tool bag with internal loops must be used In restricted areas eg derrick flare boom cranes etc tools used at height must be logged in and out to make sure that no tools have been left behind y T X Y Internal Safety wires and Securing securing loops connectors tools DROPS Reliable Securing 35 n Reliable Securing 36 Methods for securing heavy tools and hand held machines for use at height have not been adequately defined In view ofthe potential for serious damage if such tools or machines fall it is important to have clear guidelines All use of heavy tools and hand held machinery at height must be risk assessed All heavy tools and hand held machines used at height must be secured against falling when in use and while being transported Securing devices must be dimensioned in accordance with verifiable calculations and documented free fall tests Securing points for tools and machines must be in place above the work site and the securing device must be as taut as possible The fall length must not exceed the length of the securing device In restr
7. the distance it falls to determine its possible consequences It is important to note that this calculator and all others are guides only and in reality even a very light object falling from significant height can prove fatal DROPS Reliable Securing 7 When an unexpected event occurs Continuous Review Risk Assessment Change Management Lessons Learned Collaboration 8 Reliable Securing Barriers are functions and measures designed to break a specified undesirable chain of events In other words their function is to prevent a hazard such as a dropped object from manifesting itself or to mitigate the consequences by breaking an undesirable chain of events Safety barriers may be defined as People Technical or Procedural measures intended to break an undesirable chain of events Technical solutions alone can serve as barrier functions but they often need to be combined with organisational and or human solutions People and Procedural solutions can not fill barrier functions alone they must always be combined with at least one other solution DROPS Reliable Securing 9 Gold Silver Galvanised steel Zinc Magnesium 10 Reliable Securing As a basic rule only metal ofthe same or almost the same nobility should be combined in a corrosive environment Galvanic corrosion occurs when two dissimilar metals with different voltage potentials are in contact with each other in the presence of an elect
8. use The equipment must have CE approval and comply with an accepted standard The equipment must be checked at least every 6 months by a competent person LOLER The control or validity date must be shown on the equipment The choice of equipment must be made after evaluating the geometry of the work place Reliable Securing 31 Examples only 32 Reliable Securing Far too many defects have come to light in evacuation equipment In many cases there is deficient certification control and labelling of harnesses and blocks brakes Riding belts and blocks must be certified controlled inspected and labelled in line with other anti fall equipment The guide line its attachment points and connectors are also defined as antifall equipment and must be certified controlled inspected and labelled accordingly Riding belts must be connected to guide lines and blocks and stored so as to protect them from wear and tear damage from external factors It must be possible to use the equipment for the safe performance entry and evacuation operations The equipment must be checked every 6 months by a competent person and shall be marked with the next inspection date Reliable Securing 33 Example only 34 Reliable Securing There is a significant risk of dropped objects when using tools at height and a large number of such incidents are reported Functional recommendation Alltools used at height must be
9. www boltnorge no BONDURA has a unique design which uses expanding taper sleeves at both ends of the bolt to eliminate play The bolt also prevents play from re occurring Standard screws are used to push in the bolt tapers and the bolt is fixed directly to the machine component using locking screws This prevents the bolt from coming loose falling out or turning in the hole The bolt can be retightened as the equipment is exposed to wear Areas of use Clevis bolts Dolly top drive pipe rack cranes and other pipe handling equipment DROPS Reliable Securing 17 Palnut lock nuts Safety wiring DROPS Palnut lock nuts have been on the market for several decades as an alternative to locking of bolted connections Palnut locks by cutting itself into the threads on the bolt when it is tightened In the offshore context they are normally used for locking over standard nuts Areas of use Used on through bolts on fixed immobile equipment and on mobile pipe handling and drill handling equipment Safety wiring of bolts is a locking method adopted from the aviation industry In brief the method involves threading a wire through a hole in the bolt to lock it against being rotated loose The wire is twisted before being threaded and is locked to the next bolt The wire can be used to lock a maximum of three bolts as shown in the illustration Areas of use Used extensively for locking external bolted connections on dri
10. ceability at least in the form of batch marking The chain or securing wire must be as short as possible and fastened as tightly as possible over the object to be secured This will minimise the length of fall and thereby also the fall energy Securing devices must be installed maintained and inspected in accordance with the information provided in the user manual or instructions Reliable Securing 27 7 2777777 A A DIR DIL 21124 gt S PITA Minimum number of Wire rope y wire clamps 28 Reliable Securing Corrosion and incorrect installation of wire clamps are challenges in the industry Wire clamps must be of the correct number and sized to the dimension of the wire It is a requirement that wire clamps are assembled inspected and maintained in accordance with the manufacturer s user manual maintenance instructions Note Wire clamps of the U bolt type must not be used in connection with lifting operations JPS Reliable Securing 29 30 Reliable Securing Training is mandatory for all personnel using fall arrest equipment Anyone using personal protective equipment against falls from heights must have documented training The training must also cover rescue methods Nobody shall work alone or unattended when using fall arrest equipment The necessary rescue equipment must always be available at the work place Established control procedures must be followed before during and after
11. ct the DROPS Administration Team DROPS Campaign Team Silverdot Limited Banchory Business Centre Burn Road Banchory Aberdeenshire UK AB31 5ZU e admin dropsonline org t 44 0 1330 826510 f 44 0 1330 820670 w www dropsonline org CHOOSE YOUR FUTURE MAKE A DIFFERENCE
12. ers of more than 9m must incorporate a landing platform every 6m or be equipped with a fixed anti fall device Safety cages must be installed on ladders of more than 3m The safety cage must start at a maximum of 2 2m above the deck floor Try to minimise the distance between the upper part of the railing and the lower part of the cage The safety cage must continue to a minimum of 1 1m above the top level The diameter of the safety cage must be at least 70 80cm Ladders and safety cages must be inspected on a regular basis Any damage and deformation must be reported and corrected as soon as possible Reliable Securing 53 Floodlights DROPS Many floodlights installed at height are not adequately secured against falling or colliding with mobile equipment Floodlights must be positioned to avoid collision with loads or equipment Floodlights must be equipped with two independent barriers The attachment points must be integrated eg eye bolts threaded into the floodlight housing Brackets must be fitted with secondary retention Hatches for exchanging light bulbs must be hinged or secured with wire to the floodlight housing Calculations must be available for attachment points and securing devices relating to the relevant fall energies User manuals instructions must provide guidelines for the correct mounting of securing devices User manuals instructions must also provide guidelines for neces
13. h it was delivered ie it is not permitted to use it for suspending wires An umbilical roller sheave must have its own maintenance programme and be subjected to annual testing and inspection in accordance with the manufacturer s instructions User manuals instructions must provide guidelines for the correct mounting of securing devices User manuals instructions must also provide guidelines for necessary maintenance and inspection of securing devices Reliable Securing 85 86 Reliable Securing Securing hanging hoses in particular jet water hoses presents a safety problem Use of clips and chains has proven unsatisfactory With their many parts the clips themselves constitute a dropped object risk Incorrect positioning of clips and chain loops that are too long have resulted in breakage bursting and hoses falling The securing system for hoses must be designed to support the maximum loads generated by a burst hosepipe The calculation basis must be documented Safety chains must be as short as possible and installed as close to vertical as practicable The required resistance to chemicals heat and UV radiation must also be documented The securing system for hoses must be certified and traceable The user manual instructions must also provide detailed guidelines for correct installation of the hose securing system It must be possible for the facility s own personnel to carry out the installation The
14. have two independent barriers Where possible the attachment point for the safety wire should be an integrated part of the camera casing welded attachment point or eyebolts fastened to end pieces Alternatively special clasps can be fitted round the camera casing The safety wire must run from the camera casing through the bracket that is holding the camera and then through the attachment bracket before being attached securely to the structure of the crane boom Calculations must have been made and be available for attachment points and securing devices relating to the relevant fall energies User manuals instructions must provide guidelines for thecorrect mounting of securing devices User manuals instructions must also provide guidelines for necessary maintenance and inspection of securing devices Reliable Securing 65 66 Reliable Securing There have been several cases where we have discovered loose screw connections between loudspeakers and attachment braces brackets Loudspeakers must be fastened to the brackets in a manner that permits adequate locking of attachment bolts Loudspeakers must be placed where they are not at risk of being hit by mobile equipment If there is a risk of being hit by mobile equipment loudspeakers must either be protected by reinforced braces or equipped with a safety wire Calculations must have been made and be available for attachment points and securing devices relating t
15. he forklift pockets or on top of the carriers or loads Documentation must be checked out signed before transport to and from locations Reliable Securing 89 Safe use of shackles Limitations Load direction on a shackle WLL 100 WLL 70 Load on shackle bolt WLL x factor Lifting capacity Illustration for shackles gt WLL 8 5 t on small shackles the load must be distributed across the whole bolt example if a load of WLL 10 5 t is distributed across only 40 per cent of the shackle bolt s length WLL is reduced to 10 5 x 0 8 8 4 t 90 Reliable Securing Shackles must be certified and approved ie marked with the designated colour code of the year preferably by using coloured tie wraps Shackles must be equipped with two barriers nut and cotter pin Shackles must only be used for their intended purpose and manner The user must be familiar with the applicable limitations and guidelines for use Shackles are designed to support the load at the bottom of the hollow torus and evenly across the shackle bolt If shackles are exposed to loads in other places this must be taken into account during use as it will reduce capacity Point loads on the shackle bolt should be kept to a minimum as it will reduce capacity On shackles with a capacity of more than 8 5 t or with large openings the reduction factor shown at the bottom of the figure may be used to prevent deformation of the shackle bolt Rel
16. iable Securing 91 mn m m eA lt Reliable Securing 92 The design of racks for storage of material and equipment is often not appropriate to ensure safe storage Ensure that temporary storage in modules is permitted in a controlled manner with respect to type of goods duration storage area and house keeping Storage must not obstruct accessibility or evacuation of the module Ensure that the stored materials do not obstruct access to emergency equipment Storage racks and storage areas must be designed to ensure that equipment cannot accidentally drop to lower levels The heaviest equipment should be stored lowest On mobile units temporary storage space racks must be seafastened and shelves shall be equipped with baffle plates Reliable Securing 93 Unnecessary equipment at height all DROPS Inspections have revealed the frequent presence at height of equipment that is not in use In view of the fact that equipment that is not in use is often excluded from established inspection and maintenance procedures this involves a considerable risk potential Regular analyses must be made of what equipment is needed Equipment that is not in use must be removed Analyses must also be carried out to establish whether equipment should be moved to reduce the risk of collision with mobile equipment Inspection and maintenance procedures must be revised regularly This sh
17. icted areas eg derrick flareboom and cranes tools used at height must be logged in and out Reliable Securing 37 Examples only 38 Reliable Securing Numerous reported incidents relate to fallen radios pagers gas detectors and other portable equipment Functional recommendations All portable equipment used at height must be secured against falling Carrying pouches must always be used for radios and any other portable equipment with no dedicated attachment point The locks on the pouches must have a double securing mechanism to guard against unintentional opening Belt clips which allow the radio to become detached when turned 180 must not be used Belts with snap fasteners are not recommended DROPS Reliable Securing 39 Tool cabinets for work at height are now readily available and employed on many facilities Unfortunately a number of irregularities have been observed regarding securing control and registration of tools All tools stored in high cabinets must be adequately secured for use at height and they must have documented attachment points In addition to the necessary tools cabinets must be equipped with a sufficient number of correctly dimensioned safety wires with approved swage locks a sufficient number of connectors snap hooks with locking special belts for fastening tools and bag weak links for the fastening between the belt and safety wire a sufficient number of too
18. ing must have a toe board and must be covered to the greatest extent possible Canvas or a cladding material can be used This is especially important in areas where there is equipment requiring periodic maintenance JPS Reliable Securing 45 ts z a MR Reliable Securing 46 Major defects have been observed with railings in particular collapsible and movable railings Railings must be 1100mm high as a minimum and have integrated toe boards that are 100mm high Railings must have no deformations or cracks It must always be possible to insert movable railings into the fastening and insert a securing through bolt The safety bolt must be adequately locked using a securing pin or snap hook with grommet Both the safety bolt and locking must be secured in the immediate vicinity of the attachment All connections between elements in the railing must be secured with through bolts and lock nuts Use of setscrews is not acceptable in permanent joints between railings Railings and attachment points for collapsible and movable railings must be inspected on a regular basis to maintain adequate securing and functionality Reliable Securing 47 DROPS Missing and incorrectly installed toe boards are regularly Observed Often the gap between the toe board and the deck exceeds requirements Decks gangways and platforms must have toe boards at least 100mm high On sta
19. irways every step must have a toeboard at least 50mm high All landings in stairways must have toe boards at least 100mm high The gap between the deck or grating and toe board must not exceed 10mm When removing railings temporarily the checklist must include reinstallation of toe boards in accordance with the applicable rules and regulations Reliable Securing 49 50 Reliable Securing Many swing gates have been found to have hinges with neither the necessary quality of material nor the design strength to serve their intended function over time Many older gates also lack integrated toe boards Wherever possible the hinges must form an integral part of the gate ie they should be welded on Gates must open swing inwards to the platform or deck Gates must be at the same strength as surrounding railings Gates must be secured against becoming disengaged Gates must be designed to automatically return to and remain in the closed position On floating rigs the use of locking fingers should be considered so that the gate can be locked in the closed position Toe boards must be integrated in gates Swing gates must be inspected and maintained on a regular basis to ensure adequate function Reliable Securing 51 Many cases have been found of damage to ladders and safety cages as a result of collisions with mobile equipment In addition cracks have been found in safety cages especially in derricks Ladd
20. l bags with internal fastening devices Each cabinet must have a list of contents and be kept locked and one person must be designated as responsible for the cabinet The responsible person must register all tools taken from and returned to the cabinet The contents of the cabinet and the log shall be checked at the end of every shift Reliable Securing 41 At present there are a number of different ways of fastening grating to underlying structures or frames As a result of vibration and defective locking of fastenings there are numerous incidents or loose grating or loose missing fastening clips Grating must be adequately fixed to underlying structures with fastenings that do not loosen with vibration or loads Through bolts or threaded connections are recommended for fastening Fastening clips must consist of as few parts as possible Openings in the grating must not exceed 20mm If grating is cut out and reinstalled by welding the contact surfaces must be cleaned and or polished to remove galvanisation and to ensure clean steel surfaces and adequate adhesion If large areas are cut away a special frame must be installed and the necessary underlay calculated Reliable Securing 43 44 Reliable Securing Throughout the industry we have identified significant short comings in piping equipment feed throughs often where hole covers are missing All piping and equipment feedthroughs in decks and grat
21. ll and pipe handling equipment used in particular where there are no through bolts and or there is a need for simple visual control of the locking DROPS Reliable Securing 19 Nylock lock nut All metal lock nut All metal lock nut 4 Tab washer Tab plate 20 Reliable Securing Nylock L Nylock lock nuts are used extensively in the industry This type of nut is approved for dimensions up to and including 10mm Standard Din 985 nylock nuts have a temperature rating from 70 C to 120 C All metal lock nuts are recommended for use on all bolt dimensions This type of through the threaded section or top of the nut being deformed the top of the nut being split or the nut having a toothed ring under the collar This provides greater friction between the bolt underlay and nut providing a secure connection There are many varieties and suppliers on the market These nuts have an almost unlimited area of use Tab washers can be used on all dimensions and in any place designed for the use of tab washers There are several types with different areas of use for locking either nuts or bolts It is important to use the right type for each purpose Tab plates can be used on all dimensions They are used typically on machinery where it is important to prevent the bolt from rotating Correct use of lock pins DROPS Pins used in shackles are often of a non approved type which ca
22. n have serious consequences if they are knocked out of place When hoisting persons and loads you must always use shackles with double locking eg nut split pin or screwed connection with split pin Split pins such as tractor pins or hairpins must not be used For static loads you must always use shackles with double locking as described above Split pins should preferably be made of non corrosive material Approved securing pins as described above must be inspected regularly and replaced when they no longer function as intended JPS Reliable Securing 23 Before use of grade 80 eye bolts see designated lifting table Q9 El Stated WLL Right Wrong Figure showing correctly and incorrectly installed eye bolts note only grade 80 or better eye bolts shall be used offshore 24 Reliable Securing Eye bolts eye nuts must be certified and approved i e marked with the designated colour code of the year preferably by using coloured tie wraps Eye bolts nuts must only be used for their intended purpose and manner The user must be familiar with the applicable limitations and guidelines for use Eye bolts nuts for use offshore shall be at least grade 80 Eye bolts nuts for use onshore should be at least grade 80 Grade 80 eye bolts nuts are labelled with the permitted load in the least advantageous direction ie 90 degrees on the fastening bolt Eye bolts nuts must be adequately tightened prio
23. o the relevant fall energies User manuals instructions must provide guidelines for the correct mounting of securing devices User manuals instructions must also provide guidelines for necessary maintenance and inspection of securing devices Reliable Securing 67 Junction boxes and cabinets DROPS Several risk factors have been discovered relating to the incorrect location of junction boxes and cabinets to defective suspension fastening and to inadequate securing of hatches doors and covers Junction boxes and cabinets must be located where they do not obstruct passage ways evacuation routes or mobile equipment The type and design of suspension fastening must take account of calculated loads and known potential external stress factors Hinged hatches doors must be secured against unintentional disengagement and the locking device must have two barriers against opening Large detachable hatches on machinery at height and inspection hatches must be secured by a wire chain Covers must be secured by screws that are secured locked to prevent unscrewing or by the cover being secured with an internal wire or chain The securing device must be designed to support the relevant loads Reliable Securing 69 Cable ducts DROPS Many instances have been discovered of loose nuts and bolts in the joints and fastenings of cable ducts electro steel probably as a result of vibration and or fault
24. ould ensure inspections and maintenance of remaining equipment A final check must be made to ensure that no equipment materials are forgotten aloft IPS Reliable Securing 95 The potential for dropped objects during repair and installation work at height is severe and is reflected in a significant proportion of reported incidents All repair and maintenance work at height must be risk assessed All parts equipment and material used at height must be secured against falling Small parts must be stored in suitable storage containers or similar In restricted areas eg the derrick flare boom and cranes tools used at height must be logged out and in to ensure that nothing is left behind When the work is complete a final check must be carried out to ensure that no material or equipment has been left at height Reliable Securing 97 Final check of the worksite DROPS Always keep your work site tidy Tools equipment and material must be secured in a safe location at the end of each shift When the work is finished a final check and inventory count must be carried out to ensure that no tools equipment or material is left behind at height The worksite must be left in a tidy and clean state and all tools equipment and material must be returned to their designated storage place Reliable Securing 99 DROPPED OBJECTS PREVENTION SCHEME In order to identify Potential Dropped Objects it is impo
25. pproved for work at height including the appropriate lanyards and toolbags and always log tools in and out on the tool register Set up barriers beneath the work area and ensure the extent of the barriered zone is appropriate to the work height Check that grating is secure and use mats where there is the potential for small items to fall through grating Where a scaffolding platform is employed ensure toeboards are installed Remain vigilant of other activities going on around you and below you 104 DROPS Reliable Securing When the task involves loading or lifting Ensure the lifting equipment carrier or packaging is appropriate for the task and in good order Ensure containerised loads are properly stacked stored and secured Check tubulars for items left inside and employ cap ends where practicable Check tops of containers and fork lift pockets for loose items and debris When work is complete clear all scrap debris and loose items from the worksite and return all tools before removing barriers DROPS Reliable Securing 105 106 DROPS Reliable Securing DROPS Reliable Securing 107 108 DROPS Reliable Securing We thank StatoilHydro for their kind assistance in the publication of this document ROPPED OBJECTS HARM AND DO KILL For further information or details of any DROPS product including DROPS Membership DROPS Training and DROPS Workpacks visit our website or conta
26. r securing devices Reliable Securing 61 62 Reliable Securing CCTV camera location must be evaluated to prevent risk of contact with moving equipment loads Where there is danger of the camera being struck by mobile equipment loads it must either be protected by a reinforced cage or be fitted with safety wire to structure The camera should be fitted with two independent barriers on the camera casing the motorized pan tilt zoom unit the wiper motor and the lens cover The camera casing and motorized pan tilt zoom unit should be attached to the bracket and structure with adequately locked attachment bolts The attachment point for the securing devices should be integrated into the camera parts Alternatively special clamps can be used as attachment points Calculations must be available for attachment points and securing devices related to the relevant fall energies For new installations or when installing securing devices on existing equipment a user manual maintenance instructions should be available The instructions should also cover securing devices Reliable Securing 63 64 Reliable Securing There have been several cases where a crane camera has been hit by the crane during lifting operations Since bolts through the attachment bracket would be unable to withstand the forces generated by a collision of this kind it is vital to equip crane cameras with two anti fall barriers Crane cameras must
27. r to use Manufacturer installed eye bolts nuts are normally appropriate for use during installation removal of the units they are installed on eg gear boxes pumps motors and valves Eye bolts nuts must be removed after use and the threads in the equipment on which they have been used must be preserved eg by grease and a plastic plug Reliable Securing 25 Wherever possible equipment installed at height shall have integrated secondary retention Where this is not possible or where such equipment is exposed to a risk of collision the equipment must have secondary retention in the form of wires or chains and connectors that are securely attached to the structure 26 Reliable Securing Securing devices must be designed and dimensioned in accordance with the equipment supplier s calculations Wires must be locked in accordance with the manufacturer s instructions Only acid proof securing wire shall be used Wires must be locked with double press locks The locks must be made of copper and the minimum distance between the locks must be approximately equal to the length of a fully crimped lock All connectors snap hooks must be made of acid proof steel and be equipped with locks Snap hooks attached to shackles should have eyelets Chain must be made of acid proof or galvanized steel Shackles for use with securing devices should have rotating bolt with nut and cotter pin marked with CE WLL and tra
28. rolyte damp film or seawater fresh water When this happens the less noble metal becomes the anode and the more noble metal the cathode If a steel screw is fixed into a copper plate the screw will be the anode since copper is the nobler metal The screw will rust rapidly as the difference in potential is great Steel screw Current x Copper If the same steel screw is fixed into a less noble plate eg a zinc plate the screw will be the cathode and will not rust The zinc plate will corrode as it is less noble than the screw Steel screw Current I Less noble plate JROPS Reliable Securing 11 12 Reliable Securing At present bolts are being produced to 85 different industrial standards and the requirements for bolted connections vary for the different sectors depending on the given design operational and maintenance requirements Achieving a stable bolted connection will therefore require a qualified evaluation of the following factors Load design Choice of materials with a view to mechanical properties and corrosion resistance Where appropriate use of lubricant Pre tensioning and use of the correct torque equipment Need for locking bolts to secure against loss of torque pre tension secondary retention 85 of all damage to bolts etc is due to fatigue This is primarily a result of Dynamic load with inadequate pre tensioning Overload resulting in reduced pre tensioning
29. rtant to be trained in observation techniques The training must include methods for reliable securing of equipment When undertaking a DROPS inspection or sweep Allow ample time Limit the size of the area Concentrate on a small number of categories and inspect in a structured way to maintain an overview Limit the number of personnel in each area to keep an overview Findings not conforming to an established standard or checklist should be photographed given an accurate description and site reference Inspection identification and categorisation of findings are the first steps in minimising the potential for dropped objects Follow up and correction of findings are decisive factors in preventing dropped objects Reliable Securing 101 DROPS DROPPED OBJECTS PREVENTION SCHEME Before you start any task consider the potential for dropped objects Even if your task is not at height consider the environment where you will perform the task and any other activities that may be going on around you Before work commences visually inspect the work area for loose items and debris Check the equipment and structures in the work area to ensure that any fasteners bolting covers etc are properly secured Checkthat secondary retention is in place for all items secured above the work area eg lighting PA equipment etc DROPS Reliable Securing 103 When working at height Use only tools and equipment a
30. s chains and connectors 26 Correct installation of wire clamps 28 Securing of personnel 30 Derrick evacuation equipment 32 Securing of tools in use 34 Grating 42 Piping and equipment feedthroughs 44 Railings 46 Toe boards 48 Swing gates 50 Ladders 52 Floodlights 54 Light fittings 56 Navigation lights 58 2 DROPS Reliable Securing CCTV cameras integrated solutions 60 CCTV cameras non integrated solutions 62 Crane boom camera 64 Loudspeakers 66 Junction boxes and cabinets 68 Cable ducts 70 Wind walls 72 Signs 74 Valve wheels and valve handles 76 Locks on insulation cladding 78 Temporary permanent storage of gas cylinders 80 Snatch blocks 82 Umbilical roller sheaves 84 Hanging hoses 86 Load carriers 88 Correct use of shackles 90 Racks and storage 92 Unnecessary equipment at height 94 Securing of parts equipment and material 96 Final check of the worksite 98 Observation techniques 100 Pre job considerations 102 Reliable Securing 3 This document is intended to help eliminate the risk of dropped objects It applies both to equipment that we are going to procure and to equipment already in use on our own and hired installations In many cases the functional recommendations that are stipulated for the equipment in this document will set a new standard for our activities We recognise that it may be impractical to adhere to all the recommendations but the booklet sets a standard we must aspire to Also the handbook i
31. s a guide only it does not supersede the requirements of existing legislation and or corporate standards The definition of barriers that will prevent objects falling has been an important goal and these can be used in the procurement use and maintenance of equipment for work at height When procuring new equipment we should endeavour to use integrated barriers In order to minimise the danger of collision we should always evaluate the risk associated with the chosen location of equipment Equipment must be designed to povide the safest possible access for maintenance and inspection The functional recommendations set out in this handbook should be complied with through the full value chain By mere compliance with these recommendations you will help achieve the goal of zero dropped objects Who is responsible Everyone in the value chain 4 DROPS Reliable Securing PIV 1514 ssen a 001 peddouq Reliable Securing The DROPS Calculator shown opposite provides common benchmark in the classification of the potential consequences of a dropped object One of a number of similar tools the DROPS Calculator is endorsed by the DROPS Workgroup and recognised by the majority of Operators and Contractors in the global oil and gas sector While other calculators exist they all follow the same principle plotting the mass of a dropped object against
32. sary maintenance and inspection of securing devices Reliable Securing 55 Light fittings DROPS Several types of light fittings found on our facilities are inadequately secured against falling There have been several serious incidents in which both the cover and the casing of the fixture have worked loose and fallen The attachment brackets at both ends of the fixture must have secondary retention If the electricity is fed in at both ends the earth wire must be fastened so it can act as a second barrier If the electricity enters at one end only the opposite end must have secondary retention The cover must have fixed hinges and it must be possible to move these to the opposite side The component rail must be hinged and must allow for adequate securing in the closed position Emergency lights must be equipped with battery units with their own safety wires or secondary securing Calculations must be made for attachment points and securing devices relating to the relevant fall energies User manuals instructions must provide guidelines for the correct mounting of securing devices User manuals instructions must also provide guidelines for necessary maintenance and inspection of securing devices Reliable Securing 57 Reliable Securing 58 Several types of navigation light used on our facilities are inadequately secured against falling The bolts used for mounting brackets to structures must have
33. t be adequately secured against falling If Seeger rings are used for locking securing frequent inspections must be made to check for corrosion and or mechanical damage Reliable Securing 77 Locks on insulation cladding DROPS There have been many instances within the industry where pieces of insulation cladding have dropped from height due to vibration corrosion or strong winds Insulation cladding must be securely fastened to prevent locks from loosening unintentionally The locks should be secured with secondary retention either by using a bolt and lock nut or by inserting a stainless cotter pin through the securing holes in the locks or similar Maintenance routines must include inspection of the cladding to ensure that it is in good condition JPS Reliable Securing 79 Temporary permanent storage of gas cylinders Temporary storage secured with chain DROPS Gas cylinders temporarily stored are often poorly secured with rope or cargo straps Storing of gas cylinders must not obstruct passageways or escape routes Gas cylinders must be stored and secured safely Storing of gas cylinders must be risk assessed Temporarily stored gas cylinders must secured with a chain Permanent storage racks must be equipped with securing brackets chains JPS Reliable Securing 81 lock j set screw is installed 5 9 O through the nut and into the stem gt Fi
34. tronger corner mountings secured by through bolts and lock nuts The manufacturer must provide guidelines for installation necessary maintenance and inspection of wind wall panels and attachment Reliable Securing 73 74 Reliable Securing Methods for attaching and hanging up signs have in many cases proved unsatisfactory Ideally signage should be painted directly upon structure Where this is not possible Signs must be securely attached so as to ensure that they do not accidentally come loose and fall down Brackets and frames for signs must always be securely attached Where the underlying material permits sign frames should be attached using through bolts Identification labels that are painted or stuck on are recommended for identification of pipe systems If the temperature precludes this identification labels should be attached with steel tape Reliable Securing 75 Many cases have been discovered where valve wheels and valve handles for manual stop valves are not adequately secured Valve wheels and handles must have two independent barriers Where possible nuts and split pins should be used in the valve stem on stationary valve handles and wheels On large handles and wheels bolts and lock nuts should be used instead of split pins When mobile handles and wheels are used they should be secured by a bolt or locked by a split pin through the valve stem During storage handles and wheels mus
35. y installation Only bolted connections that have been approved by the supplier of the cable support system may be used for fastening and joining Pipe clips must have an adequate screw connection for functional locking When attaching the cable support system to a structure the risk of galvanic corrosion must be assessed and insulation considered where appropriate Calculations must be available for the attachment point and necessary tightening torque The user manual instructions must also provide guidelines for correct installation both in the joints and the attachment In addition the user manual instructions must provide guidelines for necessary maintenance retightening and inspection of both electro steel and bolt and screw connections Reliable Securing 71 72 Reliable Securing Many cases of damage and loose panels have been found in wind walls This is presumably due both to faulty installation and to external factors collisions with mobile equipment and exposure to wind and weather The type and method of attachment should be chosen in accordance with the manufacturer s instructions The preferred solution is through bolts with lock nuts Wind wall panels must be fastened to a separate support structure and never to the main structure Wind wall panels must always be reinforced by horizontal steel beams in accordance with the design loads Areas that are exposed to collision risk must have s
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