1. 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
Before starting, ensure you have the correct presentation, sound with your set-up, and all necessary handouts.

2. “Working to make our industry a safer place”

3. DROPS Asia Objectives 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

4. WHAT IS A DROPPED OBJECT?“ ”
Any object that falls from its previous static position under its own weight
Open the question to all delegates and capture responses on white board. Encourage everyone to contribute a definition. Summarise the definitions, noting how they are different but that they ALL are actually correct.
Reveal >>>> formal definition and explain that this is a simplistic, all embracing definition which captures all the definitions given by the delegates.

5. HOW BAD IS THE PROBLEM?
AT WORK : “ ”
Dropped Objects are among the Top 10 causes of Fatality and Serious Injury in the Oil and Gas Industry
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
At work, accidents involving dropped objects remain in the Top 10 of all reported incidents. Concerted awareness campaigns and safety directives have seen improvements made in specific areas such as Drilling operations but these improvements have not been sustained and the overall trends in the oil and gas industry shows no improvement.
>>>>
At home and at leisure the picture is no better… Official statistics note that the top three causes of fatal accidents are always the same – year in and year out… falls from height… being struck by moving vehicles… and being struck by falling objects.
(RoSPA)

6. It’s Still Happening…Real Incidents
NIOSH 2003 – 2006 Fatalities among US Oil and Gas Workers
It’s Still Happening…Real Incidents

7. It’s Still Happening…Real Incidents

8. Over 70 companies all sharing commitment and enthusiasm for dropped object prevention.
Basic remit to consider and review all avenues available for improving the industry’s 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

9. This is what we all aim to prevent!
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!

10. Even small objects can kill!!!

11. DROPS Approach to Preventing Dropped Object Incidents
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

12. Awareness and Appreciation of DROPS
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

13. Awareness and Appreciation of DROPS

14. Awareness and Appreciation of DROPS

15. 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

16. 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

17. Survey and Inspection

18. Survey and Inspection

19. Survey and Inspection

20. 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 1
Active heave cylinder hydraulic control lines, support wires Valve block, flex hoses & accumulator bottle
180 days
Hydraulic control lines pipe clamped together and secured to Active Heave Compensator with bolted flanges. Other control lines beam clamped to gin pole structure with turnbuckles and 4 part shackles Accumulator bottle pipe and support wires clamped to framework & beam clamped to gin pole structure. Valve block secured with bolted flanges.
Check beam clamps and bolts are secure and for any signs of corrosion, check all bolted connections and hoses are in good condition. Check support wires, turnbuckles and shackles, ensure shackles are fitted with split pins. 2
Cable trays, Cable conduit pipe runs & cable clamps
Cable trays with beam clamps to derrick structure. Cables secured with stainless steel tie wraps. Other cables fed through pipe work which is beam clamped to derrick & gin pole structure.
Check cable tray/conduit runs are secure, ensure all brackets are tight and check for signs of corrosion.
Survey and Inspection

21. 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

22. Control Measures : 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

23. Static and Dynamic Dropped Object
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
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

24. Managing Static Dropped Objects
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

25. 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

26. 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

27. Managing Static Dropped Objects
Secondary Retention
Managing Static Dropped Objects

28. Managing Dynamic Dropped Object Risk
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

29. Managing Dynamic Dropped Object Risk

30. DROPS System and Procedures
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

31. DROPS Guidance: Restricted Access Areas (Red Zones)

32. 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)

33. 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 Authority’s 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)

34. DROPS Guidance: Restricted Access Areas (Red Zones)
Every effort should be made to identify and define an access route to the Area Authority’s 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)

35. 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 Authority’s authorization
DROPS Guidance: Restricted Access Areas (Red Zones)

36. Enforcement & Industry Self Regulation
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