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Pipeline Construction In Pursuit Of The Zero Accident Project

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Pipeline Construction - In Pursuit of the Zero Accident Project

Pipeline Construction - In Pursuit of the Zero Accident Project

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  • A good presentation , but I do believe operators of the new hydraulic machines should become tractor drivers first. ( anyone can make them go up and down .)
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  • Very instructive and clear examples.
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  • 1. Pipeline Construction In pursuit of the “zero accident” projectproject Mainline pipeline construction is an industry that requires specialized solutions to the effective implementation of a Health and Safety Management System. If a Risky g y Management Plan is to be effective, it is essential that it be simple, streamlined, and reinforced with pipeline & right of way specific solutions that incorporate historic lessonsway-specific solutions that incorporate historic lessons learned and address the unique nature of the workforce and the fast paced work methodology. http://www.pipe-line-safety.com
  • 2. Rearranging tons of earth; securing working equipment while performing heavy lifts on extreme slopes; moving and working heavy equipment on unstable ground; blasting ROW and then rock ditch; diverting rivers; lifting and moving tons of materiel over every type of terraina d o g to s o ate e o e e e y type o te a imaginable, are daunting tasks. Pulling it off without accidents and losses is aPulling it off without accidents and losses is a formidable challenge http://www.pipe-line-safety.com
  • 3. Much of the equipment used on a pipeline ROW during mainline construction is unique to the Pipeline industryq p y http://www.pipe-line-safety.com
  • 4. Each piece of equipment has it’s own characteristics, history of accidents and inherent hazards http://www.pipe-line-safety.com
  • 5. Pipeliners are faced with extreme slopes and rugged terrain http://www.pipe-line-safety.com
  • 6. Imagine arriving on the ROW for the first time, amid the fast paced and seemingly chaotic activity, of equipment and people afoot, all in constant motion.people afoot, all in constant motion. How do you identify an unsafe act, practice or condition, if you are unfamiliar with the equipment, it’s limitations and the work methodology?t e o et odo ogy Where will the Caught Between, Struck by, Struck Against…injuries occur next? It can be a little overwhelming. Your first concern will probably be locating a safe place from which to observe the action and where you won’t be in the way. Ind str specific ha ard recognition training is essentialIndustry specific hazard recognition training is essential. http://www.pipe-line-safety.com
  • 7. The degree of success or failure of your HSSEThe degree of success or failure of your HSSE Management System (MS) is measured by the number of incidents and accidents occurring on your project. http://www.pipe-line-safety.com
  • 8. The work is hazardous strenuoushazardous, strenuous, and very fast-paced. It is undertaken at remote worksites, withremote worksites, with limited access making it difficult to monitor to control http://www.pipe-line-safety.com
  • 9. All pipeline projects attract a percentage of itinerant professionals who are accustomed to being well paid forp g p their knowledge and skills… http://www.pipe-line-safety.com
  • 10. …who have their own culture, are uniquely independent, and fiercely reluctant to changing long established worky g g g habits http://www.pipe-line-safety.com
  • 11. The workforce and supervisors may speak different languages and be from different ethnic and religiouslanguages and be from different ethnic and religious backgrounds, intelligent, but largely uneducated, often illiterate and intimidated by paper work. http://www pipe-line-safety comhttp://www.pipe line safety.com
  • 12. Many of the workers are new to and unfamiliar with the equipment and work processes and require ongoing specialized training. As the ROW enters new areas under changing labor organization or political influence, the previously trained and nowinfluence, the previously trained and now competent workforce, will have to be let go and a new group will replace them, requiring repeated re-training http://www.pipe-line-safety.com
  • 13. • Working very long hours, seven days a week, frequently well into the hours of darkness is afrequently well into the hours of darkness is a universal practice within the industry. The risks from all these hazards are compounded, as time progresses, by an increasing fatigue factor. • Each morning and often several times a day, renewed risk assessments must be made. This requires experienced and competent supervisorssupervisors. http://www.pipe-line-safety.com
  • 14. Inexperienced workers are exposed to a constantly changing menu of life threatening hazards as thechanging menu of life threatening hazards as the work progresses along the pipeline corridor and the worksite ground conditions underfoot continuously change… http://www.pipe-line-safety.com
  • 15. … bedrock, shot rock, boulders, sand, swamp, permafrost, extreme slopes side-slopeextreme slopes, side slope… …all present differing and unique hazards during the operation of heavy equipment, the use of side booms and cranes for lifting operations and the handling of materielcranes for lifting operations, and the handling of materiel http://www.pipe-line-safety.com
  • 16. …and what about the complexity of managing a fleet of vehicles logging approximately 800,000 miles a month ingg g pp y , arguably the most rugged, extreme off-road and hazardous conditions on this planet, where, at the wheel drivers are assigned whose driving experience iswheel, drivers are assigned whose driving experience is limited to driving on horizontal asphalt in an urban environment http://www.pipe-line-safety.com
  • 17. Despite all these seemingly insurmountable hurdles, an accident free project is achievable. It h b d b fhas been done before. There are specific and systemic controls that have been implemented on previous pipelinebeen implemented on previous pipeline construction projects that have proven significantly effective at reducing losses, injuries and accidentsand accidents The following slides outline a few suggestionsThe following slides outline a few suggestions based on those past and proven solutions. http://www.pipe-line-safety.com
  • 18. If "Safety First" is your motto, then molding attitudes and setting an example are your priorities. The first and most important step which cannot be over-emphasized is to t bli h li f i ti b t thestablish open lines of communication between the workers and management, to encourage the worker's suggestions, and demonstrate that you are receptive to, and show respect for their suggestions To achieve thisand show respect for their suggestions. To achieve this you have to gain the worker's respect and trust. Considering the often large cultural gap separating the rank and file worker with the manager, this is a complex andg , p delicate task and probably the single most important aspect of your HSSE Management System. Once your workers start talking to you, you are on your way t d ti d ti i th b f id t dto a dramatic reduction in the numbers of accidents and incidents. Molding the attitudes of an entire workforce is achievable. Your yard-stick for measuring success is how frequently your workers willingly and on their ownhow frequently your workers willingly and on their own initiative speak out, without fear of reprisal, about hazards they have identified. As you start to get feedback from the seeds you planted, it can be excitingy p , g and very rewarding. http://www.pipe-line-safety.com
  • 19. Establishing open lines of communication between the workers and management will reduce lossesreduce losses Empowering the workers to speak out and take action when they see something that might cause an accident requires:g g q 1. A Client delivered, specialized HSSE behavioral training workshop for Client inspection staff and incoming Contractor upper management and site supervisors. Management participation is critical. 2 A high profile project system of rewards aimed at the individual worker2. A high profile project system of rewards, aimed at the individual worker and contractor supervisors based on the identification of specific and overlooked hazards, which if not identified could have caused an accident. It should include a) daily spot awards: caps, t-shirts, coffee cups etc. b) weekly meetings where certificates and more significant gifts areweekly meetings where certificates and more significant gifts are awarded, and c) monthly award ceremonies where special recognition of a worker’s participation is recognized by prizes of significant monetary value. 3 U il l f f l3. Unilateral enforcement of zero tolerance. Only with the worker’s cooperation, participation and constant vigilance on the ROW can a zero accident project be a realityROW can a zero accident project be a reality.
  • 20. Empowering Workers Participation by Contractor foremen/site supervisors is essential Th k ill f d id if h d if h f i l f h iThe workers will not step forward to identify hazards, if they fear reprisals from their foreman. If the Contractor Project upper management buys in, the foremen will too. Financial i ti k ll t ti t th C t tincentives work well to motivate the Contractor. Rewards aimed at an individual’s participation can be very effective. Awarding hats and mementos to the individual works better than recognizing a group and giving out TVs & VCR M t lk Si ifi t fi i l d f id tif i l k d d iVCRs. Money talks. Significant financial awards for identifying overlooked and serious hazards send a clear message to the worker of management’s commitment to Safety. http://www.pipe-line-safety.com
  • 21. Money, careers and employment are frequently on the line during the course pipeline projects. The first time you as a manager allow HSSE to take second place to schedule, the news will spread through the workforce like a wild fire Everyone is watching andthe workforce like a wild fire. Everyone is watching and talking. This is how the momentum of a carefully implemented HSSE MS can become undermined. Disillusioned workers don’t participate. Safety really is an attitude.p p y y On most projects this is a common failure http://www.pipe-line-safety.com
  • 22. Money Talksy Contractors actions are based on self interest – profiting financially from compliance with HSSE requirements is a strong and effective motivational force.a strong and effective motivational force. – Baseline mandatory HSSE requirements must be incorporated into the contract. Withh ldi t f h f– Withholding a percentage of cash from progress payments, based on results of periodic HSSE Evaluations and a Performance Monitoring System – Penalties for non completion of contract on time only increases the schedule driven nature of a project and increases the likelihood of accidents when nearing completion. http://www.pipe-line-safety.com
  • 23. Identifying and prohibiting poor practices establishing clearIdentifying and prohibiting poor practices, establishing clear standards & expectations with the Contractor will reduce losses Pipe line construction, as an industry, goes back sixty years or more. The equipment and the methodology have not changed significantlyhave not changed significantly. The same accidents reoccur on one pipeline project after another The root causes of those accidents are knownanother. The root causes of those accidents are known. Focusing on the root causes of past loss-events at the start of a project and establishing standards to eliminate thoseof a project and establishing standards to eliminate those causes will prevent re-occurrences of those loss events http://www.pipe-line-safety.com
  • 24. Lack of supervision is often the root cause of accidents Due to the multitude of isolated worksites along the hundreds of miles of right of way corridor, supervision is frequently only intermittent at many locations. Buried gas pipeline A clean-up dozer is unsupervised for 45 minutes at the start of a shift. TheA clean up dozer is unsupervised for 45 minutes at the start of a shift. The project has no clear procedure for dealing with buried utilities crossing the ROW and enforcement of standards is slack. The blade snags a gas pipeline which leads to this ► http://www.pipe-line-safety.com
  • 25. Standards for controlling power line hazards If the hazards of power lines are not strongly emphasizedIf the hazards of power lines are not strongly emphasized, procedures established and strictly enforced, accidents will occur. A supervisor was not informed about a low power line crossing the ROW up ahead. The power line project procedure lacksthe ROW up ahead. The power line project procedure lacks adequate controls and is loosely enforced. It does not require a pre-job survey of access roads to identify power line hazards, nor other controls which are necessary to manage this extremenor other controls which are necessary to manage this extreme hazard. The supervisor sends an excavator out to the shoofly for loading out…
  • 26. The operator had not been trained what to do to t li f ll i t t ith li Hstay alive following contact with a power line. He attempted to get off his tractor and was subsequently electrocutedsubsequently electrocuted http://www.pipe-line-safety.com
  • 27. SIDE BOOMS O t d Sid bOperator and Side boom mechanic competency Assurance Why is it necessary? http://www.pipe-line-safety.com
  • 28. Establishing clear controls and standards with the Contractor at the start of a project will prevent re- occurrences of these accidents. These two accidents were completely avoidable If the Client hadThese two accidents were completely avoidable. If the Client had established standards and enforced them, these accidents would not have occurred. It is very surprising how quickly a side boom can lose stabilityIt is very surprising how quickly a side boom can lose stability http://www.pipe-line-safety.com
  • 29. On constantly changing worksite ground conditions: bedrock, shot rock, boulders, sand, extreme slopes, side-, , , , p , slope… side booms perform 95% of all critical lifts on a pipeline construction project. The safe operation of a side boom in these conditions requires skilled and specializedboom in these conditions requires skilled and specialized tradesmen: Operators and mechanics, who possess a set of skills and experience very different from a crane operator d d b kh h iand dozer or backhoe mechanics. Moving heavy suspended loads, and working on unstableg y p g ground, exposes the operator and his ground support crew to a constantly changing menu of life threatening hazards. Exposure to the changing weather and long shifts sevenExposure to the changing weather, and long shifts, seven days a week, often well into the hours of darkness, further compounds these hazards by the addition of fatigue and di ll h i d ditiradically changing ground conditions http://www.pipe-line-safety.com
  • 30. Poor Practice Crowning booms at Tie-in Impossible for operator to gauge strain on load line. Load line failure is sudden an lethal http://www.pipe-line-safety.com
  • 31. Is this unsafe? Poor preparation of ROW Didn’t prepare ROW to get boomsDidn t prepare ROW to get booms close enough for the lift – relying on excavator buckets to restrain counterweights to increase lifting No Construction Road, no swamp mats power beyond Caterpillar specifications http://www.pipe-line-safety.com
  • 32. Good Practice U f tUse of swamp mats Note: poor practices are not identified in this slide http://www.pipe-line-safety.com
  • 33. Poor Practice Excavator buckets are used to increase the side boom’s lifting power beyond Caterpillar specifications Often the reason is that the Contractor has notCaterpillar specifications. Often the reason is that the Contractor has not mobilized enough side booms to perform the work safely, or the foreman is inexperienced. It is a bad habit and dangerous practice that is very common and almost universally accepted in the industryand almost universally accepted in the industry. http://www.pipe-line-safety.com
  • 34. Restraining counterweights subjects a lifting operation to the potential of sudden and catastrophic failure http://www.pipe-line-safety.com
  • 35. Poor Practice Load line two blockedblocked Boom lineBoom line tight This operator was carrying his load high and close to the Boom http://www.pipe-line-safety.com
  • 36. Poor craft training Lack of operator knowledge of Cross Steering, a light rain shower and a clay ROW How can a side boom flip upside down, crush and kill the operator when descending such a slight grade ? http://www.pipe-line-safety.com
  • 37. Poor Practice – Boom line under load should never touch the bull horns Boom Line Breaks on contact with bullload should never touch the bull horns contact with bull horns Sudden failure of boom. Boom drops onto workers at tie in. http://www.pipe-line-safety.com
  • 38. Get to know the Side Boom Tractor 95% of all lifts are performed with the side boom A very high percentage of ROW hazards are associated with it use. Newer Hydraulic “High Track” Side Boom Tractor Older conventional 500 series Side BoomTrack Side Boom Tractor series Side Boom Tractor http://www.pipe-line-safety.com
  • 39. The older conventional series side boom tractors are recognized by their rear drive sprocket andg y p “oval track” profile Loss of Engine on a steep slope = Loss of Control These tractors are equipped with a manually applied, mechanical Oval track profile y braking system supplemented by a hydraulic booster. It is common practice in the pipeline industry for side booms operators to have their brake bands backed-off, beyond Caterpillar specifications. On a steep slope, in the event of an engine failure, if the operator does not apply the brake before the engine stops or immediately afterwards, before the tractor gains momentum, the tractor’s manual brakes will not stop the tractor from taking off uncontrolled down the slope It will not stop until it comes to level ground or hits otherslope. It will not stop until it comes to level ground or hits other equipment or vehicles in it’s path. http://www.pipe-line-safety.com
  • 40. Hydraulic Series side boom tractors are recognized by their rear drive sprocket andecog ed by t e ea d e sp oc et a d “high track” profile Th lifti f th t Loss of engine on a steep The lifting power of the more recent high track hydraulic side booms, is transferred from the engine to the cable drum by way of a hydraulic pump, slope = breaks engage in “fail safe” manner y y y p p, hydraulic motor and a couple of valves. The newer high track hydraulic group are reliable though not as maneuverable as the first and do notmaneuverable as the first and do not require the same level of skill to operate. Advantages High •Require less operator training. •Almost eliminates the possibility of draw works failure (catastrophic dropping of load)High Track dropping of load) •Track brakes lock on engine failure http://www.pipe-line-safety.com
  • 41. http://www.pipe-line-safety.com Boom line brake Steering Clutches
  • 42. Standard “Double Dogging” Side Boom TractorsDouble Dogging Side Boom Tractors parked with booms up should be “double dogged” which ensures that the boom or load will not fall unintentionallyload will not fall unintentionally http://www.pipe-line-safety.com
  • 43. Standard On steep slopes ensure operators stay onp p p y their tractors If the operator bumps the levers, getting out of his seat, the load will release unless the levers are set in the locked out position. In winter, bulky clothing can catch the controls on the operator’s left side and put the tractor in gear. The operator then inadvertently steps onto the moving track The track catches andoperator then inadvertently steps onto the moving track. The track catches and sweeps his foot sideways, he stumbles and his body is either sucked under the cross bar (gear in forward) or (gear in reverse) he falls to the rear, and his tractor runs over him - this usually ends in a fatality. http://www.pipe-line-safety.com
  • 44. Standard: Equipment maintenance Preferred Practice Cross spooling damages wire rope & invites i t f ilequipment failure Poor practice http://www.pipe-line-safety.com
  • 45. Standard: Equipment maintenance If you see a boom laid down for maintenance There are two wedge socket terminals on the If you see a boom laid down for maintenance check the wedge sockets There are two wedge socket terminals on the side boom’s lifting rigging. Check the wedges in both the boom and load line wedge sockets The boom line raises and lowers the boom. A point of Side boom load line blocks with similar wedge socket terminal end failure can be at the wedge socket terminal on the top boom block similar wedge socket terminal end http://www.pipe-line-safety.com
  • 46. Maintenance Standards should never be taken for granted. Contractor management competence & integrity should not be assumed It should be verified The cable that failed was steel cored & ¾ inch. Two months ft i t ll ti it d not be assumed. It should be verified. V-shape ddl f after installation it passed an inspection. Four months after that it failed. The cable parted just inside the terminal wedge saddle of home made wedge caused failure here just inside the terminal wedge socket. Only extraordinary luck prevented a fatality in this incidentincident Wedge sockets and wedges on Caterpillar side boom tractors are machined parts and critical in the lifting rigging. http://www.pipe-line-safety.com
  • 47. Contractor maintenance assurance and assurance of competency of mechanical staff is a very important. Auditing Contractor equipment before mobilization in countryAuditing Contractor equipment before mobilization in-country will reduce accidents and incidents on your project. Caterpillar Home made wedge identified in wedge side boom load line wedge socket Short cuts in Contractor maintenance should be anticipated. Side booms should be closely looked at prior to and after mobilizationshould be closely looked at prior to and after mobilization. http://www.pipe-line-safety.com
  • 48. Standards on Steep Slopes Secure equipment on Side booms should use hard bar harnesses noslopes with proper harnesses hard bar harnesses, no attachment to belly hooks http://www.pipe-line-safety.com
  • 49. Standard - Equipment Mobilization Mobilization of equipment for operation on steep slopes with “StreetMobilization of equipment for operation on steep slopes with Street Pads” designed for operation on horizontal asphalt should be prohibited “Street Pads” – three grouser bars http://www.pipe-line-safety.com
  • 50. Standard for equipment tracks Three Grouser “street pads” full of mud Single grouser pads i t fpads – full of mud appropriate for boulder-strewn steep slopes http://www.pipe-line-safety.com
  • 51. Standard - Pipe Support Serious debilitating injuries and fatalities from poorly supported pipe joints & sections are common. This type of pipe support is unacceptable It is necessary to establish and strictly enforce a uniform standard in building skid cradles, crotches and slides http://www.pipe-line-safety.com
  • 52. The skids must be a hard wood of minimumThe skids must be a hard wood of minimum specific dimensions http://www.pipe-line-safety.com
  • 53. Poor Practice Avoid this type of construction construction  This… …becomes this http://www.pipe-line-safety.com
  • 54. The pipe sections expand/lengthen in the sun during the day and contract/shrink in the cool of the night, causing significant longitudinal movement on their skid supportssignificant longitudinal movement on their skid supports. Skid supports have to be built and spaced correctly to accommodate that movement. Improved but not optimum Practice Skid Good Practice: Skid Crib. Sand bags are not the best choice of Crotch best choice of chock http://www.pipe-line-safety.com
  • 55. Good Practice coaching may be necessaryg y y Note that the weight of the pipe section onpipe section on the top skid in the “V”… …locks the dl t thcradle together minimizing casual theft of wood by localsy http://www.pipe-line-safety.com
  • 56. Mainline sections should be crotched every 4 – 6 joints and more frequently at loose ends. Serious debilitating accidents on pipe gang caused by pipe movement due toaccidents on pipe gang caused by pipe movement due to collapsing skid supports, coming off the lose end of a section are not uncommon Note: A disgruntled local with a pocket knife can in a few minutes undermine the stability of this pipe section causing a serious hazarda serious hazard http://www.pipe-line-safety.com
  • 57. Careful planning of the length of sections and incorporation of loose ends is also important…p There are the consequences for poor practices http://www.pipe-line-safety.com
  • 58. Standards at Crossings Procedures and controls are necessary at Road d R il C i id id dand Railway Crossings to avoid accidents and protect the asphalt road surface http://www.pipe-line-safety.com
  • 59. Standards at CrossingsStandards at Crossings Lack of Adequate Controls at Railroad Crossing can Damage Rails which will Derail a Traing http://www.pipe-line-safety.com
  • 60. Rails must be protected. Specific t d d t t t il t bstandards to protect rails must be established http://www.pipe-line-safety.com
  • 61. Standards at Crossings Excavating (daylighting) pressurized pipelines Strict adherence to aStrict adherence to a detailed procedure is required for excavating f i tiliti iforeign utilities crossing our ROW. http://www.pipe-line-safety.com
  • 62. Standards for Excavations Preparation of excavations for worker entry arePreparation of excavations for worker entry are critical http://www.pipe-line-safety.com
  • 63. Standard for fencing off open excavationsStandard for fencing off open excavations http://www.pipe-line-safety.com
  • 64. Bell Hole Standard E th t th ld h t i t dit h idEnsure that the welders have an escape area cut into ditch side wall and floor of trench, in the event of lateral or vertical pipe movement. http://www.pipe-line-safety.com
  • 65. Bell Hole StandardBell Hole Standard Good side wall cut back however slope isp inadequate for safe worker entry http://www.pipe-line-safety.com
  • 66. Bell Hole StandardBell Hole Standard If the pipe moves laterally, suddenly and violently two Mainline ditch wall cut back for safety of workers workers will be crushed http://www.pipe-line-safety.com
  • 67. Bell Hole StandardBell Hole Standard Good side wall cutwall cut back but ditch slope iis inadequate http://www.pipe-line-safety.com
  • 68. Hoisting Standards Poor Practice This poor practice is very difficult to monitor and control along a pipeline corridor It results in many accidents Lifting with excavator buckets iscorridor. It results in many accidents. Lifting with excavator buckets is acceptable using buckets with certified and approved factory eyes and hooks. Control can be achieved by requiring the Contractor to identify each bucket with clear markings - weld on identification tags or numbers andbucket with clear markings weld on identification tags or numbers, and carry on each machine the bucket’s certification. The contractor site supervisor must ensure this documentation, including the lifting chart for excavator is in the cab of each excavator, for cross reference/verification by, y Client inspection staff. http://www.pipe-line-safety.com
  • 69. Good Practice Factory and weld-on eyes and hooksy y http://www.pipe-line-safety.com
  • 70. Poor Practice Potential Crush Injury – Front end set in tractorPotential Crush Injury Front end set in tractor Hooking up a Choker Belt requires positioning of workers on both sides of a pipe joint, and one worker in the Danger Zone between two joints. http://www.pipe-line-safety.com
  • 71. Workers must at all times avoid placing themselves between two joints. Crush injuries of workers between two joints are not uncommon in this industry. Potential Causes & what to look out for: Earl morning frost and the operator does not arm his break bands to• Early morning frost and the operator does not warm his break bands to remove frost/ice. The boom falls outward • If the operator doesn't latch his boom, as he picks up the load line the boom comes out. If the operator reacts to seeing his boom swing out, by latching the boom brake, the load line will jerk the closest pipe joint toward the adjacent joint crushing any worker in between. • Poor boom maintenance has already been identified with respect to this set in tractor • Operator accustomed to live draw works is put on a 583 R with• Operator accustomed to live draw works is put on a 583 R with hydraulic draw works (which has no manual brake). If he has not set the safety latches and he bumps the free-fall lever, a suspended sag will drop and flop over against the adjacent pipe jointdrop and flop over against the adjacent pipe joint. • Failure of boom line - loss of boom head pin, home made wedges etc.
  • 72. Poor PracticePoor Practice Why should workers not ride on skid sloops? Note side slope on ROW y p http://www.pipe-line-safety.com
  • 73. What is wrong with this picture?at s o g t t s p ctu e http://www.pipe-line-safety.com
  • 74. What is wrong with these pictures?What is wrong with these pictures? http://www.pipe-line-safety.com
  • 75. What are these men anticipating? What is the poor practice that created this hazard? http://www.pipe-line-safety.com
  • 76. When lowering-in a pipe string under a utility crossing or flume pipe, in a deep & unsafe excavation, how do youflume pipe, in a deep & unsafe excavation, how do you attach a sling to the leading side boom’s load line hook, without having to sending a worker into the unsafe ditch? http://www.pipe-line-safety.com
  • 77. Poor Practice Avoiding this situation requires changing habits, planning and incorporating an alternate strategy in the method statement for creek crossings.Hazard: The solution to poor planning invariably is to take a chance and put a worker atand put a worker at risk. Sometimes you get away with it and sometimes you don’t Workers in unsafe A worker just climbed under the unsafe sloughing excavation Placing workers in unsafe, sloughing ditch must be avoided. No workers should be allowed to cross the ditch on the elevated flume pipe, nor climb under the fl i t f d th h th lli i h li Th th d t t t h ld under the pipe here flume pipe to feed through the pulling winch line. The method statement should include mitigation measures to avoid such hazardous practices http://www.pipe-line-safety.com
  • 78. Common accident on the bending crew. On each ll f th b di hipull of the bending machine Safety steel toe saves foot Worker inadvertently places toes under tongueunder tongue http://www.pipe-line-safety.com
  • 79. You see an operator checking his fuel tank I thi f ?Is this safe? Common hip crush injury. Operator’s hip touches counterweight lever Counterweights creep up increasingcounterweight lever. Counterweights creep up increasing pressure on the lever which speeds up the counterweight withdrawal. Operator is crushed between the tank or ROPS d t i htand counterweight. http://www.pipe-line-safety.com
  • 80. You are a lower-in inspector observing the Contractor lower in a section over the crestContractor lower in a section over the crest of and down a steep slope A very serious accident is about to happen. Can you see what is wrong?y g http://www.pipe-line-safety.com
  • 81. What Went Wrong? http://www.pipe-line-safety.com
  • 82. Lack of operator skill, poor engineering and gaps in the steep slope method statement caused this accident http://www.pipe-line-safety.com
  • 83. It takes only a moment of inattention to roll a side boom. Side boom operator competencyboo S de boo ope ato co pete cy assurance is important on every project http://www.pipe-line-safety.com
  • 84. What Went Wrong?What Went Wrong? http://www.pipe-line-safety.com
  • 85. With schedule driven pressures of a lump sum contract, it is easy to lose control and get squeezed into a corner where the cost of backing up and starting again is perceived as too expensive and/orbacking up and starting again is perceived as too expensive and/or hazardous, and where taking a shortcut is too tempting for both Contractor and Client construction delivery managers Hazards: The solution 1. Placing workers under and on the ditch side of Hazards: to poor planning invariably is to take asuspended sections 2. Using excavator to take a chance and put a worker at risk. buckets on counterweights to increase load capability of side Sometimes you get away with it andcapability of side boom The method statement should include and sometimes you don’t Worker cleaning mud off pipe and fixing holidays in coatingThe method statement should include mitigation measures to prohibit and avoid such hazardous practices in coating http://www.pipe-line-safety.com
  • 86. Potential Accident Avoiding a crush injury against the headache rack is about sequence of h k l t l i f th lki d k i ti ti i f lifthook placement, clearing of the walking deck, communication, timing of lift and coordinated movement of tractor and truck. If side boom lifts the pipe joint prematurely, it can rock forward into the headache rack, crushing anyone in it's path.y p http://www.pipe-line-safety.com
  • 87. After Equipment has been mobilized and is in-country it may be too late and tooy y expensive to make changes Fleet of personnel carriers has been mobilized Hazard Identified : Personnel i hi h t d d This accident was identified and anticipated. There was not a long wait to see the resultingcarriers high centered, and unsuitable for steep slopes and unstable in rough terrain to see the resulting accident http://www.pipe-line-safety.com
  • 88. Poor practices and substandard Contractor equipment maintenance lead to seriousequipment maintenance lead to serious accidents http://www.pipe-line-safety.com
  • 89. Equipment Standards Full height headache racks are recommendedFull height headache racks are recommended on stringing trucks to protect the driver from sudden deceleration http://www.pipe-line-safety.com
  • 90. Equipment Standards Hoe Rock Hammers require heavy wire mesh screensHoe Rock Hammers require heavy wire mesh screens fitted, facing forward and outside of the operator’s glass window. This screen is essential to protect the operator f i b k j tilfrom airborne rock projectiles. Operators struck and injured by rock projectiles is not uncommonOperators struck and injured by rock projectiles is not uncommon http://www.pipe-line-safety.com
  • 91. Good PracticeGood Practice http://www.pipe-line-safety.com
  • 92. Equipment Standards Test heads should have a pre-fabricated grating/platformp g g p incorporated into their construction for workers to stand on when performing their work: hammering wrenches on flange bolts rigging squeeze iron and compressor hoses and duringbolts, rigging squeeze iron and compressor hoses, and during blow downs. In winter, de-watering intensifies the hazards with ice build up and slippery conditions. T t H d ith f b i t d f i h tl fTest Heads with pre-fabricated frames are inherently safer. http://www.pipe-line-safety.com
  • 93. Pipe Storage Standard Pipe joints stockpiled in parallel configuration onPipe joints stockpiled in parallel configuration on side hills , creates a potential mid-section crush injury hazard to any workers caught between th j i tthese joints At every start joint, roadROW side hill slope section setup and temporary pipe stockpile even a slight needs to be corrected during Grading Operations even a slight side hill creates a serious risk…http://www.pipe-line-safety.com
  • 94. Power line support structure Protection Steel footings of towers supporting high voltage powerSteel footings of towers supporting high voltage power lines immediately adjacent to traveled routes of project vehicles should be protected with berms or concrete b ibarriers. http://www.pipe-line-safety.com
  • 95. Power line hazard management Guard Posts and rope/buntingp g http://www.pipe-line-safety.com
  • 96. End Prep Shavings Shavings are often left overnight orShavings are often left overnight or longer, on the ground or in sacks along the ROW. Often the bigger h i d d th Poor Practice shavings are recovered and the smaller pieces left on the ground and blown by the wind intoy adjacent property. This presents a hazard to workers, the public and livestock Cuts from metallivestock. Cuts from metal shavings are frequently debilitating injuries. Use of a drop cloth and immediate removal from the ROW is recommendedrecommended Improved Practice http://www.pipe-line-safety.com
  • 97. Management of Induced Voltage Pipe joints and pipe sections which run parallel to, crossp j p p p under or lie with 500 meters of an electric power transmission line are subject to an electrostatic and electromagnetic field Alternating current is induced intoelectromagnetic field. Alternating current is induced into strung pipe and welded pipe sections, which may result in a potentially lethal hazardous condition. Procedures and specialized, trained and qualified labor are required to mitigate this hazard http://www.pipe-line-safety.com
  • 98. Good PracticeGood Practice Good ditch slope, ladder, mats to supportp pp booms, compressed gas bottles lifted in cage, laborer unhooking factory swaged wire rope sling to lift concreted section for tie insling to lift concreted section for tie in. http://www.pipe-line-safety.com
  • 99. Good Practice On Stringing the use of the Vaculift mitigatesOn Stringing, the use of the Vaculift mitigates many of the risks associated with the use of slings. All workers standing clear of dangerg g g zones. Regular Scheduled maintenance is required and critical to the safe use of this equipment. There is a maximum altitude at which this equipment can safely be dused. http://www.pipe-line-safety.com
  • 100. Good Practice – Hazard Warning SignsGood Practice Hazard Warning Signs http://www.pipe-line-safety.com
  • 101. Good PracticeGood Practice http://www.pipe-line-safety.com
  • 102. It can be done safely.It can be done safely. http://www.pipe-line-safety.com