Incident Analysis: Broken Wire Rope Strand
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Questions and Answers

What was the main cause of the accident involving the batteries?

  • The FIBCs were not designed to hold the weight of the batteries
  • The site was overstocked and batteries were stacked in an unsafe manner (correct)
  • The workers were not trained to handle the FIBCs
  • The worker was not wearing proper protective gear
  • What was the consequence of the accident?

  • The worker suffered a minor injury to his back
  • The worker was not injured at all
  • The worker suffered a minor injury to his hand
  • The worker suffered a double compound fracture to his lower right leg (correct)
  • What is a contributing factor to the accident?

  • The FIBCs were not properly secured
  • The worker was not physically fit to handle the batteries
  • The worker was distracted by his colleagues
  • The lack of specific documented risk assessments and safe systems of work (correct)
  • What was the weight of the batteries that fell on the worker?

    <p>At least 300kg</p> Signup and view all the answers

    What type of containers were the batteries stored in?

    <p>Flexible Intermediate Bulk Containers (FIBCs)</p> Signup and view all the answers

    Study Notes

    Incident: Broken Wire Rope Strand

    • A single outer wire rope strand broke, lifting a chandelier with a proximity switch into the bell main wire rope sheave, which could have prevented a safe bell lock on.
    • The root cause of the incident was a design failure, as the chandelier was a tight fit, allowing movement when a broken strand passed through.
    • A direct cause of the incident was equipment damage, as a single broken outer strand was enough to lift the chandelier into the bell main wire rope sheave.

    Actions Taken

    • The proximity sensors and chandelier were relocated to a solid suitable point on the static side of the clump weight wire rope, eliminating the risk of reoccurrence.
    • A damaged length of the bell wire rope was cut back, and a load test was performed, witnessed by the Classification Society.
    • A dive trial was conducted with an empty bell to working depth to double-check suitability and length of the bell main wire rope.
    • Individual wire testing revealed reduced ductility, causing a lack of elongation in the complete wire rope and resulting in a reduced load-bearing capacity.
    • The lack of ductility was explained by the phenomenon of strain aging, influenced by steel chemistry, manufacturing methods, time, and temperature relationships.

    Incident: Lone Worker Collapsed at Onshore Site

    • A person collapsed at a workshop facility due to a non-work-related, pre-existing medical condition and was unable to call for help.
    • The person was working alone and was not discovered until the following day, despite having a phone.
    • Following the collapse, the person was able to move into a disused office area but was not found until a colleague entered the workshop and heard a call for help.

    Lessons Learned

    • The importance of suitable arrangements to monitor and track lone workers, including security patrols/checks.
    • Ensuring robust pre-employment medical screening and health surveillance measures to identify personnel who may be classed as vulnerable.
    • Consideration of the use of fall alarms for lone workers, which can automatically alert on-call service in the event of an individual falling or collapsing.

    Actions to be Taken for Lone Working

    • Fully understand what "lone working" is and subject it to a task risk assessment that addresses foreseeable emergencies, access and egress arrangements, risk of violence, vulnerable persons, local legislative requirements, and the level of supervision required.

    Incident: Watertight Doors

    • Watertight doors that ought to have been secured shut were observed open during a safety walkaround, highlighting the importance of maintaining watertight doors.

    Incident: Worker Injured by Falling Stack of Batteries

    • A worker was severely injured after batteries weighing at least 300kg fell onto him, causing a double compound fracture, fractured bones, and other injuries.
    • The incident occurred due to overstocking, unsafe stacking, and lack of documented risk assessments or safe systems of work for the correct stacking and storage of batteries.

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    Related Documents

    IMCA Safety Flash 08/24 PDF

    Description

    This quiz analyzes an incident where a broken wire rope strand caused a chandelier to lift into the bell main wire rope sheave, potentially preventing a safe bell lock. Identify the root and direct causes of the incident.

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