Intense workloads and fast-paced oil and gas operations are seven times more dangerous than the average worksite.
Accidents are more likely to occur in industries with intense workloads and fast-paced operations. However, with the various equipment and materials used in petrochemical processing, oil and gas extraction, drilling and servicing operations, the risks and hazards associated with this industry can change hourly, daily, or weekly. Although the types of workplace accidents are like other industries, workers in the oil and gas industry are seven times more likely to lose their life from these accidents than an average worker.
Recognizing and controlling hazards is critical to maintaining a safe and compliant workforce. Keeping plans and procedures updated and communicating them to employees is essential for oil and gas operations. Making sure everyone aware of and mitigating hazards can make all the difference in avoiding incidents. The name of the game is anticipation.
This article explores the top three hazards of working at heights in Oil & Gas operations, provides practical options to mitigate them and covers some of the relevant OSHA regulations that are important to know.
1. Struck-By, Caught-In, Caught-Between
Three out of every five on-site fatalities in the oil and gas extraction industry occur due to struck-by/caught-in/caught-between hazards. Workers may be exposed to these hazards from various sources, such as moving vehicles or equipment, falling equipment, and high-pressure lines.
A sometimes-overlooked component of providing a safer work environment can be the simple act of preventing access to unsafe areas. Passive fall protection systems that require no special personal protective equipment or training to use, such as guardrails and self-closing gates, two simple collective restraint items that prevent falls. Other solutions to mitigate the risk of Struck-By, Caught-In, and Caught-Between hazards include a range of Professionally Engineered fall protection systems that are designed to create designated work spaces such as work platforms and passive demarcation systems such as signs and warning lines.
Relevant OSHA standards applicable to these hazards include: Eye and face protection 1910.133, Head protection 1910.135, Foot protection 1910.136, Hand protection 1910.138, Handling materials – General 1910.176, Powered industrial trucks 1910.178 App A, Crawler locomotive and truck cranes 1910.180, Slings 1910.184, Machinery and machine guarding 1910 Subpart O, General requirements for all machines 1910.212, Mechanical power-transmission apparatus 1910.219.
2. Confined Spaces
Workers often need to enter confined spaces, such as petroleum and other storage tanks, mud pits, reserve pits, and excavated areas around a wellhead. However, there are safety and health hazards associated with confined spaces, such as the ignition of flammable gases and vapors, as well as asphyxiation and exposure to hazardous chemicals. Confined spaces that contain or have the potential to contain dangerous atmospheric hazards must be classified as permit-required confined spaces, tested before entry, and continuously monitored for safety purposes.
A tripod or davit system is a simple and easy-to-use device that provides workers with a stable support base. These systems come with attachment points and can be easily set up. Self-retracting lifelines with emergency retrieval capability provide both rescue options and fall arrest protection. On the other hand, a hoist or winch can be used to raise and lower materials and personnel. It is recommended to use both devices on your tripod or davit arm system. The employer or contractor should supply fully functional fall protection gear, including ladders equipped with vertical lifelines, personal protective equipment like safety harnesses, and appropriate training on harness use and fall protection for the workers. Other confined area solutions include Temporary Davit Arms, Tank Anchors, and Pole Rescue Kits.
Relevant OSHA and national consensus standards applicable to this hazard include: Permit-required confined spaces 29 CFR 1910.146, ANSI/ASSE Z117.1 Safety Requirements for Confined Spaces, NFPA 326 Standard for Safeguarding of Tanks and Containers for Entry, Cleaning, or Repair, Relevant industry practice documents applicable to this hazard include: API 1615 Safe Entry and Cleaning of Petroleum Storage Tanks, and Planning and Managing Tank Entry from Decommissioning Through Recommissioning.
3. Slips, Trips, and Falls
When working on a vehicle’s chassis, drivetrain, and other mechanical components, workers may need to use maintenance pits. However, if these pits are not protected, they can pose a fall hazard, which can lead to serious injuries. Employers who oversee work conducted around maintenance pits have additional responsibilities to ensure their workers’ safety. Maintenance Pit overs are a reliable solution that can help prevent accidents and protect workers from harm.
Roof and Equipment Edge Protection
Permanent and temporary guardrail systems can take the complexity and cost out of roof edge protection. Integrating these systems with existing ladders, equipment, and obstructions can provide continuous durable, and compliant fall protection. When using guardrails as a form of roof edge protection, per OSHA 1910.29(b)(1), the top edge of the guardrail is positioned 42 inches above the surface that people will be walking or working on. There is a 3-inch allowance in either direction, meaning that the height can be between 39-45 inches. Additionally, the top rail must have the capacity to withstand 200 pounds of force exerted both downward and outward.
Restraint and Arrest Horizontal Lifeline Systems
Horizontal Lifeline Systems cable-based system attached to two or more anchor points on elevated work areas can be mounted in three main applications: overhead, at foot level, or waist level. The most effective designs will require no or limited detaching and reattaching to provide continuous active work restraint or active fall arrest protection. Due to their versatility Horizontal Lifeline Systems are found in various formats and configurations within oil & gas. However, they are most common to operations that require a worker to have mobility and high degree of movement, such as moving along pipe racks, over rooftops, and during loading and unloading of trailers and railcars. OSHA requires that these systems be designed, installed, and used, under the supervision of a qualified person, as part of a complete personal fall arrest system, which maintains a safety factor of at least two. ANSI requires regular inspection of these systems.
Vertical Lifeline Systems
A vertical lifeline system allows workers to move up and down the entire height of the lifeline rather than having to disconnect and find new tie-off points along the way. Some important considerations when selecting a system include whether it is portable or permanent and if its mobile or fixed. Lanyards and vertical lifelines shall have a minimum breaking strength of 5,000 pounds (22.2 kN). Except as provided in paragraph (d)(10)(ii) of section [§ 1926.502], when vertical lifelines are used, each employee shall be attached to a separate lifeline.
Relevant OSHA and national consensus standards applicable to this hazard include Walking-working surfaces 1910 Subpart D, Powered platforms, man lifts and vehicle-mounted work platforms 1910 Subpart F, ANSI/ASSE Z359.1, Safety Requirements for Personal Fall Arrest Systems, Subsystems and Components. Relevant industry practice documents applicable to this hazard include: IADC (International Association of Drilling Contractors) Working at Height, API 54 Recommended Practice for Occupational Safety for Oil and Gas Well Drilling and Servicing Operations, API 74 Recommended Practice for Occupational Safety for Onshore Oil and Gas Production Operations.
Find a Fall Protection Partner
Lighthouse Safety provides customized fall protection solutions for various industries. Our experts offer a comprehensive range of products and services, including fall prevention, rescue equipment, and personnel training, ensuring employee safety and OSHA compliance. We specialize in the petrochemical industry’s unique fall safety needs, including drilling platforms, offshore rigs, oil & gas refineries, plastic pellet manufacturing, storage tanks, and plastic distribution. Our products are designed and manufactured to meet the highest safety standards.
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