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Worker Struck by Tensioning Tool
Country: THAILAND - Asia/Australasia
Location: OFFSHORE : Floating Production Storage Unit
Incident Date: 6 October 2017 Time: 11:00
Type of Activity: Maintenance, inspection, testing
Type of Injury: Struck by
A 4 yearly task to check the tension of bolts on the bearing of an FSO turrret was in progress. During moving the bolt tensioner, a part (the puller, weighing 13kg) fell between the bearing stud bolts of the inner (static) and outer (rotating) bearing races. Before it could be removed the FSO weathervaned trapping and compressing the tensioner part between the two rings of bolts. A crew member went to investigate further. As he crouched over the tensioner part it suddenly freed and struck him in the head causing serious injury. He was medevaced promplty to hospital onshore.
Figure 1: Turret working location
Figure 2: Tensioner part trapped between bearing race stud bolts
What Went Wrong?:
The risk of a tensioner part falling and becoming trapped between the stud bolts was not recognised in the Job Safety Analysis, work procedure or turret vendor documentation. Also as this risk was not recognised the crew member placed himself in the line of fire. No Stop Work Authority was applied when the task deviated from the expected work process. The design of the turret bearing races and stud bolts location allowed the tensioner part to become trapped and compressed when the FSO weathervaned.
Corrective Actions and Recommendations:
Safety Alert number: 293
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