WELDER FATALITY August 2003 The task Salvaging Operation

WELDER FATALITY August 2003 The task: Salvaging Operation. Included cutting and removal of equipment from site 1

DISCUSS WITH YOUR TEAM Who is likely to carry out a similar Task? What are the Hazards involved in such a task? What could go wrong? What type of controls are required to be in place to complete this Task Safely? 2

WHAT HAPPENED One of the vessels still intact The contractor Welder was torch cutting a purged and cleaned filter vessel from inside the skirt. This was the second of three filter vessels scheduled for salvaging. Collapsed portion of the cut vessel The Welder was pinned down between the ground and the vessel, when remaining vessel portion toppled once skirt was weakened from heat/cutting, pinning the welder down to his death Deceased 3

WHAT/HOW DID IT HAPPENED? PROCEDURE/SEQUENCE USED IN DISASSEMBLING VESSEL #2 Horizontal View of Vessel Cement # 1 # 3 Upper body of vessel is cut after dome removal Man way section is cut out in front along w/ horizontal cut on opposite side V. Media Filter Vessel # 2 Cutting Sequence # 4 Remaining vessel portion topples once skirt is weakened from heat/cutting Deceased Weight of upper tank body no longer counter-balances cement in tank 4

WHY THIS INCIDENT HAD HAPPENED? IMMEDIATE CAUSES • Work crew perceived the Job is routine • Work crew did not pre-plan the Job adequately • Failed to recognize hazards • No Job HSE analysis carried out • Work crew did not comply with the Permit to Work issued for the Job • Lack of Supervision 6

WHY DID THIS INCIDENT HAPPEN? UNDERLYING CAUSES • Involved Personnel lacked sufficient training & knowledge of the Applicable HSE standards and procedures • Contractor crew, including deceased, was not assessed as required per The Contractor HSE Management Process • Role & responsibilities were unclear and as a result supervision was Not effectively provided for the Job • The level of risk involved was underestimated, resulting in lower emphasis being placed on hazard management at work site 5

HOW CAN THIS JOB BE DONE SAFELY? • Assess contractor competency for the Job prior to commencement of operation • Evaluate critical activities to ensure HSE risks are properly managed • Pre-plan the Job and carry out Job Safety analysis • Communicate Hazard and controls required for the task to all concerned parties and adhere to Permit to Work System where applicable • Never underestimate the risks, even if the Job has been done before 7