Activity
Manual Handling
Lifting, pushing, pulling or carrying loads by human effort.
Newest 100 Documents
All 174 in search- 202628 Jul
Man overboard from the bulk carrier World Prize with the loss of 1 life
This investigation examines a bosun’s fatal fall into the sea during combination-ladder rigging on World Prize. It analyses normalised unsafe practices, ineffective supervision, permit compliance, incompatible flotation and harness equipment, and radio shortages. Pilot-boat recovery capability and training gaps are examined alongside subsequent corrective actions; no recommendations were made.
- 202618 Jun
Fall overboard from the crab potting vessel Amadeus (TH7) with the loss of 1 life
Investigation of a fatal fall overboard during manual crab-pot hauling on Amadeus in the North Sea. It examines low bulwark protection, biomechanical demands, almost certain significant fatigue, absent flotation and ineffective recovery arrangements. Findings address deficient safety management and regulatory oversight, with recommendations on fall prevention, handling assessment and work–rest monitoring.
- 202614 May
Worker suffered crush injury while handling unstable steel plates
A worker holding vertically balanced steel plates sustained hand, wrist and finger fractures when a plate toppled, trapping their hand and wrist. The flash examines temporary storage, removed sea fastenings, limited workspace and inadequate task risk assessment, highlighting how local conditions and past experience shaped the work.
- 202624 Mar
Person injured when pry bar slipped
A crew member fractured a right-hand knuckle after a pry bar slipped while refitting a dislodged vehicle track. The flash discusses circumstantial pressure from worsening weather, amendments to the job safety analysis and the possibility that impact gloves might have reduced injury severity without preventing it.
- 202612 Jan
LTI – back injury
An Able Seaman suffered a lower-back injury while lowering a crew transfer vessel’s gangway onto the quay. The flash examines lone manual handling, crane-position constraints, uncertain gangway weight and inadequate procedural risk controls. Lessons include ideally using two people when mechanical aids cannot be used, reviewing assessments and verifying gangway weights.
- 20254 Jun
Hand injuries dealing with sharp objects
Two incidents involved a cutter slicing through a glove during halyard maintenance and a damaged package rim cutting a crew member’s hand during manual adjustment. Lessons emphasise keeping hands clear of blades, using stable cutting surfaces where possible, wearing suitable protective gloves and inspecting packages for hazards.
- 202519 Mar
Finger injury during manual handling
A worker’s finger was crushed while manually manoeuvring a steel bar weighing around 100 kg during shoring disassembly at a land-based site. The bar rolled from a curved pick-ring. Lessons emphasise securing individual components against sudden movement, using appropriate lifting tools and becoming familiar with loads and equipment before starting.
- 20256 Mar
Person fell in engine room and injured head
An oiler working alone suffered head injuries after a pipe used to reposition a heavy cylinder head slipped, causing him to fall backwards from an unprotected elevated area. The flash highlights underestimated task complexity, familiarity and inadequate lever insertion, and recommends barriers, serious toolbox talks and avoiding lone working where possible.
- 202414 Aug
Arm injury from metal skip cover
A crew member suffered an arm injury when an unsecured heavy skip cover closed during waste disposal on a vessel’s deck. No bones were broken, and the person returned to light duties. The flash stresses securing covers, checking closing mechanisms and considering a hazard hunt for similar conditions onboard.
- 202414 Aug
LTI: fingers severed by spinning fan blade
A vessel worker lost three fingers while moving a portable blower during engine-room housekeeping after switching off its power. The fan remained in motion, its guard was inadequate and its handle obstructed. The flash highlights residual momentum, unseen moving parts and the importance of using designated handles and guards.
- 202416 Jul
Equipment fell on someone’s leg causing injury
A worker cleaning a bow thruster room suffered a leg injury when an unsecured auxiliary engine cooler shifted during equipment movement. Delayed treatment worsened the injury, and reporting took three days. The flash emphasises organised storage, securing loose parts, removing unusable spares, prompt reporting and immediate attention to injuries.
- 202422 May
Hand and finger injuries... Two recent incidents
This safety flash describes two hand injuries: a fractured little finger caused by movement of a moonpool door ram on a flat pallet, and a cut from a sharp-edged ceiling plate. Lessons address thorough task assessment, reassessment when work changes, stopping unsafe work and wearing protective gloves.
- 202427 Feb
Heavy equipment fell over during manual handling
A wheeled control cabinet toppled during manual handling, striking a crew member’s leg and bruising their knee. The flash identifies omitted wheeled-load risks, disregarded handling instructions and unsafe positioning. Lessons address task-specific assessments, pre-work discussion, manufacturer guidance and stopping unsafe work; the crew subsequently fabricated a handling ramp.
- 20232 Nov
Rig personnel exposed to unrecognized stored-energy hazard
During preparations to skid a jackup rig’s cantilever, an operating handle became stuck while a worker manually turned a skidding pin. Hydraulic release of some jack tension allowed the pin and handle assembly to rotate suddenly downwards, exposing the worker to a struck-by hazard from unrecognised stored energy.
- 202313 Jul
Finger injury during shackle handling
A crew member suffered a left middle finger crush injury while removing a 35 tonne SWL shackle during pennant wire spooling. The flash identifies incorrect shackle size, absent last-minute risk assessment and failure to intervene, and recommends appropriate tools rather than hands to release heavy shackles.
- 202312 Jun
MAIB: A heavy sheave fell over causing an LTI
A bosun working alone aboard a vessel suffered multiple leg fractures when a half-ton sheave toppled during manual relocation for offloading. The flash identifies unauthorised stowage, absent lift planning and underestimated handling risks, and calls for help and a clearly communicated plan before moving such loads.
- 202327 Mar
Serious LTI – Crew member slipped on deck breaking his leg
An engineer fractured his right fibula after slipping on a greasy deck while handling a bunker hose. Spiral access prevented stretcher evacuation. The flash examines surface contamination, hose drainage and absent manual handling assessment, recommending conditional hose capping, non-slip coatings, handling assessments and consideration of rescue drills for restricted-access areas.
- 202313 Mar
Finger crushed under Tether Management System (TMS) protection guard
A worker’s left ring fingertip was crushed while closing a Saab Seaeye TMS8 protection guard after losing grip. The flash discusses unsupported guards, cold hands, unsuitable gloves and incomplete task assessment. Included manufacturer advice specifies guard removal and refitting precautions, recommending two people and prohibiting work with only two securing pins.
- 202316 Feb
LTI: Finger crushed while moving mobile gantry crane
A bosun crushed his index finger while dragging a dismantled mobile gantry crane support leg when a wheel turned and the leg collapsed. The flash identifies inadequate planning, communication, supervision and risk assessment. Actions included a lighter crane with wheel locks, improved deck access and further safety training.
- 202216 Dec
Persons overboard from prawn trawler Reul A Chuain with loss of 1 life
Investigates two falls overboard from the prawn trawler Reul A Chuain in the Sound of Rùm, resulting in the skipper’s death. Examines unsecured net stowage, manual recovery in heavy weather, absent restraint arrangements, flotation device use, cold-water survival and improvised winch recovery. Identified risk controls and practical emergency drills had not been implemented.
- 202213 Dec
Near miss: pipe dropped from pipe supports
A pipe fell from temporary easels while a worker turned it during cleaning with an angle grinder and abrasive sanding wheel. No injury or damage occurred. The flash identifies inadequate supports and gaps in manual-handling risk assessment, recommending mechanical turning devices, stronger contractor oversight and verification of third-party operations.
- 202223 Nov
BSEE: A note on repetitive strain injuries
This safety flash reviews four strain-related incidents involving tool use, valve operation, battery handling and movement onto a drilling deck. It discusses excessive force, repetition, awkward posture and individual risk factors, calling for evaluation of engineering and administrative controls, ergonomics training and early recognition of musculoskeletal warning signs.
- 20223 Oct
Cook’s arm scalded while removing food from oven
A cook suffered an arm scald when condensed steam dripped from a tray lid during removal from a head-height oven. The lower oven was out of service, and the cook could not see the lid’s surface. Actions included repairs, maintenance changes, task risk assessment and procedure reviews, and replacement lids.
- 202228 Sep
Body Mechanics Lifting Techniques and Repetitive Motion Lead to Strain Injuries
This BSEE alert reviews four recent reports of strain injuries and symptoms associated with offshore tasks. It discusses excessive force, repetitive movement, awkward posture and individual risk factors. Recommendations include considering worker training, early recognition of musculoskeletal warning signs, and periodic evaluation of ergonomic measures.
- 20225 Sep
Fall leading to serious personal injury
A crew member fell while manoeuvring a drill tool alone aboard a moving vessel, sustaining concussion and soft tissue injuries. The flash identifies shortcomings in task risk assessment and work instructions, discusses slippery conditions and drill-floor layout, and records revised methods, handling equipment changes and a successful planned medical emergency response.
- 20224 May
MSF: Manual Handling Injury During Bulk Hose Operations
A crewman sprained his right calf while connecting a bulk hose aboard a vessel. Residual liquid, manifold angle and rigid hose-end fittings made handling awkward. The flash discusses reducing connections, draining hoses and proposed improvements to manifold arrangements and hose-draining procedures.
- 202228 Feb
Fractured finger while handling metal plates
A crew member fractured his little finger when it became trapped between a plate and frame during manual repositioning on deck. The flash identifies unsafe plate design and task assessments that omitted manual handling. Lessons describe temporary handles, magnetic lifting handles as a longer-term solution, and task-specific risk reviews.
- 202125 Nov
Dropped object: Dislodged flex-joint laydown tool component
An 85 kg load-ring half plate fell about 1.8 m to deck during flex-joint laydown-tool removal on a tilted J-Lay Tower. Nobody was injured. Manual removal replaced the approved crane-assisted method without risk assessment. The flash emphasises procedural compliance, management of change and stopping work when uncertain.
- 202119 Nov
MOB: Person fell into water during gangway installation
A crew member fell into the water while attempting to lift a portable gangway to free another person’s trapped foot, and was recovered without injury. The flash identifies communication failures, tiredness, insufficient staffing and absent risk assessment, recommending toolbox talks, improved bridge–deck coordination and sufficient supervised, rested crew.
- 20211 Oct
LTI: Three fingers badly cut while handling a long brass bar
A vessel crew member sustained cuts to three fingers when a brass bar slipped during solo removal from storage, forcing his hand against sharp mesh edges. The flash identifies misjudged weight, inadequate risk assessment and absent gloves, and recommends reviewing storage suitability, assessing lone working and reinforcing task-specific PPE requirements.
- 202116 Apr
Mooring: Increase in first aid cases involving over-exertion
This safety flash reports several recent over-exertion accidents, mostly during mooring and heavy-line handling. It identifies excessive loads, improper handling and awkward posture as causes. Actions include stretching before strenuous work, considering movements, inspecting dock areas, keeping lines clear and checking dock and vessel condition before manoeuvres.
- 202016 Dec
Broken finger during ROV maintenance
A short service employee fractured his right ring finger while removing an ROV bumper bar alone above head height. The bar snagged, then fell when he could not support its approximately 29 kg weight. Lessons emphasise task assessment, planning, supervision, competence, mentoring and pre-work toolbox talks.
- 20201 Dec
2020-002 GC 205-A Investigation of June 1, 2019, Fatality Lease OCS-G05911 Green Canyon Area Block 205-A
Investigates a fatal fall through a well hatch on the Genesis platform during slickline work. Workers mistakenly lifted the A-13 cover while intending to replace A-14’s cover. The report examines cover identification, securing, handling and task planning, and recommends improved procedures, practical training and designs distinguishing installed from stored covers.
- 20201 Dec
Labeling, Removing, Storing and Installing Hatch Covers
A slickline helper suffered fatal injuries after the wrong well hatch cover was lifted on a Gulf of Mexico facility, exposing an opening through which he fell approximately 90 feet. The alert recommends hatch identification, specific procedures, practical training and hazard review, and suggests mechanical handling to reduce proximity to openings.
- 20209 Oct
Crushed finger injury during wire transfer operations
A seaman sustained a crushed left index finger while removing a stopper chain during tow-wire transfer aboard a vessel. Premature removal of a crowbar allowed the wire to fall onto his hand. The flash examines routine-task complacency and unreviewed risk assessment, emphasising assessment, communication and keeping hands clear.
- 202015 Sep
Serious leg injury from falling winch sheave
A crew member suffered leg injuries when an umbilical winch sheave toppled during manual rolling across a vessel’s deck for refurbishment. The flash identifies shortcomings in planning, supervision, risk assessment and communication, and recommends stronger subcontractor coordination, permit checks and consideration of COVID-19 measures in work planning.
- 202024 Jul
LTI: Loss of fingertip and nail
A bosun lost his middle fingertip while storing turnbuckles during routine housekeeping aboard an anchored vessel. A turnbuckle slipped and its thread struck his finger in a restricted storage area. Actions included relocating storage bins and developing a procedure to eliminate manual handling of turnbuckles.
- 202015 Apr
UK HSE: Worker fell into lift shaft – safety controls bypassed
A worker moving a loaded trolley in a hangar suffered life-changing injuries after falling into a lift shaft. Although the exact cause was not established, investigators found faulty lift doors and routine bypassing of safety devices using an emergency release key. The flash highlights withdrawal from service or alternative working arrangements and communication.
- 20206 Mar
LTI: Finger injury caused while working with oil drums
A crew member fractured a right-hand ring finger when it became trapped between oil drums during handling aboard a vessel. The flash identifies delayed reporting and absent work procedures, recommends risk assessment and toolbox discussion, and describes an engineered drum-handling control implemented afterwards.
- 20209 Jan
Back Injury Caused by Lifting Slings
A deck crew member developed sharp back pain after carrying two bundled transit slings on his right shoulder for approximately 3–5 metres during preparations to transfer heavy weight drill pipe. Unable to continue walking, he was taken by the emergency response team to the sick bay on a stretcher and subsequently medically evacuated.
- 201922 Nov
Finger trapped and injured whilst moving hatch covers
An able seaman suffered a serious finger injury while securing a heavy forecastle hatch after mooring. Its awkward position required reaching or climbing, and the hazard was inadequately assessed. The flash describes withdrawing the hatch from mooring use, temporary alternative line routing, possible damping or relocation, and vessel-wide hazard hunts.
- 20193 May
Line of fire/pinch point – fractured fingers
During installation into a seabed frame, equipment slipped through hand-tightened clamps while being manually realigned, fracturing two fingers and amputating a fingertip. Lifting strops had been removed before securing was complete. The flash identifies missing task assessment, instructions and supervision, and describes a frame modification that eliminated the pinch point.
- 201814 Dec
Pipelay technician sustained cut to wrist whilst handling testing equipment
A pipelay technician suffered a wrist laceration requiring eight stitches when a released scanner belt slipped from the pipe after weld testing. The flash examines sharp edges, poor communication and exposed skin between glove and sleeve. Lessons address coordinated manual handling, routine-task hazard reviews and consideration of cut-proof arm protection.
- 20189 Nov
Injury sustained during manual handling of sharp object
A crew member suffered a leg injury while handling a mud agitator aboard a vessel heading to port. The chain-block-suspended load slipped while its blades were gripped with rags. Lessons include protecting sharp edges, using hands-off handling methods and gloves, and waiting for suitable personnel or port conditions where appropriate.
- 20188 Nov
Man overboard from creel fishing vessel North Star with loss of 1 life
Investigates a fatal drowning after a North Star crewman became entangled in the back rope during creel shooting and was dragged overboard. Examines manual and self-shooting arrangements, inadequate separation from running ropes, recovery difficulties, absent practical drills and unshared risk assessments. Records subsequent barrier installation and recommendations on training and safety management.
- 201830 Oct
Release of stored energy from coiled superloops
This safety flash describes two injuries during superloop uncoiling, with workers struck in the face as slings sprang upwards while fastenings were released. It discusses training introduced after the first incident, failure to seek a trained person's advice during the second, and revised instructions for third parties receiving coiled superloops.
- 201823 Aug
Unplanned stored pressure release: worker struck by gas cylinder – company fined
A safety flash describes a gas-cylinder replacement incident on Brent Delta. A charged cylinder released gas, was dropped and suffered valve shearing; both components became projectiles, severely injuring another technician. The HSE identified failures in cylinder handling safeguards and information provision, and fined the company.
- 20183 Aug
High potential near miss: unplanned handling of unexploded ordnance
A high-potential near miss involved recovering and handling wartime munitions during subsea debris clearance. ROV operations continued after ammunition emerged, and crew handled recovered items before specialist advice prompted their return to the seabed. The flash identifies information, identification and management failures, calling for reinforced stop-work authority, change management and revised procedures.
- 201827 Jul
Finger injury caused by falling wire wedge
During crane winch-wire replacement, a 15 kg wedge fell and trapped a crewman’s right hand against the deck, injuring two fingers. The flash identifies an absent holding point and grease-contaminated gloves, and describes an alternative technique using an upward-facing wire eye to support the wedge during tightening.
- 201822 Jun
LTI: cut to hand from protruding hose clip (Marine Safety Forum)
A crew member carrying boxes through a vessel’s galley cut his hand on a protruding hose clip. The vessel returned to port for hospital treatment, and he was declared unfit for work for seven days. The sharp edge was covered; limited awareness of the new work area’s hazards was considered likely.
- 201721 Dec
Finger injury while using a crowbar to try to shift a large shackle
A crew member injured his right ring finger when a crowbar slipped during shackle connection in anchor handling. The flash identifies inadequate pinch-point recognition and improper tool use, recommending capstans or tugger winches for repositioning and manual work only once rigging is safe and free of residual tension.
- 201721 Dec
Unplanned release of stored energy: Worker struck and injured by tensioning tool
A worker suffered serious head injuries when a trapped bolt-tensioner puller suddenly released during turret bearing checks on an FSO. Weathervaning had compressed the dropped component between stud bolts. The flash identifies unrecognised risks and recommends revised task analysis, troubleshooting procedures, stop-work reinforcement, awareness training and investigation of handling aids.
- 201715 Dec
Lost time injury – Person slipped on the stairs and broke his arm
An engine-room crew member broke his left arm after slipping on stairs while carrying lubrication oil aboard a vessel. The flash identifies slippery steps, failure to hold the handrail and inappropriate carrying technique. Lessons emphasise handrail use, correct carrying procedures and keeping stairs, floors and safety footwear free of oil and grease.
- 201712 Dec
Four hand and finger injury incidents
Four cases cover hand-arm vibration exposure, crushed fingers during manual frame handling, glove entanglement in a metalworking lathe and hand trapping in printing rollers. The flash discusses shortcomings in exposure limitation, health surveillance, manual-handling assessment, safe working methods, machinery guarding, training and supervision.
- 201715 Nov
Changes from dry gas to wet gas operation: guidance for HSE inspectors
Inspector guidance examines offshore installations converting from dry to wet gas operation. It addresses corrosion inhibition and monitoring, pipeline pigging and inspection, altered liquid flow, valve performance, detection and blowdown arrangements. It also covers maintenance, staffing, training, health hazards and management of change, including implications for onshore processing.
- 20172 Aug
LTI: Crush injury to middle and index finger
A rigger sustained serious middle and index finger injuries while manually moving a deck plate aboard a vessel. The flash identifies unmanaged expansion of cleaning work into plate removal, handling difficulties and unsuitable gloves. It highlights stopping changed work, managing the change and raising a new permit with task-specific risk analysis.
- 201713 Jul
Fall from height during yard visit
A yard worker fell 4 m while helping manually lower grating through a deck opening, fracturing his right ankle. His fall arrester was not anchored. The flash examines team organisation, language barriers, unused taglines and absent task-specific analysis, emphasising closer yard oversight and executive commitment to safety culture.
- 20172 Jun
LTI: Finger injury sustained handling heavy shackle pin
A safety flash describes a serious left index finger injury during insertion of a heavy shackle pin. It identifies routine-task complacency, unworn prescribed gloves and cramped working space, with pin design and rigging method as possible contributors. Easier arrangements reducing manual handling would be investigated.
- 20163 Nov
Man overboard from creel fishing vessel Annie T with loss of 1 life
Material accompanying the Annie T fatal man-overboard investigation addresses potting hazards, recovery arrangements and lifejacket use. It describes unused working lifejackets and an unsuccessful hauler recovery attempt. Annexed guidance examines rope separation, pot sequencing and drills, while a broader review evaluates flotation-device campaigns, casualty evidence and regulatory approaches.
- 2016Sep
Manual handling - Manual Handling Operations Regulations 1992 - Guidance on Regulations
Guidance explains duties under the Manual Handling Operations Regulations and an ergonomic approach to preventing musculoskeletal injury. It covers avoiding hazardous handling, assessing unavoidable tasks, mechanical assistance, workplace and load design, training and handling techniques. Assessment methods include initial filters, MAC, V-MAC, RAPP and ART, with limitations on their use.
- 20165 Feb
Finger injury during maintenance work – restricted work case
A seaman sustained a crushed fingertip while two workers manually replaced a 44 kg shackle on a rack, releasing it on an agreed count. The flash examines missing mechanical handling measures despite risk assessment and toolbox discussions, and stresses implementing controls, speaking up and stopping unplanned work.
- 20165 Feb
Finger injury: pinch point
A crewman injured his fingertip while lifting an escape hatch cover aboard a vessel. The handle and an upright pipe formed an unrecognised pinch point. Relocating the handle removed the hazard. Lessons address awareness during routine tasks, hazards introduced by equipment changes, safety observations and prompt corrective action.
- 201615 Jan
High potential near-miss: Dropped object
A polyurethane block fell approximately 36 metres during removal of upper tensioner castings on a vessel’s tiltable pipelay system. Nobody was nearby. The flash describes strenuous manual handling, a block landing outside safety barriers and an unshared shift-specific working method. Initial observations, subject to further investigation, identify planning, authorisation and communication shortcomings.
- 201523 Nov
Rigging incident: Damage to bow hand rail on a crew transfer vessel (CTV)
A crew transfer vessel’s bow rails were damaged while recovering a buoy and seabed clump weight beside a wind turbine monopile. Riggers secured the snagged line over the rail, unseen by the Master whose view was obstructed. The flash discusses the toolbox talk and warnings against tying snagged lines to vessels or over handrails.
- 201522 Oct
Everyday activity, unwanted outcome: Poor manual handling leads to back strain
A shore worker strained his back while removing a box containing an approximately 20 kg turbocharger from a 2 m shelf. Working alone, he had not anticipated its weight and held on as it fell to waist height. The flash highlights checking labels and storing heavy items at waist height where possible.
- 20152 Apr
Fatal incident during change-out of chain wheel (gypsy) on anchor handling tug supply (AHTS) vessel
A safety flash describes a fatal gypsy-wheel change-out aboard an AHTS vessel. After crane disconnection, rolling the wheel allowed its rim to enter a skid-rail gap, tipping it against two crew members. Findings address deficient risk management and design review; actions prohibit free-rolling and require reassessment of handling methods.
- 20152 Apr
MSF: “Pinch point” finger injury during hose handling
This safety flash describes a seaman’s finger injury while securing a fuel-hose saddle on a vessel operating at a platform’s leeside. The hose had been lowered using a bridle. Vessel movement caused by wind and swell shifted the saddle along the railing, pinching his finger against a securing pin.
- 20153 Mar
Near-miss: Manual handling in the office
An office storeroom near miss involved a fluorescent tube sliding towards a person’s face while an unmarked box was moved from a high shelf. Nothing fell and nobody was injured. Actions included assisted retrieval using a ladder, sealing and labelling the box, floor-level storage, assigned responsibility and supervised access.
- 201425 Nov
Dropped object incidents
Three vessel incidents involve ROV hangar securing hooks, a tensioner pad dropped during manual transfer, and a plastic LARS swing-gate arm falling during ROV recovery. The flash discusses dropped-object surveys, secondary retention, restricted access, permits and risk assessment, and encourages crews to identify and secure potential dropped objects.
- 201420 Jun
Line-of-Fire Incident Results in Facial Injuries
A rig crew held 10 to 15 turns of torque in a rod string using a rod wheel during lifting. Detachment of the running tool caused workers to lose their grip, releasing torque and producing uncontrolled backspin. A gate piece broke away and struck a worker’s face, causing major facial injuries.
- 201413 May
Injury caused by movement of wire rope under tension
An anchor wire unexpectedly slid off a flatbed trailer during beach cable installation, breaking a worker’s foot. Personnel connecting midline buoys had not recognised residual tension in the slack wire. The flash highlights stored energy and manual-handling hazards, recommending their consideration in job planning, toolbox talks and pre-job risk assessment.
- 2014Feb
Safe Patient Handling -- Preventing Musculoskeletal Disorders in Nursing Homes
Guidance on preventing musculoskeletal harm during patient handling in nursing homes. It promotes mechanical lifting and reduced manual handling, supported by management commitment, frontline participation, hazard assessment, equipment selection and training. Programme evaluation uses injury records, while common misconceptions about lifting methods and costs are addressed.
- 2013Dec
Hazards of strong oxidizers — Process Safety Beacon, December 2013
This bulletin describes a worker injured when sodium permanganate solution erupted from a pail and ignited his clothing. It discusses a suspected reaction with residual reducing material and explains oxidiser incompatibilities. Recommendations address chemical information, segregation, temporary-container safety reviews, labelling and cleanliness checks.
- 201323 Sep
Incidents involving use of scaffolding
Four scaffolding incidents concern pipe damage during a hydraulic hammer test, a crewman tripping while carrying an angle bar, alteration of scaffold support without competent inspection, and leftover boards smouldering above an exhaust line. Lessons address workplace risk assessment, clear or marked walkways, avoiding scaffold modification and removing materials after work.
- 2013Jul
Slipped messenger line while securing tug tow wire on bulk carrier Wah Shan with loss of 1 life
Investigation of a fatal accident while securing a tug’s tow wire aboard Wah Shan. Investigators considered a slipping messenger line striking the carpenter’s neck the most likely mechanism. The report examines warping-drum turns, fairlead routing, obstructed visibility, missing task-specific risk assessment, supervision and subsequent training measures.
- 201325 Jun
Loading and securing of cargo
This safety flash highlights two occasions involving unsecured cargo in containers and vehicles, resulting in unnecessary manual handling. It offers suggestions on balanced loading, protective packing, lashing and wedging, segregation of incompatible materials, secure doors and secondary retention, and planning loads to facilitate unloading.
- 20131 Mar
Improper Hand Placement Results in Minor Injury
Two employees lifted a hinged transition plate to locate a wire line sheave attachment during drilling. While lowering it, one released the plate and the other repositioned his hands. His right little finger became trapped between the transition plate and a bearing-housing support plate, resulting in a minor injury.
- 20128 Jun
Lost time injury (LTI): Crewman’s finger pinched when moving the gangway
A crewman suffered a finger pinch injury while manually stowing a replacement gangway before departure from port, leading to five weeks off work. The flash identifies inadequate risk assessment and absent management of change, and records valve modifications, revised risk assessment and changes to gangway handling arrangements.
- 201123 Dec
Crewman injured when steel plates fell against him
A crewman suffered skull and shoulder fractures when steel plates toppled during storage work aboard a vessel. Overhead hoisting was followed by manual positioning. The flash identifies inadequate temporary clamps, obstructing bulkhead brackets, crowding and the absence of a Job Hazard Analysis for creating the new storage area.
- 201120 Nov
Lack of Proper Tool Results in Finger Injury
An alert describes a maintenance crew member’s finger injury during manual removal of steel grating in an installation’s engine room. The grating section measured 3 ft by 3 ft and weighed approximately 46 kg. The title identifies a lack of a suitable tool.
- 2011Nov
Persons overboard from creelers Discovery and Breadwinner during single handed operations with loss of 2 lives
Combined investigation of two fatal losses overboard during single-handed creel fishing off Scotland. Discovery’s precise accident sequence remains uncertain; Breadwinner’s skipper became entangled while shooting creels and drowned. The report examines V-wheel haulers, potting rollers, self-shooting arrangements, gear separation, risk assessment, flotation, personal locator beacons and delayed rescue.
- 201129 Jun
Lack of safety awareness: crush injury during lifting operations
A lift supervisor suffered a minor hand crush injury while crew repositioned oil drums on a vessel’s deck. A snagged hoist wire caused the drum to trap his hand against a container. The flash identifies missing risk assessments, unfollowed procedures and task-specific training gaps, and reinforces crew responsibility and stop-work authority.
- 201120 Jan
Laying Down Joint of Casing Results in a Fall
A worker fell approximately 22 feet through a rig-floor opening while two workers were pushing a hoisted casing section towards the V-door. The load was too heavy to handle and swung back towards the rotary table. The fall caused skull and right-thigh fractures and multiple bruising.
- 20107 Jul
Fatality caused by stacked boards collapse
This HSE alert describes a worker’s death while retrieving a board from a stack leaning against a wall, alongside earlier fatal and crushing incidents. It explains the risks of losing control of heavy boards and calls for immediate review of storage and movement arrangements, suitable racking and handling aids.
- 20109 Feb
Diver falls into bell maintenance pit
A diver fell 1 m into an open bell maintenance pit aboard a vessel after moving removed grating further, sustaining injuries and losing a work day. The flash discusses pit design, omitted manual-handling and fall hazards, overdue task assessments and incomplete training, alongside a false floor and revised assessments.
- 2009Nov
Health risk management - A practical guide for managers in small and medium-sized enterprises
Practical guidance for managers of small and medium-sized enterprises on identifying occupational health hazards, assessing risks, implementing controls and checking results. Case studies illustrate chemical exposure, noise, vibration and musculoskeletal problems. It discusses workforce involvement, health surveillance, exposure measurement, engineering controls and continuing improvement.
- 200915 May
Underlying causes of offshore incidents
Research analysis of 67 offshore fatality and major-injury incidents from 2004–2008 combines investigation findings with RIDDOR data. It distinguishes direct causes, underlying causes and management failings, highlighting dropped-object impacts, deficient risk assessment, permits and supervision. Comparisons with earlier studies and inspection programmes inform recommendations for targeted inspections and further research.
- 200925 Apr
Restricted Work Case Results from Caught Between Incident
Three workers were instructed to move a mud pump air duct weighing about 80 kg manually between rooms. A fourth employee joined at the destination doorway. While lowering the duct onto the floor, his left middle finger became trapped against a pipe flange, causing swelling at the fingertip.
- 200826 Aug
Employee’s Arm Fractured While Using Pull Back Rope
This alert describes a derrick man’s severe arm fracture during tripping out of a hole. He wrapped a pull back rope around his arm to help pull a drill collar back, then lost control of the collar and could not release the rope.
- 2008Jun
Halon cylinder becomes rocket! — Process Safety Beacon, June 2008
A Halon cylinder dropped during inspection lost its valve after impact with concrete. Rapid discharge propelled it nearly 0.4 km, without injuries or significant equipment damage. The alert explains the greater thrust potential of high-flow cylinders and emphasises securing cylinders, using available valve caps and ensuring safe contractor handling.
- 200826 Jan
Failure of Counter Balanced Lids for Waste Storage Areas Result in Injuries
This alert summarises several incidents involving personnel attempting to lift counterweighted lids over waste storage areas. Reported outcomes include back strains, hands and arms becoming trapped beneath lids, and a falling lid striking a head. The supplied text identifies lid failure but gives no detailed causes or preventive measures.
- 20061 Oct
Near Miss Incident Breathing Apparatus Valve Failure
A near miss occurred while a breathing-air cylinder was lifted by its valve for sampling. Escaping air wrenched the bottle from an employee’s hand, prompting him to leave the emergency-response container. Inspection found a sheared threaded brass valve section. Cylinder pressure was between 200 and 240 bar.
- 20061 Jun
Near Miss Exploding Battery
This alert describes a battery explosion during movement by a mechanic’s helper using a two-wheeled dolly. One cable remained attached to the charged battery and fell against the other terminal, creating a direct short. The event is presented as a near miss.
- 20061 May
Temporary Placement of Mud Hose in Walkway Results in a Tripping Incident
A roustabout cleaning crew was moving items from a rig storage room. An employee stepped down approximately 12 inches towards the main deck onto a mud hose temporarily placed across the doorway walkway. Despite Danger flagging tape, the hose presented a trip hazard; the employee twisted and fractured his ankle.
- 20061 Apr
Caught Between Spooling Cable Results in an Injury
A dockside crew transferred multiplex control cable between reels by hand. After the reel became too heavy, a crane-assisted method was devised but not used by the following crew because of wind. Manual rotation resumed, trapping a worker’s arm between the reel ribs and frame and causing a compound forearm fracture.
- 20061 Mar
Standing on Casing Results in an LTI
This alert describes a worker rolling casing towards a catwalk while standing on the lower of two rows. A forklift was moving a joint from the upper row. Seeing it roll towards him, he jumped from a height of 1.06 m, landed on his right palm and sustained a reported fracture.
- 20052 Aug
Fatal Incident Results from Removed Deck Opening Cover
A subcontractor installing pipe insulation inside a concrete structure lifted a plywood board covering a floor manhole and stepped into the opening. He fell about 12 metres to a concrete floor, striking piping during the fall, and sustained fatal injuries. The alert describes the incident without providing preventive recommendations.
- 20051 May
Master Bushings set on IP’s Toe – LTI
A tourpusher fractured his left big toe while repositioning rotary master bushings after retrieving a drill pipe wiper rubber. An air tugger supported the operation, with manual pulling and pushing. The bushings obscured the operator’s view of the worker’s feet; following a slack-off instruction, his foot slipped over the rotary opening.
- 20053 Jan
Lifting techniques
This safety flash presents a member’s notes on manual lifting, prompted by an observed example of back hyperextension and strain. It describes grip, back and chin positioning, foot spacing, keeping arms close to the body, and using the body as a counterweight to the load.
- 20051 Jan
Fall From Monkey Board Results in a Fatality
This alert reports a fatal fall from a monkey board. An assistant driller climbed the derrick ladder to help raise a work platform that the derrickman could not lift fully upright. The rig was pulling out of the hole, with the platform requiring repositioning to accommodate remaining stands before running casing.