Lifting & Hoisting
Learning from Incidents
Franna Crane Dropped Object
Title: Lifting & Hoisting – Franna Crane – Dropped Generator
Duration: 5 mins 26 sec
Description:
Short video outlining the learnings from a dropped object incident involving a Franna crane
[Background music plays]
Bright, uplifting music.
[Text displays]
LEARNING FROM INCIDENT (LFI)
Franna Crane – Dropped Generator
[Text displays]
JON VOTIER
Lifting & Rigging Specialist ASME - QGC
[Video footage]
Jon Votier wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Jon is standing in front of a work site in Australia.
[Jon Votier]
In November 2018, we had a dropped object incident at the Central Processing Plant Bellevue behind me.
[Video footage]
Moving shot of a Central Processing Plant, Australia.
[Jon Votier]
Fortunately, no one was injured but it was a high-potential near miss. As you'll see in this video, our lifting contractor had all the barriers in place for a safe lift.
[Video footage]
Shot of the incident with a Franna crane and dropped generator.
[Jon Votier]
He'd carried out two lifts in the days prior to the incident using the same equipment, so what went wrong?
[Video footage]
Jon Votier wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Jon is standing in front of a work site in Australia.
[Jon Votier]
It's often the things that we can't see or can't control that are our biggest threat, so how we guard against them is crucial.
[Video footage]
Moving shot of a Central Processing Plant, Australia.
[Voiceover Steve McCalmont]
In late-November 2018, a 500-kilovolt generator was in the process was being located at site in preparation for turnaround activity at QGC's Bellevue Central Processing Plant.
[Video footage]
CCTV footage from Central Processing Plant showing crane lifting a generator and moving across a worksite. Person wearing orange PPE walking in front of the moving crane.
[Voiceover Steve McCalmont]
The crane was serviced as required and appeared to be in good working order. The generator was lifted from a flatbed truck by the crane and walked approximately 660 metres by the crane where the load is in the process of being lifted over a fence line.
[Video footage]
Steve McCalmont wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Steve is standing in front of a work site in Australia.
[Text displays]
STEVE McCALMONT
Field Manager - QGC
[Steve McCalmont]
It was during the lift phase that the load dropped to the ground.
[Video footage]
Male speaker 1 wearing Orange PPE shirt talks to camera. Male speaker 1 stands in front of stationary crane.
[Male Speaker 1]
We were out on site, one of the lads come walking down and mention that there'd been a dropped load.
[Video footage]
Shot of the incident with a Franna crane and dropped generator.
[Male Speaker 1 Voiceover]
I could see the Franna in the background and there had been a major incident, so we walked up there, cordoned off the area.
[Video footage]
Male speaker 1 wearing Orange PPE shirt talks to camera. Male speaker 1 stands in front of stationary crane.
[Male Speaker 1]
By that time there was a few blokes that were involved in the lift at the same time.
[Video footage]
Moving image of a still image from the investigation showing a damaged generator after the drop behind a fence barrier, zooming out to show crane involved in the incident, cornered off by a yellow rope barrier.
[Male Speaker 1 Voiceover]
Took control of the scene and we closed it down and started preparing for the investigation. The crane driver at the time was very shaken by the incident.
[Video footage]
Male speaker 1 wearing orange PPE shirt talks to camera. Male speaker 1 stands in front of stationary crane.
[Male Speaker 1]
It hadn't actually fully sunk yet 'til he went to hop out of the crane and the Dogman was probably still running on adrenaline to be honest.
[Video footage]
CCTV footage from Central Processing Plant showing the Franna crane in the incident lifting the generator over a fence; view is slightly obstructed by a green structure in front of the crane.
[Male Speaker 1 Voiceover]
Before the incident, there was absolutely no warning signs. The boys had been lifting with the crane beforehand, loads had been heavier and lifted longer distances. All the pre-start checks on the crane has been carried out, they'd all passed with flying colours. All the controls and measures were in place.
[Video footage]
Zoom in on CCTV footage to show Generator being lifted by the Franna crane; the generator drops in two sudden movements to grade.
[Male Speaker 1 Voiceover]
They had a permit to work, approved lift plans, SWMS, it was just one of those moments that the Swiss cheese aligned which resulted in the incident.
[Video footage]
Zoom in of still shot of the incident with a Franna crane and dropped generator.
[Male Speaker 1 Voiceover]
If he hadn't been following the lifesaving rules, we probably could have had not just one fatality but multiple, so there was absolutely no red flags that this incident was going to occur.
[Video footage]
Steve McCalmont wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Steve is standing in front of a work site in Australia.
[Steve McCalmont]
So, why on this occasion did the load drop? After an extensive investigation, a number of learnings have been identified that will help prevent an incident like this in the future. Keeping ourselves and our workmates safe.
[Video footage]
Male speaker 2 wearing Orange PPE shirt talks to camera. Male speaker 1 stands in front of stationary crane.
[Male Speaker 2]
Firstly, let's talk about the design of the part and the significance in explaining why this load was dropped.
[Video footage]
Zoom in footage of a still image from the investigation showing the inside workings of a Franna crane boom cross section; showing a white wear pad dislodge in a round compensating metal sheaf. Red text appears on screen to title ‘Internal View of Crane Boom and to point out the ‘dislodged wear pad’.
[Male Speaker 2 Voiceover]
Upon investigation, it was found that the brass screws holding the wear pad in place had failed and it caused the wear pad to get jammed in the compensating sheaf
[Video footage]
Zoom out footage of a still image from the investigation showing the inside workings of a Franna crane boom cross section; Wide shot to show length of the boom, showing a white wear pad dislodge in a round compensating metal sheaf. Red text appears on screen to title ‘Internal View of Crane Boom and to point out the ‘dislodged wear pad’. Can see the work boots of two people standing beside the crane boom.
[Male Speaker 2 Voiceover]
and this started the catastrophic cause of events.
[Video footage]
Zoom out footage of a still image from the investigation showing cut metal. Red text appears on screen to title ‘Internal View of Crane Boom and to point out the ‘guides cut by wire rope’.
[Male Speaker 2 Voiceover]
The rope then jumped off the sheaf and then came through the guides
Video footage]
Zoom out footage of a still image from the investigation showing a wire reel sitting on a wooden pallet with frayed wire from the incident.
[Male Speaker 2 Voiceover]
And then it snapped and the load came to ground.
[Video footage]
Male speaker 2 wearing Orange PPE shirt talks to camera. Male speaker 1 stands in front of stationary crane.
[Male Speaker 2]
We don't know when this occurred. The crane successfully completed lifts two days prior.
[Video footage]
Rohitesh Kumar wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Steve is standing in front of a work site in Australia.
[Text displays]
ROHITESH KUMAR
HSSE Advisor - QGC
[Rohitesh Kumar]
In this case, no one was injured. However, the potential to cause harm was extremely high. Looking at the incident and what we know, what was done well by the team that prevented them from getting them harmed?
[Text displays]
Looking at the incident and what we know, what was done well by the team that kept them safe from harm?
[Video footage]
Zoom in footage of a still image from the investigation showing cut metal.
[Rohitesh Kumar Voiceover]
The dislodged wear pad found during the investigation was not visible to the work crew and not able to be identified prior to the incident showing us that catastrophic failures may still occur.
[Video footage]
Zoom out footage of a still image from the investigation showing the inside workings of a Franna crane boom cross section; Wide shot to show length of the boom, showing a white wear pad dislodge in a round compensating metal sheaf. Red text appears on screen to title ‘Internal View of Crane Boom and to point out the ‘dislodged wear pad’. Can see the work boots of two people standing beside the crane boom.
[Rohitesh Kumar Voiceover]
Even when we are fully compliant and have all the best intentions. What equipment do you use that may have hidden faults?
[Video footage]
Zoom in footage of a still image from the investigation showing the inside workings of a Franna crane boom cross section; showing a white wear pad dislodge in a round compensating metal sheaf. Red text appears on screen to title ‘Internal View of Crane Boom and to point out the ‘dislodged wear pad’.
[Text displays]
What equipment do you use that may have hidden faults that pose a risk or have the potential to cause harm?
[Video footage]
Rohitesh Kumar wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Steve is standing in front of a work site in Australia.
[Rohitesh Kumar]
Could this pose a risk or cause harm?
[Video footage]
Zoom in on CCTV footage to show Generator being lifted by the Franna crane; the generator drops in two sudden movements to grade.
[Text displays]
What processes do you have in place to assess risks associated with the machinery and equipment you are using?
[Rohitesh Kumar Voiceover]
What will you do to ensure you assess the risk?
[Video footage]
Steve McCalmont wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Steve is standing in front of a work site in Australia.
[Steve McCalmont]
Although it did not contribute to the root cause of the incident, the generator was picked and carried 660 metres to the final lift position.
[Video footage]
CCTV footage from Central Processing Plant showing crane lifting a generator and moving across a worksite. Person wearing orange PPE walking in front of the moving crane.
[Steve McCalmont Voiceover]
We need to look at the intent of the machinery we use for our jobs and question processes that potentially add risk or aren't as efficient or safe. In this instance, the flatbed truck used to deliver the generator could have been unloaded closer to the lifting position to eliminate the travel of the Franna crane.
[Video footage]
Steve McCalmont wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Steve is standing in front of a work site in Australia.
[Text displays]
What actions will you take to challenge the task at hand and ensure you have the most appropriate equipment and machinery available?
[Steve McCalmont]
So, what actions will you take to challenge the task in hand to allow you to safely complete the work?
[Video footage]
Four men in long sleeve PPE shirts, wearing white hard hats, standing in front of plant machinery having a discussion.
[Video footage]
Rohitesh Kumar wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Steve is standing in front of a work site in Australia.
[Rohitesh Kumar]
We need to remember risk is real in all we do despite our best intentions. We must minimise gaps in our barriers because we may never know when risk might realise.
[Video footage]
Video footage of a man wearing PPE, orange shirt and navy-blue pants and work boots get into the driver’s seat of a stationary car. Sitting in the stationary car, the man points to a checklist.
[Rohitesh Kumar Voiceover]
We also need to continually question our work methodology to ensure we are working efficiently but most important, safely.
[Video footage]
Male speaker 2 wearing Orange PPE shirt talks to camera. Male speaker 1 stands in front of stationary crane.
[Male Speaker 2]
- I think the key learnings to this is that the lifesaving rules were followed. No one was under the load and it could have been a very different outcome.
[Video footage]
Jon Votier wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Jon is standing in front of a work site in Australia.
[Jon Votier]
- We were very fortunate that no one was injured in this incident due to the behaviours and the barriers in place by our crew. I ask you all to look beyond this incident and look at all the everyday activities in life that put you at threat. Do you have barriers in place that will protect you from these threats and do you action these? So, how will you consider the unknown threat moving forward? Together we can all be Goal Zero.
[Video footage]
Shell logo appears onscreen.
Sounds of Shell plays in piano tone, five tones.
Telecommunications Tower Dropped Object
Title: Telecommunications Tower Dropped Object
Duration: 2mins 58 sec
Description:
Short video outlining the learnings from a dropped object incident involving a telecommunications tower.
[Background music plays]
Bright, uplifting music.
[Text displays]
LEARNING FROM INCIDENT (LFI)
Telecommunications Tower Dropped Object
[Text displays]
ADAM BESANT
Superintendent
[Video footage]
Adam Besant wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Adam is standing in front of equipment at a supply base, Australia.
[Adam Besant]
On the 24 August 2018, a telescopic communication tower was being erected on a radio infill site using a manual winch.
[Video footage]
Moving shot over a still picture of the incident site, showing a telecommunications tower erected.
[Adam Besant]
As it was being winched upward into place, the top section weighing approximately 80 kilograms became unstable and fell 20 meters to the ground; landing approximately 1 meter from the winch operators’ original position at the base of the tower. No one was injured during the incident.
[Video footage]
Shot a telecommunications tower laying on the ground in a supply yard. Close up shot of wire rope attached to the telecommunications tower.
[Adam Besant]
However, the potential consequence of this dropped object is a fatality resulting from injury or trauma. Something none of us want to experience.
[Text displays]
ANDREW CASWELL
Superintendent
[Video footage]
Andrew Caswell wearing a white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera. Adam is standing in front of equipment at a supply base, Australia.
[Andrew Caswell]
Let’s learn a little more about the incident and the design of the equipment.
[Video footage]
Shot a telecommunications tower laying on the ground in a supply yard
[Andrew Caswell]
The telecoms tower was free issued to the contractor
[Text displays]
Free Issued Material
[Video footage]
Wide shot moving across an outdoor supply base showing stored equipment.
[Andrew Caswell]
The tower had been stored outdoors for over six years.
[Text displays]
Stored equipment
[Video footage]
Close up still shot of the base of a telecommunications tower
[Andrew Caswell]
Minimal vendor documentation was issued to the contractor.
[Text displays]
Minimal vendor documentation issued.
[Video footage]
Camera shot of a telecommunications tower. Zoom shot of the top section of the telecommunications tower.
[Andrew Caswell]
The tower did not have a mechanical stop, to prevent overrun of the telescopic section which resulted in the top section becoming unstable.
[Text displays]
No mechanical stop to prevent overrun of the wire rope
[Video footage]
Shot of worker wearing gloves holding wire rope pointing to wire rope grips
[Andrew Caswell]
The overrun kinked the wire rope; This coupled with winch cable design that used wire rope grips as a lifting point contributed to the failure of the wire rope, allowing the top section to fall to the ground.
[Video footage]
Still shot of wire rope grip on the left and swaging sleeve on the right. Animation of a red cross appears over the wire rope grip. Animated green tick appears next to the swaging sleeve.
[Text displays]
Wire rope grips are not compliant with AS-2759 for steel wire rope. Swaging sleeves are compliant.
[Video footage]
Andrew Caswell wearing white hard hat with Shell QGC logo and Orange PPE shirt with Shell QGC logo talks to camera, Adam is standing in front of equipment at a supply base, Australia.
[Andrew Caswell]
Knowing what we know about the equipment used, what can we learn to prevent and incident like this from reoccurring?
[Video footage]
Shot of truck driving past equipment in the distance at a supply base.
[Adam Besant]
Think about the equipment you have in your work area.
[Video footage]
Up-close shot of a winch with wire rope
[Adam Besant]
How is the equipment you use stored to prevent from wear or damage?
[Text displays]
How is the equipment you use stored to prevent wear or damage?
[Video footage]
Shot of worker wearing gloves holding wire rope pointing to a wire rope grip.
[Adam Besant]
And what factor can contribute to damage of stored equipment
[Text displays]
What factors can contribute to the damage of stored equipment.
[Video footage]
Up-close moving shot of wire rope with rusted wire rope grips on a telecommunications tower.
[Andrew Caswell]
Think about the equipment that you are issued to use on your worksite that is new or unfamiliar.
[Video footage]
Moving shot of two workers wearing white hard hat and orange PPE inspecting a piece of equipment at a supply base.
[Andrew Caswell]
What checks do you put in place to ensure the equipment you are using is in good working condition?
[Text displays]
What checks do you put in place to ensure the equipment you are using is in good working condition?
[Video footage]
Two workers wearing white hard hats with Shell QGC logo PPE clothing and gloves, inspecting wire rope.
[Andrew Caswell]
How do you assess if the design of the equipment or material you are using are adequate for the task you are to complete?
[Text displays]
How do you assess if the design of the equipment or material you are using are adequate for the task you are to complete?
[Video footage]
Moving shot over a still picture of the incident site, showing telecommunications tower erected
[Adam Besant]
In this incident, the winch operator to successfully erect the tower was required to be inside an exclusion zone, the team had a spotter who alerted the winch operator of the fall and he promptly moved himself from the area.
[Video footage]
Still shot of a telecommunications tower showing wire rope, laying on the ground in a supply base.
[Adam Besant]
What could we do to eliminate people entering exclusion zones and working in potential lines of fire?
[Text displays]
What could we do to eliminate people entering exclusion zones and working in potential lines of fire?
[Video footage]
Moving shot showing a winch attached to a telecommunications tower.
[Video footage]
Two workers wearing white hard hat, PPE clothing and gloves inspecting a telecommunications tower and having a discussion, pointing to parts of the equipment they are inspecting.
[Adam Besant]
In your daily activities, what barriers do you have in place to keep you safe from harm?
[Text displays]
In your daily activities, what barriers do you have in place to keep you safe from harm?
[Video footage]
Shell logo appears onscreen.
Sounds of Shell plays in piano tone, five tones.