Dropped Object Prevention in Oil & Gas

Dropped objects are a significant safety consideration across the oil & gas industry, particularly on offshore installations, drilling rigs, production platforms and other facilities where personnel routinely work at height.

Tools, equipment, components and materials can become falling objects if they are not properly secured. Effective Dropped Object Prevention (DROPS) therefore forms an important part of managing working-at-height and equipment-related risks.

What is a dropped object?

A dropped object is an item that unintentionally falls from its previous position.

This could include:

Hand tools
Power tools
Bolts and fasteners
Lighting equipment
Cameras
Instrumentation
Valves and components
Covers and panels
Maintenance equipment
Temporary equipment
Structural components

Not every dropped object is large or heavy. A relatively small tool can present a serious hazard when dropped from significant height.

Why is dropped object prevention important in Oil & Gas?

Oil & gas facilities can contain multiple levels, structures and work areas where personnel may be working above or below one another.

Offshore installations can present additional challenges including:

Significant working heights
Restricted work areas
High winds
Vibration
Corrosive marine environments
Complex equipment
Simultaneous operations
Large numbers of personnel and contractors
Critical production equipment beneath work areas

A dropped object can therefore result in injury, equipment damage, operational disruption and potentially significant financial consequences.

Effective prevention focuses on stopping the object from becoming detached in the first place and reducing the consequences if an attachment fails.

How can dropped objects be prevented?

A comprehensive dropped-object prevention strategy can include several layers of control.

1. Identify potential dropped objects

Inspect the work area and identify anything that could potentially become detached or fall.

This includes both tools being used by workers and permanently installed equipment.

2. Assess the risk

Consider:

Object weight
Potential fall distance
Location
People potentially exposed
Equipment beneath the work area
Environmental conditions
Likelihood of failure

3. Secure tools

Portable tools used at height can be secured using appropriate tool tethering systems and tool lanyards.

4. Use secondary retention

Installed equipment such as lights, cameras and other fixtures may require independent secondary retention, depending on the application and risk assessment.

Retention wires and retention nets can provide an additional layer of protection if the primary mounting system fails.

5. Control the work area

Barriers, exclusion zones and appropriate access controls can help prevent personnel from entering areas exposed to dropped-object hazards.

6. Inspect equipment

Tools, fixings, tethering systems and secondary retention equipment should be inspected in accordance with applicable procedures and manufacturer requirements.

7. Maintain good housekeeping

Loose materials, components and tools should not be left where they can become dislodged or fall.

Tool Tethering Offshore

Tool tethering is particularly important when maintenance activities are being carried out above other personnel or equipment.

Commonly tethered tools can include:

Spanners
Sockets
Ratchets
Screwdrivers
Pliers
Hammers
Torque wrenches
Specialist maintenance tools
Battery-powered tools
Pneumatic tools

The tethering system needs to be suitable for the specific tool, attachment method, working environment and intended load.

Improvised attachment methods should be avoided.

Secondary Retention in Oil & Gas

Secondary retention provides an additional layer of protection for equipment that could become a dropped object if its primary fixing fails.

For example:

Primary retention

Light fitting → mounting bracket → structural fixing

Secondary retention

Light fitting → independent retention wire → structural attachment point

Secure Tools supplies specialist secondary retention wires and retention nets that can be manufactured or configured for specific applications.

This is particularly relevant to:

Lighting
Cameras
Instrumentation
Electrical equipment
Panels
Brackets
Other equipment installed at height

DROPS and Oil & Gas

DROPS — Dropped Objects Prevention Scheme — provides resources and guidance focused on preventing dropped objects.

However, dropped-object prevention shouldn't be reduced to simply buying a tether or retention wire.

A successful programme combines:

Planning + Risk Assessment + Engineering Controls + Tool Tethering + Secondary Retention + Inspection + Training + Good Housekeeping

The appropriate controls will depend on the specific installation, activity and applicable company and regulatory requirements.

Common Oil & Gas Dropped Object Risks

Some common causes include:

Loose equipment

Equipment or components that aren't adequately secured can become detached through vibration or movement.

Corrosion

Offshore environments can accelerate corrosion and deterioration of fixings and equipment.

Vibration

Continuous vibration from machinery and equipment can contribute to loosening or fatigue.

Poor housekeeping

Loose tools, materials and components can be displaced from elevated work areas.

Inappropriate temporary storage

Tools or materials left on platforms, walkways or structures can become falling objects.

Equipment failure

Brackets, fasteners and other components can deteriorate or fail over time.

Human factors

Incorrect installation, inadequate inspection or inappropriate tool use can contribute to dropped-object incidents.

A layered approach to DROPS prevention

The strongest message for Secure Tools should be that no single product prevents every dropped-object incident.

Instead, consider the hierarchy:

1. Eliminate
Can the task be completed without exposing people to a dropped-object risk?

2. Prevent
Can equipment be securely installed or the task redesigned?

3. Secure
Can tools and equipment be tethered or fitted with secondary retention?

4. Control
Can exclusion zones or barriers prevent people entering the drop zone?

5. Inspect
Are the controls maintained and fit for purpose?

This positions Secure Tools as a specialist safety-solutions provider, rather than simply a supplier of tool lanyards.

Secure Tools — Oil & Gas Dropped Object Prevention Solutions

Secure Tools provides specialist equipment for organisations working in demanding industrial environments, including:

Tool tethering
Tethered tools
Tool lanyards
Secondary retention wires
Secondary retention nets
Working-at-height tools
Specialist industrial tools
Non-sparking tools
Bespoke tool solutions

For applications involving equipment installed at height, Secure Tools can also assist with bespoke secondary retention solutions designed around the specific equipment and attachment requirements.

Frequently Asked Questions

What is dropped object prevention in Oil & Gas?

Dropped object prevention is the systematic process of identifying, assessing and controlling objects that could fall and cause injury, equipment damage or operational disruption.

What is DROPS?

DROPS stands for Dropped Objects Prevention Scheme, an industry initiative focused on reducing dropped-object incidents.

How do you prevent dropped tools offshore?

Depending on the task and risk assessment, controls can include tool tethering, suitable tool lanyards, tethered tools, tool bags, exclusion zones, good housekeeping and appropriate inspection procedures.

What is secondary retention?

Secondary retention is an additional, independent method of securing equipment to help prevent it from falling if its primary fixing fails.

What is the difference between tool tethering and secondary retention?

Tool tethering generally secures portable tools being handled by workers. Secondary retention generally provides an additional securing method for installed equipment or components.

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