An offshore scaffolding safety innovation from RBG has attracted industry plaudits aplenty since its launch last year and has already been adopted by Apache North Sea on a number of its platforms. In this opener to OE's HSE two-parter, Bill Abbott outlines the thinking behind PlusGard.
A crucial part of managing the integrity of an asset throughout its lifecycle is the requirement to erect scaffolding at regular intervals in order to carry out tasks from general maintenance to cleaning activities. With more than 8000 scaffolds in everyday use on the UKCS alone, it is an activity that requires specialist skills and highly trained personnel due to the inherent risks of working at height and offshore.
Traditional scaffolds, while effective, have certain constraints including the time taken to complete the build and the need for a standby vessel on-site during operations, which can have major cost implications. The use of a standby vessel also means that work can only be carried out in daylight hours, which are significantly reduced in the winter months, and can be delayed in rough seas or high winds.
In addition, offshore scaffolders are required to wear fall arrest equipment inthe form of a harness, lanyard and safety reel. This is not designed to mitigate a fall, rather to reduce the distance that a scaffolder could fall, and greatly restricts operational movements as it has to be reattached to the adjacent steelwork structure each time the scaffolder repositions. This process has a significant impact on a scaffolder's productivity and the time taken to complete the project, which can in turn, have an effect on the overall productivity of the asset. While this equipment is widely used across the offshore industry, it can lead to suspension trauma which can result in serious injury or a fatality.
Improving safety and productivity Recognising the challenges faced by operators in the erection of offshore scaffolding, RBG carried out a fundamental review with a view to developing a more sophisticated system which would mitigate risk and improve safety, whilst simultaneously reducing operating costs and optimising productivity.
As part of this review, the company consulted Turner Access – scaffold material manufacturer and supplier to RBG for the last five years – which presented several new concepts. One of the proposed options was an advanced guard rail system which, although only previously used onshore in the construction, presented benefits that far outweighed those of any other potential alternative. Following a period of development and refinement by the two companies to better equip the system for the offshore environment and oil & gas industry operational requirements, the bespoke PlusGard advanced guard rail system was unveiled.
By putting a protective rail around scaffolders, the system prevents them from falling while also allowing greater freedom of movement, improving working conditions.
The PlusGard system allows for safer erection, keeping the scaffolder in a secure enclosure whilst ensuring the scaffold boards and ladder are securely advanced to the next level. Positioned in advance of the scaffolder, it facilitates an upper perimeter railing allowing for safer access. The system also provides a semi-permanent railing structure, which remains in place until the scaffolder attaches the upper level rails and worksin conjunction with existing structures offshore.
PlusGard is the first system of its kind to be used offshore, addressing all the requirements of the UK's 2005 Working at Height regulations, which specify that collective preventative measures be investigated before implementing any fall arrest equipment. It also enables scaffolders to work more freely, unlike inertia wires which restrict movement.
To date some 120 RBG employees have been put through a training programme enabling them to work with the new system.
The first offshore deployment of PlusGard came in March last year when accessing a cooling water pipe on Apache's Forties Delta platform. Using the system, RBG was able to work for six consecutive days without the need for a standby vessel, saving Apache approximately £60,000 in operating costs, mainly due to the standby vessel not being required, and the project was completed ahead of schedule.
PlusGard has since secured RBG a number of industry prizes, among them the 2010 Offshore Contractors Association and NOF Energy innovation awards and a special commendation from the Energy Institute. Since the system's North Sea debut there have been no reports of accidents or injuries.
Apache North Sea's fabric maintenance coordinator, Bob Coombe, says of PlusGard: ‘We were pleased to work with RBG on the introduction of this innovative technology. The speed of installation was particularly impressive, together with the increased working window it provided us. Critically, the system mitigated the need for a standby boat, which created significant saving. We look forward to utilising the PlusGard system across all Forties' assets and working with RBG to bring further cost reduction through innovation.' OE
About the Author
Bill Abbott, RBG's group scaffold manager, has accumulated more than 20 years' offshore scaffolding experience in design, engineering and management positions. Based in Aberdeen, he is responsible for managing the company's scaffold designs and material movements and is the technical authority on scaffold innovation.