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518
Introduction
The authors of this paper are sharing their solutions for land-based mobile Oil and Gas Drilling
rigs, but believe the philosophies and strategies presented here have application to many other
industrial situations, where working platforms are not very high.
In some parts of the world that have open spaces such as at sea, the high arctic, or some
desert areas, the rig can be kept fully or partly assembled for transport from one well location to
the next.
In most land based drilling, there are
significant transportation constraints, to protect
the highways, bridges and other users of the
transportation infrastructure.
Restrictions include limitations of the
maximum weight and size. As a result, most rigs
have to be broken down into several discrete,
transportable parts.
Figure 2
Break Down of Rig for Highway Transport
Travel restraint is a great third choice, but is limited to horizontal work platforms that have a
geometry and size that enable the worker to be tethered to an anchorage system in a way that
makes it impossible to fall off. This solution is ideal for circular platforms such as the tops of
large tanks. Irregular perimeters often make it very difficult or impossible to implement. Even a
perfectly rectangular platform requires dual tie-off to prevent the fall of a worker at a corner.
When the platform is too small (i.e., you do not have at least 7 or 8 feet from anchor to edge), or
when the system requires adjustment, but the worker has to carry tools and materials in his/her
hands, Travel Restraint becomes impracticable.
Selection of a Solution
The regulators, including US OSHA, do not decree which solution from the Hierarchy should be
used in particular situations, however, the General Duty Clause in the Regulations basically
compels employers to be aware of and follow industry best practices.
Thus, the use of solutions at or near the bottom of the Hierarchy should be avoided
whenever a practical solution that is higher in the Hierarchy is possible.
Figure 4
Racking Board, storing Pipe
Hazard Assessment
There is usually, depending on the specific Drill Rig, potential to fall dozens of feet. The walking
surface is narrow with large openings a worker can fall through. The landing area is typically
lower structures of the drill rig, consisting of steel and machinery.
Possible mitigations, following the Hierarchy of Controls:
Elimination: This job cannot be moved to ground level because the Racking must be above
the middle of each length of pipe to balance it from falling over and is normally close to the
top of the pipe. The workers manually steer pipe into and out of the fingers. Robotics is
already playing a role on some of the very large drilling platforms, but is currently too heavy,
expensive and unreliable for land-based rigs. For now, workers must be near the top of the
pipe to manually assist with the racking.
Guarding: The platform is well guarded laterally around its perimeter, when drilling, but
the guarding must be open on one side during pipe standing operations. Because the pipe
passes through the platform, and must be moved laterally from in line with the well centre, to
the racks where it is stored, the floor cannot be closed off (guarded) at the same time that a
worker is manipulating the pipe into and out of the rack.
Travel Restraint: The Width of the platform the worker stands on is too small to be able to
tether a worker from reaching and falling off the open edges.
Fall Arrest: This is the usual solution on the Racking Board. Barely visible in Figure 3, there
is a diagonal sloping line above the stabbing board that anchors two Self Retracting Lifelines.
Worker(s) wear full body harnesses and connect themselves to the SRLs.
Thus, following the Hierarchy of Controls for Fall Protection, we have legitimately
concluded that a Fall Arrest system is the best solution.
Figure 6
Building Roofs
Hazard Assessment
There is potential to fall approximately ten feet. The tops of the roofs are typically painted steel,
and very slippery when wet or covered with snow and ice. The landing area is typically a gravel
pad placed at the drilling site prior to mobilizing the Rig.
Possible mitigations, following the Hierarchy of Controls:
Elimination: The work cannot be moved to ground level because low height buildings are
infeasible (they waste the available transportation envelope and wouldnt allow users to stand
up inside them).
Guarding: The guardrails would need to be retracted or removed to transport the building.
The exposure time to manually set up and dismantle Guardrailing generally exceeds the
working time on the roof so setting it up may pose a greater risk than working without it.
Automatic Guardrailing systems (including hydraulically actuated) are possible but would be
expensive and subject to ongoing maintenance and repairs.
Travel Restraint: This is the best solution, because it prevents the fall. Discussions below will
expand on important design considerations to make this work.
Fall Arrest: This is often infeasible due to inadequate Clearance, also as discussed below.
Administrative Controls: Because Travel Restraint (or sometimes Fall Arrest) is feasible,
there is no justification to eliminate Positive Fall Protection, and therefore, a Fall
Protection Plan is not acceptable as the sole means to reduce the risk.
Figure 7
Weak HLL Anchorage
how much Clearance is required for a 60 foot long Horizontal Lifeline made of 3/8 cable on
rigid end anchorages. In a single worker fall, we expect the cable to deflect about three feet. It
is common for workers to use a 6 ft long lanyard that includes a Personal Energy Absorber
(PEA) that can deploy approximately 4 or 5 feet. The ANSI Z359.6 and CSA Z259.16
standards require a two foot Clearance Margin. When we add this up, the Clearance from the
anchorage totals 21 to 22 feet. If the building is about 12 feet wide and the HLL is installed in
the middle (6 feet from the edge), Figure 8 shows that the required Clearance is 15 to 16 feet
below the edge of the roof.
Since most of these buildings are around 10 feet high, the lanyard length would have
to reduce to 1 foot or less for Figure 8 to properly stop the fall in the available Clearance.
This is completely impractical for the worker.
Some people believe that if the worker uses an SRL instead of a lanyard, the fall distance will
be shorter. This is not a valid belief because:
The worker will experience similar Free Fall with an SRL as a lanyard when he steps
off the edge of the roof. He does not start pulling the line out of the SRL (to sense the
speed of the fall and then lock), until his Dorsal D-ring (shoulder height) goes past
the edge of the roof, about a five foot Free Fall.
Most small SRLs are not designed or intended to handle this much free fall, and will
generate large impacts that exceed what regulators would allow. In a worst case, the
impact force can sever the line where it deflects over a sharp edge of the building.
Some SRDs include a built-in energy absorber to deal with large free falls, however,
they usually will deploy more than the personal energy absorber (PEA) in a lanyard
for the same Free Fall distance.
In conclusion, low HLLs just wont work to safely arrest a fall on the Drilling Rig buildings.
3. Generally, the definition of travel restraint is that the torso, from the hips to the shoulders,
cannot leave the roof. Moving up the Hierarchy, can we use a travel restraint system to
prevent the workers torso from leaving the roof? Travel restraint forces are lower than
Fall Arrest forces, but it is still probable for
the HLL to deflect at 1 to 1.5 feet.
Figure 9 shows that the absolute
longest lanyard that could be used (on a 12
ft wide roof, with the HLL in the middle)
would be 2 feet. The problem with a lanyard
this short is that a worker connected to the
HLL will have extremely limited mobility,
and probably could not even crawl beside
the HLL.
If we can bend the conventional
Travel Restraint rules a bit, and allow the
hips to get off the roof, there would not be
any appreciable free fall and a worker can
fairly easily be dragged back on the roof
2.5 ft
2 ft 1.5
ft
Lanyard
Figure 9
The lanyard for travel restraint must be
2 feet or shorter.
1.5 ft
3 ft
Lanyard
1.5
ft
Figure 10
The lanyard for travel restraint must be
3 feet or shorter.
3 ft HLL
deflection
6 ft
lanyard
11 ft
Anchor
Height
4 ft PEA
deployment
6 ft Worker
2 ft Clearance
Figure 11
Required Anchor Height for a Horizontal
Lifeline Above the worker
We can set the post back from the edge of the roof. This reduces clearance requirements
due to the longer diagonal distance from the anchor point to the edge of the roof.
3 ft arrest
distance
2.5 ft
8.5 ft
Required
Clearance
6 ft Worker
2 ft Clearance
Figure 12
Required Anchor Height for a Horizontal
Lifeline Above the worker
SRL Systems
SRLs can only keep a worker from reaching an edge if the maximum length of line on the SRL is
less than or equal to the length of lanyard that would similarly prevent a worker from reaching the
edge. Usually, an SRL has more line than the worker needs. Even if we set the anchorage system
far enough back that we run out of SRL line before the worker reaches the edge, it is less
expensive to purchase a simple fixed length lanyard or lifeline. SRLs are typically not usable for
travel restraint.
Lanyard Systems
Travel restraint requires having the anchorage far
enough from the edge of the roof that the worker
cannot fall off the edge.
If we push the limits of what might be
considered travel restraint, Figure 13 shows that the
required setback equals 1.5 feet plus the lanyard length
plus the Anchorage System (HLL) deflection at Travel
Restraint forces. This allows a worker facing the edge
to reach the edge with his hands.
When the worker stands up, the slope of his
fixed length Lanyard will force him to stand further
from the edge.
Thus for a standard six foot lanyard, and, say, a one
foot maximum deflection of the HLL, the setback must
be 8.5 feet from the edge.
1.5 ft
Lanyard Length
HLL
Deflection
1.5 ft
Lanyard Length
HLL
Deflection
Figure 13
Required Anchor Setback to restrain
worker from falling off the roof
6 ft Anchor
Setback
Figure 14
Replace HLL with a Rigid Rail.
Use a 4 ft Lanyard.
Figure 15
Elevate the HLL so the lanyard
will restrain reaching the hazard
but the worker can still stand up.
8.5 ft Anchor
Setback
8.5 ft Anchor
Setback
Figure 16
Use Two HLLs and Y-Lanyard
For Double Travel Restraint
Figure 17
Use a 3 ft Y-Lanyard connected to
the Hip D-rings
Warnings: There are a some of critical considerations when using hip connection to the
harness for travel restraint:
Ensure there is no possibility that a worker can reach and fall off the edge of the roof.
If a worker were to fall, it is dangerous to put fall arrest impact into the workers
hips. This means that the HLL sag must be controlled and compatible with the length
of Y-Lanyard that is being used so that a fall is impossible.
Select a model of harness that can resist a backward pull on the D-rings. The design
of some harnesses does not consider the possibility of a backwards pull. Hip D-rings
are typically tested for a frontward and upward pull only (for a worker facing the
ladder, pole or other structure, using a positioning lanyard or strap connected to both
D-rings, wrapped around the structure. This
allows the worker to lean back and work with
his/her hands. If there is a short fall, the impact on
the hips is upwards, and not across the body.
Figure 18
Yellow Line Shows proposed
Horizontal Lifeline above the
Catwalk
Hazard Assessment
Figure 19
There is potential of falling six feet or more. The landing area
Pipe Standing Mechanism in the
varies from gravel or soft ground to the outside of the
middle of the platform.
platform to steel bracing and machinery on the inside of the
platform. Workers service the mechanisms once per day, and
must lean over the opening in the Catwalk to reach the points that they are servicing.
Elimination: It is theoretically possible to modify the platform height, lowering the platform
slightly below the threshold height of six feet where Fall Protection is legally required. This
however, would not appreciably improve the safety, would require a redesign of the Rig.
Guarding: Since the platform is open in the middle, there are four edges that a worker could
fall from, so there would need to be four runs of Guardrailing. When the Drilling Rig is
operating, pipe is lifted onto and rolled across the catwalk to and from the (yellow) hydraulic
mechanisms. Guardrails will need to be retracted or removed most of the time the Rig is
operating. The exposure time to manually set up and dismantle Guardrailing would be
significant and would exceed the time servicing the pipe standing mechanisms. Installing and
dismantling it for each days maintenance would likely be a greater exposure to falls than
working without fall protection. Hydraulically actuated Guardrailing schemes are possible but
would be very expensive to implement, add significant weight to the drilling rig, and would
also be subject to ongoing maintenance and repairs.
Travel Restraint: As can be seen in figure 19, the twin platforms are too narrow to create a
travel restraint system. Travel restraint is also infeasible because the hydraulic equipment
being maintained is actually outside the edges of the platform.
Fall Arrest: With the platform at an elevation of approximately six feet, we are at the
minimum elevation where any Fall Arrest System can practically work. SRLs anchored to a
rigid system above the worker generally require six feet of Clearance below the platform
(including the mandatory two foot Clearance Margin). If the worker has to kneel, the required
Clearance increases to 8.5 feet, as discussed above. The probability of a kneeling worker
falling off a platform is considered much lower than the probability of a standing worker
falling, so fall arrest protection is primarily needed by a worker who is standing.
Because of the difficulty of stopping falls so close to the ground, the CSA Z259.16
engineering standard for the design of active fall protection systems is exploring an
ammendment that will permit the engineer to reduce or even eliminate the two foot Clearance
Margin in situations where it is not possible to stop the fall within the available Clearances.
If the Qualified Fall Protection Engineer determines there is not enough Clearance to
maintain a two foot Clearance Margin, the new rules would require verification that the
impact speed upon reaching the lower level or obstruction is not greater than if the worker
had fallen from the threshold height where fall protection is legally required. The Engineer
must also warn users by stating on the drawings the circumstances where they may hit the
The only way to reduce sag is to increase the tension. Zero sag mathematically requires infinite
tension and infinitely strong end anchors.
Clearly, a horizontal lifeline to protect work on the Catwalk is completely infeasible.
Figure 20
Use of a single SRL mounted at the top of the
Mast will cause severe swing falls if the worker
gets too far from horizontally from the Mast
The horizontal velocites can be high! Sidways impact energies are created by the elevation
drop (Swing Drop Distance) from where the worker begins to swing to where the worker
impacts the structure.
In a swing fall impact, the forces are ALWAYS applied perpendicular to the spine, a
direction where the body has reduced capacity to absorb the energy (by contrast, in a vertical
fall arrest, the harness directs the impact into the workers hips and verticaly up the spine).
There are no energy absorbers to dissipate swing fall energy. In a vertical fall arrest, the PEA
can deploy. In a Swing Fall, the only energy absorber is the workers body, so injuries can be
severe.
The elevation drop experienced by the worker must be added to the required Clearance.
The ANSI Z359.6 and CSA Z259.16 standards for the design of active fall protection
systems limit the Swing Drop Distance (the drop in elevation from where the worker begins to
swing to the elevation where he impacts a structure sideways) to 4 feet or less.
This limitation was not set due to Clearance considerations AND it certainly does not
eliminate all injuries. Four feet was selected as a reasonable level of energy for the human body
to deal with in a swing impact.
20 ft
15 ft
10 ft
5 ft
0 ft
0 ft
10 ft
20 ft
30 ft
40 ft
Horizontal Distance from the Mast
Figure 21
Swing Drop Distance vs
Horizontal Distance from the Mast
Figure 22
Swing Drop Distance vs
Horizontal Distance from the Mast
50 ft
There may be some safety people who would have concerns about two Snaphooks being
connected into the same D-ring at the top end of the harness extension. While it would be
possible to construct a harness extension with two D-rings, a hazard evaluation of this dual
connection concluded:
The risk of interference between the Snaphooks is greatest if one or both Snaphooks are
loose. The tension in both SRL cables will keep the Snaphooks seperated on opposite
sides of the D-ring so there is no risk of interaction;
the modern use of 3600 lb locking gates has greatly reduced the possibility of a forced
rollout.
It was therefore deemed acceptable to use the common harness extension. Those who have
concerns about the dual connection certainly have the option of fabricating a custom harness
extension that provides two separate D-rings.
Computer Modelling
The novelty of having two SRLs connected to one worker certainly needed field testing to prove
whether the system would behave as we hoped. Before purchasing the SRLs and conducting tests,
however, we evaluated the concept using computer models. The calculations were done using
energy analysis wherein the fall energy developed by the worker is distributed into the various
energy absorbing components of the system (in this case, the two SRLs).
Skilled computer modelling can often predict behaviours that may not otherwise be
forseen, and may show why a concept wont work before going to the high expense of doing
testing. Even when the concept is expected to work, computer modelling greatly reduces the
number of tests required to get an accurate understanding of the behaviour of the system.
Computer modelling will predict some problems that can be addressed by re-design before
beginning the testing.
Accurate computer modelling requires a detailed understanding of how the equipment (in
this case, the SRLs) is going to behave. Obtaining detailed information from manufacturer s is
difficult, so we based the intial assumed performance on our experience with several SRLs.
The following properties of the SRLs were assumed by the initial computer model:
Lock-off speed of the SRL: Large SRLs often have lock-off speeds that vary from about
3 to 10 ft/s, depending on the amount of cable that is on the drum of the SRL. The lockoff mechanism generally senses the speed of the drum rotation, so when the SRL is fully
retracted, each rotation of the drum pays out more cable than when the drum is nearly
empty. The computer model included an algorithm that predicted the lock-off speeds
according to the length of line out of the SRL (controlled by the position of the worker
along the catwalk).
Average Braking Force: The braking force of an SRL critically controls the distance
required to stop the fall. The higher the force, the less deceleration distance and
Clearance is required. A number of models of SRLs were evaluated to see what braking
forces might be available. Most models were labeled as keeping the peak impact force
lower than 900 lbs, however we did find one product that labeled as keeping the impact
force lower than 1350 lbs that was rated for a maximum 420 lb user. This product was
presumed and hoped to have a braking force
80 ft
that would be 50% higher than for the other
70 ft
models we evaluated.
60 ft
50 ft
40 ft
30 ft
20 ft
10 ft
0 ft
0 ft
10 ft
20 ft
30 ft
40 ft
50 ft
60 ft
0 ft
10 ft
20 ft
30 ft
40 ft
50 ft
60 ft
80 ft
70 ft
60 ft
50 ft
40 ft
30 ft
20 ft
10 ft
0 ft
Figure 23
Computer Model Showing
Initial (blue) and Final (red) SRL Cables
and Path of the Fall (Purple)
4.0 ft
3.5 ft
3.0 ft
2.5 ft
2.0 ft
1.5 ft
1.0 ft
0.5 ft
0.0 ft
0 ft
10 ft 20 ft 30 ft 40 ft 50 ft
Horizontal Distance from the Mast
Figure 24
Computer Model Showing
Total Horizontal Swing (green)
and Vertical Fall Distance (red)
horizontal movement calculated to be greatest (more than three feet) when the worker is
next to the mast and when the worker is out at the end of the catwalk.
The computer model predicted that the proposed system could stop the fall and still
maintain a two foot Clearance Margin for a standing worker anywhere on the platform, but that a
kneeling worker may not quite have enough Clearance.
It was decided that the dual SRL option was worth exploring further by doing testing:
1. The performance of this option (in terms of stopping the fall within the available six feet of
Clearance) appeared to actually meet and in most cases exceed the performance of the
overhead rigid rail option, without the expense and difficulty of engineering a rigid rail
system onto the existing drilling rig.
2. As discussed above, the CSA Z259.16 standard was being ammended so that systems where
available Clearance is extremely limited can be used even if the worker may hit the ground.
The caveat is that impact energy must be less than would have occurred if the worker fell
from the threshold height where fall protection is legally required.
In this case, the platform is essentially at the threshold height where fall protection is legally
required, so if the fall arrest system dissipates any fall energy at all (which it does) impact
energies will be reduced below the energy from falling from the threshold height.
3. Only the kneeling worker might not have enough Clearance.
4. The probability of a kneeling worker falling off the catwalk is much lower and less serious
than for a standing worker.
5. It can be argued that less than the two foot Clearance Margin may still be safe.
It was therefore decided that the dual SRL design had a good
chance of success, so the selected SRLs were purchased to test
whether the system behaved in accordance with the computer
model.
Testing
The two selected SRLs were purchased, and the anchors for the
SRLs on Rig Mast and at the end of the Catwalk were designed and
installed. Testing was conducted on the Drill Rig on July 6, 2012.
All tests dropped a 310 lb rigid test mass (as specified by the CSA
Z259.16 standard).
Figure 25 shows test #2 with the test mass located 34 feet
horizontally from the rig mast. There was a total vertical fall
distance of 71 inches and a horizontal swing displacement of 12.5
inches in this test.
Total
Distance Vertical Horizontal
Test from Rig
Swing
Fall
No.
Mast
Distance Distance
1
N/A
>66 in
N/A
2
34.0 ft 71
in 12 1/2 in
3
34.3 ft 64 5/8 in 15 3/4 in
4
22.7 ft 60 1/4 in
6
in
5
23.1 ft 40 1/8 in 10 1/4 in
6
22.5 ft 50 1/2 in
5 5/8 in
7
46.5 ft
> 78 in
40 1/4 in
8
44.0 ft
> 90 in
44 1/2 in
Peak
Force
N/A
450 lb
545 lb
490 lb
N/A
495 lb
610 lb
440 lb
Figure 26
tabulates the test
results.
Comments
Impacted Deck
Figure 26
Tabulation of the results of Test 1 to 8
Overall,
the results were
very
disappointing.
The first test
Figure 25
Test #2: 71 inch total
vertical fall and 12.5 inch
horizontal swing
impacted the catwalk deck, greatly exceeding the expected Total Fall Distance. The test weight
was dropped from higher elevations on all subsequent tests, however, Tests 7 & 8 also saw the
test weight impacting the deck, with total vertical fall distances before impact of 6 to 7 feet.
Figure 27 plots the test results against the predictions from the computer model. The Total
Vertical Fall Distances (in red) were more than double the predictions. The Horizontal Swing
Distances were significantly less than the predictions, except when the mass was dropped near the
end of the catwalk where they were slightly greater.
What went wrong?
8.0 ft
7.0 ft
6.0 ft
5.0 ft
4.0 ft
Horizontal Swing
Distance (from
Computer Model)
3.0 ft
2.0 ft
Horizontal Swing
Distance (from Tests)
1.0 ft
0.0 ft
The peak forces of the impacts were measured on all tests. It was
startling to see that SRLs labeled as having a peak impact of 1350
lbs, gave measured impacts that were between 33% and 45% of
this value. The assumption that the average braking force would
vary from 700 to 1060 lbs was clearly wrong. The fact that the
upper SRL would have had more than 70 ft of its line extracted
meant that the computer model was predicting an average braking
force close to 900 lbs so the peak force measurements should have
been closer to 1200 lbs.
The 130 foot SRL was removed from the Drilling Rig and
was subsequently tested in a static test to determine the braking
forces. Various lengths of cable were pulled out of the device
Figure 27
before locking it off. Then we measured the force as we pulled two
Comparison of test results to computer model
inches of cable from the locked device. The load cell was set to
measure the peak force recorded during the
additional two inches of extraction, after which the
Deployment Force vs. Cable Length
residual force that the device was holding was
600
recorded.
550
10 ft
20 ft
30 ft
40 ft
50 ft
0 ft
500
450
400
350
0.0
50.0
150.0
100.0
8.0 ft
7.0 ft
6.0 ft
5.0 ft
4.0 ft
3.0 ft
Horizontal Swing
Distance (from
Computer Model)
2.0 ft
1.0 ft
0.0 ft
0 ft
10 ft
20 ft
30 ft
40 ft
50 ft
Horizontal Swing
Distance (from Tests)
Figure 29
Comparison of test results to
revised computer model
was used to estimate average braking forces to vary from 390 lbs to 550 lbs.
We also tested the braking speed of the SRLs, and concluded that the braking speed varied
from approximately 9.5 ft.s with all cable on the drum to 6.0 ft/s when all the cable had been
deployed. This allowed greater free fall than we had predicted in our original computer model.
Figure 29 shows the results of modifying the computer model to use the data from our
static braking force and and our braking speed tests. It can be seen that the curve has shifted
dramatically towards the test data, but that the predicted vertical fall distances are still a a little
less than the test results. The horizontal swings are all well below the swings predicted by the
computer model, however our computer model was based on sequencing a vertical fall and
deceleration on the upper SRL before initiating the swing. In reality, the swing should intiate
during the braking from the upper SRL, so our swing calculations are likely too conservative.
The manufacturer was contacted to discuss the results of our tests. There was agreement
that something might be wrong with the SRLs and the representatie stated that the peak braking
forces we had measured seemed a bit too low.
The SRLs were shipped to the manufacturer, who investigated and reported that the
clutches were not set to the factory specified torque. He adjusted the devices to factory
specifications (which were 30% higher than what we had measured) and shipped them back. Our
request to increase the braking force closer to what we desired was denied.
Unfortunately, by the time the SRLs came back from the manufacturer, the Drill Rig had
been shipped to the purchaser, so there was no opportunity to do followup tests. We did however,
need to complete the engineering on this project. We adjusted the SRLs braking forces in our
computer model to vary from 510 to 730 lbs.
Completion of the design:
Figure 30 shows the final clearnce charts published in the Fall Protection Plan and on the
drawings developed for our client. Note that we also stated that a kneeling worker would require
2.5 feet (0.75m) greater Clearance than shown in these charts.
Required Clearance Below Platform
2.5
91 kg worker
1.5
Adequate Clearance
0.0
5.0
10.0
Distance from Rig Mast (m)
15.0
9.0
310 lb worker
8.5
200 lb worker
8.0
7.5
7.0
6.5
6.0
5.5
5.0
Adequate Clearance
0
10
20
30
40
Distance from Rig Mast (ft)
Figure 30
Final Clearance Charts provided with the system
50
The Clearance charts shown in Figure 30 dealt with the Clearance issues in the following ways:
We provided curves for both 310 lb workers (per ANSI Z359.6 and CSA Z259.16) but
showed the reduced Clearances for a worker who weighs 200 lbs. Other weights can be
interpolated between these curves, allowing the employer to select specific workers to do
the maintenance from the catwalk to maintain the 2 foot Clearance Margin.
The 2 ft Clearance Margin is shown as a yellow band, so the employer and worker know
whether the fall is expected to be stopped before the worker strikes the ground, and when
the final elevation of the feet will be less than typical two feet Clearance Margin above
the ground.
The red band indicates the zone where the worker may (lightly) impact the ground. This is
only for falls of a 310 lb worker at the very end of the catwalk.
In the procedures, workers were instructed to mount and exit the catwalk from the stairs
next to the Rig mast, leaving little reason for a worker to be at the far end of the catwalk
where it might be possible to reach the ground in a fall.
Conclusions
1. Low Clearance fall arrest systems are very difficult to engineer. Guardrails or
Travel restraint are always the desired solution. When Fall Arrest is the only
viable option, it must be carefully engineered by a Qualified Fall Protection
Engineer.
2. For the tops of mobile buildings that are nominally 10 feet (3m) high, there is not
enough Clearance for a fall arrest system to work.
3. On the tops of mobile buildings that are low and narrow enough to transport
down public highways, a single low HLL down the middle of the roof cannot
provide a travel restraint system that will prevent a worker from falling off the
roof (unless the system is engineered for the worker to use dual hip attachment so a lanyard short enough to prevent the fall will still allow the worker to stand
while traversing the roof).
4. For situations where there are low Clearances, particularly at heights such as six
feet where some jurisdictions make fall protection mandatory, deflecting
anchorage systems such as horizontal lifelines will not stop the fall within the
available Clearances. The fall arrest option requires a non-deflecting anchorage
system such as a rigid rail.
5. For situations where there are low Clearances above a horizontal platform where
a high anchorage is available, the authors have shown that it may be feasible to
use a dual SRL system, with one SRL mounted on the high anchorage and the
other SRL mounted near the end of the platform. With current SRL technology,
this approach is likely practical for platform elevations greater than 8 feet (2.4
meters) for standing workers and 10.5 feet (3.2m) for kneeling workers. If
following some of the new design rules and philosophies that allow workers to
impact the ground at low fall energies, this system can be marginally acceptable
for platform elevations as low as six feet (1.8m).
The use of the dual SRL system must be carefully engineered by a Qualified Fall
Protection Engineer. Performance of these systems varies dramatically according to the
REAL properties of the SRLs that are specified, the elevations of the SRL anchorages, the
length of the platform, and the weight of the workers.
It is expected that better performing SRLs will soon be available, providing higher braking
forces that will dramatically improve the performance of Dual SRL systems.
Bibliography
ANSI Z359.1-2007, Safety Requirements for Personal Fall Arrest Systems, Subsystems and
Components, American Society of Safety Engineers, 2007
ANSI Z359.6-2009, Specifications and Design Requirements for Active Fall Protection
Systems, American Society of Safety Engineers, 2009
CSA Z259.2.2-14, Self Retracting Devices, Canadian Standards Association, 2014
CSA Z259.16-04, Design of Active Fall Protection Systems, Canadian Standards Association,
2004
CFR 1910.66 Appendix C, United States Occupational Safety and Health Administration
CFR 1926.502(d) (16), United States Occupational Safety and Health Administration
Small, Greg, Clearance Calculations Made Easy, Proceedings of Safety 2013, ASSE Annual
Conference, Las Vegas, NV, 2013
________. Design considerations for Travel Restraint Horizontal Lifelines, Proceedings of ISFP
Conference, Las Vegas, NV, 2013
Work-related injuries and fatalities involving a fall from height, Safe Work Australia, October
2013, ISBN [PDF] 978-1-74361-187-6 [DOCX] 978-1-74361-188-3