Improving Fall Protection in Marine Terminals

Abstract: A fatal incident arising from a sudden illness to a worker on a dock led Shell Oil to decide to enhance their fall protection at all North American terminals. The corporation identified overall performance criteria but allowed each terminal to develop their own system that addresses the unique challenges related to each terminal’s operations, accounting for the range of incoming vessels at the terminal, each with potentially different:
• Vessel egress or gangway locations
• Activities required to place the gangway on the structure
• Mooring arrangements
• Mooring line orientations at each mooring point
• Activities required to connect transfer equipment
Each design team typically developed standard OSHA guardrails to install throughout the terminal in nonoperational areas, like those seen on landside working platforms or along catwalks. Conversely, the teams typically developed dynamic guardrails in the operational areas that slide, swing, or otherwise move from blocking mooring lines and cargo transfer equipment. Only the top rail moves in some terminals, while in other terminals, both the top and midrail slide in the dynamic rails. All of this design work included input from the Operations staff to obtain the buy-in and approval from the people most likely to rely on the fall protection for their safety.
An additional challenge at the Southern California terminal was how to address the short ca. 3 -year remaining lifespan of the existing terminal which was being replaced, with some existing mooring points reused in the new terminal. The result included a multitude of elements, including (4) custom-fabricated pneumatic cages for the waterside-breasting dolphins and constructing safety shelves in the operational areas. The original intent was to move some pneumatic cages to the new terminal once in operation; however, various complications with using the cages and rising fabrication costs led Shell to use dynamic rails at the mooring points in the new terminal.

This paper will discuss several of the fall protection systems considered and implemented at the terminals. The paper will share lessons learned, both success stories, and systems that have not met expectations.

How does this project / topic contribute to the advancement of the industry and profession?: Fall protection is not a widely addressed topic in the industry and may seem to be adequately addressed by standard safeguards commonly used at terminals or required by OSHA. However, a fatal incident triggered Shell to perform a thorough risk assessment and enhance mitigations. Their efforts demonstrate it's possible to implement full fall protection on marine terminals, even in operational or working areas, advancing the limits of fall protection and safety for all occupants. Sharing insights from this project will allow other terminals to benefit from the lessons learned from the design, implementation, and use over a multi-year period.

Does the project / topic implement new and innovative techniques, materials, technologies, and delivery methods?: This topic implements innovative techniques and modifying existing technologies to enhance personnel safety at marine terminals.

What was the most challenging aspect of your project / topic and how did you handle it to ensure success?: The most challenging aspect for Shell was addressing the different conditions at each of the 10 terminals; applying the same design at each terminal was impossible. Shell used the local knowledge of operators and terminal managers to supplement the expertise of their Subject Matter Experts and consultants in tailoring the design to each facility.

Who is the target audience for this paper?: Engineers, Terminal Owners, Terminal Operators, Planners, Contractors