Oil and gas operations involve unique challenges. Among them is the handling of suspended loads, which can range from heavy equipment to essential materials, requiring special attention to ensure the safety of everyone involved.

In this article, we will explore the fundamental concepts related to suspended loads, the associated risks, the importance of preventive maintenance, the promotion of a safety culture and the innovative technologies that are shaping the future of safety in suspended load operations.

By learning about best practices and available technologies, we can contribute to a safer and more productive working environment. See below for more information on this crucial topic for industry. 

What are suspended loads?

Suspended loads are elements that are lifted and transported using equipment such as cranes, pulleys and other lifting devices. In the context of oil and gas operations, these loads are fundamental, as they often involve the movement of essential and heavy materials that are crucial to the execution of projects and operations in the sector.

The importance of suspended loads cannot be underestimated, as they play a vital role in the efficiency and safety of operations. Improper handling can lead to serious accidents, affecting not only the integrity of the equipment, but above all the safety of the workers involved.

Examples of suspended loads

• Drilling Equipment: Towers, pumps, and bits;
• Construction Materials: Metal structures and piping;
• Platform Components: Generators, transformers, and tanks.

Main risks in suspended load operations

Operations with suspended loads, especially in the oil and gas industry, involve a series of risks which, if not managed properly, can result in serious accidents. Identifying these risks is fundamental to ensuring the safety of workers and the integrity of equipment.

Identifying risks

• Load Drops: One of the most common risks, when a loose or improperly secured load falls, it can cause fatal injuries and significant material damage;
• Collisions: Occur when lifting equipment collides with structures or other equipment, resulting in damage and potential injuries;
• Equipment Failures: Poorly maintained or defective equipment can fail during operation, leading to accidents;
• Worker Exposure: Workers may be exposed to risks such as falls, crush injuries, and injuries from improper load handling.

Load falls, collisions and equipment failures

Load drops can occur due to:

• Improperly calibrated lifting equipment;
• Lack of regular inspection;
• Improper use of lifting techniques.

Collisions are usually caused by:

• Operator inattention;
• Lack of proper signage in the workplace;
• Congested work environments.

Equipment failures can be prevented by:

• Regular preventive maintenance;
• Training operators in the safe use of equipment;
• Monitoring constant monitoring of equipment condition.

It is therefore imperative that companies in the oil and gas sector implement strict safety and maintenance practices to minimize these risks and protect their workers.

Safety culture

Safety culture is a set of values, practices and behaviors that prioritize safety in the workplace. In oil and gas operations, where the handling of suspended loads is common, a strong safety culture is vital to protect the lives of workers and ensure the integrity of equipment.

Safety culture concept

A healthy safety culture means that all employees, from top management to operators, are committed to maintaining a safe environment. This involves:

• Awareness: All workers should be aware of the risks and best safety practices;
• Shared Responsibility: Safety is the responsibility of everyone, not just the safety team.

Promotion strategies

To cultivate a robust safety culture in operations, some effective strategies include:

• Regular Training: Conduct continuous training sessions to keep everyone updated on safety procedures;
• Open Communication: Establish channels where workers feel comfortable reporting concerns and suggesting improvements;
• Recognition of Best Practices: Rewarding safe behaviors can encourage others to follow suit.

Promoting a culture of safety in suspended load operations is an ongoing task that requires commitment from everyone, especially leaders. A safe working environment not only reduces risks, but also improves team morale and productivity.

Best practices for safe operations

Suspended load operations in the oil and gas industry require special attention to safety practices to ensure the protection of all involved. To achieve this, some best practices should be adopted, including continuous training, equipment maintenance, and the correct use of Personal Protective Equipment (PPE).

Continuous training

Regular training of operators is fundamental to guaranteeing safe operations. Through continuous training programs, workers can:

• Update Knowledge: Stay informed about new techniques and safety standards;
• Practice Simulations: Conduct simulations of risk situations to prepare for emergencies;
• Reinforce Awareness: Constantly remind everyone of the importance of safety in daily operations.

Additionally, it is important that the training is tailored to the specific needs of each team and operation to maximize effectiveness.

Correct use of PPE

Personal Protective Equipment (PPE) is essential to protect workers in suspended load operations. It is essential that all employees use the appropriate PPE and follow best practices:

• Helmets: Protect against impacts and falling objects;
• Safety Goggles: Protect the eyes from particles and chemical substances;
• Gloves: Should be selected according to the type of material handled to ensure adequate protection;
• Safety Boots: Offer foot protection against heavy objects and adverse conditions.

As well as using PPE correctly, it is crucial that workers are trained in how to use and maintain this equipment.

Cargo beacon pole

The load balancer pole is a specific piece of equipment for ensuring safety and efficiency in suspended load handling operations. It is therefore essential that it is used in contact with the load for the safety of workers and operations, due to its unique benefits:

• Visibility: Contrasting colors for easy identification from a distance;
• Electrical insulation: Made from non-conductive material to protect against electric shock;
• Suitable length: Keeps a safe distance from the moving load;
• Ergonomic handle: Facilitates handling and reduces operator fatigue;
• Resistance: Built with durable materials to withstand harsh working conditions;
• Light signaling: Some models have lights for operations with low visibility.

Equipment maintenance

Routine preventive maintenance is essential to guarantee operational safety. Lack of maintenance can lead to equipment failure, which is one of the main causes of accidents. For effective maintenance, consider the following practices:

• Regular Inspections: Conduct periodic checks on all equipment used in suspended load operations;
• Maintenance Records: Keep a detailed record of maintenance performed to monitor equipment performance;
• Maintenance Team Training: Ensure that the team responsible for maintenance is well-trained and up-to-date on best practices and procedures.

The importance of preventive maintenance

Preventive maintenance is an essential practice in suspended load operations in the oil and gas industry. It refers to a set of programmed activities aimed at preventing failures and ensuring the proper functioning of equipment. Unlike corrective maintenance, which is carried out after a failure has occurred, preventive maintenance acts proactively.

Definition and comparison

For a better understanding, let's look at the main differences:

• Preventive Maintenance: Conducted at regular intervals to prevent failures. Examples include periodic inspections and scheduled part replacements;
• Corrective Maintenance: Performed after identifying a problem. Examples include emergency repairs and replacement of damaged components.

Exemplos de falhas evitáveis

Some faults that can be prevented through regular maintenance include:

• Failure of lifting cables: Worn cables can break, causing loads to fall. Regular inspection can identify wear before it becomes critical;
• Pulley breakdowns: Poorly lubricated pulleys can fail, leading to accidents. Preventive maintenance ensures proper lubrication;
• Hydraulic system failures: Leaks can cause loss of control during lifting. Periodic inspections can detect leaks in time.

Benefits of preventive maintenance

Preventive maintenance brings a number of significant benefits:

• Increased safety: Reduces the risk of accidents by ensuring that equipment is always in good condition;
• Improved productivity: Well-maintained equipment operates more efficiently, reducing unexpected downtime;
• Cost reduction: Avoiding failures means less spending on emergency repairs and equipment replacements.

Preventive maintenance is not just a recommended practice, but an imperative necessity to guarantee safety and efficiency in suspended load operations in the oil and gas sector. Investing in preventive maintenance is therefore investing in a safer and more productive working environment.

Technologies to increase security

In the context of suspended load operations in the oil and gas industry, the adoption of emerging technologies has proved vital to increasing safety and operational efficiency. Technology not only helps to prevent accidents, but also to optimize processes and ensure a safer working environment for all employees.

Technological innovations

The technological innovations are transforming the way suspended load operations are conducted. Here are some of the key technologies contributing to safety:

• Load sensors: Devices that monitor the suspended load in real time, ensuring that it does not exceed safe limits;
• Remote monitoring: Systems that allow operations to be monitored remotely, enabling risk situations to be identified before they become a problem;
• Artificial Intelligence: Algorithms that analyze operational data to predict failures and suggest preventive maintenance;
• Augmented reality: Tools that offer immersive training and realistic simulations for operators, increasing familiarity with equipment and safety procedures;
• Connected safety devices: Equipment that communicates with each other, alerting operators to unsafe conditions in real time.

Intelligent suspended load monitoring: ALTAVE solution

The ALTAVE solution is an example of technology that is revolutionizing safety in suspended cargo operations.

How it works:

The ALTAVE HARPIA system uses advanced artificial intelligence and machine learning algorithms to monitor operations with suspended loads. This is done using strategically positioned cameras that capture images in real time.

These images are analyzed by the software to identify restricted areas, detect the presence of people in risk zones and recognize the proper use of Personal Protective Equipment (PPE). In addition, the system allows for the agile demarcation of restricted areas, which can be saved and reused according to operational needs.

Data transformed into intelligence:

The information collected is processed instantly, generating immediate alerts when risk situations are detected, such as the presence of people in restricted areas or the improper handling of suspended loads.

ALTAVE HARPIA compiles this data into intuitive dashboards, offering valuable insights into behavior patterns, incident frequency and the effectiveness of security measures.

This way, you can make in-depth analyses and base your strategic decisions on our reports, continuously improving operational safety.

Segurança aumentada:

Nossa solução eleva significativamente os padrões de segurança nas operações com cargas suspensas, pois, ao detectar automaticamente situações de risco, como “mão na carga” ou “homem sob carga suspensa”, o sistema previne acidentes potencialmente fatais.

Além disso, a tecnologia assegura o cumprimento rigoroso das normas de segurança do trabalho, reduzindo drasticamente a exposição a riscos e as responsabilidades legais associadas. A presença do sistema fomenta uma cultura de segurança sólida, incentivando os colaboradores a adotarem práticas mais seguras em suas rotinas.

Better operational efficiency:

Implementing the ALTAVE system results in a significant improvement in operational efficiency. By minimizing interruptions caused by security incidents, downtime and associated costs are reduced.

Automatic compliance with HSE regulations simplifies auditing processes and reduces the risk of fines. The data analysis provided by the system allows for continuous optimization of safety procedures, resulting in smoother and more productive operations.

Overall, the ALTAVE solution not only protects lives, but also contributes to a more efficient and cost-effective working environment.

About ALTAVE

ALTAVE is a Brazilian company, accredited as a Strategic Defense Company (EED), with patented technology in Brazil and abroad. The company has obtained CE marking, indicating the approval of its product quality to be marketed throughout the European Union.

ALTAVE has been offering efficient, differentiated and quality solutions for over 10 years for the Defense and Security, Energy, Mining, Ports, Agribusiness and Oil and Gas sectors.

Let's have a chat?

Contact us to learn more about how our solution can help your company!

Conclusion

Suspended load operations in the oil and gas industry present significant challenges, but also valuable opportunities to improve safety and efficiency. Throughout this article, we discuss the importance of understanding the associated risks, the need for effective preventive maintenance and the promotion of a solid safety culture among all employees.

The adoption of emerging technologies, such as our solution, can transform the way we manage these operations, providing critical data in real time and enabling more informed decisions that prevent accidents and increase productivity.