This incident, reported by the Marine Safety Forum, occurred during drydock operations involving a vessel undergoing a flag change. The event highlights the risks associated with handling equipment at height without adequate planning or task-specific knowledge.
What Happened
During a drydock period, a vessel required all lifebuoys to be re-marked due to a change in port of registry. Early in the day, the Chief Officer directed the deck crew to collect all lifebuoys. While attempting to retrieve the port-side man overboard (MOB) lifebuoy, an Able Seaman (AB) released the retaining pin while holding the connecting line to the smoke float. The AB underestimated the lifebuoy’s weight, lost grip, and the lifebuoy with the attached smoke float fell approximately 22 meters, striking the quayside edge before landing at the bottom of the drydock. The combined weight of the object was 7.6 kg.
Dock personnel were present on the dock bottom at the time, though not directly in the impact area. All work was immediately halted, and personnel evacuated the area as the smoke float discharged.
Why It Happened
The incident occurred due to a combination of inadequate planning, lack of familiarity, and insufficient risk awareness. The risk assessment and toolbox talk conducted before the task failed to identify the potential for dropped objects, particularly in a drydock environment where personnel may be working below. No control measures were implemented to restrict access to the drop zone, leaving dock personnel exposed to potential harm.
The Able Seaman (AB) assigned to collect the lifebuoys was unfamiliar with the specific setup of the man overboard (MOB) lifebuoy and its attached smoke float. This unfamiliarity contributed to his failure to disconnect the smoke float or properly secure the lifebuoy before releasing the retaining pin. Furthermore, the AB did not anticipate the greater weight of the MOB lifebuoy, which differs significantly from standard lifebuoys. When faced with an unexpected situation, he did not pause to reassess or consult with a supervisor, continuing the task without addressing the increased complexity.
Actions Taken
Following the incident, the vessel owner conducted a comprehensive review of the onboard safety procedures. A meeting was held to evaluate and improve the existing risk assessment processes, including how tasks are assigned and how simultaneous operations are managed. It was acknowledged that the task should have been delegated to a crew member familiar with the specific lifebuoy arrangement.
The pre-task briefing was found to be insufficient, lacking the detail required for safe execution. The crew was also reminded of the importance of the “Step-back” approach—encouraging individuals to pause and raise concerns if a job becomes more complex than initially expected. A dedicated session was held to reinforce the crew’s responsibility to speak up, ask questions, and stop work when unsure, emphasizing a proactive safety culture.
Lessons Learned
- Always consider dropped object risks during planning, especially when working at height.
- Assign tasks involving specialized equipment to trained and familiar personnel.
- Ensure pre-task briefings are detailed enough to cover possible variations and complications.
- Encourage a strong safety culture where crew members are empowered to stop the job and seek clarification when necessary.
- Establish exclusion zones in potential drop areas to protect personnel during overhead work.
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Source: Marine Safety Forum
