Flying metal fragment during bearing removal
Prototype · view as
What happened
During mud pump crankshaft bearing dismantling, while hammering to remove the bearing with the support of a chisel, a small metal fragment broke off from the bearing and struck the employee on the chest. As a result, a minor cut was observed on the skin surface.
Immediate action: First aid was provided on site. Work stopped and area cleared until the method was reviewed.
Incident details
- Category
- First aid case
- Activity
- Maintenance
- Work related
- Yes
- Who is responsible
- Company
- Permit to work
- Yes · PTW-0123
- Short description
- ME, Onshore Abu Dhabi Workshop | IP struck in chest by fragment
- Site type
- Company site · Onshore
- Region / country
- Middle East · UAE
- Asset
- Abu Dhabi – Workshop (Other)
- Exact location
- Workshop yard
- Job
- WO-1010 · Mud pump inspection & dismantling
- Customer
- Internal
Weather conditionsNot recorded – indoor work
- Visibility
- —
- Wind
- —
- Sea state
- —
Classification
Confirmed by HSEQ on 12 Sep 2026
Risk assessment
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Life-saving rules
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1Injured persons
RNRahul Nair
Mechanical Technician · Employee · Chest – minor cut · First aid
Mechanical Technician · Employee · Chest – minor cut · First aid
0Environmental
0Property / equipment
1Persons in charge
STSara Thomas
Workshop Supervisor
Workshop Supervisor
0Witnesses
2Investigation team
AMArjun Menon
Lead investigator · HSEQ ManagerLead
Lead investigator · HSEQ ManagerLead
PDPriya Das
HSE Advisor
HSE Advisor
No photo of the injury has been uploaded yet. Action A-0404 requires one.
Photos & video
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Documents
| File | Type | Uploaded by | Date |
|---|
Investigation summary
Completed 18 SepRoot cause analysis · 5 Whys
Select a box, then add a "why" beneath it or edit it.
ProblemFlying metal fragment during bearing dismantling caused a minor injury to the employee.
Why 1The employee was hit by a metal fragment while removing the bearing using a hammer and chisel.
Why 2The metal fragment broke off from the bearing due to the hammering impact.
Why 3A hammer and chisel were used because no bearing puller was available for this size.
Why 4The dismantling method did not adequately control the risk of flying metal fragments.
Root cause · Unsafe working procedures or instructions
Failed process · SAF01 Risk Assessment
People
No face shield worn; task familiarity
Method
Hammer & chisel method not risk assessed ★
Equipment
Correct bearing puller unavailable
Materials
Brittle, worn bearing race
Environment
—
Management
JSA not reviewed for this task
Corrective & preventive actions
All actions must be verified before the incident can go for HSEQ approval.
| ID | Action | Type | Owner | Due | Closed | Status |
|---|---|---|---|---|---|---|
| A-0405 | Install guard / use hydraulic bearing puller for all mud pump bearings Engineering control · Photo evidence required | Preventive | ST Sara Thomas | 22 Sep 2026 | — | Overdue |
| A-0404 | Obtain photograph of injury | Investigation | AM Arjun Menon | 24 Sep 2026 | 16 Sep 2026 | Closed |
| A-0403 | Obtain statements from all parties | Investigation | AM Arjun Menon | 24 Sep 2026 | 13 Sep 2026 | Closed |
| A-0402 | Obtain photographs of incident / work area | Investigation | ST Sara Thomas | 24 Sep 2026 | 12 Sep 2026 | Closed |
| A-0401 | Review and obtain copies of all relevant documentation | Investigation | AM Arjun Menon | 24 Sep 2026 | 12 Sep 2026 | Closed |
4 of 5 complete
HSEQ review
Approvals
SequentialLinked records
Audits referencing this incident
Not referenced in any audit yet.
Lessons learned
Comments
ST
Sara Thomas 2 d ago
Hydraulic puller ordered – delivery expected 30 Sep. Need an extension on A-0405.AM
Arjun Menon 1 d ago
OK – please raise an extension request with the PO attached.AM