Safety Lessons for Offshore Wind

As the U.S. builds utility scale offshore wind projects, analysis on the complete coverage of hazards needs to be performed to ensure compliance across all necessary protocols for safe execution. In this article I explore several ways this can be accomplished during the on-shore pre-assembly of the offshore wind turbine generators (WTGs) at the marine terminal, a critical element to the safe operation of the overall system.

Black & Veatch’s core cultural value is safety, so this is a topic of key interest for us. Black & Veatch has developed an award-winning Healthy Safety and Environmental (HSE) model combining the safety protocols for onshore construction with the uniqueness of the quayside environment including working at heights protocols for the Vineyard Wind 1 project. I have several key lessons learned from this program that I’d like to share:  

1. Safety is a daily practice that EVERYONE participates in

The site manager and construction manager are responsible for safety performance on projects while the site safety staff services a critical role in the implementation of safety programs. From coordinating meetings to monitoring compliance, the safety manager helps drive safe behaviors by incorporating safety in the daily activities and interacting with craft and supervisors to make sure that safety issues are being addressed. They also interact with subcontractor management and clients to ensure all parties are on the same page.

One policy implemented on our site is the Employee Involvement Process (EIP), an anonymous form noting any potentially unsafe conditions, safe working practices, good catches, environmental concerns, and any general safety related observations made on the job. The overall goal is to provide ample opportunities for employees to engage in meaningful conversations within the work crews to improve daily safety processes while promoting active safety participation within project teams. Although this form is voluntary, our culture naturally makes it an expectation. The feedback from union workers is resoundingly positive.

2. Little details make a big difference

The vast scale and complexity of the project requires every minor detail to be extensively planned. Procedures that may be routine on smaller scale projects are considerably more dangerous, which makes coordination and communication paramount to success. Unlike typical wind projects, the space available to store the quantities of large offshore wind turbine components is somewhat limited at a marine terminal, leaving zero room for error. This is reflected in the HSE program on site. Navigating these large-scale objects throughout a congested worksite while directing multiple independent groups is a logistical feat requiring significant planning and coordination. Every task is unique and the first of its kind, every lift requires its own rigging and custom protocols.

3. Extra training and protocols are a necessity

The sheer scale of such an endeavor increases the need for extensive safety protocols and trainings. Precise movement of these large heavy components requires all personnel to be confident in their ability to perform their responsibilities. Everyone on-site regardless of responsibilities undergoes three thorough safety orientations from all involved parties. Basic PPE use throughout the entire site is mandatory and reflects the level of care required for the shifting activities depending on which part of the scope is being executed. Aside from the mandatory in process inspections of the rigging and equipment during lifting execution, there are additional comprehensive pre-use inspections for all equipment to verify if any damage had occurred during last usage. To combat the number one cause of construction deaths in the United States, fall protection is emphasized. A 100% tie off rule above 6 ft anywhere and at all times is in place, with encompassing policies ensuring we do not contribute to the statistic. Additionally, all tradesmen undergo specific training in all aspects of the job. This ranges from Global Wind Organization (GWO) trainings, hazards, lock out tag out (LOTO), and other safety requirements to specific training for unique task procedures.

4. Psychological Safety

The final piece, just as critical as physical safety, is Psychological Safety. Safety works when all employees and professionals on a project have the tools readily available to speak up and address areas of concern without judgement. The Black & Veatch Safety Leadership encourages that we all practice STOP WORK EXPECTATIONS to promote the collective belief that we all have the authority to STOP unsafe acts and/or conditions when observed. This is one example of the tools Black & Veatch employees have to shape our cultural holistic safety. Culture is one of a company’s largest assets and we’re leveraging ours as one of psychological safety to build on our brand values of integrity, accountability, and responsibility.

We are at the forefront of developing a workforce with the skills and knowledge to lead us into tomorrow as we progress in building gigawatts of offshore wind already on the US backlog. Success is only possible through a cohesive communication system on the ground that starts with the individual performing the actual work.

Offshore wind projects come with a plethora of unique challenges to address where we have only touched upon one area here. With such an impressive scale, minor mistakes can translate into major errors with the size of the equipment and movement, further increasing the importance of compliance and adherence to safety protocols. The work can be summed up by a simple phrase (our mantra): Think, Plan, Act to achieve Zero Injuries Today.