A technician was using a screwdriver wedge / pry out a Teflon (PTFE) insert sleeve from a Durco plug valve. (see picture)
During the process the
screwdriver slipped
and due to the force
being applied it sprung upwards
and
hit the technician’s upper jaw.
The technician was transported to a local medical facility and was diagnosed with a broken
jaw.
Preliminary Investigation Findings
Inserts are “pressed in” during manufacture or during overhaul
and are an extremely tight fit making
them difficult to extract. The standard removal method, as recommended by the
manufacturer, is to
split the insert and then extract
it using pliers.
The recommended way to split the insert is to insert a screw driver through
the ports on the valve
and hit the screwdriver with a mallet until the insert splits.
The technician split the insert as per recommendations but then used a screwdriver to wedge / pry the insert
out rather than using the pliers resulting in the injury.
Action to Prevent Reoccurrences
The local Operations Manager is to deliver a Toolbox
Talk to workshop technicians with reference
to ensuring compliance with
manufacturer’s instructions for the disassembly of valve components.
Immediate Action Required
Workshop Managers/Supervisors to inform workshop personnel to follow manufacturer’s instructions for the disassembly of components. If an alternative method needs to be used, for whatever reason, a pre-work assessment of the additional hazards must be undertaken and appropriate actions taken to remove / reduce the risk.
VR Service Line to initiate review and determine if there are any other methods that would make removal safer.
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