Offshore work: The invisible dangers workers face every day at sea

SHAH ALAM - The deaths of three contractor personnel during maintenance work at the Sepat offshore platform off Terengganu have once again placed a spotlight on the harsh and often dangerous realities faced by offshore oil and gas workers every day.

The incident, which occurred on Sunday aboard a floating storage and offloading (FSO) vessel, involved a lifeboat maintenance operation that turned tragic when the rope or hook connected to the lifeboat allegedly detached, causing four workers to plunge into the sea.

Three workers were pronounced dead upon arrival at the hospital, while another worker remains in critical condition.

While investigations are ongoing, the tragedy saw discussions surrounding occupational hazards in offshore oil and gas operations, an industry globally recognised as one of the most high-risk working environments.

A workplace surrounded by danger

Offshore personnel work in isolated environments surrounded by heavy machinery, flammable materials, unpredictable weather, high-pressure systems and hazardous equipment, often hundreds of kilometres away from shore.

Unlike conventional workplaces, emergency response offshore can also be delayed due to weather conditions, sea state and helicopter or vessel accessibility.

Workers onboard offshore platforms, rigs and FSO vessels routinely carry out high-risk activities including:

• Heavy lifting and crane operations
• Rope access and working at heights
• Lifeboat inspections and maintenance
• Confined space entry
• Welding and hot work
• Drilling operations
• Equipment maintenance under high pressure
• Chemical handling
• Helicopter transfers
• Diving and subsea operations

Even routine maintenance work can become fatal within seconds if a mechanical component fails or safety procedures break down.

Lifeboat maintenance among known offshore risks

Although lifeboats are designed as emergency-saving equipment, maintenance and testing activities involving lifeboats are themselves considered high-risk operations in the maritime and offshore industry.

Globally, multiple fatal accidents have occurred during lifeboat drills or inspections due to hook failures, release mechanism malfunctions, wire defects and human error.

In the Sepat incident, police said the victims had boarded the lifeboat to lower themselves into the sea for maintenance work before the attachment system allegedly detached.

Such operations involve suspended loads, working over open water and dependence on mechanical integrity, where even a single point of failure can lead to catastrophic consequences.

‘Struck-by’ and ‘caught-between’ incidents remain major killers

According to findings by the Occupational Safety and Health Administration (OSHA), three out of every five fatalities in the oil and gas extraction industry stem from 'struck-by,' 'caught-in,' or 'caught-between' incidents.

These accidents frequently occur during:

• Drilling activities
• Lifting operations
• Equipment maintenance
• Handling pipes and heavy machinery
• Crane and hoisting work

Struck-by incidents refer to workers being hit by moving equipment, falling objects or swinging loads, while caught-between or caught-in incidents involve workers being crushed, trapped or pinned between machinery or structures.

Offshore environments intensify these risks due to confined spaces, moving platforms, slippery surfaces and continuous industrial operations operating around the clock.

Fatigue and mental strain also pose hidden risks

Beyond physical hazards, offshore personnel also endure long rotations away from family, physically exhausting shifts and mental stress caused by isolation and harsh working conditions.

Many offshore workers spend weeks at sea working 12-hour shifts daily in demanding weather conditions.

Safety experts have long warned that fatigue can significantly increase the risk of operational errors, lapses in judgment and workplace accidents.

Safety systems exist but risks remain

Modern offshore operations are governed by strict safety frameworks involving:

• Permit-to-work systems
• Toolbox meetings
• Hazard identification assessments
• Emergency drills
• Personal protective equipment (PPE)
• Lockout-tagout procedures
• Safety audits and inspections

However, industry observers note that even with multiple layers of safety protocols, accidents can still happen due to equipment failure, procedural gaps, communication breakdowns or human error.

Offshore contractors are also often exposed to additional risks as they are commonly assigned to specialised maintenance, lifting or inspection work.

A reminder of the human cost behind energy production

The Sepat tragedy has become a crucial reminder of the human risks behind offshore energy production, an industry that powers economies but relies heavily on workers operating in some of the world’s most unforgiving environments.

As investigations continue, the incident is expected to renew scrutiny on offshore maintenance procedures, contractor safety management and equipment integrity standards across the industry.

For many offshore personnel, danger is not occasional; it is part of the job every single day.