PSC Hand Safety India Private Limited

Oil & Gas
Hand Exposure Audit™

Engineer the Hand out of Hazard™

Oil & Gas Hand Exposure Audit for Drilling, Offshore Rigs, Pipe Yards and Rig Maintenance

This public self-assessment helps oil and gas HSE, drilling, rig maintenance, pipe yard, and lifting teams identify where hands still enter line-of-fire, pinch/crush, suspended-load, impact, hose-whip, and tubular-handling exposure zones.

10 Exposure Sections Score out of 100% Offshore · Onshore · Pipe Yards · Rig Maintenance
Scope Disclaimer: This is a hand-exposure and no-touch handling self-assessment. It is not a rig safety audit, lifting certification, drilling audit, well-control review, BOP assessment, hazardous-area electrical audit, marine-class audit, or statutory compliance certification.
0 – 25%
Exposure Driven
26 – 50%
Partially Controlled
51 – 75%
Structured Exposure Mgmt
76 – 100%
Engineering-Control Led
Hand Exposure Score
0%
Exposure Driven

What This Audit Covers

Lifting, suspended loads and tagline discipline
Tubular handling, pipe yards and stabbing operations
Tong, wrench and make-up / break-out exposure
Hammer unions, striking and impact tasks
Hose, valve and pressure-line handling
Equipment positioning and final alignment
Manual lifting, gas cylinders and portable equipment
DROPS, tools at height and elevated maintenance
Outside This Audit Rig safety, well control, BOP systems, drilling operations, hazardous-area electrical, marine-class compliance, fire & gas systems, or regulatory certification.

Scoring Guide

2
YESConsistently in place across all applicable tasks.
1
PARTIALControl exists but not consistently applied or standardised.
0
NONot in place or not practised.
—
N/ANot applicable. Excluded from total — score adjusts automatically.

Engineering Controls vs PPE — How This Audit Treats Them

In this audit, no-touch tools, push/pull tools, taglines, stabbing guides, tong handles, hose handling tools, impact-isolation tools, lifting aids, and magnetic handling aids are treated as engineering controls / distance controls because they reduce or remove direct hand exposure. They do not replace PPE, but they reduce reliance on PPE as the primary defence.

S1

Lifting & Suspended Load Control

Crane lifts, deck lifts, rig equipment moves, suspended-load positioning, hands near loads, lift planning, load path, sling handling, final placement

0
/ 0%
Are engineered tagline or load-control tools used for all crane and hoist lifts — eliminating bare-hand load guidance during all lift phases?
+2
+1
0
—
Do riggers and deck crew maintain a minimum 2-metre stand-off from suspended loads during all phases of crane movement?
+2
+1
0
—
Is direct hand contact with moving or suspended loads prohibited, actively enforced, and included in pre-lift toolbox talks?
+2
+1
0
—
Are lift plans reviewed for hand-exposure risk at the final positioning and landing stage — not only the hoist phase?
+2
+1
0
—
Are push/pull positioning tools or no-touch alignment aids used during final load placement — instead of hands guiding the load onto its landing point?
+2
+1
0
—
Are slings, shackles, and lifting gear handled and connected without fingers entering pinch zones between sling eyes, shackle pins, and load attachment points?
+2
+1
0
—
"The lift is not the risk. The moment a hand touches a suspended load — that is where the injury occurs."
Answer questions above to see section feedback.
S2

Taglines & Load-Control Practices

Anti-tangle taglines, stand-off distance, rope entanglement, polypropylene/manila rope use, load swing control, direct hand contact, safe tagline retrieval

0
/ 0%
Have polypropylene and manila ropes been fully eliminated from all load-control tasks and replaced with anti-tangle tagline tools?
+2
+1
0
—
Are anti-tangle tagline tools used for every lifted load on site — not only for critical or heavy lifts?
+2
+1
0
—
Are tagline procedures documented, trained, and verified as a mandatory item at every pre-lift toolbox talk?
+2
+1
0
—
Are workers positioned outside the load swing arc during all crane movement phases — with body positioning controlled by tagline tool, not by bracing against the load?
+2
+1
0
—
Are tagline tools inspected before each lift, and removed from service when worn, kinked, or damaged?
+2
+1
0
—
Is a tagline retrieval method in place that allows workers to recover taglines after load placement without re-entering the load path or wrapping rope around the hand?
+2
+1
0
—
Answer questions above to see section feedback.
S3

Tubular Handling & Pipe Yard Exposure

Drill pipe, casing, tubing, pup joints, pipe racks, laydown areas, rolling pipe, pipe-end pinch zones, alignment, controlled release, no manual gripping or foot stopping

0
/ 0%
High-Frequency Hand Injury Zone
Are pipe positioning tools used during tubular alignment and racking — so workers can guide and align pipe without manually gripping, cradling, or lifting the tubular by hand?
+2
+1
0
—
Is a tubular guide tool or pipe alignment aid deployed to control pipe position and achieve controlled release after alignment — without the worker maintaining hand contact until the pipe is fully seated?
+2
+1
0
—
Are workers prohibited from using hands or feet to stop, slow, or steer rolling pipe on pipe racks or laydown areas?
+2
+1
0
—
Have pipe-end pinch zones, box-and-pin connection areas, and rack-stop crush zones been formally identified, assessed, and communicated to all pipe yard and drill floor personnel?
+2
+1
0
—
Are pipe setback, rackback, and drill pipe handling tasks performed using dedicated handling tools — rather than workers manually gripping, slinging bare-hand, or carrying pipe sections by hand?
+2
+1
0
—
Is finger and hand exposure at pipe-end connections, box-and-pin joints, and pipe-wipe operations included as a mandatory item in the pre-job JSEA / JHA for all tubular running operations?
+2
+1
0
—
Answer questions above to see section feedback.
S4

Stabbing, Alignment & Connection Tasks

Casing stabbing, tubing stabbing, drill pipe connection, box-and-pin connections, thread protection, fingers near connection points, flange alignment, final alignment before make-up

0
/ 0%
Are stabbing guides in use for all casing and tubing stabbing operations — so the pipe is guided into the connection without a worker placing hands near the box-and-pin engagement zone?
+2
+1
0
—
Are drill pipe and casing connection alignment tasks performed using a connection guide or tubular guide tool — not by workers manually steadying the pipe end with their hands?
+2
+1
0
—
Are workers trained on the specific crush and pinch risks at box-and-pin, coupling, and thread engagement zones — and is hand placement near active stabbing zones formally prohibited?
+2
+1
0
—
Is flange alignment achieved using alignment tools or push/pull positioning aids — not by workers placing fingers between flange faces or bolt holes to guide alignment?
+2
+1
0
—
Are thread protectors removed and replaced using tools rather than bare hands, and are fingers kept clear of the thread profile during protector removal on heavy tubulars?
+2
+1
0
—
Are stabbing, alignment, and connection tasks included as a mandatory hand-exposure assessment item in every JSEA / JHA for tubular running operations?
+2
+1
0
—
"The connection point is where the hand should never be. It is where it most often is."
Answer questions above to see section feedback.
S5

Tong, Wrench & Make-Up / Break-Out Exposure

Tong handle grip, backup tong positioning, tong jaw arc, spinning chain line-of-fire, finger wrap-around, high-torque manual wrenching, extension handles

0
/ 0%
Critical Strike & Crush Zone
Are tong handles designed or configured to prevent finger wrap-around grip near the tong jaw and chain zone — so hands cannot enter the jaw arc during make-up or break-out?
+2
+1
0
—
Is the backup tong bar positioned and secured without requiring workers to place hands near the tong body or reaction point during active make-up or break-out operations?
+2
+1
0
—
Are workers formally trained on the specific line-of-fire arc of tong handles, backup tong bars, and spinning chains — and is this covered in every pre-job briefing before tong operations?
+2
+1
0
—
Is manual wrenching with conventional spanners on high-torque connections formally risk-assessed for hand exposure — including the specific risk of hand position if the wrench slips?
+2
+1
0
—
Are extension handles or hands-off positioning aids used to create distance between the hand and the connection point during high-torque wrench and tong operations?
+2
+1
0
—
Are finger pinch risks at tong jaws, chain links, and make-up/break-out reaction zones assessed as mandatory items in every JSEA / JHA before tong or wrench operations begin?
+2
+1
0
—
Answer questions above to see section feedback.
S6

Hammer Union, Hammering, Striking & Impact Tasks

Hammer unions, HUWE wrench use, chisel/punch tasks, pins, wedges, seized components, sledgehammer use, strike line, hand-held impact exposure

0
/ 0%
Highest Hand Injury Frequency in Oilfield Operations
Are hammer unions aligned, started, tightened, and loosened without placing fingers between union components — using dedicated tools or aids throughout the full operation?
+2
+1
0
—
Are hammer union tightening and loosening tasks performed using a dedicated hammer-union wrench and handle system — rather than workers holding or positioning the union by hand while striking?
+2
+1
0
—
Are hammer union operations performed without hands in the strike line — with workers clear of the swing arc of the hammer during all striking operations?
+2
+1
0
—
Are punch and chisel holder tools used for all punching, pin-driving, and wedge-striking operations — is direct hand-holding of chisels or drift pins during hammer strikes formally prohibited?
+2
+1
0
—
Are impact isolation tools or Fingersaver-type tools available and deployed wherever a hammer and a hand-held guide would otherwise be used together?
+2
+1
0
—
Is line-of-fire risk for all striking, hammering, and impact tasks assessed as a mandatory item in every JSEA / JHA — covering both the primary strike direction and any rebound or secondary movement?
+2
+1
0
—
Answer questions above to see section feedback.
S7

Hose, Valve & Pressure-Line Handling

High-pressure hoses, hose dragging, hose whip zones, hose ends and couplings, pressurisation/depressurisation, valves, manifolds, flange faces, avoiding direct hand gripping of hose ends

0
/ 0%
Are hose handling tools used when connecting and disconnecting high-pressure hoses — keeping hands away from hose ends and coupling faces during connection and release?
+2
+1
0
—
Are workers positioned outside the hose whip zone during all pressurisation and depressurisation sequences — and is the whip zone formally defined in the task risk assessment?
+2
+1
0
—
Are hoses dragged, repositioned, or routed using handling tools or pull lines — not by workers gripping the hose body or hose end with bare hands under load?
+2
+1
0
—
Is manual holding of valves, flanges, or heavy manifold components during fit-up and alignment replaced by mechanical support, positioning tools, or lifting aids?
+2
+1
0
—
Is hand placement near flange faces, pump ports, manifold connections, and pressure-line interfaces formally assessed before each maintenance task involving these components?
+2
+1
0
—
Are maintenance tasks with residual pressure, stored energy, or unexpected movement risk reviewed for line-of-fire hand exposure before work begins — including valve operation and manifold changeover tasks?
+2
+1
0
—
Answer questions above to see section feedback.
S8

Equipment Positioning & Final Alignment

Skid packages, baskets, generators, mud pumps, containers, BOP-related components, heavy equipment, maintenance components, final landing and alignment before bolting or connection

0
/ 0%
Are push/pull positioning tools or no-touch alignment aids used during the final landing of skid packages, generators, containers, and heavy equipment — instead of workers using hands to guide loads onto their mounting points?
+2
+1
0
—
Is final bolt-hole alignment for heavy equipment, baskets, and mud pump components achieved without fingers entering the bolt hole or flange gap to feel for alignment?
+2
+1
0
—
Are cargo handling tasks for containers, baskets, and large equipment performed using load-control and positioning aids — with hands kept outside the pinch zone between the load and the landing surface?
+2
+1
0
—
Is final positioning of maintenance components — including pump covers, motor housings, gearboxes, and BOP-related subcomponents — performed with mechanical or tool support rather than manual holding in position?
+2
+1
0
—
Is hand exposure during final load alignment — including the moment just before a load touches down — specifically addressed in every lift plan and pre-task risk assessment?
+2
+1
0
—
Are load control, stand-off, and no-touch positioning requirements communicated to all personnel involved in equipment positioning operations — including crane operator, banksman, and maintenance crew?
+2
+1
0
—
Answer questions above to see section feedback.
S9

Manual Lifting, Gas Cylinders & Portable Equipment

Gas cylinders, gas bottles, valves, pipe sections, portable equipment, awkward loads, two-person lifts, hand/finger exposure during lifting, carrying, setting down, and releasing

0
/ 0%
Are gas cylinders and gas bottles moved, positioned, and set down using a dedicated cylinder handling tool or grip aid — rather than being manually dragged, tilted, or balanced by hand?
+2
+1
0
—
Are portable lifting aids or assist devices used for handling heavy valves, portable equipment, and awkward loads — removing the need for workers to grip, cradle, or hold them in position manually?
+2
+1
0
—
Are magnetic handling aids used for ferrous components — steel plates, flanges, pipe sections — where direct gripping would place fingers in a pinch or crush zone?
+2
+1
0
—
During two-person manual lifts, are hand and finger positions formally discussed before lifting — specifically identifying crush points at set-down surfaces, door frames, rack edges, and equipment bases?
+2
+1
0
—
Are portable pipe sections, short tubulars, and pup joints moved using handling tools or slings — rather than workers carrying them on the shoulder or cradling them with bare hands at the pipe ends?
+2
+1
0
—
Is hand and finger exposure during the release and set-down phase of manual lifts — the moment the load contacts the surface — formally identified as a risk and controlled in task planning?
+2
+1
0
—
Answer questions above to see section feedback.
S10

DROPS, Tools at Height & Elevated Maintenance

Dropped objects, derrick/mast/basket work, elevated maintenance, tool tethering, secondary retention, tool registers, hand exposure while receiving or releasing tools at height

0
/ 0%
Are all tools used at elevation tethered or fitted with secondary retention — without exception — before work begins at the derrick, mast, monkey board, or work basket?
+2
+1
0
—
Is a formal dropped-object risk assessment completed before every elevated maintenance task on the rig structure — covering both the exposure of workers below and the hand exposure of workers at height?
+2
+1
0
—
Are exclusion zones established and enforced directly below all active elevated work areas — preventing workers from entering the drop zone during tool operations at height?
+2
+1
0
—
Are tool control registers maintained and verified before and after every elevated task — confirming all tools are accounted for and no untethered items remain at height?
+2
+1
0
—
Is hand exposure during overhead maintenance tasks — reaching, steadying, receiving tools, guiding components into position — specifically included in pre-task risk assessments for elevated work?
+2
+1
0
—
Is the transfer of tools and equipment to and from elevated work positions controlled — using tool bags, pouches, or hoisting lines rather than hand-to-hand passing between levels?
+2
+1
0
—
Answer questions above to see section feedback.
"If the hand can reach the hazard zone — the system is incomplete."

Your Score is Ready

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0 % Exposure Driven

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PSC Oil & Gas Hand Exposure Report

0%
Exposure Driven
⚠ One or more sections were assessed based on SOP/procedure only or marked as unverified. SOP-only or unverified sections should be field-verified before final action planning.

Section-by-Section Breakdown

Section Score Frequency Basis Priority

Top 3 Priority Exposure Areas

Exposure Gap Analysis

Sections scoring below 60% are shown below with recommended PSC / HSF control categories.

Recommended Next Steps

🔍
Request PSC Oilfield Hand Exposure Review
On-site or remote review of your highest-risk tasks mapped to specific engineering controls.
🛠
Request Oilfield Tool Mapping
Match no-touch handling tools to your lowest-scoring sections. Scoped to your rig type and task list.
📡
Book No-Touch Tools Webinar
Live session with PSC engineers — tools demonstrated on oilfield tasks similar to yours.
📋
Deploy Internally
Share with tool pushers, HSE leads, and rig supervisors as a structured exposure baseline.
🔍 Request Hand Exposure Review 🛠 Request Tool Mapping 📡 Book No-Touch Webinar ✉ Contact PSC

Frequently Asked Questions

What is a hand exposure audit?
A hand exposure audit is a structured self-assessment that identifies where workers' hands enter hazard zones during industrial tasks — including line-of-fire positions, pinch and crush points, suspended-load contact, impact zones, hose-whip areas, and tubular-handling pinch points. Unlike a general safety audit, it focuses specifically on the gap between where hands are and where they should never be, and maps that gap to engineering controls that remove or reduce direct hand contact.
Is this a full rig safety audit?
No. This is a hand-exposure and no-touch handling self-assessment only. It does not assess rig safety, well control, BOP systems, drilling operations, hazardous-area electrical compliance, marine-class systems, lifting certification, or any statutory regulatory requirement. Those assessments require qualified specialist auditors and formal certification processes. This audit is scoped specifically to hand exposure, line-of-fire, pinch/crush zones, impact tasks, tubular handling, hose and valve work, and engineering controls that reduce direct hand contact.
Who should use this audit?
This audit is designed for HSE managers, rig supervisors, tool pushers, drilling engineers, maintenance leads, pipe yard supervisors, lifting coordinators, and any operations or safety professional working in offshore rigs, onshore drilling sites, pipe yards, well services, FPSO operations, or rig maintenance and fabrication environments. It can be completed individually or used as a team baseline assessment to identify where engineering controls for hand exposure are missing or inconsistently applied.
What does the score mean?
The score is expressed as a percentage out of 100, adjusted for any N/A questions you exclude. It reflects how consistently engineering controls and no-touch handling practices are in place across your operation. A score of 0–25% indicates hands are routinely entering hazard zones with little or no engineering control in place. 26–50% means some controls exist but application is inconsistent. 51–75% means a structured system is developing but gaps remain. 76–100% means engineering controls are embedded and consistently applied. The score is a self-assessment indicator — not a certification or compliance rating.
What happens after completing the audit?
After completing the audit, you can unlock your full Hand Exposure Report by entering your details. PSC will send a one-time personalised report with recommended engineering controls mapped to your lowest-scoring sections and your facility type. You can also request a PSC Oilfield Hand Exposure Review for an on-site or remote assessment, request tool mapping to match specific no-touch handling tools to your task list, or book a No-Touch Tools Webinar to see PSC and HSF tools demonstrated on tasks similar to yours. The audit can also be printed or saved as a PDF to share with your HSE team, rig supervisor, or management.