Manual Handling Safety Procedure

Pars Oil & Gas Company Manual Handling Safety Procedure HEALTH, SAFETY AND ENVIRONMENT PROCEDURE Manual Handling Safety Procedure DOCUMENT ID - PR-26-POGC-001 REVISION 0.0

Pars Oil & Gas Company Pages 21 Revision 00 Manual Handling Safety Procedure Document ID. PR-26-POGC-001 HSE Department Manual Handling Safety Procedure Document Authorization Document Type Security Classification Document Authority/Owner Document Custodian Safety Procedure Unrestricted P.O.G.C HSE Document Author HSE-S564392 Approved By M.Ansari HSE-S593443

Table of Contents 1. INTRODUCTION... 3 2. PURPOSE... 3 3. SCOPE... 3 4. RESPOSIBILITIES... 3 5. PROCEDURES... 5 5.1 GENERAL... 5 5.2 ASSESSMENTS... 5 5.3 REDUCING THE RISK OF INJURY... 7 5.4 GOOD HANDLING TECHNIQUES... 9 5.5 KINETIC METHOD (SEE FIGURES 3, 4 AND 5)... 13 6. TRAINING... 14 7. DEFINITIONS & ABBREVIATIONS... 14 8. REFERENCES... 15 9. APPENDIXES... 16 SUGGESTION FORM September 2012- Manual Handling Safety Page 2

1. INTRODUCTION Pars Oil and Gas Company (POGC), a subsidiary of National Iranian Oil Company (NIOC), was established in 1998. POGC is a developmental and manufacturing organization that specializes in the fields of engineering and management of development projects, production, operation and integrated management of oil and gas reservoirs. POGC s mission is to ensure sustainable and preservative production and development of Iran s oil and gas industry in the areas under its responsibility, development of oil and gas value chain as well as optimization of energy supply processes at national, regional and international levels. POGC is also in charge of development of joint and non-joint oil and gas fields of the country including South Pars, North Pars, Golshan and Ferdowsi. Aimed at creating superior value and boosting the level of satisfaction of the beneficiaries and with an approach focusing on sustainable, integrated and knowledge-oriented production and development, the company feels committed to comply with national and international requirements, regulations and standards in such areas as quality, safety, as well as occupational and environmental health. 2. PURPOSE This procedure and guidance information has been developed to ensure that all persons carrying out manual handling duties handle the load in the safest possible manner, thereby avoiding sprains and strains to their back and other parts of the body. 3. SCOPE This procedure is to be used by POGC employees, members of the Contractor Project Management Team, Supervisors and Subcontractors who supervise and control persons carrying out manual handling duties. This procedure and guidance will also provide assistance in the necessary training of personnel involved in manual handling. 4. RESPOSIBILITIES 4.1 Site Manager To ensure that the manual handling of loads are kept to a minimum and that all persons carrying out manual handling duties are trained in the correct techniques and take a consideration to subcontractors to do these techniques. 4.2 HSE Manager September 2012- Manual Handling Safety Page 3

To monitor manual handling duties by conducting assessments on load handling. To arrange training for all persons concerned in correct manual handling techniques and provision of information on weights to be lifted. 4.3 HSE Supervisor/Field Supervisors To monitor manual handling duties by conducting assessments on load handling and provision of information on weights to be lifted. To ensure that the manual handling of loads are kept to a minimum and that all persons carrying out manual handling duties are trained in the correct techniques. 4.4 Contractor area Manager It is the Contractor s responsibility to provide a safe procedure and a safe working environment, which includes: Safe plant and equipment; Safe protective equipment; Manual handling aids if necessary; Rest or exercise breaks during tiring or repetitive tasks. Task planning before work begins; Employee training about potential hazards and skills required; Clearing the way to avoid bumping into or tripping over things; and Suitable protective clothing should be provided and worn 4.5 All employees All employees have a responsibility and duty to: work safely; participate in hazard identification, risk assessment and risk control when requested by theirs supervisor follow any information, training and instruction received from subcontractor Use the risk controls that have been provided by subcontractor. Handle, move materials properly and safely Use the correct methods for handling and manual of load and equipment while working at site September 2012- Manual Handling Safety Page 4

5. PROCEDURES 5.1 General 5.1.1 Fatal manual handling accidents are extremely rare, however back injuries are the greatest single cause of sick leave. Sprains and strains are the result of excessive or incorrect use of bodily force; such injuries can lead to permanent disability. 5.1.2 No person(s) should be required to lift carry or move any load which, by reason of its size and weight is likely to jeopardize their health or safety. 5.1.3 Assessments need to be made on items to be lifted and considerations as to whether the load needs to be handled at all, or whether the requirement for manual handling can be minimized will need to be taken into account. If load handing is essential, the first step should be consideration of mechanical lifting equipment. This requirement should take place during the planning stage of the activity. 5.1.4 If as a result of such planning and assessments it is determined that Manual Handling is the only method applicable, information on the loads to be handled and adequate training must be provided to the persons involved in the manual handling tasks. 5.1.5 Employees could be trained to recognize loads whose weight, in conjunction with their shape and other feature, and the circumstances in which they are handled, might cause injury. In general, unfamiliar loads should be treated with caution and, if undue strain is felt, the task could be reconsidered. 5.2 Assessments Many operational and administrative tasks can involve manual handling, so a hazard identification process is best, using: direct observation; and incident report analysis. Risk assessments by management normally do as follow as. 5.2.1 Identify the Hazard Manual handling activities exert force during a task (lifting, lowering, pushing, pulling, carrying or moving; holding or restraining any person or thing). Consequently, it covers many tasks and these occur in every workplace, every day. Manual handling September 2012- Manual Handling Safety Page 5

affects all employees to a degree and is potentially a major health and safety risk in particular areas. Examples of manual handling tasks include: Office based work; Pushing trolleys; Lifting bags, suitcases or packages; Loading or unloading cargo; Handling equipment; Moving stock or stores; Shifting furniture; Unpacking or packing containers; Sorting mail Placing boxes on shelves 5.2.2 Assess the Risk Factor Contractor/Subcontractor should study all manual handling tasks that pose a risk to health and safety. A workplace handling risk factor assessment could be considered as follow as: Actions and movements of the task; Duration and frequency of the task; Workplace layout and geometry where the task in terms of movement distance, direction, obstacles, Posture and position of the person; Location of the load, distance and direction moved; weights and forces ; Characteristics of the loads and equipment used; Organization of work; Environment factors such as temperature, humidity, illumination, noise, vibration, frictional stability of the foot, etc. Skills and experience of the person; Age, physical capacity or special needs of the person; Opportunities to vary work or have breaks; and Clothing worn. September 2012- Manual Handling Safety Page 6

Problems could be addressed in a practical way by looking at the same factors of "task", "load", "working environment" and "individual capability" to see where improvements can be made, for example: APPENDIX II will assist the assessment of risks involved. 5.2.3 Type of Injury Most manual handling injuries are strains and sprains and the most frequently injured part of the body is the back. Some manual handling back and neck injuries can cause workers long months of pain and rehabilitation. Serious strain injuries may require surgery and occasionally may cause life-long disability and loss of career. Manual handling tasks can also cause in slips, falls and crush incidents, involving cuts, bruises and broken bones. Manual handling injuries can also cause hernia, strained heart muscles and occupational overuse syndrome (OOS). Most manual handling injuries can be prevented by instruction, training and supervision. Risk assessments should to be reviewed with experience of the tasks, when there is a change in the handling operations and if a manual handling injury occurs. 5.3 Reducing the Risk of Injury Risks identified must be reduced, so far as is reasonably practicable, by taking "appropriate" steps as followed. The effectiveness of measures taken should be monitored and, if they do not have the desired effect, the situation should be reappraised. 5.3.1 Job design The best approach to preventing manual handling injuries is to avoid risks in the first place through safe design of processes. For the safe design of the work the supervisors could be mentioned that: Minimize the risk by engineering that means manual handling are designed with minimum risk; Minimize the risk by administrative that means introduce job rotation, implement a safe lifting policy, provide appropriate training; Provision personal protective equipment Working environment design for safely manual handling tasks; Individual capability could be improved by information and training September 2012- Manual Handling Safety Page 7

5.3.2 Risk mitigation If the risk assessment has shown a need to redesign a job then consider the following where applicable: Modify the object the object being handled may be modified or repackaged into a bigger or smaller weight or a different size or shape; Modify workplace layout the layout of equipment and furniture may be modified or rearranged. Rearrange materials flow the timing, and paths of materials flow may be modified; Different actions, movements, forces undertake a task in a different way using different actions movements and forces. Provision of mechanical aids or similar devices, such as a gin wheel or scaffold crane to minimize risk of injury Provide personal protective equipment e.g. non-slip footwear to prevent slips, trips and falls while performing manual handling activities; Remove unnecessary tasks; Prevent double handling; Prevent heavy carrying; Provide rest breaks during heavy or repetitive work; Manual handling by team lifting; Varying the operator position and posture; Identifying and controlling work peaks ; Isolate the hazard from the person. Containers used are constructed and maintained so no risk to health when manually handled; Allowing the employee to control their workflow; Regular monitoring and review. Records of injuries or near misses and assessing if incidents rising or falling; 5.3.3 Administrative control September 2012- Manual Handling Safety Page 8

Administrative control of manual handling hazards is a could be mentioned to comply that: Development of safe systems of work; Maintain housekeeping procedure; Purchasing strategies that seek to control the introduction of manual handling hazards to the workplace; Supervision walk-through and staff meeting discussions issues ; Development of risk assessment systems Implementation of a manual handling training. Although the primary effort in reducing the risk of injury should be put into the three factors quoted above, also employees have duties to keep their health and safety. 5.4 Good Handling Techniques Good handling techniques are essential in the prevention of injury from manual handling operations. The correct method of lifting is to use the strong leg and thigh muscles and to maintain the natural shape of the spine throughout the lift. (See the APPENDIX I. Illustration). The following points should be emphasized in training programs and the capability of employees to follow such advice should be considered in good handling techniques: 5.4.1 Plan the Moving Think before moving/handling. Where is the load to be placed? Use any appropriate handling aids. Do you need help with the load? Ensure there are no obstructions to the lift. For a long lift, such as ground to shoulder height, consider resting the load midway, if possible, in order to change grip. Quick mention could be considered as follow as: Keep the load close to the waist. Adopt a stable position. Get a good hold. Start in a good posture. Don t flex the back any further while lifting. Avoid twisting the back or leaning sideways September 2012- Manual Handling Safety Page 9

Keep the head up when handling Move smoothly. Don t lift or handle more than can be easily managed. Put down, and then adjust. If precise position of the load is necessary. 5.4.2 Good lifting and lowering The guideline weights in Figure below are weight limits for manual operations involving lifting and lowering at different "movement zones". They assume that the load is readily grasped with both hands and that the operation takes place in reasonable working conditions with the handler adopting a proper posture (such as straight back, bend knees etc.). Source: Guidance on Manual Handling Operation Regulations HSE Note: Further assessment is needed when the load to be handled is greater than 16 Kg. Read the bellow accompanying text before interpreting this diagram. Figure 1 The limits for lifting and lowering in above figure should be reduced if the handler twists to the side during the operation.( For example: the limits could be reduced by about 10% where the handler twists through 45 degrees and by about 20% where the handler twists through 90 degrees). The limits for lifting and lowering in above figure are applicable for relatively infrequent operations for example up to approximately 30 operations per hour where the pace of work is not forced, adequate pauses for rest or recovery are possible and the load is not supported for any length of time. They could be reduced if the operation is repeated more frequently. As a rough guide the limits should be reduced by 30% where the operation is September 2012- Manual Handling Safety Page 10

repeated once or twice per minute, by 50% where the operation is repeated around five to eight times per minute, by 80% where the operation is repeated more than twelve times per minute. It is also assumed that the load is held against the body and is carried no further than about 10 meters without resting. If the load is carried over a longer distance without resting the limits may need to be reduced. 5.4.3 Good Handling for Pushing and Pulling For pushing and pulling loads, the limit for starting or stopping the load is a force of about 20kg (200 newtons). The limit for keeping the load in motion is a force of about 10kg (100 newtons). It is assumed that the force is applied with the hands between knuckle and shoulder height. If this is not possible, the limits may need to be reduced. No specific limit is intended as to the distance over which the load is pushed or pulled provided that there are adequate opportunities for rest or recovery. The load has not to be moved for more than about 20 m without a break The person through ill health can t push or pull the load Handling Devices Aids such as barrows and trolleys could have handle heights that are between the shoulder and waist. Devices should be well maintained with wheels that run smoothly. Lifting may be replaced by controlled pushing or pulling in certain cases, such as sliding or rolling an object along. However uncontrolled sliding or rolling, particularly of large or heavy loads, may introduce additional risks thus increasing the risk of injury. For both pulling and pushing a secure footing is necessary and the hands need to be applied to the load between waist and shoulder height wherever possible. September 2012- Manual Handling Safety Page 11

Pulling: Wrong Right Pushin g: Wrong Right Figure 2 5.4.4 Posture Bend the knees so that the hands, when grasping the load, are as nearly level with the waist as possible. Do not keel or over flex the knees. Keep the back straight (tucking in the chin helps). Lean forward a little over the load, if necessary, to get a good grip. Keep shoulders level and facing in the same direction as the hips. September 2012- Manual Handling Safety Page 12

5.4.5 Grip Try to keep the arms within the boundary formed by the legs. The optimum position and nature of the grip will depend on the circumstances and individual preference, but it must be secure. A hook grip is less fatiguing than keeping the fingers straight. If it is necessary to vary the grip as the lift proceeds, do this as smoothly as possible. 5.4.6 Correct Method of Lifting Do not jerk. Carry out the lifting movement smoothly, keeping control of the load. Move the feet. When turning to the side, move the feet; do not twist the trunk. Keep close to the load. Keep the load close to the trunk for as long as possible. Keep the heaviest side of the load next to the trunk. If a close approach to the load is not possible, try sliding it towards you before attempting to lift it. Put down, and then adjust. If precise positioning of the load is necessary, put it down first, and then slide it into the required position. 5.5 Kinetic Method (see Figures 3, 4 and 5) The Kinetic Method relies on using the strong leg muscles rather than the weaker back muscles, and using the momentum of the body weight to initiate movement in the desired direction. Personnel should be on the look out for splinters, projecting nails and sharp wire whenever they prepare to lift or carry loads. Also ensure that the space to set down the load has been identified and prepared. The person carrying the load should be able to see over the top of the load. When lifting, the chin should be held in and care taken not to bend the head forwards or backwards. The knees should be bent to a crouching position, the back held straight, but not necessarily vertical. A firm grip must be obtained with the palm of the hand and the roots of the fingers - using finger tips means more effort and a chance of dropping the load. Arms must be held as close to the body as possible so that the body takes the weight instead of the fingers, wrists, arms and shoulders. If possible opposite sides of the object should be gripped. Lifting must be done with the thigh muscles, by straightening the legs, lifting by easy stages from floor to knee, knee to carrying position. When carrying, do not change grip - rest the load on some support and then change. To set the object down, the lifting procedure should be reversed. Gloves must be worn when handling sharp or slippery objects. Do not wear rings. Do not stand holding a heavy load for any longer than absolutely necessary. Safety boots or shoes September 2012- Manual Handling Safety Page 13

must be worn. Special protective equipment must be worn when handling dangerous liquids or chemicals. When a load is being lifted and carried by a group of men, the same basic principles as above should apply. One man must be in charge and responsible for giving instructions. Use skids, levers or rollers to assist in moving heavy loads. Use chains or ropes to pull loads out of ditches etc. Notice: We will recommend to consider the National Iranian Oil Company (N.I.O.C.) safety regulations, PART 3: Methods and work safety conditions for more details. 6. TRAINING If manual handling has been assessed as a risk then appropriate training could be provided. Training could include: The risks to health from manual handling; Safe manual handling techniques; Correct and safe use of any assigned specialized equipment such as mechanical aids; Correct and safe use of any assigned PPE; Specific manual handling hazards; Safe work procedures; Using manual handling aids 7. DEFINITIONS & ABBREVIATIONS Contributory factors (manual handling): The factors of load, environment, people, task and management that can contribute to the incidence and severity of manual handling hazards Hazardous manual handling Involves any of the following: Repetitive or sustained application of force Repetitive or sustained awkward posture Repetitive or sustained movement Application of high force Exposure to sustained vibration Manual handling of loads that are unstable, unbalanced or difficult to hold September 2012- Manual Handling Safety Page 14

Manual handling: Activities such as lifting, pushing, pulling, holding, throwing and carrying. It also includes repetitive tasks such as packing, typing, assembling, cleaning and sorting, using handtools, and operating machinery and equipment. Musculoskeletal disorders (MSD): An injury or disease that arises in whole or part from manual handling in the workplace, whether occurring suddenly or over a long period of time. Personal protective equipment: Items of personal equipment worn for protection of some sort: ear muffs, gloves and boots are examples. Task Analysis: Task analysis comprise of the methodical investigation of activities specific to a task. Workplace design: The design of the workplace by implication in relation to the characteristics of the people who will use the workplace and the work that will be done in it 8. REFERENCES 1991 National Institute for Occupational Safety and Health (NIOSH) Lifting Equation, Proposed American Conference of Governmental Industrial Hygienists (ACGIH) Lifting Tables, and Snook and Ciriello Psychophysical Tables (Liberty Mutual Research 1978, rev. 1991). Guidance on Manual Handling Operation Regulations 1992 HSE Manual Handling Mr.H.Googoonani- Isfahan university publishers. 2003 Lifting and carrying Mr.H.Googoonani nile Ab publisher- isbn:964-7912-10-2- Second edition- 2005 OSHA Standards (Occupational Health and Safety Administration) Ed:2007 NIOSH Standards (National Institute of Safety and Health) Ed:2007 ILO Standards (International Labor Office) Ed:2003 WHO Standards (World Health Organization) Ed:2006 OEL Standards Ed: 1998 September 2012- Manual Handling Safety Page 15

9. APPENDIXES APPENDIX I :Illustrations APPENDIX II : Manual Handling Risk Assessment Table APPENDIX I :Illustrations September 2012- Manual Handling Safety Page 16

FIGURE 1: MANUAL HANDLING THIS STIFFENS THE LEGS & BACK SO THAT THE FEET DO NOT ADJUST FOR MOVEMENT HANDS HAVE TO REACH OUT EXCESSIVELY ELBOWS JUT OUT FROM THE BODY EXCESSIVE END OF FINGER PRESSURE OCCURS THE LEGS & BACK RELAX FOR MOVEMENT FEET ADJUST TO ALLOW FOLLOW THROUGH WITH LOAD ELBOWS TEND TO REMAIN INTO BODY GOOD HAND HOLD OCCURS September 2012- Manual Handling Safety Page 17

FIGURE 2: MANUAL HANDLING FIGURE 3: MANUAL HANDLING September 2012- Manual Handling Safety Page 18

APPENDIX II : Manual Handling Risk Assessment Table Job Description: Area: Unit: Company Name: Position/Job Title: Name: Signature: Date/Time: Yes / No Factors Questions Remark The tasks The loads The working environment Individual capability Other factors Do they involve: - Holding or manipulating loads at distance from trunk? - Unsatisfactory bodily movement or posture, especially: * twisting the trunk? * stooping? * reaching upward? - Excessive movements of loads, especially: * Excessive lifting or lowering distance? * Excessive carrying distances? - Excessive pushing or pulling of loads? - Risk of sudden movement of loads? - Frequent or prolonged physical effort? - Insufficient rest or recovery periods? - A rate of work imposed by a process? Are they: - Heavy? - Bulky or unwieldy? - Difficult to grasp? - Unstable, or with contents likely to shift? - Sharp, hot or otherwise potentially damaging? Are there: - Space restraints preventing good posture? - Uneven, slippery or unstable floors? - Variations in level of floor or work surfaces? - Extremes of temperature or humidity? - Conditions causing ventilation problems or gusts of wind? - Poor lighting conditions? Does the job: - Require unusual strength, height etc? - Create a hazard to those who might reasonably be considered to have a health problem? - Require special information or training for its safe performance? Is movement or posture hindered by personal protective equipment or by clothing? Other Recommendation and Safety Precaution Issued by CONTRACTOR HSE Supervisor : Name : Signature : September 2012- Manual Handling Safety Page 19

SUGGESTIONS FOR THE POGC MANUAL HANDLING SAFETY PROCEDURE MANAGER, HSE Department Pars Oil & Gas Company Tehran I.R. Iran Please consider the following suggestion(s) relative to the POGC Manual handling safety procedure: (Signature) (Date) (Address) Contact Telephone Number Contact FAX Number September 2012- Manual Handling Safety Page 20