Manual Handling

Document Title: Manual Handling
COPI Doc No.: ID-G-BU-00000-00000-00407
Originator: COPI
COPI Group Owner: HSE
Area: General
Location: General
System: General
Document Type: Procedure
Discipline / Subdiscipline: General / General
Old COPI Document No.: COPI-HS-ST-00001 Sec. M.003 Manual Handling
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY
INFORMATION BELONGING TO CONOCOPHILLIPS INDONESIA AND
MUST NOT BE WHOLLY OR PARTIALLY REPRODUCED Manual Handling
NOR DISCLOSED WITHOUT PRIOR WRITTEN Rev2 (1).pdf
PERMISSION FROM CONOCOPHILLIPS INDONESIA
Henry Rizki Not

2 IFU 1 July 14 Issued for Use Rizki Amelia Tri laksono
Matakupan Amelia Req’d
Fred Aty Aty Not Not

1 IFU 17 Dec 07 Issued for Use
McFadden Supriyadi Supriyadi Req’d Req’d
Fred HSE Jim
0 IFU Feb 03 Issued for Use
McFadden Coordinators Taylor
Sr.
Unit Owner VP Ops
Rev Status Issue Date Reason for Issue Prepared Checked Manager
Approvals
Printed initials in the approval boxes confirm that the document has been signed.
The originals are held within Document Management.
Paper Copies are UNCONTROLLED - Check in HSE Intranet for latest available Revision –
COPI CONTROLLED copies should be RED stamped
Procedure: ID-G-BU-00000-00000-00407 Rev. 2
Manual Handling
ConocoPhillips Indonesia Page 2 of 14
Revision Sheet
ConocoPhillips Indonesia Inc. Ltd
REVISION DATE DESCRIPTION OF CHANGE
0 Feb 2003 Issued for Use

1 17 Dec 2007 Reformat document, no changes in contents.
Add:
Section 3. Potential Hazards

 Fatigue & injuries as result of manual handling
 Two groups of injuries may result from manual handling
 Three groups of MSDs
 Types of back injuries
Section 4. Definition
 Ergonomics
 Fatigue
 Manual handling
 Musculoskeletal disorders (MSDs)
 Team lifting
2 24 Jun 2014 Section 5. Roles & Responsibilities
Section 6. Safe Weight Guidelines

Maximum weight to be lifted with two hands, under ideal
conditions is 23 kg (before : 40kg).
Section 7. Procedures
7.1 Risk Assessment
7.1.1 Categories of Manual Handlings Risk Assessments
7.1.2 Repetitive Manual Material Handling Activities
7.1.3 Manual Material Handling Flowchart
7.3 Leverage Zone for Lifting Techniques
7.4 Proper Lowering Technique
7.5 Good Handling Technique when Pushing and Pulling
7.6 Good Handling Technique using Mechanization
Additional Approvers/Reviewers (Function Representative)
Name Department Signature Date
Hendrawan Wicaksono Onshore Operations
Teguh Yuwono Offshore Operations
Fendra Lopulalan Well Operations Manual Handling

Rev2 (2).pdf
Dody Yuhanes Projects
Manual Handling
CONTENTS
CONTENTS................................................................................................................................................... 3
1 Purpose .................................................................................................................................... 4
2 Application .............................................................................................................................. 4
3 Potential Hazards .................................................................................................................... 4
4 Definition ................................................................................................................................. 4
5 Roles & Responsibilities ........................................................................................................ 5
6 Safe Weight Guidelines .......................................................................................................... 5
7 Procedures .............................................................................................................................. 6
7.1 Risk Assessment ................................................................................................................................. 6
7.1.1 Categories of Manual Handlings Risk Assessments ................................................................ 7
7.1.2 Repetitive Manual Material Handling Activities......................................................................... 7
7.1.3 Manual Material Handling Flowchart ........................................................................................ 7
7.2 Proper Lifting Techniques ................................................................................................................... 8
7.3 Leverage Zone for Lifting Techniques ................................................................................................. 9
7.4 Proper Lowering Technique .............................................................................................................. 10
7.5 Good Handling Technique when Pushing and Pulling ...................................................................... 10
7.6 Good Handling Technique using Mechanization ............................................................................... 10
8 Awareness & Training .......................................................................................................... 12
APPENDIX A .............................................................................................................................................. 13
Manual Handling
1 Purpose
This procedure establishes guidelines for safe manual lifting and handling of loads. This procedure is
intended to eliminate the use of manual material handling when possible and to provide employees with
the tools to properly plan for, identify hazards associated with material handling, mitigate those risks, and
safely perform manual material handling operations.
2 Application
This procedure applies to all personnel, both employee and contractor, working in ConocoPhillips
Indonesia facilities.
3 Potential Hazards
Back injury can result when heavy loads are lifted manually; or if there is twisting of the back while lifting.
Manual handling can result in fatigue, and lead to injuries of the back, neck, shoulders, arms or other
body parts. Two groups of injuries may result from manual handling:
• Cuts, bruises, fractures, et cetera due to sudden, unexpected events such as accidents
• Damage to the musculoskeletal system of the body (muscles, tendons, ligaments, bones, joints,
bursa, blood vessels and nerves) as a consequence of gradual and cumulative wear and tear
through repetitive manual handling.
These injuries are called ‘musculoskeletal disorders’ (MSDs) and can be divided into 3 groups:
• Neck and upper limb disorders
• Lower limb disorders
• Back pain and back injuries
Types of Back Injuries:

 Degenerative disc disease - Associated with the aging process
 Abnormal posture - Working in an awkward position
• Muscle dysfunction of reaction or an injury
Stress causes muscles to tighten up, which creates a strain on muscles that support the back
• Changes in joints, stiff and immobile, usually caused from under use.
Excessive joint movement - caused by the aging process
4 Definition
Ergonomics is a science that applies data on the physical and psychological capabilities and limitation of
people to the design of jobs, tasks, equipment, tools, facilities and the environment so that people can be
safe, healthy, effective, productive and comfortable.
Fatigue is a loss of work capacity resulting from preceding work. It is usually associated with a loss of
efficiency and reduced capability. Fatigue is both a physical and a psychological state.
Manual Handling
Manual handling - the transporting or supporting of a load by one or more workers and includes lifting,
putting down, pushing, pulling, carrying or moving a load.
Musculoskeletal disorders (MSDs) - injuries or disorders of the muscles, nerves, tendons, joints,
cartilage, an disorders of the nerves, tendons, muscles and supporting structures of the upper and lower
limbs, neck, and lower back that are caused, precipitated or exacerbated by sudden exertion or prolonged
exposure to physical factors such as repetition, force, vibration, or awkward posture.
Team lifting is the condition when two or more people moving or handling a load together, especially
when the load is too heavy (more than 23kg), too bulky or too long to be moved.
5 Roles & Responsibilities

5.1 Site Line Management
Ensure that this procedure is being implemented in his/her site.
5.2 Supervisor
Ensure their workforce to carry out tasks in accordance with this procedure and provide
appropriate equipment and tools related with manual handling.
5.3 HSE Advisor
Provide guidance/advice about appropriate manual material handling techniques, engineering
controls, and work practices at field.
5.4 Workforce
Understand and adhere to this procedure or when applicable/needed this guideline will provide
best practice), participate in the development of work plans and methods that eliminate the need
for manual material handling and perform a hazard assessment for manual material handling
tasks.
5.5 Industrial Hygiene Team
Industrial Hygiene Team is responsible for developing, implementing and administering controls
of manual handling procedure, by:
 Coordinating manual handling assessment (combination of self-assessment by workers
and assessment by IH Team)
 Providing training
 Providing advice on manual handling implementation.
6 Safe Weight Guidelines

The Revised National Institute of Occupational Safety and Health (NIOSH) Lifting Equation (1994)
provides guidelines for evaluating two-handed manual lifting tasks. It defines a Recommended Weight
Limit (RWL) as the weight of the load that nearly all healthy workers can lift over a substantial period of
time (e.g., eight hours) without an increased risk of developing lower back pain. The maximum weight to
be lifted with two hands, under ideal conditions, is 23 kg.
Manual Handling
The RWL is based on six variables that reduce the maximum weight to be lifted to less than 23 kg.
Consult the Revised NIOSH Lifting Equation (1994) for information to help assess complex lifting tasks.
7 Procedures
All work involving lifting and handling of loads should be evaluated to assess the type of equipment
necessary to lift and handle the load to be moved. All manual lifts should be planned to eliminate any
twisting of the back during the lift.
7.1 Risk Assessment

Where manual handling is unavoidable, a risk assessment shall be conducted and actions shall be taken
to mitigate those risks prior to beginning the task. Every effort shall be made to determine weights of
materials to be handled. This information can be obtained in places such as material packaging, shipping
documents, product specifications, engineering documentation, etc. In cases where weights cannot be
accurately determined through due diligence, treat material conservatively and utilize mechanical lifting
aids and/or team lifting techniques. All risk assessments shall utilize the hierarchy of controls when
determining risk mitigations methods.
 Engineering Controls
 Eliminate the need for manual handling through substitution, design of task, etc.
 Utilization of mechanical lifting devices
 Administrative Controls
 Perform fewer lifting tasks in a given amount of time
 Rotate workers periodically
Job rotation means rotating employees through different jobs. Job enlargement means
increasing the variety by combining two or more jobs or adding tasks to a particular job. To
be effective, both improvements rely on changing jobs and tasks so that they differ in the:
 Muscles or body parts used
 Working postures
 Amount of repetition
 Pace of work
 Amount of physical exertion required
 Visual and mental demands
 Environmental conditions
 Utilize lifting aids such as straps, hooks, etc. (this is particularly important when
addressing pinch point hazards associated with manual material handling tasks)
Manual Handling
7.1.1 Categories of Manual Handlings Risk Assessments

These risk assessments fall into two categories:
Category 1 – Loads less than 23 kg per personnel. Other factors, including repetition, body position,
physical condition of employee, pre-existing conditions, need to be considered in this assessment.
 Personal Risk Assessment – This assessment shall be conducted by the personnel referring to
Appendix A. Documentation is not required.
Category 2 – Loads 23 kg or greater per employee
 Manual Handling Risk Assessment – This assessment shall include all personnel involved in the
lift and shall be documented on Appendix A. Contractor companies may use their company
specific form or equivalent to this form. This risk assessment also needs approval from
Supervisor.
7.1.2 Repetitive Manual Material Handling Activities

 Some manual material handling activities that are repetitive in nature and are performed in
the same location with the same load may be specifically assessed following Revised NIOSH
Lifting Equation.
 COPI or Contractor Supervisor and HSE Advisor will determine if tasks meet this criteria
 The Risk Assessment will be performed by the personnel who routinely perform the task and
the COPI or Contractor Supervisor responsible for the work.
 The Repetitive Manual Material Handling Risk Assessment shall be reviewed by the
Supervisor annually and documented on the assessment form.
7.1.3 Manual Material Handling Flowchart
This flowchart shall be used to make the determination of which Risk Assessment method to be used.
Manual Handling
7.2 Proper Lifting Techniques

All workers should use mechanical means to lift heavy objects whenever possible. Safe manual lifting
requires the following steps:
ASSESS THE LOAD

Plan the lifting, inspect the load for size, shape, potential instability, and possible area
to grip.
STEP 1 Where are you placing the load?
Are handling aids or assistance available?
Check your path is clear to where the object will rest.
Have you removed any obstructions for access / exit routes?
FEET POSITION
STEP 2 Keep your feet flat and 30-40 cm (about hip width) apart with one foot ahead of the
other for a solid stance.
ADOPT GOOD POSTURE
Bend the knees ensuring hands are close to waist when lifting.
STEP 3 Do not kneel or over flex the knees.
Keep the back straight (tuck in chin – this helps align body) lean forward a little to allow
a better grip, keep shoulders level and facing the same direction as the hips.
GET A FIRM GRIP
Try to keep the arms within the boundary formed by the legs.
The optimum position and nature of the grip depends on the circumstances and
STEP 4 individual preferences, 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 progresses, do so as smoothly as possible,
preventing jerking or sharp movements.
DON’T JERK
STEP 5
Carry out the lifting movement smoothly, keeping control of the load.
MOVE THE FEET
STEP 6
Never twist the trunk when turning to the side.
KEEP CLOSE TO THE LOAD
Keep the load as close to the trunk for as long as possible.
STEP 7 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 – THEN ADJUST
If precise positioning of load is necessary put it down first, then possible slide it into
STEP 8
position.
Know your limits, get help for difficult loads.
Manual Handling
7.3 Leverage Zone for Lifting Techniques

Here are the lifting techniques recommendations based on human’s upper body zone. These techniques
should be applied when applicable.
Green Zone
In the Green Zone, elbows are comfortably by your side; reach extends from
the chin to your thighs. Because the weight of your load is closer to you,
keeping the elbows close reduces the stress on your body. This is the
preferred position for lifting and carrying.
Yellow Zone
In the Yellow Zone, elbows are up to 6 inches away from your body; reach
extends from high on your head to your knees. Because the weight of your
load is further from you, the forces on your body are increased.
Red Zone
In the Red Zone, elbows are greater than 6 inches from your body. This
position puts the greatest stress on your body. This position is to be avoided.
of the meanings in this term of references.
There are five areas of the Red Zone:
• Near – elbows straight out forward or sideways
• Far – elbows straight out plus bending at waist; increases strain on back
and shoulders
• High – elbow above shoulder; reduces circulation
• Low – elbows below waist or below knees with legs straight
• Ultra – one or both elbows behind you (for example, reaching behind you)
Manual Handling
7.4 Proper Lowering Technique

Lowering is preferable to lifting. However, ones should be careful not to exert themselves. Follow the tips
below when lowering a load.
 Bend the knees to let leg muscles support the weight.
 Slowly lower it; do not drop the load.
 Avoid sudden movements.
 Lower the load at the same time if working with a partner.
7.5 Good Handling Technique when Pushing and Pulling

 When pushing, arms should be flexed at the elbow, extended to about half their length, thereby
allowing the operator to regulate effort as necessary by flexing and extending the arms.
 The force is applied with the hands between knuckle and shoulder height when pulling and
pushing a load.
 Push or pull in the forward and backward direction rather than from side to side in relation to the
body.
 If possible, choose to push a load than to pull it.
 Design and use simple pushcarts of appropriate size for carrying materials.
7.6 Good Handling Technique using Mechanization

To avoid Manual Handling Operations, think about mechanization and using handling aids such as:
• A conveyor
• A pallet truck
• An electric or hand-powered hoist
• A lift truck.
Manual Handling
Thing to be put as considerations when using mechanical handling aids are:

 What will be carried (assessing size, weight and other pertinent parameters)
 Overall weight and size capacity demands (using worst case load weight and size estimates)
 The terrain and anticipated travel path (identifying the presence of ramps, severe floor
irregularities, steps or other obstacles)
 Pertinent environmental conditions (extremes in temperature, water or chemical exposures, etc.)
 How frequently the unit will be used (infrequently to constantly)
 Information pertaining to the people who will use the device (user population characteristics
versus load and device characteristics), as necessary and appropriate
Employees who will use handling aids must be trained to help ensure personal safety and proper
utilization of the unit. Instituting a preventive maintenance program for materials handling equipment often
helps with significantly reducing injury risk exposure and with keeping the aid operating as intended.
Manual Handling
8 Awareness & Training

Workers need training and hands-on practice with new tools, equipment, or work practices to make sure
they have the skills necessary to work safely. Training is most effective when it is interactive and fully
involves workers. Training should be given to the workers with a job task related with manual handling,
such as (but not limited to):
 Logistic catering crew
 Rustabout
 Helideck assistant
 Storeman
 Helicopter license officer
9 References
Manual Lifting & Handling of Material ConocoPhillips Ponca City Refinery
Manual Material Handling ConocoPhillips Alaska
Lembaga Teknik dan Manajemen Industri ITB
Ergonomics Guidelines for Manual Material Handlings NIOSH
A Guide to Manual Materials Handling and Back Safety, Occupational Safety and Health Division N.C.
Department of Labor
Manual Handling
APPENDIX A
Manual Handling Risk Assessment and Control Measure Checklist COPI
Problems to look for when

Ways of reducing the risk of injury
making an assessment
Can you:
The tasks, do they involve:  Use a lifting aid?
 Holding loads away from the body?  Improve workplace layout to improve
 Twisting, stooping or reaching upwards? efficiency?
 Reduce the amount of twisting and stooping?
 Large vertical movement?
 Avoid lifting from floor level or above shoulder
 Long carrying distances?
height, especially heavy loads?
 Strenuous pushing or pulling?  Reduce carrying distances?
 Repetitive handling?  Avoid repetitive handling?
 Insufficient rest or recovery time?  Vary the work, allowing one set of muscles to
rest while another is used?
 Push rather than pull?
Can you:
The working environment, are there:  Remove obstructions to free movement?
 Constraints on posture?  Provide better flooring?
 Bumpy, obstructed or slippery floors?  Avoid steps and steep ramps?
 Variations in levels?  Maintain good housekeeping practices, clean
 Hot/cold/humid conditions? slippery surfaces？
 Gusts of wind or other strong air movements?  Prevent extremes of hot and cold?
 Poor lighting conditions?  Improve lighting?
 Restrictions on movements or posture from  Provide protective clothing or PPE that is less
 Clothes or personal protective equipment restrictive?
(PPE)?  Ensure your employees’ clothing and footwear
is suitable for their work?
The loads, are they:
 Heavy, bulky or unwieldy? Can you make the load:
 Lighter or less bulky?
 Difficult to grasp?
 Easier to grasp?
 Unstable or likely to move unpredictably (like
 More stable?
animals)?
 Less damaging to hold?
 Harmful, eg sharp or hot?
 If the load comes in from elsewhere, have you
 Awkwardly stacked? asked the supplier to help, eg. provide
 Too large for the handler to see over? handles or smaller packages?
Can you:
Individual capacity, does the job:  Pay particular attention to those who have a
 Require unusual capability, eg above-average Physical weakness?
strength or agility?  Take extra care of pregnant workers?
 Endanger those with a health problem or  Give your employees more information, eg
Learning/physical disability? about the range of tasks they are likely to
 Endanger pregnant women? face?
 Call for team handling?  Find others to help (team handling)?
Handling aids and equipment: Can you:

 Is the device the correct type for the job?  Provide equipment that is more suitable for
 Is it well maintained? the task?
 Are the wheels on the device suited to the floor  Carry out planned preventive maintenance to
surface? prevent problems?
 Do the wheels run freely?  Change the wheels, tires and/or flooring so
 Is the handle height between the waist and that equipment moves easily?
shoulders?  Provide better handles and handle grips?
Manual Handling
 Are the handle grips in good order and  Make the brakes easier to use, reliable and
comfortable? effective?
 Are there any brakes? If so, do they work?
Can you:
Work organization factors:  Change tasks to reduce the monotony?
 Is the work repetitive or boring?  Make more use of workers’ skills?
 Is work machine or system-paced?  Make workloads and deadlines more
 Do workers feel the demands of the work are achievable?
excessive?  Encourage good communication and
 Have workers little control of the work and teamwork?
working  Involve workers in decisions?
 Provide better training and information?
List any special precautions:
COPI or Contractor Supervisor:

COPI HSE Advisor:

Manual Handling

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Document Title: Manual Handling

COPI Doc No.: ID-G-BU-00000-00000-00407

Henry Rizki Not

Fred Aty Aty Not Not

ConocoPhillips Indonesia Inc. Ltd

REVISION DATE DESCRIPTION OF CHANGE

0 Feb 2003 Issued for Use

Section 3. Potential Hazards

Section 6. Safe Weight Guidelines

Additional Approvers/Reviewers (Function Representative)

Name Department Signature Date

Hendrawan Wicaksono Onshore Operations

Teguh Yuwono Offshore Operations

Fendra Lopulalan Well Operations Manual Handling

Types of Back Injuries:

5 Roles & Responsibilities

6 Safe Weight Guidelines

7.1 Risk Assessment

7.1.1 Categories of Manual Handlings Risk Assessments

7.1.2 Repetitive Manual Material Handling Activities

7.1.3 Manual Material Handling Flowchart

7.2 Proper Lifting Techniques

ASSESS THE LOAD

7.3 Leverage Zone for Lifting Techniques

7.4 Proper Lowering Technique

7.5 Good Handling Technique when Pushing and Pulling

7.6 Good Handling Technique using Mechanization

Thing to be put as considerations when using mechanical handling aids are:

8 Awareness & Training

Manual Handling Risk Assessment and Control Measure Checklist COPI

Problems to look for when

Handling aids and equipment: Can you:

COPI or Contractor Supervisor:

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