Real Life Incident: Solo Handling Of 28.5 Kg Under-Piston Hatch Cover Results In Hand Injury

During planned maintenance, an engine crew member was attempting to close an under-piston inspection hatch cover on the main engine. Nearby crew saw him struggling and asked if he needed help, but he waved away their offer and continued to work alone.

Although proper personal protective equipment was used, the heavy cover (28.5 kg) slipped and fell onto the victim’s hand. First aid was applied immediately, with follow-up medical treatment and monitoring, and the victim ultimately recovered.

The company investigation found, among others, that the hazard posed by the heavy inspection cover was not identified in the risk assessment or toolbox talk. The requirement for two-person lifting was not specified. Lack of warning signage near the cover contributed to unsafe practices.

Lessons learned

• Heavy covers should always be dismantled and mounted by two persons, regardless of whether crewmembers are using a chain block or not.
• Ideally, there should be two long studs mounted at the top position of every cover to keep it in position during dismantling/mounting.
• Work permits and toolbox talks should reinforce safe lifting techniques and roles to prevent solo handling.
• Stop Work Authority should be exercised by all crew if perceived unsafe actions are observed.
• Supervisory presence is crucial during potentially hazardous tasks.