Lifting process vessel lids

Use solutions with the least risk

Many manufacturers use kettles, cooking pots or mixing pots. These are often raised up off the floor and can be fitted with heavy lids that need to be opened when introducing ingredients, for inspection and during cleaning. Many lids are constructed from stainless steel and are therefore very heavy.

The following solutions can help employers control risks to employees lifting process vessel lids. These solutions may help eliminate or reduce the risk of employees developing a musculoskeletal disorder (MSD).

Solutions are listed in order, from those considered most effective to those considered less effective.

Employers should make sure employees use the handling solutions with the least risk, so far as reasonably practicable.

Solutions with reduced risks are an alternative only if least-risk methods are not reasonably practicable.

Employers should start implementing risk controls for the heaviest or highest-volume products first.

The following guidance also describes high-risk actions that can cause an MSD. Employers have a duty to eliminate or reduce the risk of MSDs so far as is reasonably practicable, and should make sure employees do not perform high-risk actions, if practicable.

Consultation

So far as reasonably practicable, employers must consult with employees and any health and safety representatives (HSRs) when identifying hazards and providing risk control measures. Consultation should include discussions about how employees will lift process vessel lids, making sure that risk control measures do not create new hazards. WorkSafe has guidance on consultation, including consultation with HSRs.

Lifting and lowering heavy lids

High-risk actions that can cause an MSD

• Using high force lifting and lowering lids.
• Exerting high force in an awkward posture.

Potential source of risk

• Weight of the lid.

Handling solutions

Preferred solution with the least risk

• Automate lid raising and lowering by fitting a pneumatic ram to kettle lids in combination with a counterbalance to lift and lower lids. Install a locking hinge or purpose-built restraining device so employees are not required to hold the lid.

Solutions with a reduced risk

• Install a counterbalance to assist lifting and lowering in combination with reducing the frequency of lifting and lowering by:
  • installing inspection windows to eliminate the need to lift kettle lids for tasks such as inspection
  • installing hatches within lids to introduce ingredients
  • installing an automatic material-feed system so the kettle is only opened for cleaning

Lifting and lowering lids in awkward positions

High-risk actions that can cause an MSD

• Using high force lifting and lowering lids.
• Exerting high force in an awkward posture.

Potential source of risk

• Lid in awkward position.

Handling solutions

Preferred solution with the least risk

• Automate lid raising and lowering by fitting a pneumatic ram to kettle lids in combination with a counterbalance to lift and lower lids. Install a locking hinge or purpose-built restraining device so employees are not required to hold the lid.

Solutions with a reduced risk

• Provide clear access to vessels and ensure movements required are performed above mid-thigh height and below shoulder height by elevating the vessel or by adding a platform to raise the employee.
• Allow lid to open up past vertical and be supported in that position.

Your legal duties

Employers

The Occupational Health and Safety Act 2004 (OHS Act) requires employers to provide and maintain a working environment that is safe and without risks to health, so far as reasonably practicable. An employer contravenes this duty if they fail to:

• provide or maintain plant or systems of work that are, so far as reasonably practicable, safe and without risks to health
• make arrangements for ensuring, so far as reasonably practicable, safety and the absence of risks to health in connection with the use, handling, storage or transport of plant or substances
• maintain, so far as is reasonably practicable, each workplace under the employer's management and control in a condition that is safe and without risks to health
• provide, so far as is reasonably practicable, adequate facilities for the welfare of employees at any workplace under the management and control of the employer
• provide information, instruction, training or supervision to employees of the employer as is necessary to enable those employees to perform their work in a way that is safe and without risks to health

Employers also have an obligation to consult, so far as is reasonably practicable, with employees and any HSRs on matters related to health and safety that directly affect them, or that are likely to directly affect them. This duty to consult also extends to independent contractors, including employees of the independent contractor, engaged by the employer in relation to matters over which the employer has control.

Employees

While at work, employees also have duties under the OHS Act to take reasonable care for their own health and safety and the health and safety of others who may be affected by their acts or omissions in the workplace. Employees must also co-operate with their employer's actions to make the workplace safe and comply with the OHS Act and Regulations.

The WorkSafe website has guidance about the occupational health and safety (OHS) responsibilities of employers and employees.