HAZARDS AND RISK ASSESSMENT FOR CYLINDER HEAD LIFTING DURING MAIN ENGINE OVERHAUL

Hazards identified with the cylinder head lifting job:

1. Lifting/ handling hazards: The cylinder head is heavy (several tonnes); incorrect slinging, an overloaded or defective crane/ chain block, or a swinging load can cause the head to fall, crushing personnel or damaging the engine.
2. Falling objects: Tools, bolts, or components dropped from height can injure personnel below.
3. Crushing/ trapping: Personnel can be trapped between the head, the lifting gear, or the engine structure.
4. Hot surfaces/ burns: The cylinder head and its components (exhaust valve, injectors) are hot; contact can cause burns.
5. Pressurised/ hazardous fluids: Residual fuel, oil, cooling water, and combustion gases in the head can leak or spray; fuel/ oil are flammable and toxic.
6. Moving machinery: The engine or turning gear could be operated while personnel are working, causing injury.
7. Confined/ restricted space: Working in the engine room/ crankcase area with limited access and poor lighting.
8. Manual handling: Lifting/ carrying heavy components manually can cause musculoskeletal injury.
9. Electrical hazards: If electrical equipment (crane, tools) is used, there is a risk of electric shock.
10. Slips/ trips: Oil/ water on the floor, and loose tools, cause slips and trips.
11. Falling from height: Working on the engine top/ platforms without proper guardrails or fall protection.
12. Noise: The engine room is noisy, affecting communication and hearing.

How to carry out a risk assessment for the job

1. Identify the task and its steps: Break the cylinder head lifting job into steps (preparation, slinging, lifting, moving, landing, refitting).
2. Identify the hazards for each step (as listed above).
3. Assess the risk: For each hazard, determine the likelihood and severity of harm, and assign a risk rating (e.g. low/ medium/ high) using a risk matrix.
4. Determine control measures: For each hazard, identify measures to eliminate or reduce the risk, e.g.:

• Use a certified crane/ chain block of adequate SWL, with certified slings/ lifting gear; inspect the gear before use.
• Use the correct lifting points/ slinging arrangement per the maker's manual; balance the load.
• Keep the area below clear of personnel; use barriers/ warning signs.
• Allow the head to cool before handling; use heat-resistant gloves/ PPE.
• Drain and isolate the fuel/ oil/ water systems; blank off connections; use drip trays.
• Secure the engine (turning gear disengaged and locked, tag "not to run"); isolate starting air.
• Provide adequate lighting and access (scaffolding/ platforms with guardrails).
• Use correct manual-handling techniques and mechanical aids.
• Use the correct PPE (helmet, safety shoes, gloves, goggles, hearing protection).
• Ensure good communication (radio/ signals) between the crane operator and the team.

1. Record the risk assessment and obtain the necessary permits (permit-to-work, hot-work if applicable).
2. Brief all personnel on the risk assessment and the control measures before starting.
3. Review the risk assessment during the job if conditions change, and after completion.