6.1 Personal Protective Equipment (PPE) & Risk Assessment Onboard

6.1 Personal Protective Equipment (PPE) & Risk Assessment Onboard

Merchant shipping operates within an inherently hazardous environment where heavy steel machinery, extreme marine weather, high-voltage electrical circuits, and hazardous chemical cargoes create constant operational risks. The Directorate General of Shipping (DG Shipping), Ministry of Ports, Shipping and Waterways, Government of India, places paramount importance on occupational safety training for General Purpose (GP) Ratings. Trainee seafarers must thoroughly master the Code of Safe Working Practices for Merchant Seafarers (COSWP), the technical specifications and maintenance of Personal Protective Equipment (PPE), structured risk assessment procedures, the conduction of Toolbox Talks (TBT), and ergonomic manual handling techniques.

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1. Code of Safe Working Practices for Merchant Seafarers (COSWP)

The Code of Safe Working Practices for Merchant Seafarers (COSWP) is published by the UK Maritime and Coastguard Agency (MCA), primarily for UK-registered merchant ships. It explains UK duties and practical safe working methods. For applicable Indian ships, rule 20 of the Merchant Shipping (Maritime Labour) Rules, 2026, implements occupational health and safety protection in accordance with MLC Standard A4.3. Apply the ship’s flag-state requirements and Safety Management System (SMS).

Legal Status and Accessibility

• Onboard Access: UK rules require carriage of COSWP on applicable UK ships and ready access for seafarers. On other flags, follow the administration’s requirements and keep the ship’s safety instructions accessible.
• Duty of Compliance: Shipowners must provide safe working arrangements; seafarers must follow safety instructions and use safeguards correctly. Report hazards and defective equipment through the SMS.

The Shipboard Safety Committee

Under MLC Standard A4.3, ships with five or more seafarers must have a Shipboard Safety Committee. Seafarer safety representatives participate in its work. The following is a typical arrangement, with the Master as chairman as described in COSWP:

                    +------------------------------+
                    |       MASTER (CHAIRMAN)      |
                    | - Ultimate safety authority  |
                    +--------------+---------------+
                                   |
        +--------------------------+--------------------------+
        |                                                     |
+-------+----------------------+            +-----------------+-----------------------+
|       SAFETY OFFICER         |            |      ELECTED SAFETY REPRESENTATIVES     |
| (Chief Officer / 2nd Engr)   |            | - Deck Rating Representative            |
| - Daily safety inspections   |            | - Engine Rating Representative          |
| - Accident investigations    |            | - Catering Rating Representative        |
| - Risk assessments & permits |            | - Direct voice for crew safety concerns |
+------------------------------+            +-----------------------------------------+

1. The Master (Chairman):
   • Holds overall statutory command and ultimate responsibility for health, safety, and environmental protection onboard.
   • Reviews and endorses safety committee recommendations, allocating vessel resources for hazard rectification.
2. The Safety Officer:
   • Appointed under the applicable flag-state rules and company procedures. COSWP places appointment with the company; an appropriately trained officer, such as the Chief Officer, may perform the role, with assistance from other departments.
   • Key Duties: Conducts daily safety inspections of working areas; investigates accidents, injuries, and near-miss occurrences; maintains statutory safety records; verifies Permit to Work (PTW) documentation; promotes occupational safety awareness among junior ratings.
3. Safety Representatives:
   • Chosen to represent seafarers under the flag-state arrangements; departmental representation helps include deck, engine and catering concerns.
   • Under UK rules described in COSWP, representatives need two years’ consecutive sea service after age 18; a tanker representative also needs at least six months on tankers.
   • Key Duties: Represent ratings' views at committee meetings; inspect work locations following safety complaints; accompany the Safety Officer during hazard inspections; encourage fellow ratings to adopt safe working practices without fear of management reprisal.
4. Safety Committee Meetings:
   • Convened at regular intervals, typically once every month, or immediately following a serious accident, high-potential near-miss, or major operational change.
   • Record decisions, corrective actions and follow-up in the minutes. Make them available to the crew and relevant shore managers according to the company’s SMS.

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2. Personal Protective Equipment (PPE): Standards, Inspection & Maintenance

Personal Protective Equipment (PPE) comprises specialized garments and equipment designed to shield seafarers from physical, chemical, electrical, or biological hazards. It is vital to remember that PPE does not eliminate the hazard; it serves solely as the final barrier between the worker and injury.

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3. Risk Assessment and The Toolbox Talk (TBT)

Every operational task performed on a merchant vessel—whether routine paint chipping, mooring line handling, or overhauling a purifier—carries inherent hazards. Modern maritime safety culture relies on proactive risk assessment to identify hazards before work commences.

The Hierarchy of Hazard Controls

When evaluating risks, the shipboard team must apply controls in a strict descending hierarchy. Controls at the top of the pyramid are fundamentally more reliable than those at the bottom.

   +-------------------------------------------------------------+
   | 1. ELIMINATION       (Physically remove the hazard)         |  Most Effective
   +-------------------------------------------------------------+
   | 2. SUBSTITUTION      (Replace hazard with safer alternative)|       ^
   +-------------------------------------------------------------+       |
   | 3. ENGINEERING       (Isolate people from the hazard)       |       |
   +-------------------------------------------------------------+       |
   | 4. ADMINISTRATIVE    (Change the way people work)           |       |
   +-------------------------------------------------------------+       v
   | 5. PPE               (Protect worker with personal gear)    |  Least Effective
   +-------------------------------------------------------------+

1. Elimination: Completely remove the hazard from the workplace. For example, instead of sending a rating overside on a stage to paint the vessel's flare at sea, the job is deferred to drydock where shore scaffolding is erected.
2. Substitution: Replace a hazardous material or tool with a less hazardous one. For example, substituting toxic, highly volatile solvent-based paint strippers with biodegradable, water-based degreasing agents.
3. Engineering Controls: Implement physical engineering measures that isolate crew members from the danger. Examples include installing fixed protective machinery guards around rotating winch drums and lathe chucks, fitting acoustic enclosures over diesel generators, or installing mechanical explosion-proof extraction fans in paint lockers.
4. Administrative Controls: Establish procedures, policies, and training to regulate work practices. Examples include issuing Permits to Work (PTW), implementing Lockout/Tagout (LOTO) protocols, scheduling mandatory rest periods under STCW to combat fatigue, and posting warning signs.
5. Personal Protective Equipment (PPE): The final line of defense. Used only when hazards cannot be engineered out completely. Relies entirely on individual human compliance and equipment condition.

Conducting a Toolbox Talk (TBT)

A Toolbox Talk (TBT) is an informal yet structured safety briefing conducted at the physical job site immediately prior to commencing any work. It bridges the gap between written safety procedures and real-time execution.

• Leadership: Led by the job supervisor (e.g., Bosun on deck, Fitter or Second Engineer in the workshop).
• Attendees: All crew members assigned to the work party, including trainee GP ratings.
• Core Elements Covered:
  • Task Brief: Clear explanation of what needs to be done, sequence of steps, and expected completion time.
  • Hazard Identification: Specific hazards associated with the job (e.g., ship roll, wet decks, pressurized lines, overhead crane movements, toxic fumes).
  • Individual Role Allocation: Assigning precise duties to each crew member according to skill level.
  • PPE and Tool Verification: Confirming that correct tools (e.g., insulated hand tools, non-sparking brass hammers) and PPE are staged, inspected, and properly worn.
  • Emergency Procedures & Stop Signals: Establishing clear verbal commands or hand signals to pause or abort the operation in an emergency.

Stop-Work Authority (SWA)

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4. Safe Manual Handling & Kinetic Lifting Principles

Unsafe manual handling can cause musculoskeletal injuries, including back sprains and disc injuries, among deck and engine ratings. Moving heavy machinery spares, grease drums, paint cans, and mooring lines aboard a rolling, pitching vessel requires strict adherence to kinetic lifting techniques.

The Kinetic Lifting Technique (Step-by-Step)

     1. FEET POSITION                 2. SQUAT POSTURE                 3. SMOOTH DRIVE

         [ O ]                             [ O ]                            [ O ]
           |                                 |                                |  Load held
      /----+----\                       /----+----\                      /----+----\ close
     /     |     \                     /     |     \                    /   [===]   \ to chest
          / \                               / \                              / \   
         /   \                             /   \                            /   \  Drive with
       _/     \_                         _/__   __\_                      _/     \_ leg muscles
   Feet shoulder-width apart,         Knees bent, back straight,       Push up with powerful
   one foot slightly forward           firm palm grip on load          quadriceps, do NOT twist

1. Stop and Assess:
   • Check the load's weight, dimensions, and center of gravity.
   • Inspect for sharp edges, slippery grease, protruding wire snags, or hot surfaces.
   • Verify that the path of travel is completely free of trip hazards, lashing eyes, oil slicks, and open deck manholes.
2. Adopt a Stable Base:
   • Stand with feet hip- to shoulder-width apart.
   • Place one foot slightly forward beside the load to maintain balance against ship rolling motions.
3. Bend the Knees, Not the Back:
   • Lower the body by bending the knees and hips into a squat.
   • Maintain the spine's natural straight posture (head held upright, chin tucked, chest thrust forward).
   • Avoid bending forward with locked knees; holding a load away from the body increases its lever arm and the load on the lower back.
4. Secure a Full Palm Grip:
   • Grasp the load using the entire palm and roots of the fingers, not just the fingertips.
   • Use gloves with non-slip grips.
5. Lift Smoothly with Leg Muscles:
   • Keep the load close to the body throughout the lift, with its heavier side nearest the trunk.
   • Straighten the legs smoothly, driving upward with the powerful quadriceps and gluteal muscles.
   • Avoid jerky, abrupt upward thrusts.
6. Never Twist While Carrying:
   • Never twist the waist or torso while holding or lifting a heavy object.
   • To change direction, pause and turn the entire body by moving the feet.

Safe Weight Limits Onboard

• Assess Each Lift: There is no single weight that is safe for every seafarer or task. Consider the load’s weight and grip, lifting height, reach, frequency, route, individual capability and deck conditions. Weight guidelines are screening aids, not guaranteed safe limits.
• Vessel Motion: Rolling and pitching impair balance and can increase handling forces. Reassess the operation; postpone it if necessary. Use suitable mechanical aids or a planned team lift, with enough people of similar height lifting together on one person’s command. Do not assume that halving a nominal limit makes heavy-weather lifting safe.