Write a risk assessment for Generator major overhauling
A person submitted this question to Rosie's free generator. The asker's identity is neither imported nor published.
Rosie's answer
Published by SALUSA major generator overhaul should be managed as a high-risk planned maintenance activity using a documented risk assessment, job safety analysis (JSA), permit-to-work, and energy isolation plan before work starts. The safest default is to place the generator and all associated systems in an electrically safe work condition unless justified energized work is absolutely necessary. Planning should identify each task step, the hazards created at that step, the body parts at risk, and the control method, with engineering and work-practice controls used before PPE. A pre-job briefing should define scope, roles, boundaries, communication, rescue arrangements, and hold points for verification. [12] [8] [14]
A practical risk assessment and JSA for generator overhaul should cover at least these work phases: shutdown and handover, isolation and LOTO, electrical testing and proving dead, removal of guards/covers, disassembly, rotor/stator inspection, lifting and rigging, cleaning, machining or repair, hot work, confined space entry if applicable, reassembly, testing/commissioning, and return to service.
Typical major hazards include electrical shock, arc flash, arc blast, unexpected start-up, stored electrical/mechanical/hydraulic/pneumatic energy, suspended loads, pinch/crush points, dropped objects, slips/trips/falls, heat, noise, dust, solvents and chemicals, fire/explosion, oxygen deficiency or toxic atmosphere in enclosed spaces, and ergonomic strain from heavy components.
- Electrical: shock from exposed conductors, induced voltage, backfeed, capacitor discharge, arc flash during switching, racking, testing, or troubleshooting
- Mechanical: rotor movement, coupling rotation, spring force, gravity from suspended or unsupported parts, pinch points during alignment and assembly
- Stored energy: capacitors, excitation systems, batteries, hydraulic accumulators, pneumatic pressure, compressed springs, residual rotation, thermal energy
- Lifting/rigging: crane failure, incorrect center of gravity, sling failure, side loading, load swing, dropped rotor or end shields, personnel under suspended loads
- Confined space: oxygen deficiency, toxic or flammable atmosphere, poor ventilation, restricted egress, engulfment or obstruction, rescue delay
- Hot work: ignition of oil mist, insulation dust, solvents, hydrogen or battery gases, burns, smoke/fume exposure, fire spread
- Occupational hygiene: noise, silica or insulation dust, solvent vapors, welding fumes, skin/eye contact with chemicals
- Ergonomic and access hazards: awkward postures, manual handling, ladders/scaffolds, poor lighting, cluttered work areas
[11] [15] [14] For lockout/tagout and electrical isolation, establish a written equipment-specific isolation procedure covering every energy source connected to the generator and auxiliaries: incoming feeders, control power, excitation circuits, batteries, UPS/DC systems, space heaters, turning gear, lube oil pumps, seal oil systems, cooling water, compressed air, hydraulics, and any remote or automatic start signals. Identify all sources, interrupt load current, open each disconnecting means, visually verify isolation where possible, apply individual locks/tags, release stored energy, and then test before touch on every phase and conductor using an adequately rated tester checked before and after use. [7] [7] [7]
LOTO must include verification of isolation and control of complex/group lockout. Each exposed worker should apply a personal lock, pushbuttons or selector switches must not be the sole means of de-energizing, and tagout alone should be used only when lockout is not possible. For multi-crew or multi-shift overhaul work, appoint one qualified person in charge, maintain a written group LOTO plan, account for all personnel, and require incoming workers to apply their locks before outgoing workers remove theirs. Before re-energization, confirm all tools, jumpers, grounds, restraints, and temporary protections are removed and all personnel are clear. [7] [9] [9]
Where any task could expose workers to energized parts above 50 V, perform an electrical risk assessment addressing shock and arc flash. The preferred control is de-energization; energized work should be limited to justified tasks such as testing, troubleshooting, or where de-energizing creates greater hazard or is infeasible. Establish shock and arc-flash boundaries, barricade the area, keep unqualified persons out, use properly rated test instruments and insulated tools, and require a documented live-work permit authorized by a qualified supervisor when live work cannot be avoided. [3] [5] [9]
- Identify all electrical sources including normal, alternate, induced, stored, and backfeed sources
- Establish limited/restricted approach boundaries and arc-flash boundary
- Barricade and post signs; keep unqualified persons outside boundaries
- Use adequately rated meters, leads, gloves, and insulated tools
- Use the left-hand rule where appropriate during switching operations and stand out of the line of fire
- Do not remove covers, rack breakers, or open energized compartments without task-specific procedure, PPE, and authorization
- Ground or discharge capacitors and other stored electrical energy before contact
[9] [3] [7] Stored energy controls must extend beyond electrical isolation. Before disassembly, block against rotation, lower or support suspended or elevated parts, relieve hydraulic and pneumatic pressure, bleed or blank lines where needed, secure moving parts, discharge capacitors, isolate batteries, and verify zero mechanical motion. Treat springs, couplings, flywheels, turning gear, and elevated components as hazardous until restrained or proven safe. If the overhaul involves associated vehicles or mobile equipment, hazardous energy can also include gravity, pressure, springs, battery energy, thermal energy, and unexpected motion. [4] [15] [7]
For lifting operations, prepare a lift plan for heavy generator components such as rotors, stators, end shields, coolers, and couplings. Verify component weights, center of gravity, crane and hoist capacity, rigging configuration, sling angles, lifting points, floor loading, travel path, and exclusion zones. Use only inspected and rated lifting gear, assign a competent lift supervisor and signaler, keep personnel clear of suspended loads, and use tag lines where needed to control swing. Support components positively before removing fasteners, and never rely on jacks or hoists alone where blocking or stands are required. [11] [6] [17]
If any part of the overhaul requires entry into a generator casing, plenum, pit, or other space meeting confined-space criteria, use a permit-required confined space program. Complete the entry permit, isolate all energy sources, drain/flush/purge as needed, secure the area, verify atmospheric testing before entry, and continue monitoring when conditions or work activities can change the atmosphere. Provide an attendant outside the space, maintain communication, ensure rescue arrangements are in place, and use retrieval systems where required. Mechanical ventilation is usually necessary; natural ventilation alone is often not reliable. [2] [2] [13]
- Entry area free of debris; barriers and warning signs in place
- Atmospheric monitoring completed and recorded on permit; continuous monitoring when required
- Energy sources isolated/locked out; electrical equipment grounded where applicable
- Space drained, flushed, or purged as needed
- No compressed gas cylinders brought into the space
- Forced-air or exhaust ventilation provided; warning system for ventilation failure
- Retrieval equipment, communication equipment, fire extinguishers, GFCI, safe/low-voltage lighting, and non-sparking tools provided as needed
- Entrants, attendant, supervisor, and rescue contacts identified and trained
[1] [1] [13] For hot work, require a separate hot-work permit integrated with the overhaul permit and, if applicable, attached to the confined-space permit. Identify fire, heat, flammable/explosive atmosphere, electrical, mechanical, and stored-energy hazards; remove combustibles; isolate fuels and oils; verify atmosphere is safe; provide ventilation; assign a fire watch; keep extinguishers immediately available; and maintain the fire watch for at least 30 minutes after completion. Use non-sparking tools and intrinsically safe or low-voltage lighting where required, and never block entry/exit or bring gas cylinders into a confined space. [4] [4] [4]
PPE should be selected from a documented hazard assessment and matched to the task. For generator overhaul this commonly includes hard hat, safety glasses with side protection, face shield as needed, hearing protection, cut-resistant or general work gloves, chemical-resistant gloves for solvents/oils, arc-rated clothing and voltage-rated rubber gloves for electrical tasks, protective footwear with toe protection and slip resistance, and respiratory protection where dust, fumes, or vapors cannot be otherwise controlled. For electrical exposure, use shock and arc-flash PPE rated for the voltage and incident energy. PPE is the last line of defense and does not replace isolation, guarding, ventilation, or safe work practices. [12] [5] [18]
- Head: protective helmet selected for impact and electrical exposure where applicable
- Eyes/face: safety glasses, goggles, or face shield for flying particles, dust, chemicals, and grinding
- Hands: task-specific gloves such as cut-resistant, chemical-resistant, heat-resistant, or electrician's insulated rubber gloves
- Feet: safety boots with toe protection; slip-resistant, puncture-resistant, chemical-resistant, or insulated footwear as needed
- Body: arc-rated clothing for electrical tasks; protective clothing for oils, solvents, and hot work
- Hearing: hearing protection for high-noise disassembly, grinding, and testing
- Respiratory: appropriate respirator only under a respiratory protection program when ventilation and other controls are insufficient
- Fall/retrieval: harness, lifeline, and tripod where confined-space or fall hazards require them
[16] [17] [2] A robust permit-to-work system for generator overhaul should include, as applicable: master maintenance permit, LOTO certificate, electrical isolation certificate, confined-space permit, hot-work permit, lifting permit/critical lift plan, line-breaking permit, and energized electrical work permit. Each permit should define scope, exact equipment/location, hazards, isolations, boundaries, PPE, authorized workers, validity period, gas-test results where applicable, emergency contacts, and hand-back/close-out requirements. No permit should be issued until the JSA and isolations are verified in the field. [9] [2] [4]
Emergency response planning should be completed before work starts. The plan should cover electric shock, arc flash burn, fire, smoke/fume exposure, confined-space rescue, dropped load/crush injury, chemical splash, and medical emergencies. Define alarm and communication methods, rescue team notification, access/egress routes, isolation points, first-aid/CPR capability, eyewash/shower locations where chemicals are present, and the nearest emergency medical support. For confined spaces, rescue capability must be arranged in advance and attendants must never enter impulsively to attempt rescue without authorization and equipment. [2] [4] [5]
From an OSHA and electrical-safety compliance standpoint, the overhaul program should align at minimum with: OSHA 29 CFR 1910\.147 for control of hazardous energy; 29 CFR 1910\.333 for selection and use of work practices near exposed energized parts; 29 CFR 1910\.146 for permit-required confined spaces where applicable; PPE requirements under 29 CFR 1910 Subpart I; and recognized electrical safe-work practices in NFPA 70E for establishing an electrically safe work condition, shock/arc-flash risk assessment, boundaries, permits, and PPE. Crane/rigging, welding/hot work, respiratory protection, and walking-working surfaces standards may also apply depending on scope. Compliance should be demonstrated through written procedures, training, permits, field verification, and supervision by qualified persons. [10] [5] [10]
A concise safe work procedure is: plan the overhaul; review drawings/manuals; perform site walkdown and JSA; identify all hazards and permits; shut down and isolate all energy sources; apply group and personal LOTO; release and verify stored energy; prove de-energized; establish boundaries and barricades; verify lifting arrangements and access controls; complete confined-space and hot-work controls if applicable; perform the overhaul using task-specific procedures and PPE; maintain housekeeping and continuous supervision; reassemble and inspect; remove temporary grounds/tools/restraints; clear personnel; remove LOTO in sequence; test and recommission under controlled conditions; and close permits with lessons learned.
Sources used for this answer
[1] Personal Protective Equipment (PPE) Hazard Assessment Tool
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Open source documentSource excerpt
# Hazard assessment worksheet: Eye and face protection (cont.) ## PPE required (cont.) OSHA Oregon OSHA Department of Consumer and Business Services # Hazard assessment worksheet: Head protection Salem Central Office [redacted street address]. NE Salem, OR [redacted postal code] Phone: [redacted phone] Toll-free: [redacted phone] osha.oregon.gov Work task: Date ## Potential hazards No hazards requiring head protection Overhead objects that could fall Exposed pipes or beams (less than 6.5 feet overhead) Energized electrical equipment Other hazard: <table><tr><th>PPE required</th></tr><tr><td>None required</td></tr><tr><td>Impact Type I</td></tr><tr><td>Impact Type II</td></tr><tr><td>Electrical Class G (general)</td></tr><tr><td>Electrical Class E (electrical)</td></tr><tr><td>Electrical Class C (conductive)</td></tr><tr><td>Other PPE:</td></tr></table> 440-5871 (07/23/COM)
[2] Personal Protective Equipment (PPE) Hazard Assessment Tool
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Open source documentSource excerpt
# Hazard assessment worksheet: Leg protection (cont.) ## PPE required (cont.) OSHA Oregon OSHA Department of Consumer and Business Services # Hazard assessment worksheet: Hand protection Salem Central Office [redacted street address]. NE Salem, OR [redacted postal code] Phone: [redacted phone] Toll-free: [redacted phone] osha.oregon.gov Work task: Date ## Potential hazards - No hazards requiring hand protection - Harmful or hazardous temperatures - Chemicals that can be absorbed into the skin or cause burns - Energized electrical equipment - Mechanical equipment that can cause bruises, abrasions, cuts, punctures, fractures, or amputations Other hazard: ## PPE required None required - Cut resistant gloves General-purpose work gloves Chemical resistant gloves ............... Insulated gloves Heat and flame resistant gloves Latex or nitrile gloves Electrician's insulated rubber gloves Cotton, leather, or anti-vibration gloves Other PPE: 440-5871 (07/23/COM)
[3] Oregon OSHA Program Directive | Control of Hazardous Energy – Enforcement Policy and Inspection Procedures (Lockout/Tagout)
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Open source documentSource excerpt
# CHAPTER 2 -- ENFORCEMENT POLICIES AND PROCEDURES (cont.) NOTE: Other OR-OSHA Instructions, such as A-62 for the permit required confined spaces standard and A-212, for the electric power generation, transmission and distribution standard also address CSHO safety policy. Therefore, CSHOs must follow the LOTO standard requirements, which include the group LOTO and the verification of isolation provisions before inspecting, servicing and maintenance activities work on machinery or equipment. For example, if a CSHO performing a fatality investigation determines that it is necessary to inspect a potentially hazardous area of the bridge on an overhead crane, then the inspector would need to determine whether or not the employer's energy control procedure for the crane is compliant with the LOTO standard. The CSHO could, after determining the employer's procedure is compliant, then coordinate his activities with the host. This would, in part, entail applying his personal LOTO device on the appropriate energy isolating device(s) or group lockout mechanism and witnessing the verification that isolation and deenergization have been accomplished. After all of the LOTO control standard control measures are implemented, the CSHO may then enter the bridge area to inspect. NOTE: At no time must any CSHO personally perform any machine/equipment shutdown, energy source isolation or servicing/maintenance work on any machine/equipment as part of the LOTO evaluation. All verification of energy isolation must be performed by the employer's authorized or primary authorized employee(s) in accordance with their energy control procedures and witnessed by the CSHO. Additionally, if the overhead crane investigation scenario involves employee exposure to unguarded live electric circuits, such as an unguarded live electric bus, then the electric utilization equipment must be de-energized (e.g., lockout and tagging by a qualified employee) in accordance with the Selection and use of work p…
[4] Toolbox Talk: Arc Flash Hazards
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Open source documentSource excerpt
# ARC FLASH HAZARDS (cont.) ## HOW CAN YOU PROTECT YOURSELF FROM THE HAZARDS OF ARC FLASH? (cont.) • De-energizing would create a more significant hazard, or it is necessary for the interests of health and safety that the electrical work is carried out while the equipment is energized (e.g., it may be required for life-saving equipment to remain energized and operating while electrical work is carried out on the equipment). • It is necessary that the electrical equipment to be worked on is energized for the work to be carried out correctly. • It is necessary for testing or troubleshooting. • There is no reasonable alternative means of carrying out the work. ## NOTE: USE APPROPRIATE LOCKOUT, TAGOUT, AND HAZARDOUS ENERGY CONTROL PROCEDURES TO ISOLATE ENERGIZED EQUIPMENT WHEN A CIRCUIT BREAKER OR OTHER DISCONNECT TURNED OFF. THE BEST ARC FLASH PROTECTION IS TO DE-ENERGIZE EQUIPMENT BEFORE WORKING ON IT! IS Second Best Choice for Arc Flash Protection: Use appropriately rated personal protective equipment (PPE). Arc flash personal protective equipment (PPE) is a combination of clothing and safety equipment worn for protection from arc flash and shock hazards by a person performing electrical work. Primarily, arc flash PPE is divided into the following subgroups: • Head, face, neck, and chin protection • Eye protection • Hearing protection • Body protection • Hand and arm protection • Foot and leg protection ## GENERAL ELECTRICAL SAFE WORK PRACTICES All employees working on or near electrical equipment shall follow general safe work practices, including: • Maintain housekeeping procedures in the work area, e.g., prevent slip trips and falls; eliminate fire hazards; control dust; prevent falling hazards; clear clutter. • Plan and analyze each step of a work task to ensure safety. • - Maintain appropriate work boundaries for qualified electrical workers (QEW) and unqualified workers. • Use properly rated and tested test equipment (e.g., multimeter). …
[5] Confined Space Guide for General Industry
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# ATTACHMENT A # Hot Work Permit Sample (attach to Entry Permit) XYZ Company Date: <empty> Issue time: <empty> Expiration time: <empty> Location of permit space: <empty> Work tasks: <empty> Potential Hazards Authorized Workers O Toxic O Electrical Entrants: O Corrosive O Mechanical O Flammable/Explosive O Fire/heat Attendant(s): O Radioactive O Spills Fire/safety watch: O Energy release O Oxygen Enrichment - O Stored energy Procedures/Precautions: O Procedures O Communications O Entry permit O Ventilation O Training O CPR/first aid O Rescue plan O Sprinkler system in service O Charged fire hose O Surfaces wetted down O Shower/eyewash located Safety Equipment: O Hard hat O Eye protection O Hearing protection O Foot/hand protection O Protective clothing O SCBA O Respirator: <empty> O Tripod O Barricade/cones O Communication devices O First aid kit O Fire extinguisher O: <empty> Vessel Prep/Isolation: O Cleaning/purging O Ventilation O Signs/barriers O Lagging cloths/tarps O Lockout/tagout O Blanking/bleeding O Disconnect mechanical linkages O Secure moving parts O: <empty> O: <empty> O: <empty> Special Tools - O Low voltage - O Non-sparking - O Tools inspected for frayed/broken wires - O Lighting intrinsically safe Special Work Procedures - O Never bring gas cylinders or other large equipment into space - O Never block entry/exit with equipment - O Shut down during breaks or overnight - O Fire watch to remain 30 minutes after completion of hot work O Entry authorizer (name, title, date): <empty> Emergency contact: <empty> 52 2
[6] Protection From Electric Shock and Arc Flash
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Open source documentSource excerpt
# Protection from Electric Shock and Arc Flash Journeyman Technical Information Paper 2 OBED LEB 10 1808 BAITDING-C REHICYA FEDEBLOW ROBAR About 50 electrical workers are killed in construction every year in the U.S. by electric current and many more are injured. Over half of the deaths are from working on energized ("live") electric circuits without proper protection - often when it was not necessary to work "live." At least one-third of the electrocutions occur at low voltage, under 600 volts. This paper discusses precautions for electricians, but does not cover electric utility work. ## Electric hazards Electricity-related hazards include electric shock and burns, arc-flash burns, arc-blast impacts, and falls. - Electric shock and burns. An electric shock occurs when electric current passes through your body. This can happen when you touch an energized part. If the electric current passes across the chest or head, you can be killed. At high voltages, severe burns can result. - Arc-flash burns. An electric arc flash can occur if a conductive object gets too close to a high-amp current source or by equipment failure (for instance, while opening or closing disconnects). The arc can heat the air to temperatures as high as 35,000° F, and vaporize metal in the equipment. The arc flash can cause severe skin burns by direct heat exposure and by igniting clothing. - Arc-blast impacts. The heating of the air and vaporization of metal creates a pressure wave that can damage hearing and cause memory loss (from concussion) and other injuries. Flying metal parts are also a hazard. - Falls. Electric shocks and arc blasts can cause falls, especially from ladders or unguarded scaffolding. ## Electric Safety Principles Plan every job. Decide on your approach and step-by-step procedures. Write down first-time procedures. Discuss hazards and procedures in a job briefing with your supervisor and other workers before starting a job. Your employer should already have or dev…
[7] Confined Space Permit Form
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# Confined Space Entry Assessment Form/Permit <table><tr><th colspan="6">Preparation</th></tr><tr><td>Yes</td><td>N/A</td><td></td><td>Yes</td><td>N/A</td><td></td></tr><tr><td></td><td></td><td>Entry area free of debris and objects</td><td></td><td></td><td>No compressed cylinders in space</td></tr><tr><td></td><td></td><td>Warning barriers and signs in place</td><td></td><td></td><td>Host employer and/ or contractor notified</td></tr><tr><td></td><td></td><td>Atmospheric monitoring conducted</td><td></td><td></td><td>Entry and emergency procedures reviewed</td></tr><tr><td></td><td></td><td>Other hazards identified and isolated</td><td></td><td></td><td>Personnel have been trained</td></tr><tr><td></td><td></td><td>Hot work permitted</td><td></td><td></td><td>Personnel informed of potential hazards</td></tr><tr><td></td><td></td><td>Energy sources isolated/locked out</td><td></td><td></td><td>Electrical equipment is grounded</td></tr><tr><td></td><td></td><td>Confined space drained and flushed</td><td></td><td></td><td></td></tr></table> <table><tr><th></th><th></th><th colspan="4">Equipment Required</th></tr><tr><td colspan="3">Yes N/A</td><td>Yes</td><td>N/A</td><td></td></tr><tr><td></td><td></td><td>Forced air or exhaust ventilation</td><td></td><td></td><td>Non-sparking tools used</td></tr><tr><td></td><td></td><td>Ground fault interrupters (GFCI)</td><td></td><td></td><td>Low voltage lighting used</td></tr><tr><td></td><td></td><td>Retrieval Equipment</td><td></td><td></td><td>Equipment rated for explosive atmospheres</td></tr><tr><td></td><td></td><td>Fire Extinguishers</td><td></td><td></td><td>Communication Equipment</td></tr></table> <table><tr><th colspan="6">Personal Protective Equipment Required</th></tr><tr><td>Yes</td><td>N/A</td><td></td><td>Yes</td><td>N/A</td><td></td></tr><tr><td></td><td></td><td>Hard Hat</td><td></td><td></td><td>Protective Clothing</td></tr><tr><td></td><td></td><td>Eye/Face Protection</td><td></td><td></td><td>Hearing Pro…
[8] Confined Space - Introduction
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# Why is working in a confined space more hazardous than working in other workspaces? (cont.) ## What should be done when preparing to enter the confined space? (cont.) The results of the tests for these hazards are to be recorded on the Entry Permit along with the equipment or method(s) that were used in performing the tests. Air testing is often ongoing, depending on the nature of the potential hazards and the nature of the work. Conditions can change while workers are inside the confined space and sometimes a hazardous atmosphere is created by the work activities in the confined space. For more information see our OSH Answers document on Confined Space - Atmospheric Testing. ## How are hazards controlled in confined spaces? Hazards and risks associated with a confined space must first be identified through a risk assessment. After this is done, a hazard control program can be put in place. The traditional hazard control methods found in regular worksites, which are implemented based on the hierarchy of controls, can be effective in a confined space. The most effective controls are elimination and substitution, if these are not possible or if there is remaining risk, then engineering controls should be considered. Administrative controls should also be put in place to complement other controls. The last measure to consider is personal protective equipment. However, often because of the nature of the confined space and depending on the hazard, special precautions not normally required in a regular worksite may also need to be taken. Elimination removes the hazard (e.g., finding another way to complete a job without entering a confined space) and substitution replaces a hazard with a safer one (e.g., using cold work methods instead of hot work). An engineering control commonly used in confined spaces is mechanical ventilation. The entry permit system is an example of an administrative control used in confined spaces. Personal protective equipment (such as res…
[9] Arc Flash
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Open source documentSource excerpt
# Arc Flash (cont.) ## What elements should be considered when doing an arc flash risk assessment? (cont.) Whenever possible, do not work on energized equipment. Always follow lockout/tagout procedures as part of a hazardous energy control program. Other protective measures include: - Making sure conductors and circuit parts are in a safe working condition - Using lower energy equipment or current energy limiting devices - Guarding energized electrical conductors and circuit parts - Using arc flash approach boundaries, including barricades - Increasing the working distance - Using non-contact instruments or procedures, where possible - Using non-sparking tools - Implementing work permits, safe work procedures, and job planning - Posting signs alerting of the hazards - Wearing shock and arc flash personal protective equipment (PPE) ## What would be included in preventive maintenance? Preventive maintenance includes: - Regular inspection for wear and tear of insulation, corrosion, poor connections, overheated electrical conductors, excessive pitting of contacts, or excessive moisture, water, or ice on the equipment. - Regular measurements of critical components. - Routine inspections of circuit breakers and relays (develop a testing schedule based on the manufacturer's instructions or the InterNational Electrical Testing Association (NETA) guidelines). - Follow established maintenance requirements, including a parts replacement schedule. - Keep electrical drawings current. ## What are approach boundaries? Boundaries are used to limit how close workers and others should be to the equipment or circuits, especially when work is being done. Arc Flash CCOHS
[10] Personal Protective Equipment (PPE) Guide
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# Option 2 # Job Hazard Analysis for Personal Protective Equipment (PPE) Assessment Job/Task: Location: <table><tr><th>Job/Task Step</th><th>Hazard Type</th><th>Hazard Source</th><th>Body Parts At Risk</th><th>Severity</th><th>Probability</th><th>Risk Code</th><th>Control Method¹</th></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr></table> (1) Note: Engineering, work practice, and/or administrative hazard controls such as guarding must be used, if feasible, before requiring employees to use personal protective equipment. Certification of Assessment *Name of work place: <empty> *Address: <empty> *Assessment Conducted By: <empty> Title: <empty> *Date(s) of Assessment: <empty> Implementation of Controls Approved By: <empty> Title: <empty> Date: <empty> Page 24 24 24
[11] Personal Protective Equipment (PPE) Hazard Assessment Tool
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# Hazard assessment worksheet: Head protection (cont.) ## Potential hazards (cont.) OSHA Oregon OSHA Department of Consumer and Business Services # Hazard assessment worksheet: Foot protection Salem Central Office [redacted street address]. NE Salem, OR [redacted postal code] Phone: [redacted phone] Toll-free: [redacted phone] osha.oregon.gov Work task: Date ## Potential hazards - No hazards requiring foot protection - Heavy objects such as barrels or tools that might roll onto or fall on a worker's feet - Sharp objects such as nails or spikes that could pierce the soles or uppers of ordinary shoes - Molten metal Hot, wet, or slippery surfaces Energized electrical equipment Other hazard: ## PPE required None required Steel toe shoes Boots or shoes metatarsal guards Slip resistant soles Puncture resistant soles Chemical resistant boots Insulated boots or shoes Other PPE: 440-5871 (07/23/COM)
[12] Protection From Electric Shock and Arc Flash
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# De-Energizing (cont.) ## Lockout/tagout program (cont.) entirety. ensuring all energy sources are under lockout/tagout and to account for all people on the job. There should be a written plan addressing the specific details and naming the person in charge. Removal of lockout/tagout devices. Lockout and tagout devices should be removed only by the person installing them. If work is not completed when the shift changes, workers arriving on shift should apply their locks before departing workers remove their locks. Return to service. Once work is completed and lockout/tagout devices removed, tests and visual inspection must confirm that all tools, mechanical restraints, electric jumpers, shorts, and grounds have been removed. Only then is it safe to re- energize and return to service. Employees responsible for operating the equipment and needed to safely re-energize it should be out of the danger zone before equipment is re-energized. Temporary release. If the job requiring lockout/tagout is interrupted for testing or positioning equipment, follow the same steps as in return to service (above). ## Working On or Near Live Circuits Working on live circuits means actually touching energized parts. Working near live circuits means working close enough to energized parts to pose a risk even though you make be working on de-energized parts. Common tasks where you need to work on or near live circuits include: - Taking voltage measurements - Opening and closing disconnects and breakers - Racking breakers on and off the bus - Removing panels and dead fronts - Opening electric equipment doors for inspection. There should be standard written procedures and training for these common tasks. For instance, when opening and closing disconnects, use the left-hand rule when possible (stand to the right side of the equipment and operate the disconnect with your left hand). For other situations where you might need to work on or near live circuits, your employer should in…
[13] Personal Protective Equipment Hazard Assessment
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Open source documentSource excerpt
# What types of PPE may be necessary? Your hazard assessment should determine if your employees need any of the following types of PPE: - Eye and face protection ◆ Fall protection - Foot protection • Hand/general skin protection - Head protection • Hearing protection • Leg protection ● Personal floatation device • Respiratory protection • Torso/general body protection ## How to do a PPE hazard assessment ## Do a baseline survey to identify workplace hazards A baseline survey is a thorough evaluation of your entire workplace - including work processes, tasks, and equipment - that identifies safety and health hazards. A complete survey will tell you what the hazards are, where they are, and how severe a potential injury could be. ## Suggestions: Use safety data sheets (SDS) to identify chemical hazards. A safety data sheet has detailed information about a hazardous chemical's health effects, its physical and chemical characteristics, and safe handling practices. Review equipment owner and operator manuals to determine the manufacturer's safety warnings and recommended PPE. Conduct a job-hazard analysis (JHA) - a method of identifying, assessing, and controlling hazards associated with specific jobs. A JHA breaks down a job into tasks. You evaluate each task to determine if there is a safer way to do it. A job-hazard analysis works well for jobs with difficult-to-control hazards and jobs with histories of accidents or near misses. JHAS for complex jobs can take a considerable amount of time and expertise to develop. You may want to have a safety professional help you. Have an experienced safety professional survey your workplace with you. 4
[14] Personal Protective Equipment (PPE) Guide
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Open source documentSource excerpt
# Hazard Assessment For PPE (cont.) ## Instructions: (cont.) Option 1 # PPE Hazard Assessment Certification Form *Name of work place: <empty> *Work place address: <empty> *Required for certifying the hazard assessment. Work area(s): <empty> *Assessment conducted by: <empty> *Date of assessment: <empty> Job/Task(s): <empty> Use a separate sheet for each job/task or work area *Required for certifying the hazard assessment. Use a separate sheet for each job/task or work area EYES: Work activities, such as: [ ] abrasive blasting [ ] sanding [ ] chopping [ ] sawing [ ] cutting [ ] grinding [ ] drilling [ ] hammering [ ] welding [ ] punch press operations [ ] other: <empty> Work-related exposure to: [ ] airborne dust [ ] flying particles [ ] blood splashes [ ] hazardous liquid chemicals [ ] intense light [ ] other: <empty> Can hazard be eliminated without the use of PPE? Yes [ ] No [ ] If no, use: [ ] Safety glasses [ ] Side shields [ ] Safety goggles [ ] Dust-tight goggles [ ] Shading/Filter (#<empty>) [ ] Welding shield [ ] Other: <empty> FACE: Work activities, such as: [ ] cleaning [ ] foundry work [ ] welding [ ] siphoning [ ] mixing [ ] painting [ ] pouring molten metal [ ] dip tank operations [ ] other: <empty> Work-related exposure to: [ ] hazardous liquid chemicals [ ] extreme heat/cold [ ] potential irritants: <empty> [ ] other: <empty> Can hazard be eliminated without the use of PPE? Yes [ ] No [ ] If no, use: [ ] Face shield [ ] Shading/Filter (#<empty>) [ ] Welding shield [ ] Other: <empty> HEAD: Work activities, such as: [ ] building maintenance [ ] confined space operations [ ] construction [ ] electrical wiring [ ] walking/walking under catwalks [ ] walking/workng under conveyor belts [ ] walking/workng under crane loads [ ] utility work [ ] other: <empty> Work-related exposure to: [ ] beams [ ] pipes [ ] exposed electrical wiring or components [ ] falling objects [ ] machine parts [ ] other: <empty> Can hazard be eliminated without the us…
[15] Confined Space Entry Permit
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Open source documentSource excerpt
# Confined space entry permit Permit date: <empty> Work shift: [ ] 1st [ ] 2nd [ ] 3rd Expires: <empty> Time started: <empty> Permit space to be entered (name and location of space): <empty> Purpose of entry: <empty> ## Names of trained, authorized individuals Emergency contact information Entry supervisor: Emergency responder: Entry attendant: Contact person: Authorized entrants: Phone number: Authorized entrants: Time: ## Pre-entry checklist Do not enter this permit space until the following "needs action" conditions are corrected: <table><tr><th>OK</th><th>Needs action</th><th></th></tr><tr><td></td><td></td><td>Before entering the permit space, the supervisor or designee must notify the rescue team. IDLH conditions require at least one rescue team member located outside the space.</td></tr><tr><td></td><td></td><td>A minimum of two employees must be assigned to work involving permit space entry. One employee must remain outside the permit space at all times</td></tr><tr><td></td><td></td><td>The surrounding area must be surveyed to show that it is free of hazards such as drifting vapors from tanks, piping, sewers, or vehicle exhaust.</td></tr><tr><td></td><td></td><td>Those responsible for operation of the gas monitor have been trained.</td></tr><tr><td></td><td></td><td>Gas monitor calibration tests and functional test (fresh air calibration) have been performed this shift on the gas monitor. If so, by whom?</td></tr><tr><td></td><td></td><td>The atmosphere will be continuously monitored while the space is occupied, if required by entry procedure.</td></tr></table> <table><tr><th colspan="8">Pre-entry requirements</th></tr><tr><td>Requirements</td><td>Yes</td><td>No</td><td>N/A</td><td>Requirements</td><td>Yes</td><td>No</td><td>N/A</td></tr><tr><td>Lockout-tagout/de-energize</td><td></td><td></td><td></td><td>Hot work permit</td><td></td><td></td><td></td></tr><tr><td>Pipes(s) broken or capped or blanked</td><td></td><td></td><td></td><td>Fall …
[16] Personal Protective Equipment (PPE) Guide
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Open source documentSource excerpt
# Option 2 ## Job Hazard Analysis Assessment for PPE: Instructions 1. - Conduct a walk through survey of your business. For each job/task step, note the presence of any of the following hazard types (see table below) their sources, and the body parts at risk. Fill out the left side of the hazard assessment form (for help, see samples on p.29-30). Gather all the information you can. • Look at all steps of a job and ask the employee if there are any variations in the job that are infrequently done and that might have missed during your observation. you • - For purposes of the assessment, assume that no PPE is being worn by the affected employees even though they may actually be wearing what they need to do the job safely. - Note all observed hazards. This list does not cover all possible hazards that employees may face or for which personal protective equipment may be required. Noisy environments or those which may require respirators must be evaluated with appropriate test equipment to quantify the exposure level when overexposure is suspected. <table><tr><th>Hazard Type</th><th>General Description of Hazard Type</th></tr><tr><td>Impact</td><td>Person can strike an object or be struck by a moving or flying or falling object.</td></tr><tr><td>Penetration</td><td>Person can strike, be struck by, or fall upon an object or tool that would break the skin.</td></tr><tr><td>Crush or pinch</td><td>An object(s) or machine may crush or pinch a body or body part.</td></tr><tr><td>Harmful Dust</td><td>Presence of dust that may cause irritation, or breathing or vision difficulty. May also have ignition potential.</td></tr><tr><td>Chemical</td><td>Exposure from spills, splashing, or other contact with chemical substances or harmful dusts that could cause illness, irritation, burns, asphyxiation, breathing or vision difficulty, or other toxic health effects. May also have ignition potential.</td></tr><tr><td>Heat</td><td>Exposure to radiant heat sources, splashes or spills…
[17] Protection From Electric Shock and Arc Flash
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Open source documentSource excerpt
# De-Energizing ## An Electrically Safe Work Condition The most important principle of electric safety is, assume electric circuits are energized unless you make sure they are not. Test every circuit and conductor every time you work on them. The National Fire Protection Association lists six steps to ensure conditions for electrically safe work.** - Identify all sources of power to the equipment. Interrupt - the load current, then open the disconnecting devices for each power source. : - Where possible, visually verify that blades of disconnecting devices are fully open or that drawout-type circuit breakers are fully withdrawn. - Apply lockout/tagout devices in accordance with a formal, written policy. - Test each phase conductor or circuit part with an adequately rated voltage detector to verify that the equipment is de-energized. Check the voltage detector before and after each test to be sure it is working. - Properly ground all possible sources of induced voltage and stored electric energy (such as, capacitors) before touching. If conductors or circuit parts that are being de-energized could contact other exposed conductors or circuit parts, apply ground-connecting devices rated for the available fault current. The process of de-energizing is “live” work and can result in an arc flash due to equipment failure. When de- energizing, follow the procedures described below in "Working On or Near Live Circuits." ## Lockout/tagout program Your employer should establish a written lockout/tagout program and train employees in the program. The program should cover planning for locating and labeling energy sources, identifying employees at risk, how and by whom the equipment is de-energized, releasing of stored energy, verifying that the circuit is de-energized and can't be restarted, voltage testing, grounding requirements, shift changes, coordination with other jobs in progress, a procedure for keeping track of all involved personnel, applying and removing…
[18] Oregon OSHA Program Directive | Control of Hazardous Energy – Enforcement Policy and Inspection Procedures (Lockout/Tagout)
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Open source documentSource excerpt
# CHAPTER 3 -- INSPECTION GUIDANCE (cont.) - III. Vehicle Hazardous Energy Control. A. Background. Serious injuries and death have occurred and continue to occur from inadequate hazardous energy control during vehicle servicing and maintenance activities. In 1991, the U.S. Court of Appeals for the District of Columbia remanded the LOTO standard to OSHA for further consideration of the ways in which the final rule applies to all general industry workplaces. OSHA, in the March 30, 1993 Federal Register (Vol. 58, No. 59), reaffirmed and further explained the reasons for applying the standard to vehicle servicing and maintenance. The scope and application sections of the preamble to the hazardous energy control standard provide that the LOTO standard applies to all “general industry workplaces." The standard's coverage includes vehicles, such as, but not limited to, automobiles, trucks, tractors, refrigeration transport vehicles, and material handling equipment. B. Hazardous Energy. Generally speaking, for purposes of vehicle servicing and maintenance, hazardous energy refers to: mechanical motion; potential energy due to pressure, gravity, or springs; battery-generated electrical energy; thermal energy, including chemical energy; and other forms of energy, which can cause injury to employees working in, on, or around machines or equipment. Any vehicle [e.g., internal combustion engines such as gasoline, natural gas and diesel powered vehicles; electric-powered vehicles; hybrid (gasoline/electric) vehicles] may contain the following types of hazardous energy, such as, but not limited to: 1. Chemical energy due to contact with battery acid, coolant, lubricants; 2. Electric battery shock, arc, and burn hazards; 3. Explosion hazards associated with air bags; 4. Fire and explosion hazards associated with the fuel and fluid systems; 5. Gravitational energy (mechanical) hazards caused by elevated vehicles (e.g., unsafe use of automotive lift equipment) or v…
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