Write a risk assessment for portable appliance testing at an electrical inverter production facility
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Published by SALUSPortable Appliance Testing (PAT) in an Electrical Inverter Production Facility ==============================================================================
Assessment Date: \[DATE]
Assessor: \[ASSESSOR NAME]
Department/Area: \[DEPARTMENT/AREA]
Review Date: \[REVIEW DATE]
1\. Assessment Scope
This risk assessment covers portable appliance testing activities carried out within an electrical inverter production facility, including pre-use inspection, isolation, functional testing, recording of results, and management of defective portable electrical equipment. It applies to PAT technicians, electricians, maintenance personnel, supervisors, and any affected workers who may be present in the testing area. The assessment includes testing of plug-connected portable appliances, test instruments, extension leads, and associated accessories used in production, maintenance, offices, and support areas where inverter manufacturing activities occur. It also covers the control of electrical hazards arising from isolation, lockout/tagout, verification of de-energization, exposure to live parts during testing, shock and arc flash risks, and the safe removal from service of defective equipment. Exclusions: this assessment does not cover fixed electrical installation testing, high-voltage commissioning, detailed machine maintenance beyond PAT scope, or specialist work on energized equipment unless specifically authorized under a separate live-work permit and competent-person procedure.
2\. Risk Assessment Methodology
A task-based risk assessment methodology has been used, combining hazard identification, evaluation of who may be harmed, and selection of controls using the hierarchy of controls. Risk has been rated using a 5x5-style qualitative matrix with consistent categories for likelihood (Rare, Unlikely, Possible, Likely, Almost Certain), severity (Negligible, Minor, Moderate, Major, Catastrophic), and overall risk rating (Low, Medium, High, Extreme). The assessment assumes that electrical circuits are energized unless positively verified otherwise, and that de-energization, lockout/tagout, and test-before-touch principles are mandatory where practicable. Controls prioritize elimination of exposure by de-energizing equipment, followed by engineering controls, administrative controls, and PPE. Where live testing is unavoidable, work must be limited to competent persons under an authorized safe system of work with documented verification, approach boundaries, and appropriate PPE.
3\. Risk Matrix Reference
The following matrix is used to evaluate risk levels based on likelihood and severity:
| Likelihood |
|---|
| Rare | Unlikely | Possible | Likely | Almost Certain | | Severity | Catastrophic | Low | Low | Low | Medium | Medium | | Major | Low | Low | Medium | Medium | High | | Moderate | Low | Medium | Medium | High | High | | Minor | Medium | Medium | High | High | Extreme | | Negligible | Medium | High | High | Extreme | Extreme |
4\. Hazard Identification and Risk Evaluation
1\. Contact with energized conductors or exposed live parts during PAT setup, probe connection, or fault-finding.
Potential Consequences: Electric shock, burns, involuntary muscle contraction, secondary injuries from falls or sudden movement, and in severe cases fatal electrocution. [6] [3]
Affected Persons: PAT technicians, electricians, maintenance staff, and nearby unqualified workers if boundaries are not maintained.
Initial Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Possible | Major | High |
Control Measures
- Eliminate exposure by de-energizing the appliance and isolating it from supply before testing wherever practicable.
- Use lockout/tagout or equivalent hazardous energy control to prevent inadvertent re-energization.
- Use only properly rated and tested PAT equipment and voltage detectors suitable for the circuit and environment.
- Establish and enforce work boundaries so unqualified persons cannot enter the testing area.
- Require competent persons to perform testing and to verify de-energization before contact.
- Wear electrical PPE appropriate to the task, including insulated gloves where required and eye/face protection when there is a risk of arc or flash exposure.
Residual Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Unlikely | Major | Medium |
2\. Arc flash or arc blast during switching, isolation, breaker operation, or testing of equipment that remains energized for functional verification.
Potential Consequences: Severe burns, eye injury, hearing damage, pressure-wave trauma, ignition of clothing, and potential fatality. [1] [4]
Affected Persons: PAT technicians, electricians, supervisors nearby, and any person within the arc flash boundary.
Initial Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Unlikely | Catastrophic | High |
Control Measures
- Avoid energized work; de-energize equipment before testing whenever possible.
- If energized testing is necessary, use a written live-work permit and task-specific risk assessment authorized by a qualified supervisor.
- Apply arc flash approach boundaries, barricades, and warning signs to keep others out of the hazard zone.
- Use appropriately rated arc flash PPE selected for the expected incident energy or PPE category.
- Increase working distance and use remote or non-contact test methods where feasible.
- Use insulated tools and maintain correct body positioning to reduce exposure.
Residual Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Rare | Catastrophic | High |
3\. Failure to isolate all energy sources, including stored energy, backfeed, or residual charge in inverter-related equipment and associated accessories.
Potential Consequences: Unexpected energization, shock, arc flash, equipment damage, and injury during testing or re-connection. [6] [8]
Affected Persons: PAT technicians, maintenance personnel, and anyone working on the same equipment or circuit.
Initial Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Possible | Major | High |
Control Measures
- Identify all energy sources before work begins, including mains supply, control circuits, capacitors, batteries, and any auxiliary feeds.
- Apply a formal lockout/tagout procedure with individual locks where required.
- Dissipate or restrain stored energy and verify isolation using an adequately rated test instrument.
- Check the test instrument before and after use to confirm correct operation.
- Use a written sequence for shutdown, isolation, verification, and return to service.
- Maintain current electrical drawings and equipment instructions to support accurate isolation.
Residual Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Unlikely | Major | Medium |
4\. Use of defective, damaged, or incorrectly calibrated test instruments, leads, adapters, or probes.
Potential Consequences: False readings, failure to detect a fault, electric shock to the tester, equipment damage, and unsafe return to service of defective appliances. [2] [1]
Affected Persons: PAT technicians, maintenance staff, and end users of equipment returned to service.
Initial Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Possible | Moderate | Medium |
Control Measures
- Inspect test instruments, leads, and accessories before each use for damage, contamination, or wear.
- Use only calibrated, properly rated equipment suitable for the voltage and test category involved.
- Remove defective test equipment from service immediately and quarantine it for repair or replacement.
- Follow manufacturer instructions and maintenance schedules for PAT equipment.
- Record calibration status and inspection results as part of the testing system.
- Use test boxes or enclosed test arrangements where practicable to reduce contact with live circuits.
Residual Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Rare | Moderate | Low |
5\. Defective portable appliances being returned to service or left available for use after a failed PAT result.
Potential Consequences: Electric shock, fire, equipment failure, production disruption, and injury to operators or maintenance staff. [10] [10]
Affected Persons: Production workers, maintenance personnel, cleaners, contractors, and visitors who may use the appliance.
Initial Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Likely | Major | High |
Control Measures
- Clearly label failed equipment as defective and remove it from service immediately.
- Physically isolate defective items to prevent inadvertent use, including quarantine storage or lockable defect cages.
- Repair only by competent persons and retest before return to service.
- Maintain a defect register and traceability for failed items, repairs, and retest outcomes.
- Communicate defect status to affected departments and supervisors without delay.
- Do not bypass safety features or permit temporary use of known defective equipment.
Residual Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Unlikely | Major | Medium |
6\. Inadequate competence, training, or supervision of personnel performing PAT or interpreting results.
Potential Consequences: Incorrect test selection, missed defects, unsafe isolation, improper PPE use, and increased likelihood of shock or arc flash incidents. [4] [7]
Affected Persons: PAT technicians, supervisors, nearby workers, and anyone relying on the test outcome.
Initial Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Possible | Major | High |
Control Measures
- Restrict PAT and electrical isolation tasks to competent persons with documented training and experience.
- Provide task-specific instruction on test methods, safe isolation, lockout/tagout, and defect recognition.
- Use supervision and authorization controls for any trainee or less experienced worker.
- Require job briefing before work starts to confirm hazards, boundaries, and emergency arrangements.
- Verify competence periodically through observation, assessment, and refresher training.
- Do not allow unqualified persons to enter restricted areas or perform live testing.
Residual Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Unlikely | Major | Medium |
7\. Poor housekeeping, trailing leads, clutter, or wet/contaminated floors in the PAT work area.
Potential Consequences: Slips, trips, falls, dropped equipment, damaged test leads, and accidental contact with energized parts. [1]
Affected Persons: PAT technicians, maintenance staff, production workers, and visitors passing nearby.
Initial Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Likely | Moderate | High |
Control Measures
- Maintain a clean, dry, and orderly work area before and during testing.
- Route leads to avoid walkways and use cable management where needed.
- Remove unnecessary materials, packaging, and obstructions from the testing zone.
- Stop work if water, oil, conductive dust, or other contamination creates an unsafe condition.
- Use suitable footwear and keep the area well lit.
- Inspect the area before starting and after completing the task.
Residual Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Unlikely | Minor | Low |
8\. Manual handling and repetitive movement associated with moving appliances, test boxes, and equipment between test points and storage areas.
Potential Consequences: Musculoskeletal strain, sprains, dropped equipment, and minor impact injuries.
Affected Persons: PAT technicians and maintenance personnel.
Initial Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Possible | Minor | Medium |
Control Measures
- Use trolleys, carts, or lifting aids for heavier or awkward appliances.
- Plan the work area to minimize unnecessary carrying and repositioning.
- Store equipment at suitable heights to reduce bending and overreaching.
- Train workers in safe manual handling and team lifting where required.
- Break repetitive tasks into manageable batches and rotate duties where practicable.
Residual Risk Assessment
| Likelihood | Severity | Risk Rating |
|---|---|---|
| Unlikely | Minor | Low |
5\. General Control Measures
- Implement a written electrical safe system of work for PAT activities.
The system should define who may perform PAT, how appliances are selected, how isolation is achieved, how defects are handled, and how results are recorded and authorized for return to service. [3]
- Use a formal lockout/tagout and verification process for appliances and associated circuits.
Apply locks and tags where energy-isolating devices permit, verify de-energization with a suitable test instrument, and control stored energy before any contact with conductors or terminals. [6] [8]
- Maintain clear segregation between testing areas and normal production activity.
Use barriers, signage, and supervision to keep unqualified persons away from live testing, defect quarantine areas, and any equipment under test. [3] [5]
- Ensure all PAT equipment, test leads, and PPE are suitable for the voltage, fault level, and task conditions.
Inspect before use, maintain calibration, replace damaged items immediately, and select PPE based on the specific electrical hazard and expected incident energy. [4]
- Keep electrical drawings, appliance registers, defect logs, and maintenance records current.
Accurate records support safe isolation, traceability of failed items, trend analysis, and timely corrective action. [2]
6\. Emergency Preparedness
- Provide immediate response procedures for electric shock, including isolation of power, emergency stop use where applicable, first aid, and prompt summoning of emergency services. Workers must not touch a casualty until the source of energy is confirmed isolated. [1]
- Prepare an arc flash emergency response plan that includes evacuation of the area, medical response for burns, and control of secondary hazards such as fire or smoke. Emergency arrangements must reflect the possibility of severe thermal injury and blast effects during energized testing or switching. [1]
- If a defective appliance or test instrument shows signs of overheating, smoke, or abnormal noise, stop work immediately, isolate the item if safe to do so, and remove it from service. Escalate the event as a near miss or incident and preserve the equipment for investigation. [2]
- Where live testing is authorized, ensure the work area has a clear rescue and communication arrangement, including a means to summon assistance quickly and a defined person in charge of the task. [3]
7\. Training Requirements
- Electrical Safety Awareness for PAT Activities: All personnel involved in PAT must understand electrical shock hazards, arc flash hazards, the importance of de-energization, and the limits of their authority. Training should emphasize that circuits are to be treated as energized until verified otherwise and that only competent persons may perform testing or isolation tasks. [1]
- Recognize shock and arc flash hazards.
- Understand when work must stop and be escalated.
- Know the boundaries between qualified and unqualified persons.
- Lockout/Tagout and Verification of Isolation: Authorized employees must be trained to identify energy sources, apply lockout/tagout devices, dissipate stored energy, and verify de-energization using an adequately rated test instrument. Training must also cover removal of devices, shift handover, and return-to-service steps. [6]
- Identify all sources of power.
- Apply personal locks where required.
- Test before touch and verify the tester before and after use.
- Competency in PAT Equipment Use and Defect Recognition: Technicians must be trained in the correct use, limitations, inspection, and calibration requirements of PAT instruments, as well as how to identify defective appliances and remove them from service. Training should include interpretation of pass/fail criteria and documentation requirements. [4]
- Pre-use inspection of test leads and adapters.
- Calibration awareness and equipment care.
- Defect tagging, quarantine, and retest requirements.
- Emergency Response and First Aid for Electrical Incidents: Workers must be trained to respond to electric shock, burns, and arc flash events, including isolation of power, raising the alarm, first aid, and incident reporting. Training should include the location and use of emergency equipment and the requirement not to re-energize until the area is made safe. [1]
- Raise alarm and isolate energy.
- Do not touch casualties until safe.
- Report and preserve evidence for investigation.
8\. Monitoring and Review
Review Frequency: Annually and after any electrical incident, near miss, significant equipment change, or change in PAT method or scope.
| Monitoring Type | Frequency | Responsible Party | Description |
|---|---|---|---|
| Regular Inspection | Before each use and daily when PAT is in progress | PAT technician / supervisor | Inspect test instruments, leads, adapters, PPE, barriers, and the work area for damage, contamination, poor housekeeping, or unsafe conditions before testing begins. |
| Performance Indicator | Weekly | Electrical supervisor / maintenance lead | Review the number of failed appliances, repeat defects, near misses, and any deviations from the safe system of work to identify trends and corrective actions. |
| Audit | Monthly | HSE representative / electrical competent person | Audit compliance with lockout/tagout, verification of isolation, defect quarantine, recordkeeping, and PPE requirements for PAT activities. |
| Calibration and Test Equipment Verification | In accordance with manufacturer instructions and at defined intervals, at least annually where applicable | Electrical maintenance / calibration coordinator | Verify calibration status and functional condition of PAT instruments and voltage detectors, including pre-use checks and formal calibration records. |
| Procedure Review | After any incident, near miss, equipment change, or process change | HSE manager / electrical responsible person | Review the risk assessment, safe work procedure, and training needs whenever an electrical incident occurs or when equipment, layout, or work methods change. |
9\. Special Circumstances
- Night work or reduced staffing increases the likelihood of delayed assistance, reduced supervision, and poorer visibility; additional lighting, communication checks, and supervision are required. [1]
- Lone working should be avoided for live testing or isolation tasks. If unavoidable, a permit, communication check-in system, and emergency escalation arrangement must be in place. [3]
- Wet conditions, condensation, conductive dust, or contamination in the inverter production environment can increase shock risk and reduce the reliability of test equipment; work should stop until conditions are controlled. [2]
- Contractor or outside personnel performing PAT or related electrical work must be informed of site lockout/tagout rules, boundaries, and emergency arrangements before starting work. [9]
Approval and Sign-off
This risk assessment has been reviewed and approved by:
Assessor: _________________________ Date: __________
Manager/Supervisor: _________________________ Date: __________
Safety Representative: _________________________ Date: __________
This risk assessment must be reviewed annually and after any electrical incident, near miss, significant equipment change, or change in pat method or scope. or when significant changes occur.
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Sources used for this answer
[1] FACT SHEET: The Control of Hazardous Energy (Lockout/Tagout)
Page 3
Open source documentSource excerpt
## Energy-control procedures (cont.) THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT) • No potential for stored or residual energy or re-accumulation of stored energy exists that could harm employees after shutdown. When re-energization is required as part of a service activity, temporary removal of lockout or tagout devices is allowed. This temporary exemption applies in limited situations and only for the time required to perform the task. ## Requirements for controlling hazardous energy: - Notify all affected workers • Identify energy sources and energy-isolating devices • De-energize equipment • Secure energy-isolating devices in a safe position • Dissipate or restrain potential energy that cannot be isolated • Verify equipment isolation by starting or testing When multiple people are involved in service or maintenance, group lockout is permitted. It is also permissible to transfer lockout or tagout devices during shift changes when written procedures are followed. ## Requirements for returning equipment to service: ● Inform co-workers that lockout or tagout devices will soon be removed • Remove tools and replace all equipment components • Ensure all workers are clear of the equipment ● Verify power controls are off or in a neutral position • Remove the lockout or tagout device and re-energize equipment ## Periodic inspection At least annually, employers must inspect and certify all energy-control procedures. Authorized employees other than those using the procedures being inspected must perform the inspections. The inspection certification must identify the equipment, inspection date, person performing the inspection, and all employees included in the inspection. Inspections must verify all of the following: • Lockout and tagout procedures are adequate. • Authorized and affected employees know their procedure responsibilities. • Procedures are being followed. ## Resources - Division 2/J, General Environmental Controls - Division 2/S, E…
[2] Protection From Electric Shock and Arc Flash
Page 2
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…
[3] Arc Flash
Page 3
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
[4] Arc Flash
Page 4
Open source documentSource excerpt
# Arc Flash (cont.) ## What are approach boundaries? (cont.) An arc flash boundary is the term used to describe the distance at which a person without personal protective equipment (PPE) may get a second-degree burn if an arc flash occurs. It is assumed that a second-degree burn occurs when the incident energy received by the skin equals 5 J/cm2 (1.2 cal/cm2). A second-degree burn is usually treatable. There are two types of boundaries that are used: - Limited approach boundary - the distance from an exposed energized electrical conductor or circuit part a person may approach when a shock hazard exits (i.e., if the person is wearing appropriate PPE and are supervised by a qualified person). - Restricted approach boundary - the distance from an exposed energized electrical conductor or circuit part a qualified person (only) may approach when there is an increased likelihood of electric shock due to electrical arc over combined with inadvertent movement. Flash boundary Limited approach boundary Restricted approach boundary Any exposed and energized conductor or circuit part The distance of the boundaries will vary, and depend on: - the system present (alternating-current or direct-current systems) - the voltage range (phase to phase) or the nominal potential difference - the presence of equipment including fuses, relays, circuit breakers, exposed movable conductors or fixed circuit parts - the use of devices to restrict inadvertent movement Arc Flash CCOHS
[5] Toolbox Talk: Arc Flash Hazards
Page 2
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). …
[6] Lockout/Tagout Oregon: OSHA’s guide to controlling hazardous energy
Page 10
Open source documentSource excerpt
# Controlling hazardous energy (cont.) ## 5. Verify equipment isolation Verification means purposely confirming that equip- ment is separated from its energy source; therefore, it is "isolated." The authorized employee must verify that: ▸ Equipment has been properly turned off/shut down. ▸ Energy-isolating devices were identified and used to effectively isolate energy. ▸ Lockout or tagout devices have been attached to the energy-isolating devices. ▸ Stored energy has been removed or controlled. Attempting to restart the equipment is one way to confirm isolation; however, testing equipment ensures that capacitors have been properly discharged, hazardous heat has dissipated, and excessive pressures have been relieved. Best practice: Some companies refer to their energy control program as "Lock, Tag, Try" or "Lock, Tag, Test" to emphasize this important verification step. Warning A word about electrical testing: "A qualified person shall use test equipment to test the circuit elements and electrical parts of equipment to which employees will be exposed and shall verify that the circuit elements and equipment parts are deenergized." [1910.333(b)(2)(iv)(B)] P.D. A-164 Electrical Safety ## Lockout (LO), tagout (TO), or lockout/ tagout (LOTO)? How to decide ## Option 1: Lockout (LO). Lockout follows an estab- lished procedure for placing a lockout device, such as a padlock, on an energy-isolat- ing device to create a physical barrier of protection. If an energy-isolating device can accept a lockout device, you must use lockout. DANGER A PELIGRO 2 Locked out (LO) ## Option 2: Tagout (TO). Tagout is a procedure for placing a warning tag or sign - a tagout device - on an energy-isolating device that cannot accept a lockout device. Tagout devices must control hazardous energy at least as effectively as lockout devices. Since tagout Tagged out (TO) during devices do not provide the vehicle maintenance same physical barrier to hazardous energy as lockout devices…
[7] Arc Flash
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Open source documentSource excerpt
# Arc Flash (cont.) ## What are approach boundaries? (cont.) Important to arc flash boundaries is the role of qualified persons. A qualified person is someone who has been trained in and has knowledge about the construction and operation of the equipment or work methods. They must be familiar with appropriate techniques, policies and procedures, work permits, PPE, insulating and shielding materials, insulated tools, test equipment, etc. For example, unqualified workers should remain a distance away from the exposed energized conductors or circuit parts (including any equipment or objects they may handle). They should not cross into the arc flash boundary unless they are wearing appropriate PPE and are supervised by a qualified person. At no time should an unqualified person enter the restricted approach boundary. Qualified person may enter the restricted space provided any necessary work permits, PPE, tools, equipment, and measures necessary to reduce the likelihood of contact are taken. ## How is arc flash personal protective equipment (PPE) chosen? Workers must know how to select, use, and care for the necessary PPE, and understand the limitations of the PPE. The CSA standard Z462:21 "Workplace Electrical Safety" provides two methods that can be used to determine what type of PPE is required for a specific job: 1. The incident energy analysis 2. The arc flash PPE category While either method can be used, only one method should be used at a time when working on the same piece of equipment (not both). The first method, incident energy analysis, is based on the distance between the worker's face and chest to the source. It uses the value of the estimated energy of the flash to determine the level of protection that must be provided by the PPE. The second method, arc flash PPE category method, uses the arc flash risk assessment of the tasks and equipment condition to determine if arc flash-rated PPE is required. Once determined that arc flash PPE is require…
[8] Electrical Safety Handout
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Open source documentSource excerpt
# Electrical Safety Protecting Employees from Electrical Hazards Electrical Safety focuses on preventing electrocution and other electrical hazards by establishing standards for electrical equipment, work practices, and training, with a strong emphasis on lockout/tagout procedures and safe distances from energized lines. Injury Free Culture IF? What IF I could go my entire career Injury Free? Injury Free is a cultural attitude. It is a way of thinking that prevents injuries, makin safety a high priority at both the personal and organizational levels. ## Common Causes of Electrocution . Contact with Overheard Power lines • Contact with Live Circuits [redacted email] • Not following Lock/Tag-out procedures - Poorly Maintained Extension Cords • Defective Power Tools ## Shock Severity ## Arc Blast/Flash When an arc fault occurs, the result is a massive electrical explosion. The light and heat emitted by the explosion is known as the arc flash, and the pressure wave is known as the arc blast. Low voltages can be extremely dangerous because, all other factors being equal, the degree of injury increases the longer the body is in contact with the circuit. ## Lockout/Tagout (LOTO) Lockout-tag-out (LOTO) is a safety procedure which is used in industry to ensure that dangerous machines are properly shut off and not able to be started up again prior to the completion of maintenance or servicing work. • Place Lock & Tag on each disconnecting means used to de-energize circuits • Attach a lock to prevent operating the disconnecting means • Place a Tag with each lock • Only the person who places the lock may remove it ## Electrical Standards VOSH's electrical standards are based on the National Fire Protection Association Standards NFPA 70, National Electric Code, and NFPA 70E, Standard for Electrical Safety for Employee Workplaces. ## Training Employees must receive adequate training on electrical safety procedures and hazards. Qualified employ…
[9] 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.) D. Energize the machine and employ effective employee protection while testing or positioning machinery; and E. Turn off all systems, isolate the machine from the energy source, and reapply lockout or tagout devices as specified, if additional servicing or maintenance is required - See 1910.147(d). This temporary exception applies only for the limited time required for testing or repositioning the machine/equipment or its components. When an energized state is no longer required, the authorized employees must again de-energize the machine/equipment and resume the energy control measures. Paragraph (f)(1) of the standard does not allow the employer to disregard the requirement for locking out or tagging out during other portions of the servicing or maintenance operation. XIII. Outside Personnel. Outside servicing and maintenance personnel, such as contractors, service representatives, or employees from a temporary employment agency engaged in general industry activities are subject to the requirements of this standard. These requirements are necessary when outside personnel work on machines or equipment because their activities have the same or greater potential for exposing employees to servicing or maintenance hazards as would exist if the on-site employer's own employees were performing the work. If outside contractors service or maintain machinery, the on-site employer and the contractor must inform each other of their respective lockout or tagout procedures. The performance-oriented nature of the standard permits the outside (contractor) employer to use either: the host employer's energy control procedure, which some companies will require; its own procedures; or a combination of the two procedures, provided the resulting procedure meets the requirements of the LOTO standard. In some instances, for example, the host employer will prohibit the contractor from shutting down and isolating the host's equipment and the …
[10] Protection From Electric Shock and Arc Flash
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Open source documentSource excerpt
# 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…
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