Electrical

Useless Machine Kits and Free Plans

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Those of you who have been in my class have seen this little toy. I have it labeled “LOCK-OUT/TAG-OUT NOT REQUIRED even though it’s an electrical device, because it’s smarter than most. It doesn’t do much, but as I say, I’m easily amused. In fact, all it does if you flip the toggle switch on the top is turn itself back off… hence the safety without LOTO. Turn it on and a little plastic piece comes out, turns itself back off and then quickly retreats into the box for the next round.

You can buy kits or find your way to free plans here. There are also some entertaining videos to watch of useless boxes in action.

Use this file to print your own label.

Fatality #6 for Coal Mining 2012

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On Friday, March 23, 2012, a 37-year old electrician, with approximately 3½ years experience (approximately 1½ years as an electrician), was killed when he contacted the energized conductors of a shuttle car trailing cable. He was making the final electrical connections for a replacement cable reel when he was electrocuted.

Best Practices

  • Develop a hazard analysis work plan before conducting repairs.
  • Always lock and tag-out electrical equipment prior to electrical work.
  • Perform your own lock and tag-out procedure. Never rely on others to de-energize or disconnect a circuit for you.
  • Use proper Personal Protective Equipment (PPE) for all electrical work.
  • Ensure that all electrical circuits and circuit breakers are identified properly before troubleshooting or performing electrical work.
  • Use properly rated non-contact voltage testers to ensure that circuits are de-energized.
  • Eliminate personal distractions when working on equipment.

For more information related to Lock and Tag safety, click on the following link on the MSHA Web site: Lock and Tag Safety

Click here for: MSHA Preliminary Report (pdf),  MSHA Investigation Report (pdf).

Fatality #9 for Metal/Nonmetal Mining 2011

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On September 13, 2011, a 38 year-old miner with 3 years of experience was killed at a portable sand and gravel operation. The victim opened the 480 volt feeder box at the motor control center and started to remove the leads when he received a fatal shock.

Best Practices

  • Be trained on all the electrical tests and safety equipment necessary to safely test and ground the circuit being worked on.
  • Conduct a risk assessment.
  • Use properly rated Personal Protective Equipment (PPE) including Arc Flash Protection such as a hood, gloves, shirt, and pants.
  • Positively identify the circuit on which work is to be conducted.
  • De-energize power and ensure that the circuit is visibly open.
  • Place YOUR lock and tag on the disconnecting device.
  • Verify the circuit is de-energized by testing for voltage using properly rated test equipment.
  • Ensure ALL electrical components in the enclosure are de-energized.
  • Ground ALL phase conductors to the equipment grounding medium with grounding equipment that is properly rated.
Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report(pdf), Overview(powerpoint), Overview (pdf).

Fatality #12 for Coal Mining 2011

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On Wednesday, July 27, 2011, a 39-year-old miner with 22 years of mining experience was electrocuted while welding to connect two pipes together. He was working in the ceiling of the filter room of a preparation plant. This area, where the welding was being conducted, was wet and the illumination was limited. The victim contacted an energized welding electrode.

Best Practices

  • Do not touch an energized electrode with bare skin.
  • Avoid wet working conditions. A person’s perspiration can lower the body’s resistance to electrical shock. Do not drape electrode wires or leads over your body.
  • Work in a confined space only if it is well ventilated and illuminated.
  • Do not use the plant structure as the work (return) conductor. Connect the work cable (return) as close to the welding area as practical to prevent welding current from traveling unknown paths and causing possible shock, spark, and fire hazards.
  • Insulate yourself from work and ground by using and/or wearing dry insulating mats, covers, clothes, footwear, and gloves. Inspect welding gloves for damage prior to welding and ensure the gloves are dry.
  • Use only well maintained equipment. Frequently inspect welding wires or leads for damaged or exposed conductors. Replace or repair wires or leads immediately if damaged.
  • Use voltage reduction safety devices (if available) for arc welders.

For additional information, please see MSHA’s Safety Target Packages at http://www.msha.gov/Safety_Targets/MaintenanceMNM/Welding 20safety.pdf

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf).

NIOSH Lock-Out Tag-Out Publication

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NIOSH has issued a new Workplace Solutions publication on Using Lockout and Tagout Proceduresto Prevent Injury and Death during Machine Maintenance. The four page publication reviews the exposure of the hazard in OSHA industries and the OSHA Standard. It examines a case report of a fatality involving a Millwright and lists recommendations for employers, workers, and manufacturers. You can download a copy in pdf format here.

Fatality #16 for Metal/Nonmetal Mining 2010

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MNM Fatality 16 2010

On October 10, 2010, a 42 year- old contract electrician with 4 years of experience was seriously injured at a granite operation. The victim and two co-workers were installing ground fault indicator lights in a circuit breaker enclosure when an arc flash occurred. The circuit breaker enclosure contained a bottom feed circuit breaker. All three workers were hospitalized and the victim died on October 12, 2010.

Before YOU perform electrical work:

  • Be trained on all the electrical tests and safety equipment necessary to safely test and ground the circuit being worked on.
  • Conduct a risk assessment.
  • Use properly rated Personal Protective Equipment (PPE) including Arc Flash Protection such as a hood, gloves, shirt, and pants.
  • Positively identify the circuit on which work is to be conducted.
  • De-energize power and ensure that the circuit is visibly open.
  • Place YOUR lock and tag on the disconnecting device.
  • Verify the circuit is de-energized by testing for voltage using properly rated test equipment.
  • Ensure ALL electrical components in the enclosure are de-energized.
  • Ground ALL phase conductors to the equipment grounding medium with grounding equipment that is properly rated.
  • Install warning labels on the terminal covers of bottom feed circuit breakers stating the “Bottom terminal lugs remain energized when the circuit breaker is open.”

Click here for: MSHA Preliminary Report (pdf), MSHA Investigation Report (pdf), Overview (powerpoint), Overview (pdf).

Fatality #4 for Metal/Nonmetal Mining 2009

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On April 7, 2009, a 36 – year old supervisor with 15 years of experience was fatally injured at a sand and gravel dredging operation. The victim was attempting to connect the 4160 volt cable for the dredge to load side terminals in the electrical panel when he came into contact with energized 4160 volt line side terminals.

Best Practices

Before YOU perform electrical work:

  • Be trained and knowledgeable in the task.
  • Be trained on all the electrical test and safety equipment necessary to safely test and ground the circuit being worked on.
  • Use properly rated Personal Protective Equipment including Arc Flash Protection such as a hood, gloves, shirt, and pants.
  • Positively identify the circuit on which work is to be conducted.
  • De-energize power and ensure that the circuit is visibly open.
  • Place YOUR lock and tag on the disconnecting device.
  • Verify the circuit is de-energized by testing for voltage using properly rated test equipment.
  • Ensure all electrical components in the cabinet are de-energized.
  • Ground ALL phase conductors to the equipment grounding medium with grounding equipment that is properly rated.

Click here for: MSHA Investigation Report(pdf), Overview(powerpoint), Overview(pdf)