Maintenance is not only necessary to ensure reliability of technical structures or productivity of the company, regular maintenance has an important role in providing safer and healthier working conditions as well. Lack of maintenance or inadequate maintenance can cause serious and deadly accidents or health problems.

Maintenance itself is a high-risk activity. It is estimated that around 10-15% of all fatal accidents and 15-20% of all accidents in the Industry are related to maintenance operations. Scientific studies indicate that occupational diseases and work-related health problems (such as hearing problems, musculoskeletal disorders etc.) are also more prevalent among workers involved in maintenance activities.

Maintenance operations typically include both disassembly and reassembly, often involving complicated machinery. This can be associated with a greater risk of human error, increasing the accident risk. Working under time-pressure is also typical for maintenance operations, especially when the shutdowns or high-priority repairs are involved.

In view of the above it becomes important to train the Maintenance persons to understand the risks that are involved in the work they carry, what are the techniques that can be used to mitigate the risks and the appropriate PPEs that are required to be used during a specific maintenance activity.

Focus Areas

• Understanding the specific hazards related to Maintenance activity
• Identification of relevant PPEs and their Maintenance
• Techniques used to test, inspect and maintain various tools required for carrying out Maintenance
• Documentation that proves useful to improve Safety in Maintenance
• Instil confidence in the Maintenance Personnel to carry out their activity without fear of getting injured and still keeping the Mean Time To Repair (MTTR) under control
• Help organizations to achieve their Safety Targets (Zero fatality, Zero Lost Work Day case etc.) thereby avoiding any costly hospitalization and unnecessary civil / criminal litigations

Background

Key Takeaways

• Working with Electricity – PPE requirements, Inspection of PPEs, Inspection of Test instruments, Lock out requirements and Lock out Process
• Working at Height – PPE requirement, Inspection of PPEs, Ladders and their inspection, Anchorage points
• Working in Confined Space – Identification of Confined space, Examples of Confined space, Hazards in Confined space, PPEs requirement and Work Permit
• Working with Robot – Potential Hazards and their mitigation
• Working under heavy items - Potential Hazards and their mitigation
• Working in Fuel Yard - Potential Hazards and their mitigation
• Lifting Loads by Rigging – Hoisting and Rigging Hazards, Elements affecting the Hoisting safety, Factors affecting the lifting capacity, Slings and Hoisting hooks, Shackles and Eye Bolts
• Working with Chemicals – Hazards while working with chemicals, PPE requirements, Step-by-Step description of Material Safety Data Sheet (MSDS)
• Welding and Gas Cutting – Potential Hazards, PPE requirements

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