Industrial Maintenance Safety Manual

Industrial Maintenance Safety Programs

The safety programs needed for industrial maintenance depend on the equipment, systems, and work performed. A comprehensive manual may include programs covering:

• Lockout/Tagout
• Electrical Safety
• Arc Flash Safety
• Machine Guarding
• Confined Space Entry
• Welding, Cutting and Hot Work
• Fall Protection
• Personal Protective Equipment
• Crane and Rigging Safety
• Overhead Crane Safety
• Forklift and Powered Industrial Truck Safety
• Aerial Lift Safety
• Ladder and Stairway Safety
• Hand and Power Tool Safety
• Hazard Communication
• Respiratory Protection
• Compressed Gas Cylinder Safety
• Job Safety Analysis
• Emergency Action Plan
• First Aid

Programs that do not apply to the company’s maintenance activities can be removed, while additional programs should be included when specialized equipment or processes create additional hazards.

Industrial Maintenance Safety

Maintenance work differs from routine production because employees often work on equipment while guards are removed, systems are opened, components are disassembled, energy sources are isolated, and normal operating conditions are intentionally changed.

Maintenance planning should consider:

• Scope of work
• Equipment condition
• Hazardous energy
• Process chemicals
• Electrical hazards
• Pressure
• Temperature
• Stored energy
• Moving equipment
• Access
• Falls
• Confined spaces
• Simultaneous operations
• Required permits
• Emergency conditions

Employees should understand the work scope and required controls before maintenance begins.

Pre-Job Planning

Maintenance work should be evaluated before employees begin the task.

Pre-job planning may include:

• Identifying the equipment.
• Defining the work scope.
• Reviewing applicable procedures.
• Identifying energy sources.
• Determining isolation points.
• Reviewing drawings or diagrams.
• Identifying required PPE.
• Determining access requirements.
• Identifying permits.
• Coordinating with operations.
• Evaluating nearby work.
• Planning equipment startup and return to service.

The level of planning should reflect the complexity and hazards of the work.

Job Safety Analysis

A Job Safety Analysis (JSA) can help identify hazards and controls before maintenance begins.

JSAs may be appropriate for:

• Equipment repair
• Equipment installation
• Lockout/tagout
• Electrical maintenance
• Troubleshooting
• Line breaking
• Confined-space entry
• Hot work
• Elevated maintenance
• Crane and rigging operations
• Pump maintenance
• Conveyor maintenance
• Valve replacement
• Motor replacement
• Shutdown and turnaround work
• Non-routine maintenance

The JSA should identify the steps of the task, associated hazards, and controls needed to perform the work safely.

When conditions or the work scope change, the JSA should be reviewed and updated as necessary.

Lockout/Tagout

Control of hazardous energy is one of the most important elements of industrial maintenance safety.

Employees performing servicing or maintenance where unexpected energization, startup, or release of stored energy could cause injury should follow applicable energy-control procedures.

Hazardous energy may include:

• Electrical
• Mechanical
• Hydraulic
• Pneumatic
• Chemical
• Thermal
• Gravity
• Pressure
• Springs
• Stored energy

Simply shutting equipment off with its normal operating controls does not constitute energy isolation.

Energy-Control Procedures

Equipment-specific energy-control procedures should identify the steps necessary to safely shut down, isolate, block, secure, and verify equipment before servicing.

Procedures may identify:

• Energy sources
• Energy-isolating devices
• Shutdown sequence
• Lockout or tagout locations
• Stored-energy controls
• Verification methods
• Restart procedures

Authorized employees should understand and follow the applicable procedure.

Lockout/Tagout Verification

Before maintenance begins, authorized employees should verify that isolation has been effective.

Verification may include:

• Attempting normal operating controls
• Testing electrical circuits
• Checking pressure gauges
• Verifying valves
• Inspecting mechanical blocking
• Confirming stored energy has been relieved

After verification, controls used for testing should be returned to the appropriate position.

Employees should never assume equipment is de-energized merely because another employee says it has been shut down.

Stored Energy

Stored energy can remain after primary energy sources have been isolated.

Examples include:

• Hydraulic pressure
• Pneumatic pressure
• Steam
• Process pressure
• Elevated equipment
• Flywheels
• Springs
• Capacitors
• Heated materials
• Pressurized accumulators

Stored energy should be relieved, disconnected, restrained, blocked, dissipated, or otherwise rendered safe before work begins.

If stored energy can reaccumulate, employees should continue to verify that safe conditions are maintained.

Group Lockout/Tagout

Industrial maintenance frequently involves multiple employees, crafts, or contractors working on the same equipment.

Group lockout/tagout procedures should provide each authorized employee with protection equivalent to personal lockout/tagout.

Procedures should address:

• Primary responsibility
• Group lockboxes when used
• Individual employee locks
• Shift changes
• Personnel changes
• Contractor coordination
• Verification

Each authorized employee should apply and remove their own personal lock or equivalent protection as required by the procedure.

Shift and Personnel Changes

Maintenance activities may continue across multiple shifts.

Procedures should ensure continuous energy-control protection during shift or personnel changes.

Incoming employees should understand:

• Equipment status
• Existing isolations
• Work completed
• Work remaining
• Stored-energy conditions
• Special hazards

Locks should not simply be removed at the end of a shift without an orderly transfer of protection.

Electrical Safety

Industrial maintenance employees may encounter electrical panels, motors, disconnects, controls, transformers, wiring, equipment, and temporary electrical systems.

Electrical equipment should normally be placed in an electrically safe condition before maintenance when required.

Only qualified employees should perform electrical work requiring specialized knowledge or work on or near exposed energized electrical parts.

Employees should understand the limitations of their electrical qualifications.

Arc Flash Safety

Electrical maintenance may expose qualified employees to shock, arc-flash, and arc-blast hazards.

Electrical safety procedures should address:

• Shock hazards
• Arc-flash hazards
• Approach boundaries
• Equipment condition
• De-energization
• Energized work
• Appropriate PPE
• Test instruments
• Job briefings

Where applicable, electrical equipment labeling and available electrical-safety information should be reviewed before work begins.

Energized Electrical Work

Working on energized electrical equipment should not become routine merely because shutting equipment down is inconvenient.

When energized work is permitted under applicable requirements, appropriate procedures should be established.

Planning may include:

• Justification for energized work
• Shock-risk assessment
• Arc-flash risk assessment
• Approach boundaries
• PPE
• Insulated tools
• Barricades
• Job briefing
• Energized electrical work permit when required

Only qualified employees should perform energized electrical work.

Electrical Testing and Troubleshooting

Some troubleshooting and diagnostic activities may require equipment to be energized for testing.

Employees should establish controls appropriate to the electrical hazard.

After testing is complete, equipment should be de-energized and appropriate energy-control procedures implemented before repair or physical servicing begins when required.

Employees should not treat troubleshooting as authorization to perform unrelated maintenance on energized equipment.

Test Instruments

Electrical test instruments should be suitable for the circuits and environment in which they are used.

Employees should inspect:

• Meter condition
• Test leads
• Probes
• Insulation
• Connectors
• Required ratings

Qualified employees should understand the limitations of their test instruments.

A known-source test may be appropriate before and after verifying absence of voltage.

Machine Guarding

Maintenance employees frequently work on machinery with guards, covers, barriers, and interlocks.

Machine guards should remain in place during normal operation.

Employees should not remove or bypass guards unless necessary for authorized servicing or maintenance and required hazardous-energy controls have been established.

After maintenance, required guards and safety devices should be restored before equipment is returned to normal operation.

Temporary Guard Removal

When guards must be removed for maintenance:

• Shut down equipment as required.
• Control hazardous energy.
• Restrict access.
• Maintain removed guards and hardware.
• Inspect the work area before startup.
• Reinstall guards before normal operation.

Employees should not leave operating machinery inadequately guarded after completing maintenance.

Interlocks and Safety Devices

Interlocks, presence-sensing devices, emergency stops, light curtains, guards, and other machine-safety devices should not be bypassed merely to make maintenance faster.

When temporary bypassing is necessary for authorized testing or adjustment, additional controls should be established and the safety system restored before normal operation.

Defective safety devices should be reported and corrected.

Conveyor Maintenance

Conveyors can expose employees to nip points, moving belts, rollers, chains, sprockets, stored tension, gravity, and unexpected startup.

Before servicing conveyors:

• Shut down equipment.
• Isolate hazardous energy.
• Control stored energy.
• Block elevated components.
• Prevent unintended material movement.
• Verify isolation.

Employees should not reach into or climb onto operating conveyors unless specifically permitted by an appropriate procedure that protects them from the hazards.

Pump Maintenance

Pump systems may contain electrical, mechanical, hydraulic, chemical, pressure, and thermal hazards.

Before maintenance:

• Isolate electrical energy.
• Close required valves.
• Relieve pressure.
• Drain or purge hazardous material when necessary.
• Control temperature hazards.
• Verify isolation.

Employees should anticipate trapped pressure or material between valves and equipment.

Valve Maintenance

Valves may isolate hazardous chemicals, steam, compressed air, water, gases, or other process materials.

Before removing or servicing a valve, employees should verify:

• Process isolation
• Pressure relief
• Drainage
• Temperature
• Chemical hazards
• Required PPE

Employees should not loosen flanges, fittings, or valve components until the potential for hazardous release has been evaluated.

Line Breaking

Opening process piping can expose employees to unexpected releases of pressure, chemicals, gases, steam, hot liquids, or other hazardous materials.

Line-breaking procedures should address:

• Identification of the correct line
• Process shutdown
• Isolation
• Lockout/tagout
• Pressure relief
• Drainage
• Flushing or purging
• Temperature
• PPE
• Employee positioning
• Spill containment

Employees should assume residual material may remain in a line even after draining.

Flange and Pipe Opening

When opening piping, employees should position themselves to minimize exposure to an unexpected release.

Fasteners should be loosened using a controlled method appropriate to the system and procedure.

Employees should not place their face or body directly in front of a flange, fitting, plug, cap, or other potential release point.

Required chemical-resistant PPE and face protection should be used when exposure is possible.

Pressure Systems

Industrial maintenance may involve:

• Compressed air
• Hydraulic systems
• Steam
• Process piping
• Pressure vessels
• Gas systems
• Pneumatic equipment

Pressure should be relieved before equipment is opened or disassembled when required.

Employees should verify that gauges and indicators accurately reflect system conditions and should consider the possibility of isolated pockets of trapped pressure.

Hydraulic Systems

Hydraulic systems can retain extremely high pressure after equipment is shut down.

Employees should:

• Isolate energy.
• Lower or support elevated components.
• Relieve pressure.
• Avoid checking leaks with bare hands.
• Use appropriate tools and methods.
• Inspect hoses and fittings.

High-pressure fluid injection injuries require prompt medical attention.

Pneumatic Systems

Compressed air and pneumatic systems can create stored-energy and projectile hazards.

Before servicing:

• Isolate the air supply.
• Relieve stored pressure.
• Secure moving components.
• Verify isolation.

Employees should never use compressed air to clean themselves or another person.

Steam and Hot Systems

Steam, hot water, heated equipment, furnaces, ovens, process piping, and other thermal systems can cause severe burns.

Maintenance planning should address:

• Isolation
• Temperature
• Pressure
• Cooling time
• PPE
• Residual materials

Employees should verify that equipment has reached a safe condition before opening or servicing it.

Confined Space Entry

Industrial maintenance employees may enter tanks, vessels, pits, vaults, ducts, process equipment, and other confined spaces.

Confined spaces should be identified and evaluated before entry.

Permit-required confined-space procedures may address:

• Entry permits
• Atmospheric testing
• Ventilation
• Isolation
• Lockout/tagout
• Entrants
• Attendants
• Entry supervisors
• Communication
• Rescue

Maintenance schedules should not be allowed to bypass required confined-space protections.

Confined Space Isolation

Maintenance in confined spaces may require isolation from:

• Process piping
• Mechanical equipment
• Electrical energy
• Hydraulic systems
• Pneumatic systems
• Material flow
• Steam
• Chemicals

Isolation methods should be appropriate to the hazards and applicable procedures.

Employees should verify required isolation before entry begins.

Confined Space Rescue

Rescue provisions should be established before permit-required confined-space entry.

Planning should consider:

• Space configuration
• Atmospheric hazards
• Retrieval systems
• Rescue personnel
• Communication
• Response time
• PPE
• Respiratory protection

Employees should not make an unplanned entry into a hazardous confined space to attempt a rescue.

Welding, Cutting and Hot Work

Maintenance employees frequently perform welding, cutting, brazing, soldering, and grinding.

Before hot work begins:

• Evaluate combustible materials.
• Control flammable substances.
• Inspect adjacent areas.
• Provide appropriate fire extinguishing equipment.
• Establish fire watch when required.
• Evaluate ventilation.
• Review process hazards.

Hot-work permits should be used when required.

Hot Work on Process Equipment

Hot work on tanks, vessels, piping, or process equipment requires additional evaluation.

Equipment that has contained flammable, combustible, toxic, or reactive materials should not be assumed safe merely because it has been drained.

Appropriate isolation, cleaning, purging, atmospheric testing, and authorization should be established before hot work begins.

Compressed Gas Cylinders

Maintenance operations may use oxygen, acetylene, shielding gases, nitrogen, refrigerants, and other compressed gases.

Cylinders should be:

• Properly identified
• Secured
• Protected from damage
• Stored appropriately
• Transported using suitable equipment

Valve-protection caps should be installed when required.

Employees should understand the hazards associated with each gas they use.

Hand and Power Tools

Maintenance employees use a wide range of tools, including:

• Grinders
• Drills
• Saws
• Impact tools
• Torque tools
• Pneumatic tools
• Hydraulic tools
• Portable electrical tools
• Hand tools

Tools should be inspected before use, appropriate for the task, and used according to manufacturer instructions.

Guards and safety devices should not be removed or defeated.

Damaged tools should be removed from service.

Grinding Safety

Grinding operations may expose employees to flying particles, sparks, noise, rotating equipment, and wheel failures.

Employees should:

• Inspect grinding wheels and discs.
• Verify compatibility with the tool.
• Verify rated speed.
• Maintain guards.
• Use required PPE.
• Control sparks.
• Secure workpieces when necessary.

Grinding should be evaluated as hot work when sparks could ignite combustible materials.

Portable Electrical Equipment

Portable electrical tools, extension cords, and temporary power equipment should be inspected and maintained.

Employees should report:

• Damaged cords
• Missing ground pins
• Cracked housings
• Damaged plugs
• Exposed wiring
• Defective switches

Electrical equipment should be appropriate for the environment in which it is used.

Fall Protection

Maintenance employees may work on:

• Roofs
• Platforms
• Structural steel
• Equipment
• Tanks
• Mezzanines
• Elevated piping
• Ladders
• Aerial lifts

Fall hazards should be evaluated before work begins.

Protection may include guardrails, personal fall arrest systems, positioning systems, covers, platforms, or other appropriate methods.

Aerial Lifts

Aerial lifts may be used for lighting, piping, electrical, HVAC, structural, and equipment maintenance.

Only trained and authorized employees should operate aerial lifts.

Employees should:

• Inspect equipment.
• Evaluate the work area.
• Maintain required electrical clearances.
• Use required fall protection.
• Follow manufacturer requirements.
• Avoid exceeding platform capacity.

Employees should not climb on platform rails to obtain additional reach.

Ladders

Ladders used for maintenance should be appropriate for the task and inspected before use.

Employees should:

• Maintain three points of contact.
• Use ladders on stable surfaces.
• Avoid standing above permitted levels.
• Keep the body appropriately positioned.
• Protect ladders from vehicle and equipment traffic.
• Select nonconductive ladders where electrical hazards require them.

Damaged ladders should be removed from service.

Scaffolds

Maintenance projects may require supported, mobile, or other scaffold systems.

Scaffolds should be erected, inspected, accessed, and used according to applicable requirements.

Employees should understand scaffold capacity, access, fall protection, falling-object hazards, and prohibited practices.

Crane and Rigging Operations

Maintenance employees may use cranes, hoists, chain falls, come-alongs, gantry systems, and other lifting equipment to remove or install motors, pumps, valves, machinery, and equipment components.

Lift planning should address:

• Load weight
• Rigging
• Center of gravity
• Equipment capacity
• Load path
• Landing area
• Employee positioning

Employees should remain clear of suspended loads.

Rigging

Slings, shackles, hooks, lifting beams, hoist rings, and other rigging equipment should be selected for the intended load and inspected as required.

Rigging personnel should consider:

• Load weight
• Sling angles
• Hitch configuration
• Sharp edges
• Load stability
• Rigging capacity

Damaged rigging should be removed from service.

Overhead Cranes and Hoists

Industrial facilities may use overhead cranes, jib cranes, monorails, chain hoists, and other lifting systems.

Employees should:

• Inspect equipment as required.
• Observe rated capacity.
• Control loads.
• Follow signaling procedures.
• Avoid side loading unless permitted.
• Keep employees clear of suspended loads.

Hoists should not be overloaded or modified contrary to manufacturer requirements.

Forklifts and Powered Industrial Trucks

Forklifts may be used to move maintenance equipment, parts, tools, motors, materials, and supplies.

Only trained and authorized employees should operate powered industrial trucks.

Operators should inspect equipment, observe capacity, maintain visibility, control speed, and remain alert to pedestrians.

Forklifts should not be improvised as personnel-lifting devices.

Personal Protective Equipment

PPE should be selected based on the hazards associated with the maintenance task.

Common maintenance PPE may include:

• Hard hats
• Safety glasses
• Goggles
• Face shields
• Work gloves
• Chemical-resistant gloves
• Safety-toe footwear
• Hearing protection
• High-visibility apparel
• Respiratory protection
• Fall protection
• Electrical PPE

Employees should inspect PPE before use and replace damaged equipment.

Hazard Communication

Maintenance employees may work with lubricants, solvents, cleaners, paints, adhesives, fuels, refrigerants, treatment chemicals, welding materials, and process chemicals.

The Hazard Communication Program should address:

• Chemical inventory
• Labeling
• Safety Data Sheets
• Employee training
• Chemical storage
• Non-routine tasks
• Protective measures

Maintenance employees should review hazards before working with unfamiliar chemicals or opening process systems containing hazardous substances.

Respiratory Protection

Maintenance work may expose employees to welding fumes, dust, vapors, gases, process chemicals, or other airborne contaminants.

Engineering and work-practice controls should be used as required.

When respirators are necessary, the Respiratory Protection Program should address:

• Respirator selection
• Medical evaluation
• Fit testing
• Training
• Inspection
• Cleaning
• Storage
• Cartridge or filter replacement
• Program evaluation

Respirators should not be used as a substitute for required engineering controls when those controls are feasible and required.

Hearing Conservation

Industrial maintenance may involve high-noise equipment, grinders, impact tools, compressed air, machinery, and process areas.

Employee noise exposures should be evaluated.

A Hearing Conservation Program should be implemented when required.

Employees should use hearing protection appropriate to their exposures and receive required training.

Contractor and Host-Employer Coordination

Industrial maintenance contractors frequently perform work inside operating customer facilities.

Before work begins, the contractor and host employer should exchange relevant hazard information and coordinate applicable safety procedures.

Coordination may include:

• Hazardous energy
• Process chemicals
• Confined spaces
• Emergency procedures
• Hot work
• Electrical hazards
• Traffic
• Simultaneous operations
• Restricted areas
• Facility-specific rules

Contractor employees should understand which procedures apply to their work.

Simultaneous Operations

Maintenance activities may occur while production, construction, cleaning, material handling, or other maintenance work continues nearby.

Pre-job planning should consider how one activity could affect another.

Potential conflicts may include:

• Hot work near chemical operations
• Crane lifts over work areas
• Electrical shutdowns
• Process releases
• Vehicle traffic
• Work above or below other employees
• Shared energy sources

Work should be coordinated to prevent one operation from creating uncontrolled hazards for another.

Non-Routine Maintenance

Non-routine work often presents greater risk because employees may have less experience with the task and established procedures may not fully address the conditions.

Before non-routine maintenance:

• Define the work.
• Identify hazards.
• Review energy sources.
• Determine required permits.
• Complete a JSA when appropriate.
• Identify qualified personnel.
• Coordinate with affected operations.
• Establish emergency procedures.

Employees should stop and reevaluate the work when unexpected conditions are discovered.

Equipment Troubleshooting

Troubleshooting may require employees to observe equipment while it is operating or energized.

The need to diagnose a problem does not eliminate applicable safety requirements.

Troubleshooting procedures should distinguish between:

• Observation
• Testing
• Adjustment
• Servicing
• Repair

When the task changes from diagnostic work to servicing or repair, required hazardous-energy controls should be implemented.

Adjustments and Minor Servicing

Some minor servicing activities may occur during normal production operations.

Before relying on an exception to normal lockout/tagout procedures, the company should verify that the work actually meets applicable criteria and that effective alternative protection is provided.

Convenience, production pressure, or short task duration alone does not justify bypassing hazardous-energy controls.

Shutdowns and Turnarounds

Plant shutdowns and turnarounds can involve large numbers of employees and contractors performing maintenance simultaneously.

Planning should address:

• Work scopes
• Energy isolation
• Group lockout/tagout
• Contractor coordination
• Confined spaces
• Hot work
• Crane operations
• Scaffold access
• Electrical work
• Chemical hazards
• Material staging
• Emergency response
• Shift changes

Shutdown schedules should allow sufficient time to perform work safely.

Startup After Maintenance

Returning equipment to service requires careful coordination.

Before startup:

• Inspect the work area.
• Remove unnecessary tools and materials.
• Reinstall guards.
• Verify components are assembled.
• Confirm employees are clear.
• Remove locks and tags according to procedure.
• Notify affected employees.
• Restore energy in a controlled sequence.

Employees should anticipate unexpected movement, leaks, pressure, vibration, or other abnormal conditions during initial startup.

Equipment Commissioning

Newly installed or substantially modified equipment should be evaluated before normal operation.

Commissioning may include:

• Inspection
• Guard verification
• Electrical checks
• Control-system testing
• Safety-device testing
• Leak testing
• Rotation checks
• Emergency-stop verification
• Employee training

Temporary commissioning conditions should not become permanent operating practices.

Preventive Maintenance

Preventive maintenance can reduce equipment failures that expose employees to emergency and unplanned repair work.

Programs may address:

• Scheduled inspections
• Lubrication
• Component replacement
• Guard inspection
• Electrical maintenance
• Safety-device testing
• Leak detection
• Manufacturer recommendations

Maintenance records should be maintained as appropriate to the equipment and facility.

Maintenance Shop Safety

Maintenance shops should be organized to control hazards associated with tools, machinery, chemicals, welding, compressed gases, parts storage, and material handling.

Work areas should provide:

• Adequate lighting
• Clear aisles
• Appropriate storage
• Machine guarding
• Fire protection
• Chemical controls
• Electrical safety
• Suitable work surfaces

Shop machinery should be operated only by employees trained and authorized to use it.

Housekeeping

Maintenance work can create hoses, cords, tools, removed components, spills, scrap, packaging, and other hazards.

Employees should maintain orderly work areas and keep:

• Exits clear.
• Electrical panels accessible.
• Walking surfaces clear.
• Emergency equipment accessible.
• Tools organized.
• Materials stable.

Maintenance areas should be cleaned before equipment is returned to normal operation.

Slips, Trips and Falls

Leaks, lubricants, coolants, hoses, cords, removed parts, tools, and uneven surfaces can create slip and trip hazards.

Spills should be cleaned promptly.

Cords and hoses should be routed to minimize trip hazards.

Employees should report damaged walking surfaces, stairs, platforms, railings, and grating.

Heat and Cold Stress

Maintenance work may be performed outdoors, in mechanical rooms, near hot process equipment, in refrigerated areas, or during facility shutdowns with reduced environmental controls.

Heat- and cold-stress procedures should address:

• Appropriate clothing
• Drinking water
• Rest
• Acclimatization
• Warming or cooling opportunities
• Employee monitoring
• Recognition of symptoms
• Emergency response

Temperature conditions should be considered during pre-job planning.

Emergency Procedures

Industrial maintenance operations should plan for foreseeable emergencies.

Potential emergencies include:

• Electrical incidents
• Chemical releases
• Fires
• Confined-space emergencies
• Equipment failures
• Hydraulic injection injuries
• Falls
• Dropped loads
• Process releases
• Medical emergencies

Employees should know how to stop work, secure the area when possible, summon assistance, and communicate the location and nature of the emergency.

Industrial Maintenance Safety Training

Employees should receive training appropriate to their assigned maintenance responsibilities and exposures.

Training may include:

• Lockout/tagout
• Electrical safety
• Arc flash
• Machine guarding
• Confined spaces
• Hot work
• Fall protection
• Aerial lifts
• Ladders
• Crane and rigging safety
• Hand and power tools
• Hazard communication
• PPE
• Respiratory protection
• Emergency procedures

Training should be documented and updated when equipment, processes, procedures, employee responsibilities, or regulatory requirements change.

Building an Industrial Maintenance Safety Manual

An Industrial Maintenance Safety Manual should be customized to the company’s actual maintenance activities rather than relying solely on a generic industrial or manufacturing safety manual.

A maintenance contractor performing mechanical repairs and equipment installations may require a different combination of programs than an in-house maintenance department responsible for electrical systems, process piping, conveyors, boilers, production machinery, building systems, and preventive maintenance.

A contractor performing shutdown and turnaround work may require additional procedures for group lockout/tagout, confined spaces, hot work, cranes and rigging, scaffolding, contractor coordination, and simultaneous operations.

The manual should reflect the equipment serviced, energy sources, electrical systems, process hazards, maintenance tools, lifting equipment, employee qualifications, facility conditions, and customer requirements applicable to the work.

The completed safety manual should provide practical procedures employees and supervisors can use while supporting OSHA compliance, employee training, pre-job planning, JSAs, inspections, incident investigations, contractor coordination, preventive maintenance, and the company’s overall safety-management system.

Customized Industrial Maintenance Safety Manuals

Get an Industrial Maintenance Safety Manual customized for your machinery, electrical systems, LOTO procedures, process piping, pumps, conveyors, pressure systems, confined spaces, hot work, maintenance shops, shutdowns and turnarounds, cranes and rigging, aerial lifts, chemicals, and other industrial maintenance hazards.