On-Site Electric Motor Dismantling Safety Guidelines for Malaysia Industries

This document outlines the essential safety requirements to be followed when dismantling electric induction motors on-site. It integrates general safety legislation with common industrial hazards for full compliance and risk mitigation.

1. Core Legislative Framework

All work must comply with the primary occupational safety and health legislation in Malaysia.

Occupational Safety and Health Act (OSHA) 1994: This is the principal act ensuring the safety, health, and welfare of employees. It mandates employers to identify and mitigate workplace risks.
Factories and Machinery Act 1967 (Regulations still applicable): While the main act is largely superseded by OSHA 1994, specific regulations concerning machinery safety, such as those for fencing and guarding, remain crucial until fully replaced.

The Department of Occupational Safety and Health (DOSH) is the governing body that enforces these regulations.

2. Hazard Identification, Risk Assessment, and Risk Control (HIRARC)

A site-specific HIRARC is mandatory before any dismantling work commences. Industrial environments present unique hazards that must be considered.

Key Hazards in an Industrial Environment:

Electrical Hazards: Stored energy in motor components, unexpected energization, and high voltage exposure.
Mechanical Hazards: Heavy components (rotors, casings), rotating parts of adjacent machinery, and risks associated with lifting equipment.
Hazardous Materials: Inhalation of industrial dust (which may contain silica or other harmful particulates), exposure to lubricating oils, greases, and potentially hazardous cleaning solvents.
High Temperatures: Motors can be located in areas with high ambient temperatures, posing a risk of burns from hot surfaces.
Confined Spaces: Depending on the motor's location, it may be considered a confined space, requiring specific entry permits and atmospheric testing.
Slips, Trips, and Falls: Uneven surfaces, oil spills, and scattered tools and components are common hazards.

3. Safe Work Systems & Procedures

A systematic approach is crucial to ensure safety throughout the dismantling process.

3.1 Permit-To-Work (PTW) System

A PTW is a formal documented system used to control high-risk activities. For motor dismantling, this is a critical step.

The PTW ensures that all hazards have been identified, and necessary precautions are in place before work begins.
It must be authorized by a designated person and communicated to all personnel involved in the task.
Training on PTW systems is often conducted to ensure all workers, including contractors, understand the procedures.

3.2 Lockout/Tagout (LOTO) Procedure

LOTO is a non-negotiable safety procedure for any work on powered equipment.

The goal of LOTO is to prevent the unexpected release of hazardous energy during servicing or maintenance. Inadequate control of hazardous energy accounts for a significant number of serious industrial accidents.

6 Steps for Effective LOTO:

Preparation: Identify all energy sources (electrical, mechanical, pneumatic, etc.).
Shutdown: Power down the equipment using the normal stopping procedure.
Isolation: Isolate the motor from all energy sources.
Lockout/Tagout Application: Each authorized employee affixes their personal lock and tag to the energy-isolating device.
Stored Energy Check: Verify that any stored energy (e.g., in capacitors) has been safely discharged.
Isolation Verification: Attempt to start the equipment to ensure it is properly isolated before beginning work.

3.3 Dismantling Work Procedure

A Job Safety Analysis (JSA) should detail the step-by-step process for the task.

Area Preparation: Cordon off the work area, ensure proper lighting and ventilation, and remove any unnecessary obstacles.
Mechanical Disconnection: Disconnect the motor from the driven load (e.g., pumps, fans, conveyors).
Electrical Disconnection: After LOTO verification, disconnect electrical cables from the motor terminal box.
Component Removal: Systematically remove motor components such as cooling fans, guards, and the terminal box cover.
Heavy Lifting: Use certified and inspected lifting equipment (e.g., cranes, chain blocks) for removing heavy parts like end shields and the rotor. Ensure personnel are clear of the lifting zone.
Housekeeping: Keep the work area clean and organized. Store dismantled parts in a designated laydown area to prevent trip hazards.

4. Personal Protective Equipment (PPE)

Employers must provide appropriate PPE, which must be approved by DOSH-SIRIM. The PPE required for this task includes:

Protection Type	Specific PPE	Purpose
Head Protection	Safety Helmet	Protection from falling objects.
Eye Protection	Safety Goggles/Face Shield	Protection from dust, flying particles, and chemical splashes.
Hand Protection	Insulated Electrical Gloves & Heavy-Duty Mechanical Gloves	Protection from electrical shock and from cuts, abrasions, and chemical contact.
Foot Protection	Steel-Toed Safety Boots (DOSH-SIRIM certified)	Protection from falling objects, punctures, and slips.
Respiratory Protection	Dust Mask or Respirator (e.g., N95)	Essential to prevent inhalation of harmful dusts and particulates.
Body Protection	Full-body Coveralls	Protects skin from dust, dirt, grease, and minor chemical splashes.
Hearing Protection	Earplugs or Earmuffs	Necessary if working in high-noise areas.

5. Competency and Training

All personnel involved in the dismantling work must be competent and trained.

Competent Person (Electrical): Any electrical isolation and disconnection must be performed by a competent person certified by the Malaysian Energy Commission (Suruhanjaya Tenaga).
Training: Workers must receive training on the specific hazards of the job, the HIRARC, LOTO procedures, manual handling techniques, and the correct use of PPE.
Supervision: A designated supervisor must oversee the entire dismantling operation to ensure procedures are followed correctly.