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2023 Second Alert LTI#12 AC Technician suffered finger injury while doing AC maintenance
During HVAC routine maintenance a technician was replacing belts on an Air Handling Unit (AHU) motor and blower. The technician used a screwdriver to attempt to remove and replace the belts without loosening the tension, this resulted in a fractured middle finger when the screwdriver slipped, and the finger was crushed under the belt.
How do you identify and select the right tool before starting maintenance work? How do you identify pinch points and line-of-fire hazards before beginning a maintenance task? How do supervisors ensure they remain focused on supervision rather than becoming part of the work crew? How can workers challenge shortcuts that have become accepted practices over time? What could happen when experience and confidence replace compliance with procedures? No shortcuts, no line of fire, no hands in pinch points
The Permit Holder was performing the physical work instead of maintaining effective supervision of the work team as required by the permit process A shortcut was taken by attempting to remove the belt using a screwdriver instead of first releasing the belt tension through the designed adjustment process. An inappropriate tool was used for the task, creating a pinch-point hazard and increasing the likelihood of a sudden release of stored energy. The HVAC method statement and risk assessment did not adequately identify the hazards associated with belt tension release and replacement activities Over-reliance on experience and familiarity with the task resulted in poor hazard recognition and acceptance of unsafe work practice

Category:Second AlertsDocument Type:Safety
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