A primary crusher mantle change is a multi-day lockout on the largest rotating equipment most people ever work near. The energy is electrical at medium voltage, hydraulic at high pressure, and — the one that kills — gravity: material in the feed hopper, a suspended mantle, a conveyor with a load on it.
Group lockout is the norm: a dozen people over several shifts on one job, one lockbox, and a person in charge whose identity changes at every handover.
MSHA and OSHA both apply depending on the site, and the record needs to satisfy whichever inspector arrives.
Electrical isolated, hydraulics bled, and the hopper still has forty tonnes above the work. Blocking is an isolation point, and it needs verifying like one.
Day shift leaves; night shift arrives; the box is locked and the key is in someone's truck. Nobody can say who is in charge.
A lock left on by someone who went home is cut off to restart. The standard permits it under (e)(3) — with a procedure, and a record. Usually there is neither.
Real isolation-point structure, illustrative tags, equipment that does not exist. Free to read and download. An example to learn from — not a document to adopt.
Full isolation of CR-101 for mantle change. Includes upstream CV-200 feed conveyor isolation per interlock requirement.
- 10 isolation points
- 1 must stay energised
Annual haul rope inspection with tower sheave assembly change. ANSI B77.1. Evacuation drive must remain available throughout.
- 11 isolation points
- 2 must stay energised
The box, the locks in it, who holds the key, and the transfer of that custody at handover — each a recorded, attested event.
When a lock must be removed without its owner, the record names who did it and why, and the event log shows it separately from ordinary removals — never folded in.
Mechanical blocks and gravity restraints carry the same apply-and-verify attestation as an electrical disconnect.
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