THE CONTROL OF HAZARDOUS ENERGY LOCKOUTTAGOUT Course Objectives
THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT)
Course Objectives 1. Provide the necessary tools for each of our job sites to develop their own site specific Hazardous Energy Control Program. 2. Provide Awareness to our Management, Supervisors and employees of the types of Hazardous Energy Sources in their work areas and the proper methods to control them. 3. Reduce Injuries and Equipment Damage through the development and implementation of a Hazardous Energy Control Program at each of our Job Sites.
Team Activities u Team #1 1. Explain the overview of Lockout / Tag Out. 2. Historically, what percentage of Lock Out / Tag Out citations involve the failure to have a formal Energy Control Program? 3. Employers are required to train Authorized Employees in what topics? 4. Define Authorized Employee. 5. Define Affected Employee. 6. What type of training is required for Affected Workers?
Team Activities u Team #2 1. Define Capable of being locked out. 2. Define Energized. 3. Define Energy Isolating Device. 4. Define and list all the energy sources in your manual, list any others that might not be included in the definition section. 5. Define Lockout / Tag Out 6. Define Lockout Device.
Team Activities u Team #3 1. List each of the steps in the “Where to Begin Section” of your manual. 2. List all of the characteristics of Lockout / Tag Out Devices. 3. What are the advantages of Lockout over Tag Out? 4. If only a Tag Out is used, what are the steps to be taken? 5. What are the limitations of a Tag Out? 6. What are the training requirements for Lockout / Tag Out?
Lockout/Tag out Overview u Covers the parking, servicing and maintenance of equipment where the unexpected movement, energization or start up of equipment, or release of stored energy could cause injury.
Lockout/Tag out Overview u Establishes minimum performance requirements for controlling hazardous energy.
History u u u More citations More costly fines 95% of all lockout/tag out citations involve the failure to have a formal Energy Control Program in place
Definitions u Authorized Employee: – A person who locks or tags out equipment in order to perform servicing or maintenance
Definitions (continued) u Affected employee: – Job requires employee, operate or use equipment on which servicing or maintenance is being performed under lockout and tag out conditions – Job requires the employee to work in an area in which such servicing or maintenance is being performed. Note: Becomes an authorized employee when that employee's duties include performing daily inspections, servicing or maintenance.
Definitions (continued) u Capable of Being Locked Out: – An energy isolating device is capable of being locked out if it has a hasp or other means of attachment to which, or through which, a lock can be affixed, or it has a locking mechanism built into it.
Definitions (continued) u Energized: – Connected to an energy source or containing residual or stored energy, vehicles parked on grades and not chocked or blocked against motion. – Parts or equipment that are being repaired that have moving parts that can be affected by GRAVITY.
Definitions (continued) u Redundant forms of isolation: Redundant forms of isolation exceed what is required or natural. “ALL ENERGY SOURCES MUST BE ISOLATED, BLOCKED, BLED OFF, DE-ENERGIZED, LOCKED AND TAGGED RENDERED HARMLESS BY SOME OTHER MEANS PRIOR TO ANY WORK BEING PERFORMED ON ANY EQUIPMENT OR MACHINERY. ” Always refer to the Operators/Owners Operating and Maintenance Manual for their recommendations.
Definitions (continued) u Servicing/maintenance activities include: “Parking the equipment” in preparation for: Constructing Installing Setting up Adjusting Inspecting Modifying Lubricating Cleaning or unjamming equipment. Making adjustments or tool changes.
Definitions (continued) Energy isolating device: – A mechanical device that physically prevents the transmission or release of energy: " Wheel Chocks " Properly engineered and installed devices to prevent the movement of suspended objects. " Manually operated electrical circuit breaker " A disconnect switch " Line valve " A block " Any similar device used to block or isolate energy Note: Push button, selector switches and other control devices are not energy isolating devices.
Definitions (continued) u Energy Sources: GRAVITY – – – – – Mechanical Hydraulic Electrical Gas Pneumatic Water Chemical Thermal Other stored energy (Springs, capacitors, etc. )
Definitions (continued) u Lockout/Tag out: – The placement of a lock / tag on an energy isolating device, in accordance with an established procedure, to ensure that the energy isolating device and the equipment or any of its parts being controlled cannot be operated or moved in any manner until the lock and tag are removed.
Definitions (continued) u Lockout device: Gravity lockout devices include: Chock Blocks, Cribbing when necessary to prevent movement of suspended or moving parts.
Definitions (continued) A device that utilizes a positive means such as a lock either key or combination type, to hold an energy isolating device in a safe position and prevents the energizing of the equipment. Included are blank flanges and bolted slip blinds.
Definitions (continued) Tag out device: A warning device, such as a tag and a means of attachment Can be securely fastened to an energy isolating device in accordance with an established procedure to indicate that the energy isolating device and the equipment being controlled can not be operated until the tag is removed. DANGER LOCKED OUT DO NOT OPERATE This Lock/Tag may only be removed by NAME: ________ DEPT : ________ EXPECTED COMPLETION DATE: ________ TIME: _________
Purpose u Requires employers to train “authorized” employees: – How to properly park and prepare for shutdown. – When and how to shut down machinery. – Drain and isolate all energy sources. – Verify the absence of energy. – Verify the existence of a redundant form of isolating the energy sources. – Safely restart equipment when maintenance or repair is complete.
Purpose u Mandated awareness training of “affected” workers (equipment operators, etc. )
Energy Control Program u Must clearly and specifically outline the: – Purpose – Scope – Authorization – Rules – Techniques to be utilized for lockout/tag out, and means to enforce compliance. DANGER LOCKED OUT DO NOT OPERATE This Lock/Tag may only be removed by NAME: ________ DEPT : ________ EXPECTED COMPLETION DATE: ________ TIME: _________
Energy Control Program (continued) u Must include: – A statement of the intended used of the procedure – Specific steps for shutting down, isolating, blocking, and securing equipment to control hazardous energy or movement. – Specific steps for the placement, removal and transfer of lockout devices or tag out devices and the responsibility for them. – Requirements for testing equipment to determine and verify the effectiveness of lockout devices, tag out devices, and other energy control measures.
Gravity
Gravity
Fatality Update Gravity Incident
Photo of the equipment involved and the facts surrounding the accident. u u u u Equipment parked on 10 – 15 degree slope. The mechanic and the operator were attempting to troubleshoot the starter of the dozer. The mechanic and the operator were positioned on the rear tire. The only means of working on the starter is from the tire or from behind the tire. Parking Brake disengaged. Mechanic turned starter and it built up enough pressure to release the braking system. The rubber-tired dozer rolled 32 feet downhill and the operator of the machine was crushed between the rear tire and the hydraulic tank.
Fatality (Update) u Possible Primary Cause – Attempting Maintenance work while the equipment was not located on firm and level ground. – Not properly chocked, blocked or restrained. u Contributing Causes – Parking brake was disengaged and not re-checked prior to working on the equipment.
Fatality (Update) u Corrective Actions – All equipment will be on flat ground, chocked or a piece of heavier equipment must be placed in such a manner as to prevent movement of the equipment that will be worked on before maintenance work begins. – Whenever work is to be performed on a piece of equipment, the Master Mechanic must be at the location of the repair and assure that the equipment is in a safe configuration to be worked on. This is required on this job site only.
Grader Operator Fatality 5 Mistakes = One Fatality
Where to Begin Conduct a hazard assessment by identifying each piece of equipment that is used, serviced, or maintained. Identify the steps to properly park the equipment and lockout / tag out for GRAVITY. Determine the requirements for lockout : If there is more than one primary energy source to the equipment, document each source.
Where to Begin (continued) Document all energy sources: – Hidden – Direct The hazard posed. The magnitude or measurable degree of danger. Special or unusual conditions. Proper isolations and devices.
HAZARD ASSESSMENT FOR MACHINERY OR EQUIPMENT
Team Activities u Teams 1, 2, and 3: 1. Take a few minutes and choose a machine or a piece of equipment here at your job site. 2. Notify the Instructor of the machine or equipment that you have chosen as a team to prevent duplication. 3. Following the items listed in the”Where to Begin Section” of your manual and the Hazard Assessment Form provided by the instructor, conduct a Hazard Assessment for the piece of equipment or machine that you have chosen.
Lockout/Tag out Devices Durable: All devices must be capable of withstanding the workplace environment. All tags and their means of attachment must be sturdy enough to prevent inadvertent removal
Lockout/Tag out Devices (continued) Standardized Lockout/tag out devices must be Standardized A device that utilizes a positive means such as a lock either key or combination type, to hold an energy isolating device in the safe position and prevents the energizing of the equipment. – Included are blank flanges and bolted slip blinds. " Singularly identified " The only device(s) used for controlling energy " Not be used for other purposes " Devices must have the same color, shape, or size. " The format and print of tags should be standardized
Lockout/Tag out Devices (continued) Substantial Removal of lockout devices should be extremely difficult to remove, requiring the use of excessive force and the help of tools such as bolt cutters. Tag out devices and their attachments must be tough enough so that they can’t be accidentally removed.
Lockout is a more effective means of ensuring de-energization of equipment than tag out. If an energy-isolating device can’t be locked out, tag out may be used. “Tag out may be used in place of lockout if it can be demonstrated that it will offer equivalent protection to that offered by lockout. ”
Example of Good Lockout/Tag out Devices
Example of Good Lockout/Tag out Devices
Tag out When only a tag is used because equipment cannot be locked out, the following steps must be taken: – – – Removing an isolating circuit element (fuses). Block equipment against motion. Block machine (control switch). Disconnecting the Battery cables from the terminals. Air start equipment will require that the air be bled from the system. (All equipment with air start systems must be properly blocked against motion prior to the air systems being bled) – Removing the keys. – Opening an extra disconnecting device. – Other means of isolation.
Tag out (continued) Tags must be placed where the lockout device would have been placed A legend must be used such as: – Do not start – Do not open – Do not close – Do not energize – Do not operate
Tag out Limitations Tags are attached to energy isolation devices, but they are only a warning. They do not provide the protection offered by a lockout procedure. A tag is never to be bypassed or ignored, and it may not be removed without the specific authorization of person responsible for it. ”Tags may only be removed by the authorized person who tagged the device out”.
Tag out Limitations (continued) Tags must be clearly visible and easily understandable by any employee who may be in the area Tags and their attaching materials must be able to withstand any adverse environmental conditions in the workplace
Tag out Limitations (continued) Tags must be clearly understood and respected to be effective. – Workers should guard against false sense of security. Tags must be carefully secured to the energy-controlling devices so that they can’t easily be detached by accident during use.
Annual Inspections Certain circumstances lend themselves to the opportunity for an inspection: – Routinely scheduled cleaning and maintenance – Major repairs. – Daily walk-around inspections. – Construction of new equipment. – Installation of new equipment. – Modification or adjustment of equipment
Designating an Inspector Periodic inspections must be performed by an authorized employee other than the one(s) using the energy control procedure Who can inspect: – Department manager – Project management – Safety manager – Others
Employee Reviews Lockout – Must include a review between the inspector and each authorized employee. Tag out – Must be a review between the inspector and each authorized and affected employees. – Review should cover each employee's responsibility under the procedure being inspected, as well as the limitations of tags.
Certifying Inspections Must certify that the required periodic inspections have been performed. Certification must identify the following: – The equipment on which the energy control procedure was used. – The date of the inspection. – The employees included in the inspection. – The name of the person performing the inspection.
Follow-up audit A follow-up audit must be conducted to ensure that all deficiencies noted have been corrected. Documentation must identify: – The equipment on which the lockout procedure is being utilized. – The date of the inspection. – Employees interviewed. – Employee(s) performing the inspection.
Specific Requirements A training program must consist of: – Effective initial training – Periodic retraining as necessary – Certification that training has been given to all employees covered by the policy and procedure. Certification must become part of employee record and contain. – Employee's name – Date of training
Specific Requirements (continued) Training must be provided to ensure that the purpose and function of the energy control program are understood by employees. That the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees.
Type of Training The amount and kind of training is based upon: – The relationship of each employee’s job to the equipment being locked or tagged out. – The degree of knowledge relevant to hazardous energy that he/she must possess. " Need to know.
Authorized Employee u Each authorized employee must receive the following training: – The purpose of the procedure – Ability to recognize applicable hazardous energy sources in the workplace. – The type and magnitude of the energy available in the workplace. – Understanding the means and methods of isolating and/or controlling the various types of energy sources. – Ways to verify that energy isolation is effective.
Affected Employees All affected employees must be instructed in the purpose and use of the lockout/tag out system. “Create awareness” There are “No Excuses” for injuries that result from ignorance, carelessness, complacency, or lack of an Energy Control Program.
Other Employees All other employees (including new hires) whose work operations are or may be in an area where lockout/tag out may be utilized. These employees must be instructed: – About the procedure – That they are prohibited from starting up or reenergizing any locked-out or tagged-out equipment they encounter.
Retraining Must be conducted for all authorized and affected employees whenever: – There is a change in job assignment. – Change in equipment, machinery, or processes that presents a new hazard. – A change in the lockout/tag out procedure.
Retraining (continued) Must be conducted whenever a periodic inspection reveals, or whenever the authorized employee has reason to believe that there are deviations from or inadequacies in the employee's knowledge or use of the lockout/tag out procedures.
Group Lockout/Tag out When servicing and/or maintenance is performed by a crew, craft, department or other group, they must utilize a procedure that affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout/tag out device.
Group Lockout/Tag out (continued) Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tag out device. Provisions must be in place for the authorized employee to ascertain the exposure status of individual group members with regard to the lockout/tag out of the equipment. There are “No Excuses” for injuries that result from ignorance, carelessness, complacency, or lack of an Energy Control Program.
Group Lockout/Tag out (continued) Lockout/tag out control responsibility is designated to an authorized employee to coordinate affected work forces and ensure continuity of protection. Each authorized employee must affix a personal lockout/tag out device to the group lockout device, group lock box, or comparable mechanism when he/she begins work, and must remove those devices when he/she stops working on the equipment being serviced or maintained. There are “No Excuses” for injuries that result from ignorance, carelessness, complacency, or lack of an Energy Control Program
When Shift or Personnel changes occur “Continuity of lockout/tag out protection must be ensured by following specific procedures for shift and personnel changes, including the orderly hand-off of lockout/tag out devices. ”
Unusual Conditions Machines need to be tested or repositioned during servicing: – When necessary, under special condition, the procedure can allow the temporary removal of locks or tags and the reenergization of the equipment. " Example, when power is needed for the testing or positioning of equipment.
Unusual Conditions (continued) Subject to the following restrictions: – Equipment must be cleared of tools and material – Employees must vacate the equipment areas – An Inspection shall be made to assure there are no exposures if an unexpected release of energy occurs. – The lockout/tag out device must be removed only by the authorized employee who applied it – Energization may then be allowed by testing or positioning – All systems must be de-energized, the employee or equipment must be isolated from energy source, and the lockout/tag out devices reapplied.
Contractors – Must inform each other of all applicable lockout/tag out procedures. – Both employer and contractor must ensure that their employees understand will respect each others Energy Control Program. – They should work together to assure compliance with their programs.
Typical Shutdown Procedure Notify affected employees. Use the specific procedures as outlined for the appropriate situation: Park the equipment properly assuring that Gravity sources are eliminated. Shut off energy source(s) to affected equipment. – Use normal stopping or running procedures for the machine. Isolate the equipment from the energy source.
Shutdown Procedures (continued) Affix lock(s) and tag(s) to each energy source controlling device. Relieve all stored energy from capacitor banks, springs, compressed air, hydraulics, steam, etc. Verify isolation of energy has occurred by trying equipment.
Removal of Lockout / Tag Out and Start-Up Procedures 1. Ensure that nonessential items are removed from equipment. 2. 3. Ensure that equipment components are intact. 4. Ensure that all implements are grounded or blocked against gravity hazards. 5. Notify all affected employees and site supervisor before reenergizing the equipment. 6. 7. Remove lockout / tag out device. Check area to ensure that all affected employees are safely positioned or removed from the area. Reenergize equipment to ensure safe operation.
Summary Accidents can happen when improper methods for Controlling Hazardous Energy Sources are used. Equipment will occasionally malfunction, when it does; assure your self that the equipment is parked properly and in a safe configuration to allow repairs to be made. People will still make mistakes. If our employees are properly trained to a Site Specific Control of Hazardous Energy Program and they are properly supervised, we can reduce the number of mistakes. Each of our Job Sites World Wide shall develop and implement a Project Specific / Job Site Specific Program for the Control of Hazardous Energy Sources. Upon completion, implementation and training of the Control of Hazardous Energy Program, any Violation of the program should involve disciplinary action up to and including immediate dismissal. There are “No Excuses” for injuries that result from ignorance, carelessness, complacency, or lack of an Energy Control Program.
Team Activities u Team 1, 2, and 3, 1. Each team will choose the case study from the following pages that coincides with your team number. 2. Read the narrative for your Case Study and go to the next page and answer each of the Questions to be considered regarding the Case Study you have been assigned.
CASE STUDY #1 WORKER KILLED BY MIXING MACHINE NARRATIVE: An employee was assigned the task of cleaning the inside of a sand mixer. The task was conducted during a break in the production cycle, caused by routine maintenance work. He did this without anyone else’s knowledge. While he was engaged in this, out of sight and hearing of the others, an electrician started the machine, killing the man inside. This plant had a written lockout procedure, training had been given, and all affected employees (including the deceased), were issued keys and locks.
QUESTIONS TO BE CONSIDERED þDo you believe there are multiple causes? þWhat caused the death of the worker? þAre multiple safety violations involved? þWhat could upper management have done? þWhat could the supervisor have done? þWhat could the co-workers have done? þTo what extent was attitude responsible? þTo what extent is a lack of written policy responsible? þTo what extent is a lack of training responsible? þDo you believe there is a single cause to this accident that, if removed would have prevented it?
CASE STUDY #2 WORKER KILLED BY HIGH VOLTAGE NARRATIVE: A 13, 800 -volt main circuit breaker was under routine inspection. A test instrument was used to check for electrical energy. No electrical energy was detected at the primary power contacts in the circuit breaker. To verify the operation of the tester, the sensitivity was readjusted and checked against a known 120 -volt receptacle. The tester was found to be operable. As the journeyman electrician approached one of the contacts with a shop towel, an explosion, engulfed him in flames. The power from the public utility company to the main circuit breaker had not been shut off.
QUESTIONS TO BE CONSIDERED þ þ þ þ þ What caused the death of the worker? Do you believe there are multiple causes? Are multiple safety violations involved? What could upper management have done? What could the supervisor have done? What could the co-workers have done? To what extent was attitude responsible? To what extent is a lack of written policy responsible? To what extent is a lack of training responsible? Do you believe there is a single cause to this accident that, if removed would have prevented it?
CASE STUDY #3 DECAPITATED BY SHEARING MACHINE NARRATIVE: An employee was removing scrap from beneath a large shear when a fellow employee hit the control button activating the blade. The blade cycled and decapitated the employee cleaning scrap. The company had no written lockout procedure and workers had not been trained or advised regarding the hazards associated with machinery.
QUESTIONS TO BE CONSIDERED þ þ þ þ þ What caused the death of the worker? Do you believe there are multiple causes? Are multiple safety violations involved? What could upper management have done? What could the supervisor have done? What could the co-workers have done? To what extent was attitude responsible? To what extent is a lack of written policy responsible? To what extent is a lack of training responsible? Do you believe there is a single cause to this accident that, if removed would have prevented it?
A SMALL TRUTH TO MAKE LIFE 100%
A SMALL TRUTH TO MAKE LIFE 100%
A SMALL TRUTH TO MAKE LIFE 100% Hard work H+A+R+D+W+O+R+K 8+1+18+4+23+15+18+11 = 98% Knowledge K+N+O+W+L+E+D+G+E 11+14+15+23+12+5+4+7+5 = 96%
A SMALL TRUTH TO MAKE LIFE 100% Love L+O+V+E 12+15+22+5 = 54% Luck L+U+C+K 12+21+3+11 = 47% (don't most of us think this is the most important? ? ? )
A SMALL TRUTH TO MAKE LIFE 100% Then what makes 100%? Is it Money? Money. . . NO!!!!! M+O+N+E+Y = 13+15+14+5+25 = 72% Leadership? Leadership. . . NO!!!! L+E+A+D+E+R+S+H+I+P = 12+5+1+4+5+18+19+9+16 = 89%
A SMALL TRUTH TO MAKE LIFE 100% Could the answer be SAFETY? SAFETY. . . NO!!!! S+A+F+E+T+Y = 12+5+1+4+5+18+19+9+16 = 76%
A SMALL TRUTH TO MAKE LIFE 100% Every problem has a solution. Let’s look a little further for the solution to achieving that 100%. One thing we haven’t explored yet is ATTITUDE.
A SMALL TRUTH TO MAKE LIFE 100% ATTITUDE A+T+T+I+T+U+D+E 1+20+20+9+20+21+4+5 = 100% It is OUR ATTITUDE towards Life, Work, and Safety that makes OUR Life 100%
A SMALL TRUTH TO MAKE LIFE 100% QUALITY Q+U+A+L+I+T+Y 17+21+1+12+9+20+25 = 105% Quality includes Life, Work, Safety and ATTITUDE
A SMALL TRUTH TO MAKE LIFE 100% There are “NO EXCUSES” for a poor attitude regarding Life, Work, Safety and Quality
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