Transcript PSU Lockout/Tagout Training

Lockout/Tagout Training for
Authorized Employees
Murray State University
Objectives
• Clarify requirements of Lockout/Tagout
(LOTO) Program
• Ensure everyone is aware of their role
within LOTO Program
• Provide an opportunity to discuss
concerns related to LOTO Program
Training Outline
I.
II.
How Do Injuries Occur During Servicing?
What is LOTO?
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III.
IV.
V.
VI.
Types of hazardous energy
When should LOTO be applied
Energy isolation devices
LOTO Basics
General LOTO procedure at MSU
Special Situations
“Safe or Unsafe” Exercise
I. How Injuries Occur During the
Servicing of Equipment?
• BLS study on injuries while
servicing equipment revealed:
– 80% failed to turn off equipment
– 10% equipment activated by
someone else
– 5% failed to control potential
energy
– Most of remaining 5%
disconnected power but failed to
verify effectiveness
II. What is LOTO?
• “LOTO” is a technique used to prevent
energy from being released during the
servicing of equipment. This is
accomplished by placing locks on
energy isolation devices prior to starting
work.
Types of Hazardous Energy
• What types of hazardous energy are subject
to LOTO?
Types of Hazardous Energy
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Electrical
Pneumatic
Hydraulic
Mechanical
Thermal
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Chemical
Radiation
Steam
Spring-Driven
Suspended Parts
•Some energy sources can be turned on/off.
•Others can only be dissipated or controlled.
Potential Energy vs. Kinetic Energy
Potential energy can be converted to kinetic!
Goal of LOTO is to achieve “Zero Energy State”
When is LOTO applied?
“…during the servicing of equipment”.
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Adjusting
Inspecting
Modifying
Replacing parts
Tool changes
• Clearing jams
• Lubricating
• Cleaning
There are some situations where LOTO is not required…
Exceptions to LOTO
• Normal production operations
• Routine, repetitive, & integral to production
• Guards/safety devices not bypassed
• Body part not placed in the point of operation or
other dangerous area during machine cycle
• Need to use alternative measures for protection
• Cord & plug connected equipment
• Plug is only source of energy
• Plug is under continuous control of one person
Energy Isolation Devices
“…accomplished by placing locks on energy isolation devices…”
Device that physically prevents the
transmission or release of energy
Examples:
• Electrical disconnect
switch
• Electrical breaker switch
• Hydraulic valve
• Pneumatic valve
• Line valve
Pushbuttons, selector
switches, and other
control circuit devices are
NOT energy isolation
devices.
Review of LOTO Definition
• “LOTO” is a technique used to prevent
energy from being released during the
servicing of equipment. This is
accomplished by placing locks on
energy isolation devices prior to starting
work.
III. LOTO Basics
All employees fit into one of the following
LOTO roles:
“Authorized employee”
• Services equipment & authorized to apply
LOTO.
“Affected employee”
• Operates or uses equipment being serviced
under LOTO.
“Other employee”
• Works in an area where LOTO being used.
LOTO Basics
• Preferred means of
controlling hazardous
energy is LOCKOUT IN
CONJUNCTION WITH
TAGOUT.
• Each isolation point must
have both a lock and a tag
attached to it.
• Locks must be standardized
& used only for LOTO.
• Tags must indicate lock
holder & date of application.
IV. General MSU LOTO Procedure
STEP 1
ID Energy
Sources
STEP 2
Notify
Others
STEP 3
Shutdown
Equipment
STEP 4
Isolate
Equipment
STEP 5
LOTO
Equipment
STEP 6
Release Stored
Energy
STEP 7
Verify
Isolation
STEP 8
Perform
Servicing
STEP 9
Release
from LOTO
Step 1: ID All Energy Sources
• Know types & magnitude of energy
associated with equipment.
• ID all energy sources feeding the
equipment (including potential energy).
• Gather appropriate control devices.
• Clarify any questionable identification of
energy sources before proceeding.
Step 2: Notify Others
• Verbally notify all “affected” and “other”
employees of impending shutdown.
• Not all equipment will have someone
“assigned” to it.
Step 3: Shut Down Equipment
• Use normal stopping
procedures to shut
down equipment.
• Push “Stop” button,
open toggle switch,
etc.
Step 4: Isolate Equipment
• After shutdown, operate
all energy isolation
devices so equipment is
disconnected from
energy sources.
• Turn electrical
disconnect to “OFF”
position; open circuit
breaker; close valve,
etc.
Step 5: LOTO the Equipment
• Attach locks & devices to
each isolation point.
• Tag must accompany each
lock.
• Good idea to also tag point of
operation if located remotely
from isolation points.
• What if equipment won’t
accept a lock?
Step 6: Release Stored Energy
• Ensure all potential or
residual energy is
controlled.
 Block elevated parts.
 Block/release springs.
 Relieve system pressure.
 Drain fluids.
 Vent gases.
 Allow system to cool.
 Discharge capacitors.
 Stop rotating flywheels.
Step 7: Verify Isolation
• Before any servicing begins, verify
effectiveness of LOTO.
• Use normal starting procedure or
otherwise verify “Zero Energy State”.
• Return controls to “OFF” position after
testing.
• Verification is the step which is most
frequently skipped during evaluations.
Step 8: Perform Servicing
• Complete required service work.
• Avoid doing anything that could
potentially reactivate the equipment.
• OK to interrupt LOTO, but must be
reapplied if servicing is to continue.
Step 9: LOTO Release
• All locks, tags, & devices removed by
same person who applied.
• Remove all tools from equipment area.
• Replace all machine guards.
• Verbally inform all “affected” & “other”
employees that LOTO is complete.
• Ensure area is clear prior to restart.
V. Special Situations
• Group LOTO
– Each employee applies own locks/tags to each
isolation point.
– EHS must OK alternative procedures.
• Shift changes
– Oncoming employee attaches locks/tags prior to
outgoing employee removing theirs.
– EHS must OK alternative procedures.
• Lock removal procedure
– Supervisor must be notified if lock owner not
present.
Summary
• All hazardous energy sources must be controlled
(kinetic & potential).
• Control via energy isolation device (do not rely on
control circuit).
• Only use designated lock for LOTO.
• Tags must accompany all locks.
• Nine-step general procedure – remember to verify
isolation.
• Protection must be ensured during special situations.