Transcript Lockout Tagout

The Safe Isolation of
Machinery and Equipment
using Lockout Tagout
Tim Hughes
Total Lockout (Safety) Ltd
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Daryl Wake
Smart Staff International
I want to talk to you about worker safety!!
Every year, numerous Alcoa workers are injured so
badly that they miss a day of work. Our safety
record is better than the general workforce,
especially considering that our employees work
with metals that are 1500 degrees and we have
machines that can rip a man’s arm off. But it’s not
good enough. I intend to make Alcoa the safest
company in America. I intend to go for zero injuries
October 1987
Source: “Is this the best CEO speech ever..? Digicast.com.au , M. Claire-Ross,
Sept. 2012
Paul O’Neill – CEO, Alcoa
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Summary & Learning Objectives
• Anecdotal incidents of LOTO failure [prepare
to be shocked…]
• Legal requirements
• When & how to implement?
• Understanding the hardware
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Why should we be concerned about LOTO?
• HSE Statistics 2011/12
– 173 workers killed at work
– 111,000 injuries to employees under RIDDOR
• Mostly manual handling, slips and trips, falls from height.
However………
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Why is LOTOTO important
• Man dragged in to a wood chipper during
landscaping job!
– While attempting to clear a blockage with his feet, he
became entangled and was drawn into the machine.
• Prosecution: Lack of adequate training and risk awareness.
• Father of 3 pinned by a moving milk machine”
– While carrying out routine maintenance on a
container loading machine, it was somehow activated,
pinning him inside.
• Prosecution: Failure to isolate.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Three sub-contractors from a specialist engineering company undertaking
maintenance work were drenched in a liquid jet of caustic soda when repairing a
valve on a line running from a detergent tank. Up to 6,000 litres of the chemical
spilled out from the container. One worker was temporarily blinded and one of
his colleagues suffered 25 per cent burns left him with scars and continuing
sensitivity, making it difficult for him to tolerate heat. The third man suffered
minor skin burns and irritation to his eyes.
The men had not been given adequate instructions or appropriate personal
protective equipment. The company employing the men had not managed their
contractors properly or carried out suitable risk assessments for the work that they
had been asked to do.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
•
Two electricians suffered life-threatening injuries when they were engulfed by a
fireball at a factory as they were about to clean debris from a damaged fuse box.
One of the electricians is still undergoing treatment for his burns, nearly five years
on, and will never be able to return to work. There had been a fire in the fuse box
during the previous afternoon but live cables had been routed through it so that
the cooling equipment at the factory could continue to operate. This meant the
company avoided having to shut down the plant for 36 hours. A suitable risk
assessment had not been carried out for the work and management at the
company had allowed the work to go ahead without the electricity supply being
isolated, even though this went against their own work procedures.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
•
An employee lost an arm at a giant industrial auger as he was carrying out repairs.
He initially attempted a repair with the electrical power to the auger incorrectly
isolated and without completing the permits for work required by company policy.
The repair failed, so he attempted another repair the following day. However, both
he and his supervisor failed to check that the power had been isolated, in breach of
company procedures.
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When the supervisor accidentally activated the machine, his colleague's arm was
removed above the elbow. Although the facilities to correctly isolate the machines
were available, and the worker’s employer had trained its workforce in safety, it
failed to provide the injured man with initial training or any additional information
about the equipment he was working on or about company procedures. In
addition, the plant manager did not supervise work correctly, which meant
company permits to work were frequently not completed
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
•
Judge Slates engineering firm for shambolic safety....
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Engineering Firm fined £300k after investigation uncovers repeated failings that
put employees at risk of death for several years.
Isolation valve jammed while closing.
Maintenance worker crushed when stored energy caused the valve to suddenly
closed.
HSE Investigation reveals ineffective isolation procedure.
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Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
What is LO/TO/TO?
Control Measure
Risk Assessment
http://www.hse.gov.uk/pubns/indg163.pdf
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Permit to Work
In summary...
• A safe method to work on
machinery, equipment and other
energy sources.
• The placement of a lockout device
on an energy isolating device and
the equipment being controlled
cannot be operated until the
lockout device is removed.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
What energy sources present a risk?
Electrical
Mechanical
Hydraulic/Pneumatic
Flow i.e. liquid/gas
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Also consider…
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Kinetic energy - moving/spinning shafts, inertia
Springs
Chemicals and Acids
Asphyxiants
Radiation – X-Ray, ionizing, lasers, microwave, RF
Thermal – steam, cryogens
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Legal references
• Provision & User of Work Equipment
Regulations 1998 (PUWER)
• Electricity at Work Regulations 1989 (EAWR)
• BS7671:2008 17th Ed. Wiring Regulations
• Health & Safety at Work etc Act 1974
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
The employers role...
Provision & Use of Work Equipment Regulations (1998)
– Regulation 19 (1): Every employer shall ensure that where
appropriate work equipment is provided with suitable means
to isolate it from all its sources of energy.
– Regulation 19 (3) : Every employer shall take appropriate
measures to ensure that re-connection of any energy source
to work equipment does not expose any person using the
work equipment to any risk to his health or safety.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Legal references…cont’d
Provision & Use of Work Equipment Regulations (1998)
• 277: An isolating switch or valve may have to be
locked in the off or closed position to avoid an unsafe
reconnection.
Source: http://machinerysafety101.com
Source: Brady Corporation
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Legal references…cont’d
Provision & Use of Work Equipment Regulations (1998)
• 278: If work on isolated equipment is being done by more than one
person, it may be necessary to provide a locking device with multiple locks
and keys. Each will have their own lock or key, and all locks have to be
taken off before the isolating device can be removed. Keys should not be
passed to anyone other than the nominated personnel and should not be
interchanged between nominated people.
aka: Group Lockout
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Legal references…cont’d
The Electricity at Work Regulations (1989)
• Regulation 12 Para 188 – Suitable means of isolation
– (b) include, where necessary, means directed at preventing
unauthorised interference with or improper operation of the equipment,
for example means of locking off;
• Regulation 13 – Precautions for work on equipment made
dead: Adequate precautions shall be taken to prevent electrical
equipment, which has been made dead on order to prevent danger while
work is carried out on or near that equipment, from becoming electrically
charged during that work if danger may thereby arise.
– Para 195: Ideally a means of locking off an isolator can be used.
Where such facilities are not available, the removal of fuses or links
and their being held in safe keeping can provide a secure arrangement
if proper control procedures are used.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Fuse removal…
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Legal references…cont’d
BS7671:2008 17th Ed. Wiring Regulations
• Where an isolating device is located
remotely from the equipment it
serves, it is necessary, for
compliance with Regulation
537.2.1.5, for the device to be
provided with a means of securing it
in the open (OFF) position. This
can be achieved by, for example, a
locking arrangement on an MCB, a
locked distribution board with only
one key or with a removable key or
handle which is one of a kind.
Source: Master Lock Corporation
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Section 8: Health & Safety at Work etc. Act 1974
No person shall intentionally or recklessly interfere
with or misuse anything provided in the interests of
health, safety or welfare in pursuance of any of the
relevant statutory provisions.
OSHA GUIDELINES – The Control of Hazardous Energy
1940.147 (a) (1) (i)
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
When to Lockout/Tagout?
• There are two occasions for gaining access to
potentially hazardous machinery or processes.
– Unplanned access e.g. clearing a blockage
– Planned access e.g. scheduled maintenance or
repair.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
When to Lockout/Tagout?
Any interaction with a potential hazard, energy
source.
– Planned Access
– Unplanned Access
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Equipment
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Safety Padlock
Multi Hasp
Tag
Speciality Device
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
One padlock – one key
• Unique key number recorded against
end-user register.
• Key is trapped in the lock when
shackle is open.
• Key cannot be duplicated at highstreet key cutters.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Considerations for Effective Isolation Systems
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Sites should appoint a standout accountable
representative, supported by a steering
committee.
Define the responsibilities and
accountabilities of the persons performing
isolations.
Establish the training and competency
requirements for permit issuers, permit
holders and persons performing isolations.
Ensure hazards associated with the planned
activity are identified, appropriate
mitigations documented and the work is
authorised by a responsible person.
Define isolation design criteria and process.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
Considerations for Effective Isolation Systems
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Define the controls which apply to personnel
accessing machinery that may start and stop
automatically or by instruction from a remote
location.
Control and approve any software overrides, hardwire bridging or interlock bypassing.
Control isolations which span one or more shift
handovers.
Identify any points of isolation and provide
personnel performing the work with unique,
secure, control of the point of isolation.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
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Define how a competent person in ensuring safe
isolation is achieved before commencing work.
Determine the actions required if there is any doubt
safe isolation was achieved.
Manage isolations for interacting and/or
simultaneous activities and where there is potential
for multiple sources of energy (e.g. work on electrical
ring feed systems).
Develop systems to manage the isolation of HSE
critical systems.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
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Manage changes which may affect the scope of
the permit-to-work and/or the isolation
standard(s) required, including changes to planned
tasks and the action to be taken by the permitholder in response to an emergency.
Verify isolated equipment/plant is returned to a
safe operating condition before it is brought back
into service.
Scheduled auditing/reviewing of the system,
regularly analysing audit findings.
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
Systematic Steps for Successful LOTO
1)
2)
3)
4)
5)
6)
Prepare and notify
Shutdown
Isolate
Apply lockout devices
Release stored energy
Verification
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
LOTO Equipment – Padlocks
Padlocks should:
• Be keyed to suit business needs, consider:
o Personal – Uniquely keyed / Keyed to differ
o Keyed alike – Used for multiple isolations
• Not be combination locks.
• Not have an unauthorised second-party master
override key.
• Be kept under the exclusive control of the owning
individual, and key (s) shall not be transferred to
another person for lock removal
Other considerations:
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Corrosion
Non-conductive
UV
Length of shank
Colour
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
LOTO Equipment – Padlocks
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
Hardware Considerations - Tags
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
Hardware Options Permit Control Boards
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
Electronic PTW / LOTO Systems - Options
SAGE - ‘Suprpass’
PetroTechnics – ‘ISSoW’
CGE – ‘Permit Board’
ApplyIt – ‘IntelliPermit’
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
"Creating Practical Workplace Systems"
Video clips…
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Spoiler Alert
No animals were harmed in the making of
this film !!!
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
How to avoid the accident
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
But the dangers are real…….
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com
Thank you for watching….
www.totallockout.com
www.smartstaffinternational.com
@totallockout
@wakedj
http://www.linkedin.com/company/total-lockout-safety-ltd
Copyright © 2013: Total Lockout (Safety) Ltd, Braintree, Essex, CM7 2YW – Website: www.totallockout.com