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LOCKOUT/TAGOUT Hazardous Energy Control

Welcome!

Objectives

• Gain a greater awareness of the requirements detailed in Oregon Administrative Rules. • Understand the importance of a hazardous control plan.

• Discuss energy control procedures, training, and periodic inspection criteria.

Part I: Scope and Application

29 CFR 1910.147

The Control of Hazardous Energy (Lockout/Tagout)

(c)(1)

Energy Control Program.

The employer shall establish a program consisting of

energy control procedures

employee training

and

periodic inspections

to ensure that before any employee performs any

servicing or maintenance

on a machine or equipment where the

unexpected

energizing, start up or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from the energy source, and rendered inoperative.

What are the three key elements of an energy control program?

Procedures Training Inspections

Scope: The lockout/tagout rule covers the following employees: Authorized Affected Other

Affected Employee

Authorized Employee

Other Employee

Person who services or performs maintenance on machines or equipment. Person who operates or uses a machine or equipment which is being serviced or has maintenance being performed.

Person who works in an area where lockout/tagout procedures are being used.

Procedures must be followed when...

...servicing and/or maintenance when unexpected energization, start-up or release of stored energy could cause injury.

What is servicing or maintenance?

Some workplace activities considered to be

“Servicing and/or maintenance”

of machinery and equipment” include: Adjusting... inspecting... modifying... constructing... re-tooling...

lubricating... removing jams... cleaning...

Sources of Energy

List as many sources of energy as possible that could cause injury

Pneumatic Hydraulic Mechanical Kinetic Thermal Radiation Nuclear Electrical

This standard does not apply to:

•

Installations under the control of electric utilities.

•

Exposure to electrical hazards from work on, near, or with conductors or equipment in electric utilization installations.

•

Oil and gas well drilling and servicing.

•

Normal production operations…unless: Guards, or other devices are removed/bypassed; or Employees place themselves in an area where work on materials, etc., is actually being performed; or Employees place themselves in any area considered dangerous during the normal operating cycle.

•

Work on cord and plug connected equipment.

•

Hot tap operations, under special conditions.

Part 2: The Written Energy Control Plan A written Energy Control Plan must include the scope, purpose, authorization, rules, and techniques used to control hazardous energy, and the means to enforce compliance, including: 1. A specific statement of intent to use the procedures; 2. Specific procedures to shut down, isolate, block and secure machines or equipment; 3. Specific procedures to place, remove and transfer lockout/tagout devices; 4. Assigning responsibility for lockout/tagout devices; 5. Requirements and procedures to test machines and machinery to determine and verify effective lockout/tagout devices, and other energy control measures.

Why is a comprehensive written plan critical to a successful lockout/tagout program?

It holds people accountable!

It establishes a “boiler plate”.

It allows for effective procedures.

It ensures training will be conducted.

It ensures the periodic inspections will be conducted.

What are some reasons a lockout/tagout program may not work effectively?

People may not respect it. Leadership may be lacking.

Accountability may not be clearly established.

Training may not be effective and/or monitored.

Supervisors may be leading by wrong example.

Who’s responsible….who’s accountable….and for what?

Steps to developing a successful program

1. List all equipment or machines that need servicing or maintenance.

2. Identify those machines which could unexpectedly start up or release stored energy while being serviced or maintained.

3. Determine the steps in the maintenance or servicing task; and 4. Review each step for the potential of a hazard from all energy sources.

Part III: Lockout/Tagout Procedures

Step 1 - Prepare for Lockout

As a minimum the following information should be reviewed:

•

Types and magnitudes of energy;

•

Hazards posed by that energy; and

•

Methods to effectively control the energy.

Particularly close attention must be given to energies (such as gravity, electrical, high pressure) that can be stored or re-accumulated after shut-down.

Prior to shutdown all affected employees will be notified to clear their work area and/or any other area that might be hazardous.

What means or methods can be used to ensure the above review and notification is conducted prior to lockout/tagout?

Step 2 - Shutdown

•

Machinery and equipment that is capable of being locked out should be shut down in an orderly manner using shutdown checklist procedures.

•

If more than one authorized employee is involved in shutdown, the maintenance team leader should make sure all assistants have accomplished their tasks and are aware that shutdown will occur.

Step 3 - Isolation

All energy isolation devices should be located and operated to completely de-energize and isolate the equipment. The authorized employee will verify operation of each energy isolation device. An

“ energy isolating device

” physically prevents… ...the transmission or release of energy.

What are some examples of energy isolation devices?

T/F Pushbuttons, selector switches and other control

circuit type devices are energy isolating devices.

Step 4 - Lockout/Tagout Application

Lockout Devices

•

Lockout devices must be used to secure energy isolating devices unless the machinery or equipment is not capable of being locked out.

•

Only authorized employees will affix lockout/tagout devices.

•

Lockout devices must be able to hold energy isolation devices in a “safe” or “off” position.

Tagout Devices

•

Tagout devices will be used only if machinery or equipment is not capable of being locked out.

•

Only authorized employees can affex tagout devices.

•

Tags will clearly state that moving energy isolating devices from the “safe” or “off” position is strictly prohibited.

•

If a tag cannot be affixed to the energy isolating device, it will be located as close as safely possible to the device so that the tag is obvious to anyone attempting to operate the device.

Which is the pereferred method:

Lockout or Tagout?

Machinery or equipment is “ capable of being locked out ” if:

•

It has a hasp or other means to attach a lock; or

•

It has a built in locking mechanism

•

Does not have to be dismantled or altered to achieve lockout.

When can an employer use a tagout system?

1. When an energy isolating device is not capable of being “locked out”.

2. If employer can demonstrate (prove) that using a tagout system will provide full employee protection.

What two tests must be met to demonstrate full employee protection?

1. Tags can be placed where lockout devices would have been placed. 2. The employer demonstrates equivalent protection can be obtained with tags.

How?

Opening an extra disconnect Removing a valve handle Removing a circuit or fuse Blocking a ram etc…….

More on Protective Hardware…..

Materials and hardware must be provided by the employer. Each lockout/tagout device must be singularly identified as being used only for lockout/tagout.

Lockout/tagout devices must be standardized and substantial.

They must identify the user Lockout devices must be substantial enough to prevent removal without excessive force or unusual techniques.

Tagout devices must be substantial enough to prevent inadvertent or accidental removal. They must be

•

Non-reusable

•

Attachable by hand

•

Self-locking

•

Non-releasable with not less than 50 lb locking strength

•

Design/characteristics at least equivalent to a one piece, all environment-tolerant nylon cable tie.

What are some examples of lockout devices?

Padlocks C/B lockouts Gate valve lockouts Fuse lockouts Lockout hasps Wall switch lockouts Ball valve lockouts Plug lockouts

Step 4 - Lockout/Tagout Application Before applying and after removing lockout/tagout devices, the authorized employee… ...must notify all affected employees.

A “

tagout device

” is a prominent warning device, such as a tag and a means of attachment, which 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...

... may not be operated until the tagout device is removed.

Step 4 - Lockout/Tagout Application T/F All newly installed machines or equipment must have energy isolating

devices capable of accepting a lockout device.

T/F If you replace, major repair, renovate or modify a machine or piece of

equipment it must have an energy isolating device capable of accepting a lockout device.

Step 5 - Stored Energy

•

Stored Energy.

rendered safe. Immediately after applying lockout or tagout devices, the authorized employee will ensure all potentially hazardous stored or residual energy is relieved, disconnected, restrained, and otherwise

What are some examples of stored or residual energy?

•

Remember!

If stored energy can be re-accumulated to a hazardous level, authorized employees must continually verify that the machinery or equipment is safely isolated until the possibility of re-accumulated energy no longer exists.

Step 6 - Verify!!!!!

•

Verification of Isolation.

energized . Before starting work on a machine or equipment that is locked or tagged out, the authorized employee will verify that the machinery or equipment is actually isolated and de-

How do you verify that a machine or equipment is actually isolated or deenergized?

Release from Lockout/Tagout

Equipment

•

Make sure machinery or equipment is properly reassembled.

•

Inspect machinery or equipment to make sure nonessential items have been removed.

Employees

•

Make sure all employees are safely positioned outside danger zones.

•

Notify affected employees that lockout/tagout devices have been removed and that energy is going to be reapplied.

Release from Lockout/Tagout

Removing lockout/tagout devices

•

Only the authorized employee who applied the lockout/tagout device may remove that device. Exception - The employer can remove the lockout device provided that specific procedures and training for such removal have been developed, documented, and incorporated in the employer’s energy control program.

At a minimum, the following procedures must be in writing: Verification by the employer that the authorized employee who applied the device is not at the facility; All reasonable efforts to contact the authorized employee to inform him/her that his/her lockout device has been removed; Ensure that the authorized employee has this knowledge before resuming work at the facility.

Quick Review Who does the authorized employee notify prior to removing any lockout/tagout devices?

T/F The authorized employee also notifies the affected employee

after lockout/Tagout devices have been removed and before equipment has been started.

If the authorized employee is not available, who is authorized to remove the lockout or tagout device?

Additional Requirements

•

Testing/Positioning Machines or Equipment.

Whenever lockout/tagout devices are removed to test or position machines and equipment, or their components, the authorized employee must complete full shutdown, isolation, and release from shutdown procedures.

T/F Modified/shortened procedures may be used to isolate and startup equipment when testing? Why are employees injured so frequently while testing the machinery or equipment during maintenance?

Outside Personnel

•

Outside servicing personnel, contracted to perform maintenance or other services requiring lockout/tagout procedures, must not begin work until the maintenance supervisor is satisfied that their lockout/tagout procedures are at least equivalent to company procedures.

•

The employer must also ensure company employees understand and comply with contracted personnel lockout/tagout procedures, is used.

Who is responsible if an employee is injured because an outside contractor did not follow proper lockout/tagout procedures?

Shift/Personnel Changes

•

Written procedures must be developed to address lockout/tagout procedures during a shift change.

What is the intent or purpose of the procedures above?

Shift/Personnel Changes

•

Written procedures must be developed to address lockout/tagout procedures during a shift change.

What is the intent or purpose of the procedures above?

Ensure the continuity of protection!

Part IV: Lockout/Tagout Training

General Requirements

•

Training in lockout/tagout must be provided to all employees who may be in an area where energy control procedures are used.

•

This training will make sure that the purpose and function of the energy control program are understood and that employees gain the needed knowledge and skills to safely apply, use, and remove energy controls

Minimum training will include: Authorized employees must be able to recognize hazardous energy sources, types and magnitudes of energy in the workplace, and methods and means necessary to isolate and control the energy.

Affected employees must be able to recognize the purpose and use of energy control procedures .

Other employees must be able to recognize procedures and prohibitions of the energy control program

What are effective training strategies for each level of training?

Training on Tagout Devices If tagout devices are used, further training on tagout systems need to emphasize that: a. Tags are warning devices only and do not provide a physical restraint that lockout devices provide. b. Tags must not be removed without the authorized employee’s approval, and should never be bypassed, ignored, or otherwise defeated. c. Tags must be legible, and understandable by all employees. d. Tags must be able to withstand environmental conditions in the workplace. e. Tags may give employees a false sense of security.

F. Tags must be securely attached to prevent being accidentally detached during use.

Retraining Employees will participate in retraining at the following times: 1. Change in job assignment.

2. Change in machinery or equipment, or 3. Change in operating procedures, or 4. You note deficiencies in their understanding or performance!

Part IV: Lockout/Tagout Annual Inspections Annual inspections on lockout/tagout procedures must be conducted by an authorized employee other than the one(s) using the energy control procedure being inspected. The purpose of the inspection is to correct any deviations or inadequacies in the procedures.

Are ALL the energy sources deenergized?

Is this level of protection adequate?

Do all authorized employees know their responsibilities?

The inspector and authorized employee(s) will review responsibilities under the energy control procedure.

Part IV: Lockout/Tagout Annual Inspections The employer must certify that the inspection was conducted. Elements of the certification should include: a. Identification of equipment or machinery b. Date of inspection c. Employees included in the inspection d. Person performing inspection

How often must lockout/tagout inspections occur? Who must conduct the inspection?

If any of the conditions below exist, the employer must write procedures: The machine or equipment has potential for stored or residual energy, or reaccumulation of stored energy after shutdown which could endanger employees; or The machine or equipment has more than a single energy source; or The isolation and locking out of any single energy source will not completely de-energize and deactivate the machine or equipment; or The lockout device is not under exclusive control of an authorized employee performing the servicing or maintenance; or The servicing or maintenance of the machinery or equipment creates hazards for other employees; or The employer has had accidents involving the unexpected activation or re energizing of the machine or equipment during servicing or maintenance.