Lockout Tagout Training Module 30jan2018 3b3za

Lockout-Tagout Training Program  2006 RiskAnalytics, LLC

 2006 RiskAnalytics,Page LLC

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Disclaimer The information, suggestions and recommendations contained herein are for general informational purposes only. This information has been compiled from sources believed to be reliable. No warranty, guarantee, or representation, either expressed or implied, is made as to the correctness or sufficiency of any representation contained herein. Reliance upon, or compliance with, any of the information, suggestions or recommendations contained herein in no way guarantees the fulfillment of your obligations under your insurance policy or as may otherwise be required by any laws, rules or regulations. This Information should not be construed as business, risk management or legal advice, or legal opinion.

 2006 RiskAnalytics, LLC

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Learning Objectives  

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Understand the purpose of the energy control program Recognition of applicable hazardous energy sources, and the methods necessary for energy control Discuss the primary causes of injury from hazardous energy Understand the steps necessary to properly control hazardous energy when servicing equipment Know the responsibilities of Authorized and Affected employee in of / tagout

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Introduction 

Workers servicing machinery and equipment are exposed to injuries from the unexpected energization, startup of the machinery or equipment, or release of stored energy in the equipment  

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Most injuries and fatalities are a result of improper hazardous energy control procedures  A Bureau of Labor Statistics study on injuries suffered when servicing equipment showed    

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120 fatalities and 50,000 injuries each year Workers injured from exposure to hazardous energy lose an average of 24 work days for recovery

80% failed to turn off equipment 10% equipment activated by someone else 5% failed to control potential energy Remaining 5% failed to effectiveness Page 4

The “Fatal Five” 

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Main Causes of Lockout/Tagout Injuries: 1.

Failure to stop equipment before servicing

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Failure to disconnect equipment from power source

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Failure to dissipate (bleed, neutralize) residual energy

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Accidental restarting of equipment

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Failure to clear work areas before restarting

All injuries resulting from inadequate hazardous energy control procedures can be prevented

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Types of Hazardous Energy 

Mechanical – the potential energy and kinetic energy present in the components of a mechanical system 

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Electrical – energy as a result of a generated electrical power source or a static source 

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Common injuries: shock, burns, and electrocution

Thermal – energy as a result of mechanical work, radiation, chemical reaction or electrical resistance 

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Kinetic – energy possessed by virtue of its motion • Common injuries: fracture, contusion, laceration, and amputation Potential – energy stored by the mechanical system • Common injuries: fracture, contusion, laceration, and amputation

Common injuries: burns

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Types of Hazardous Energy, continued 

Chemical -- energy released as a result of chemical reactions 

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Hydraulic – energy released as a result liquids under pressure 

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Common injuries: and contusions

Pneumatic – energy released as a result of compressed gasses under pressure 

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Common injuries: burns

Common injuries: burns and contusions

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What is Lockout-Tagout? 

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Lockout-Tagout is a hazard avoidance technique used to prevent energy from being accidentally released during the servicing of equipment The Lockout-Tagout standard requires the adoption and implementation of written practices and procedures to:   

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Shut down equipment Isolate it from its energy source or sources Prevent the release of potentially hazardous energy while maintenance and servicing activities are being performed

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Energy Control Program – 3 Core Components

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Energy control procedures that detail the scope, purpose, authorization rules and techniques to be utilized for the control of hazardous energy

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Periodic inspections of the energy control procedures to ensure that the procedures and the requirements are being followed

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Employee training and ongoing retraining to ensure that the energy control programs are understood

Written Procedures

Inspections

Training

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Lockout-Tagout Procedures are Required IF… 

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A worker must remove or by machine guards or other safety devices, or A worker is required to place any part of their body into a point of operation or into the danger zone associated with the machine's operation Examples of activities where proper Lockout-Tagout procedures would be required include    

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Installing Lubricating Cleaning and un-jamming machines or equipment, and Making adjustments or tool changes

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Definition of Players

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Authorized employee: An employee who locks or tags machines or equipment in order to perform servicing or maintenance

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Affected employee: An employee who is required to use machines or equipment on which servicing is performed under the Lockout/Tagout standard or who performs other job responsibilities in an area where such servicing is performed

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Other employees: All employees who are or may be in an area where energy control procedures may be utilized

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Responsibilities of Authorized Employees    

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Identify all energy sources Notify all affected employees in the area of work Shut down the equipment at the operating controls Isolate all energy sources to equipment Lock and tag all isolating devices Dissipate all stored or residual energy sources. the isolation Remove lock and tag when repair and testing are complete Notify all affected employees that lock and tag were removed

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Responsibilities of Affected Employees    

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Never interfere or tamper with a lock or tag Stay clear of the area as much as possible Never attempt to assist Report any unusual situation or unsafe condition to your supervisor

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Energy Isolation Devices A mechanical device that physically prevents the transmission or release of energy such as…  

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Circuit breakers; Disconnect switches Line valves Slide gates Blind flanges

NOTE: Push buttons, selector switches and other control circuit type devices are not energy isolating devices

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Types of Lockout Devices      

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Keyed and combination locks Ball valve locks Gate valve locks Group lockout hasp Circuit breaker locks Valve hand wheel cover

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Lockout Device Requirements Devices Must... 

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Be capable of withstanding the environment to which they are exposed Be singularly identified Be the only devices used for controlling energy Not be used for other purposes Be standardized within the facility in of color, shape, or size. Indicate the identity of the employee applying the devices Prevent removal without the use of excessive force or unusual techniques

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Tagout Requirements Tagout must be… 

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Be capable of withstanding the environment to which they are exposed Able to withstand corrosive environments such as areas where acid and alkali chemicals are handled and stored Standardized in print and format Substantial in order to prevent inadvertent or accidental removal Able to be attachable by hand, self-locking, and non-releasable with a minimum unlocking strength of no less than 50 pounds Inclusive of a legend such as: Do Not Start, Do Not Open, Do Not Close, Do Not Energize, Do Not Operate. Page 17

Lockout vs. Tagout 

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If an energy-isolating device is capable of being locked out, a lock out system must be used If an energy-isolating device is not capable of being locked out tagout may be used, provided training and more rigorous periodic inspections are implemented

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General Energy Control Procedures Step 1 Identify Energy Sources

Step 4 Isolate Equipment

Step 7 Isolation

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Step 2 Notify Others

Step 3 Shut Down Equipment

Equipment

Step 6 Release Stored Energy

Step 8 Service Equipment

Step 9 Release From LOTO

Step 5 Lockout-Tagout

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General Energy Control Procedures Step 1: Identify Energy Sources 

Understand the types and magnitude of the specific energy associated with equipment being serviced  

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Hazards of energy being controlled Method or means to control the energy

Identify all energy sources feeding the equipment including potential energy Identify and obtain the appropriate control devices Clarify any questionable identification of energy sources before proceeding

Step 1 Identify Energy Sources Page 20

General Energy Control Procedures Step 2: Notify Others 

Verbally notify all “affected” and “other” employees of impending shutdown

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that not all equipment will have someone “assigned” to it

Step 2 Notify Others  2006 RiskAnalytics, LLC

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General Energy Control Procedures Step 3: Shut Down Equipment 

Use standard equipment operating procedures to shut down equipment   

Push “Stop” button Open Toggle switches Close valve

Step 3 Shut Down Equipment  2006 RiskAnalytics, LLC

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General Energy Control Procedures Step 4: Isolate Equipment Energy Sources 

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Operate all energy-isolating devices so that the equipment is isolated from its energy sources Be sure to isolate ALL energy sources!  

Primary supplies Any secondary energy sources

Step 4 Isolate Equipment  2006 RiskAnalytics, LLC

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General Energy Control Procedures Step 5: Lockout – Tagout the Equipment 

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Locks or tags must be applied to each device Must be applied by an Authorized employee Locks must be affixed in a manner that will hold the energy isolating devices in a "safe" or "off" position Tags must be affixed in a manner that will clearly indicate that the operation or movement of energy isolating devices is prohibited Step 5 Lockout-Tagout

Equipment  2006 RiskAnalytics, LLC

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General Energy Control Procedures Step 6: Release Stored Energy 

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Ensure all potential or residual energy is controlled Block or brace springs and any elevated parts that could fall due to gravity Relieve trapped system pressure Bleed lines and vent valves to drain fluids and gasses Discharge capacitors If stored energy can re-accumulate, monitor it to make sure it stays below hazardous levels

Step 6 Release Stored Energy Page 25

General Energy Control Procedures Step 7: Isolation 

Before work begins, an authorized employee must that the machine has been properly isolated and de-energized

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Make sure all danger areas are clear of personnel

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that the main disconnect switch or circuit breaker can’t be moved to the on position.

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Use normal starting procedure or otherwise the system is completely deenergized

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Return controls to “OFF” position after testing

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Verification is the step which is most frequently skipped during evaluations

Step 7 Isolation

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General Energy Control Procedures Step 8: Service Equipment 

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Complete required service work according to manufacturer’s recommendations Avoid doing anything that could potentially reactivate the equipment Do not by the lockout if installing new piping or wiring

Step 8 Service Equipment  2006 RiskAnalytics, LLC

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General Energy Control Procedures Step 9: Release From Lockout-Tagout 

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Inspect work area to ensure that all tools and spare parts have been removed and that all of the equipment components are operationally intact Replace all machine guards Ensure that all employees have been safely positioned or have cleared the area. Each / tagout device must be removed from the energy-isolating device by the employee who applied the device. Notify “affected” and “other” employees that the / tagout devices have been removed before the equipment is started

Step 9 Release From LOTO Page 28

General Energy Control Procedures Special Circumstances For Release - Testing 

Lockout-tagout devices may be removed temporarily to test and /or reposition the equipment under the following procedures: 

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The equipment must be cleared of tools and materials Employees must be removed from the machine or equipment area All / tagout devices may then be removed Authorized employees may then energize and test or position the equipment

Following testing or positioning, all systems must be de-energized and energy control measures reapplied

Special Circumstances For Release Page 29

General Energy Control Procedures Special Circumstances For Release – Shift Change

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If servicing lasts more than one shift, lockout/tagout protection must not be interrupted

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When the authorized employee who applied the LOTO device is not available to remove it, the device can only in an emergency and only under the direction of the supervisor  Must the authorized employee is not in the facility  Must make all reasonable efforts to employee who applied the device  Must insure that the authorized employee knows the LOTO device has been removed

Special Circumstances For Release Page 30

General Energy Control Procedures Special Circumstances – Group Lockout-Tagout 

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Group / tagout must afford protection for each employee equivalent to that provided by a personal lockout or tagout device Each authorized employee must affix a personal / tagout when work begins and remove it when work is completed Group must designate a single authorized employee to serve as overall supervisor

Special Circumstances  2006 RiskAnalytics, LLC

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Summary 

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 2006 RiskAnalytics, LLC

Lockout-Tagout prevents energy from accidentally being released while a machine or equipment is being serviced There are 6 types of hazardous energy common to most work environments – Mechanical, Electrical, Thermal, Chemical, Hydraulic and Pneumatic Most injuries and fatalities are a result of improper hazardous energy control procedures If an energy-isolating device is capable of being locked out, a lock out system MUST be used General energy control procedures follow a 9-step process Only the authorized employee may attach and remove the / tagout device Affected employees or any other employees should NEVER remove or tamper with a / tagout device Page 32