LOCKOUT/TAGOUT PROGRAM

Transcription

1 LOCKOUT/TAGOUT PROGRAM PURPOSE The purpose of this program is to prevent the unexpected energization or start-up of machines and equipment, or the release of stored energy, in order to prevent workplace injuries, amputations, fatalities, and property damage, during construction, service, and maintenance activities. This program is for all work activities by Winger Companies, herein referred to as Winger, employees requiring implementation of Lockout/Tagout (LOTO) procedures. WHY LOCKOUT/TAGOUT IS NECESSARY If a lockout is not performed correctly, uncontrolled energies could cause: Electrocution from: contact with live circuits, energy stored in batteries and capacitors Cuts, bruises, crushing, amputations, death, resulting from: entanglement with belts, chains, conveyors, rollers, shafts, impellers, springs, raised dies, lifts or any equipment that could slide, fall, or roll Entrapment by bulk materials from bins, silos, or hoppers Drowning in liquids in vessels or tanks Burns: contact with hot parts, materials, steam, oil, or equipment such as furnaces and boilers Fires and explosions Steam, Air, and hydraulic lines are den-energized by bleeding, draining, and cleaning out so that no pressure remains in lines or reservoir tanks. Pipes that could carry air, steam, chemicals, oil, gasses, or other hazardous substances must be blinded to ensure no substance will pass through that point if the system is accidentally activated Injuries from hazards requiring personal protective equipment (PPE) when exposed to chemicals, oil, heat, steam, sharp surfaces, etc. Incidents and injuries from others performing work in areas above, below or nearby Often power sources are inadvertently turned on, or valves opened mistakenly before the work is completed, resulting in serious injuries, fatalities and property damage. It is important to not only ensure all power sources are properly locked out, but also that they remain locked out until the work is completed. WHEN LOCKOUT/TAGOUT IS REQUIRED A Lockout/Tagout Program is established to provide a systematic method for preventing injury or death to personnel during maintenance, servicing and cleaning activities by disabling machinery or equipment to prevent the unexpected release of potentially hazardous energy. Lockout/Tagout is required: Whenever an employee is required to remove or bypass a guard or other safety device Revised August 2018 Page 1 of 14

2 Whenever an employee is required to place any part of his or her body into an area on a machine or piece of equipment where work is actually performed or where an associated danger zone exists Before adjusting or changing equipment parts or accessories Before disconnecting electrical power Before opening piping systems WHAT IS THE EXCEPTION? Lockout/Tagout regulations do not apply to: Minor tool changes Cord and plug connected equipment Hot tap operations provided that the employer demonstrates the following: o Continuity of service is essential; o Shutdown of the system is impractical; o Documented procedures are followed, and special equipment is used which will provide effective protection for employees. EXAMPLES OF ENERGY CONTROL HAZARDS Three men were doing maintenance inside an asphalt pug mill type mixer. One employee was still inside the mixer when the power was turned back on, thereby starting the mixer. He was killed instantly. Cause: failure to disconnect power source and lock out. A cotton gin operator climbed into a jammed cotton cleaner/separator. The toggle switch controlling the operation of the gin was turned off but not locked out. For some reason, someone accidentally turned the machine back on, not knowing the gin operator was inside the gin. The operator s left leg was pulled through the feed rollers. Cause: failure to disconnect power source and lock out. A warehouse man was repairing an air-operated valve which he had turned off but not disconnected and locked out. During the repair operation he slipped and inadvertently turned on the switch which let air into the valve. His hand was caught and crushed in the valve. Cause: failure to disconnect power source and lock out. A maintenance employee was changing V-belts on an exhaust fan. He de-energized the fan before starting work. However, he did not block the blades of the fan. The suction in the duct work turned the fan blades, and his hand was caught in the V-belt drive. Cause: failure to block out potential energy sources. A grain elevator employee got one arm caught in the conveyor belt he was working on and then had the second arm pulled in as he tried to free himself. It took paramedics 20 minutes just to get him disengaged. Cause: failure to disconnect power source and lock out. TYPES OF HAZARDOUS ENERGY INCLUDE: 1. ELECTRICAL: Servicing equipment often exposes employees to normally guarded electrical wires and components. Make sure all power is off and Revised August 2018 Page 2 of 14

3 locked out. Types of electrical sources are power transmission lines, machine power cords, motors, solenoids, stored electrical energy in capacitors, etc. Electrical circuits must be checked by qualified workers with proper and calibrated electrical testing equipment to ensure equipment could not become energized with the switch in the off position. 2. MECHANICAL: Types of mechanical energy include: Kinetic - energy in motion. Energy of moving machinery can cause lacerations, fractures, loss of life, or amputations. Potential - stored energy. Machines in motion can cause injury or death. Stop all equipment before repairs or adjustments. Be aware of energy stored in machinery, weights and springs, pistons under pressure and hydraulic controls. Lockout all sources of energy. Gravitational - what goes up, must come down. During maintenance ensure all parts that can fall or move are physically blocked from moving. Examples would be brake cylinders, actuators, counterweights, raised loads, flywheels, materials in supply lines of bins or silos, conveyors, etc. 3. PNEUMATIC: Uncontrolled release can cause injury. Rapid depressurization creates extreme low temperature. Properly vent all systems before starting work. Pneumatic systems are air lines, pressure reservoirs, accumulators, air surge tanks, rams, cylinders, etc. 4. HYDRAULIC: Energy of liquids under pressure can cause equipment to move, rapid release can cause injury or ejection of system parts. Relieve pressure slowly into a proper container. Examples are hydraulic presses, rams, cylinders, hammers, etc. 5. THERMAL: Extreme heat or cold can burn or freeze your skin. Hot equipment and fluids will burn you. Quick release of compressed gases can freeze your skin. Ensure all heat sources are blocked and allow equipment to reach a safe temperature before servicing. Revised August 2018 Page 3 of 14

4 6. CHEMICAL: Energy created by a chemical reaction between two or more substances. Acids, bases and other chemicals release energy when they react with your skin or other materials. Chemicals have energy that can start fires, cause skin burns and generate harmful gases or fumes. Before working release, drain or vent all fluid lines in a controlled manner. EMPLOYEE ROLES 1. All equipment shall be locked out and tagged out to protect against accidental or inadvertent startup or operation when such equipment is being serviced, inspected or repaired. 2. Authorized Employee A person who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment. Authorized employees must: Recognize hazardous energy sources and their type and amount of energy; Isolate and control energy to prevent accidents; Perform OSHA s specific, required lockout/tagout steps. 3. Affected Employee An employee whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed. An affected employee becomes an authorized employee when that employee s duties include performing servicing or maintenance covered under this section. Shall be instructed why the lockout/tagout is important and how it works; The importance of not trying to remove or work around locks or tags. 4. Other Employees Shall understand the basic principles of lockout/tagout. Shall be instructed about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out. Whenever outside servicing personnel are to be engaged in activities requiring lockout/tagout, the on-site employer and the outside employer shall inform each other of their respective lockout/tagout procedures. The on-site employer shall ensure that his/her employees understand and comply with the restrictions and prohibitions of the outside employer's energy control program. WINGER LOCKOUT DEVICES & TAGS All equipment shall be locked out and tagged out to protect against accidental or inadvertent start-up or operation when such equipment is being serviced, inspected or repaired. Revised August 2018 Page 4 of 14

5 Each person assigned to work on machines or equipment requiring lockout shall place a personnel lockout/tagout padlock on the energy-isolating device(s). When an energy-isolating device cannot accept multiple padlocks or tags, a multiple lockout hasp or lock box shall be used. If an energy-isolating device is capable of being locked out, it must be locked out. Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, breaker clips, plug buckets, blank flanges, threaded pipe caps or plugs, expansion plugs, pancake flanges, handwheel caps, lever locks or other hardware shall be used for isolating, securing or blocking of machines or equipment from energy sources. Winger issued personal lockout locks will be red in color. Winger employees may be required to use different colored locks depending on customer requirements. Equipment locks will be Master Red locks with 2 shank. Use only use the personal lockout/tagout padlock and tags issued to you. DO NOT use another person s padlock. DO NOT use a customer s lockout/tagout padlock. DO NOT attach your lockout/tagout padlock on the last hole of the Group Lock Box or scissor multi-lock hasp. Instead, use another scissor multi-lock hasp to attach your padlock to. It is important that you do not use the last slot as someone behind you may need to lock out also. DO NOT use red locks and tags for any other purpose other than lockout/tagout such as toolboxes, lockers, job boxes, conex boxes, etc. DO NOT remove another person s lock unless proper procedures have been followed such as the Winger Lockout Removal Form. Employees must control their keys at all times. DO NOT leave the key inside the padlock. ALWAYS keep your key with you. Report the loss of any Winger issued lock to your foreman or safety team. When an energy-isolating device is not capable of accepting a lockout/tagout padlock, then and only then, will a tagout program be utilized. When this is the case, the tagout device shall be attached at the same location that a padlock would have been and the tagout system must provide a level of safety equivalent to that obtained by using a lockout/tagout program. Tags shall be standardized, (DANGER DO NOT OPERATE). Tags must be durable and be able to withstand the local environmental conditions for the maximum period of time that the tag will be in use. Tags shall be attached using a non-reusable type, attachable by hand, self-locking, and nonreleasable with a minimum unlocking strength of no less than 50 pounds and having the general Revised August 2018 Page 5 of 14

6 design and basic characteristics of being at least equivalent to a one-piece, all environmentaltolerant nylon cable tie. Tags must be legible even if they get dirty and damp. They must have your name, company name, date, and equipment description you are locking out. COORDINATION WITH OTHER LOCKOUT/TAGOUT PROCEDURES 1. In most cases, Winger personnel (outside employer) will be working on machines or equipment that is under the jurisdiction and control of our customers (on-site employer) lockout/tagout program. It is absolutely essential that lockout/tagout procedures are communicated with all the parties involved and that the procedures set forth by this program are met at a minimum. 2. Winger supervision shall ensure that their personnel understand and comply with the requirements of the energy control procedures being used by the facilities where they are working. 3. If machinery is already locked out or tagged out upon arrival at the job site, Winger supervision shall review existing facility procedures and implement Winger lockout/tagout device(s) and/or personnel padlocks where necessary. GROUP LOCKOUT BOXES 1. If group lockout boxes are utilized, the authorized employee in charge of the lockout procedures for a specific piece of equipment has the prime responsibility of monitoring and managing the group lockout procedures. This includes notification, isolation processes, lockout devices, verification of energy isolation, and padlock removal. 2. Keys to padlock(s) that isolate the energy for the equipment or machinery will be placed into the group lockout box. All affected employee(s) shall affix his/her own personal padlock onto the group lockout box before beginning work and shall remove his/her own personal padlock at the end of each work shift and/or when work is complete. SHIFT OR PERSONNEL CHANGES When work necessitating a lockout/tagout is not completed on a given shift and work continues into the next shift, off-going personnel involved shall remove their lockout/tagout padlock(s) and on-coming personnel shall monitor these situations, and if necessary, install their own lockout/tagout padlock(s). LEAVING AN INCOMPLETE JOB Personnel who must leave an incompleted job shall not remove their padlock(s) immediately, but shall: 1. Notify supervision that they must leave. 2. Remove their padlock(s) only under the guidance of supervision that will use additional padlocks for the remainder of the task. This will ensure that equipment or machine(s) being worked on or serviced are locked out at all times. Revised August 2018 Page 6 of 14

7 REMOVING AN ABSENT EMPLOYEES LOCKS Removal of personnel lockout/tagout padlocks: Each personnel lockout/tagout padlock shall be removed by the employee who applied the padlock. When the employee who applied the lockout/tagout padlock is not available to remove it, that padlock may be removed under the direction of Winger supervision provided that: 1. Verification has been made that the employee who applied the padlock is not at the site or facility. 2. All reasonable efforts have been made to contact the employee to inform them that their padlock was removed. 3. Ensure the employee has the knowledge that their padlock was removed before they resume work at the site or facility. 4. Use the Winger Lockout Removal Form to document the steps listed above. A Winger LOTO Removal Form must be utilized in order to remove a Winger employee s lock from a lockbox. 5. AT NO TIME, IS THE EQUIPMENT OR MACHINERY TO BE LEFT WITHOUT ISOLATION PROTECTION. CONTROL PROCEDURES Control procedures involve developing separate, detailed written lockout procedures for each identified machine, device or process that may require to be locked out at some time. The procedure should identify: The person responsible for performing the lockout. The person responsible for ensuring that the lockout is properly performed such as facility supervisor or site supervisor. The energy sources to be controlled by the lockout. The location of control panels, power sources, switches, interlocks, valves, blocking points, relief valves and/or blanking and bleeding points (review schematics). Special hazards (for example, a flywheel that spins for minutes after power is removed, electrical capacitors, etc.) Personal protective equipment that must be used or worn (for example chemical or electrical PPE). Step by step lockout procedure; what is locked out and how. Testing procedure to ensure that all energy sources are controlled. Step by step procedure for removing the lockout. Revised August 2018 Page 7 of 14

8 SINGLE SOURCE LOCKOUT A single source lockout is when a machine or piece of equipment that has ONE energy source that can be readily identified and isolated by a single source point. For example, a circuit breaker in an electrical panel to cut off power from a light fixture, fan, sump pump, instrumentation, HVAC, electric motor, etc. ELECTRICAL LOCKOUT Shut down machine using normal operational shutdown procedure and controls. This should be done by, or in consultation with the equipment operator. After ensuring that the machinery has been completely shut down, and all controls in the off position, don the appropriate personal protective equipment and open the main disconnect switch located in the field. Some AC or DC drive units are located in a switch room or Motor Control Centers (MCC), normally operated by electricians. In the case of DC drive units, a motor blower switch and a field switch must also be switched off which are located inside of the cabinet. Only employees that have had NFPA 70E training and are qualified electricians are authorized to perform this lockout. If training has been conducted to allow other persons to operate this switchgear, records should be kept of that training. If racking out is required in a MCC, a qualified electrician must be contacted. If fuses are to be removed, qualified personnel must use fuse pullers due to the proximity of the bus bar that is still energized. Removal of fuses only does not constitute a lockout. Caution: Remember when disconnecting switches stand clear of the box, to one side, and face away while operating the switch with your off hand. This is to minimize the risk of injury should the switch explode due to arcing. When opening the main disconnect, a quick step to the right or left (as applicable) should be taken, as the knives disengage or when closing the main disconnect, the knives engage. Using a Winger equipment lock and tag, lock the disconnect switch in the off position. Remove the key and retain in the group lockout box. Apply your Winger personal lockout lock on the lock box. Each person working on the equipment must apply their personal lock. The lock of the person doing the work or in charge must be installed first, remain throughout and be removed last. Test the main disconnect switch and make sure it cannot be moved to the on position. Try to start the equipment using the normal operation controls and point of operation switches to make sure that the power has been disconnected. In some instances, there may be more than one power source feeding equipment and steps must be taken to ensure that all sources are effectively locked out. Other sources of energy that could create a hazard while working on the equipment must also be de-energized and appropriately locked out. This can include flywheels, gravity, springs, capacitors, compressed air, hydraulics, steam and other pressurized or hazardous liquids and gases. When the work is completed, prior to removing the last lock, make sure the operation controls are still in the off position so that the main disconnect switching is done under no load. Revised August 2018 Page 8 of 14

9 Ensure all blocks, tools and other foreign materials are removed from equipment. Also ensure that all personnel that may be affected are informed that the lock(s) will be removed. Remove locks and tags, and close the main disconnect switch if permission has been granted. When the work has not been completed during the first shift, Winger policy for shift change will take effect. SEQUENCE OF A LOCKOUT/TAGOUT SYSTEM PROCEDURE 2. Prepare for shutdown: Before an authorized or affected employee turns off a machine or equipment, the authorized employee shall have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy. All written LOTO procedures must be followed to ensure proper LOTO steps have been taken. 3. Notification of affected and authorized employees: All affected and authorized employees shall be notified that a lockout/tagout system is going to be utilized, the equipment to be involved, and the reason(s) why. Authorized personnel shall be informed of the energy source(s) to be controlled, and the method or means to control the energy. Notification shall be given before the energy controls are put in place, and after the energy controls are removed. It is necessary to communicate with all affected, authorized and other personnel before the controls are removed for safety coordination purposes. 4. Equipment or machine shut down: Shut off or shut down the equipment or machine using the specific procedures established for that piece of equipment or machine. 5. Equipment or machine isolation: Identify and release the points of energy from the equipment to be worked on. Position the switch, valve or other energy-isolating device(s) to the off or open position so that the equipment is isolated from the energy source(s). Stored energy, (such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems and air, gas, steam or water pressure, etc.), shall be dissipated or restrained by a method such as repositioning, blocking, bleeding down, etc. 6. Apply lockout/tagout device(s): Lockout/tagout devices shall be affixed to each energy-isolating device by authorized employees. Position of each energy-isolating device shall be in the off or safe position. Designated lockout/tagout padlocks are to be used. 7. Verification of isolation: Prior to starting work, an authorized employee must verify that isolation and de-energization of the equipment or machine has been accomplished. As an Revised August 2018 Page 9 of 14

10 additional safety precaution, Winger policy is that a double verification process will be performed by at least two trained employees. This process will be performed by Winger Supervision/Foremen in conjunction with customer authorized employees. The following steps shall be performed: Verify that all personnel are safely positioned clear from the danger zone. Verify the isolation of the equipment by: Test starting the equipment by operating the start/stop push button(s) or other normal operating control(s). Use monitoring instruments such as a voltmeter to test electrical circuits to determine that there is no electrical energy available to the machine or equipment. Or use a combination of both steps listed above depending upon the type of machinery or equipment involved, the complexity of the system, or other factors. Return operating control(s) to the neutral or off position after verifying the isolation of the equipment. 8. Return to service: Before lockout/tagout devices are removed and energy is restored, authorized employees shall ensure the following: Equipment and machine inspection: Inspect the work area to ensure that non-essential items (i.e. tools, parts and materials) have been removed and to ensure that machine or equipment components are operationally intact. Employees: Verify that all employees have been safely positioned or have cleared the area. Notification: After lockout/tagout devices have been removed, and before the equipment is started, affected employees shall be notified that the lockout/tagout devices have been removed. TESTING OF MACHINES OR EQUIPMENT In some circumstances, employees need to temporarily restore energy to a machine or piece of equipment during servicing or maintenance to test and/or reposition the machine or piece of equipment. Lockout or tagout devices may be removed temporarily in order to perform these tasks. The following actions should be followed: 1. Machine or equipment must be cleared of all tools and materials. 2. Employees must be removed from the machine or equipment area. 3. Remove lockout or tagout devices. 4. Energize all systems and reapply energy control measures 5. Authorized persons may then proceed to energize and test or position the equipment or machinery. Revised August 2018 Page 10 of 14

11 6. Following testing or positioning, all systems must be de-energized and energy control measures reapplied to continue servicing and/or maintenance EXEMPTION TO A LOCKOUT/TAGOUT SYSTEM PROCEDURE Certain single-energy-source equipment can be exempted from the written procedures requirement but only if eight specific conditions are met. Written procedures are not required for a particular machine or equipment, when all of the following elements exist: 1. The machine/equipment has no potential for stored or residual energy after shutdown which would endanger an employee. 2. The machine or equipment has a single energy source, that is identifiable and capable of isolation; 3. The isolation and locking out of that energy source will completely de-energize and deactivate the machine or equipment; 4. The machine or equipment is isolated from that energy source and locked out during servicing or maintenance; 5. A single lockout device will achieve a locked-out condition; 6. The lockout device is under the exclusive control of the employee performing the servicing or maintenance; 7. The servicing or maintenance does not create hazards for other employees; and 8. The employer, in utilizing this exception, has had no accidents involving the unexpected activation or re-energization of the machine or equipment during service or maintenance. PERIODIC INSPECTION A certified periodic inspection of the lockout/tagout procedure shall be conducted at least annually by a competent person to ensure that the program and requirements of the OSHA standard are being followed. Revised August 2018 Page 11 of 14

12 These periodic inspections will be performed by one of the safety team members during jobsite inspections and safety observations. TRAINING REQUIREMENTS (C)(7) Employer shall provide training to ensure that the purpose and function of the energy control program are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees. The training shall include the following: Each authorized employee shall receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control. Each affected employee shall be instructed in the purpose and use of energy control procedures. All other employees whose work operations are or may be in an area where energy control procedures may be utilized, shall be instructed about the procedure, and about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out. When tagout systems are used, employees shall also be trained in the following limitation of tags: Tags are essentially warning devices affixed to energy isolating devices, and do not provide the physical restraint on those devices that is provided by a lock. When a tag is attached to an energy isolating means, it is not to be removed without authorization of the authorized person responsible for it, and it is never to be bypassed, ignored, or otherwise defeated. Tags must be legible and understandable by all authorized employees, affected employees, and all other employees whose work operations are or may be in the area, in order to be effective. Tags and their means of attachment must be made of materials which will withstand the environmental conditions encountered in the workplace. Tags may evoke a false sense of security, and their meaning needs to be understood as part of the overall energy control program. Tags must be securely attached to energy isolating devices so that they cannot be inadvertently or accidentally detached during use. Employee Retraining Retraining shall be provided for all authorized and affected employees whenever there is a change in their job assignments, a change in machines, equipment or processes that present a new hazard, or when there is a change in the energy control procedures. Additional retraining shall also be conducted whenever a periodic inspection under (c)(6) Periodic Inspection reveals, or whenever the employer has reason to believe, Revised August 2018 Page 12 of 14

13 that there are deviations from or inadequacies in the employee s knowledge or use of the energy control procedures. The retraining shall reestablish employee proficiency and introduce new or revised control methods and procedures, as necessary. The employer shall certify that employee training has been accomplished and is being kept up to date. The certification shall contain each employee s name and dates of training. Files will be kept in the employee s safety training folder. Revised August 2018 Page 13 of 14

14 SOURCE CREDITS U.S. Department of Labor, Occupational Safety and Health Administration, Mechanical Contractors Association of America, Safety Info, Business & Legal Reports, Inc. Industrial Accident Prevention Association (IAPA) Michigan Occupational Safety and Health Administration (MIOSHA) Oklahoma State University (OSU), Program for the Control of Hazardous Energy Cargill Corn Milling North America Alliant Energy Corporation Sheet Metal and Air Conditioning Contractors National Association (SMACNA) DOCUMENT CONTROL Revised July 17, 2003 Revised July 5, 2006 Reviewed October 23, 2006 Revised February 27, 2009 Revised October 9, 2011 Revised January 26, 2012 Revised August 16, 2012 Revised April 2, 2013 Revised May 30, 2015 Revised October 19, 2016 Revised February 16, 2017 Revised September 13, 2017 Revised August 1, 2018 Revised August 2018 Page 14 of 14