Title: Control of Hazardous Energy Lockout / Tagout Program

Transcription

1 Document Number: P-SF Issue Date: 05/12/08 Revision Number: original Revision Date: Written By: Scott Cole Bradshaw, Dave Long, Gary Martin, Rick Saari, Al Sumrada, Jack Title: Control of Hazardous Energy Lockout / Tagout Program PURPOSE: This program establishes the minimum requirements for protecting Lake County employees, contractors and visitors from injury due to the unexpected energization, startup, or release of stored energy in machines or equipment. This program provides a consistent means by which any individual may be assured that a potentially hazardous system is properly shut down and isolated prior to starting service or maintenance activities. SCOPE: I. This procedure is applicable to all employees, visitors and contractors performing work on Lake County properties. II. Lockout / Tagout (LOTO) procedures must be followed whenever personnel are in, on or around equipment for the purposes of maintenance, cleaning, repair, inspection or servicing operations. III. In situations where the LOTO procedure involves isolating multiple energy sources, machine specific LOTO procedures and checklists must be followed by the employees performing the LOTO task. IV. Due to the unique requirements for electrical and electronic equipment, certain troubleshooting and repair functions must be performed with the equipment energized. This work, where required, is to be performed by qualified personnel only and must be approved by a supervisor (see definition of qualified personnel ). V. This program does not apply to machines or equipment when ALL of the following exist: A. The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees; and B. The machine or equipment has a single energy source which can be readily identified and isolated; and C. The isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment; and

2 D. The machine or equipment is isolated from the energy source and locked out during servicing or maintenance; and E. A single lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; and F. The servicing or maintenance does not create hazards for other employees; and G. The Department has not had any accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance. RESPO SIBILITIES: It is the responsibility of every Lake County (LCDU) employee to be familiar with the LOTO program and procedures in order to safely isolate the equipment that they are about to service or maintain. It is also the responsibility of all employees and contractors to properly isolate equipment by using only Department approved locks and tags. Failure to comply with these policies and procedures shall result in disciplinary action. Willfully defeating or bypassing a lockout without completing a Lock Removal Form or, for emergency situations, superintendent permission, is considered a major offense as documented in the Employee Policy and Procedure Handbook. DEFI ITIO S: I. Affected Employee - Any employee performing work requiring the control of hazardous energies in accordance with this program. II. Alternate Measures - Tools, special devices, procedures, or other protection used to prevent an employee from being exposed to a hazard. An Intermediate Energy State (IES) is considered an alternate measure. III. Assigned Operator Operators assigned by the site superintendent. IV. Authorized Employee - An individual, who by training, has acquired the skills and has been given the authority by the Department to perform a specific task or assignment related to this program. V. Certification of Proficiency - A system or method to verify and document a learned skill by using a test or exam, supervised demonstration or other equivalent means. VI. Energy Isolating Devices - A mechanical device that physically prevents the transmission or release of energy. Such devices include, but are not limited to the following: A. Manually operated electrical circuit breakers. B. Manually operated primary electrical disconnect switches. C. Manually operated blocking valves. D. Blocking pins or similar devices. E. Hook, locking chains or chain falls that can be locked in position. F. Other similar devices with visible indication of the position of the device. G. Removal of mechanical linkages. H. Installation of grounding wires. I. This term does not include a push button, selector switch or other control circuit type devices. Page 2

3 VII. Energy Control Procedure - A written procedure that identifies process and equipment energy sources and specifies methods for isolation and verification to achieve a safe LOTO. VIII. Energy Sources Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal or other energy. Further clarification on energy sources is defined below: A. Electrical - Alternating and direct current sources, static electricity or stored electrical energy in devices such as capacitors. Note: The Department uses many capaciters and uninteruptable power supplies (UPS) which need to also be deenergized when working on electrical-powered equipment. B. Chemical - Energy release through direct contact or by combining chemical substances. C. Thermal - Heat generated form electrical, combustion, chemical and mechanical (friction) sources. D. Pneumatic - Gaseous systems operating at positive (compressed) or negative (vacuum) pressures. E. Hydraulic - Fluids pressurized to perform work. F. Mechanical Potential - Movement of a body or an object by gravity, spring or striking force. IX. Exception - Certain tasks performed by qualified personnel require all circuit voltage to be present, such as checking amperage on a starter. Where the requirements of this program render it infeasible to perform work of this nature, the work shall be performed in accordance with the requirements specified in OSHA through , Safety-Related Work Practices. X. Exclusive Control - A switch, button or plug, which is both visible and within arm s reach of the exposed individual. XI. Hazardous Energy - Any level of energy present that can cause unexpected or unwanted movement, activation or flow which could result in injury or property damage. XII. Intermediate Energy State (IES) - The state of energy of equipment in which designated hazardous energy sources are at zero (ZES) while maintaining other designated energies to perform minor troubleshooting and adjustments or other minor, routine and repetitive servicing activities that are required to operate the equipment. XIII. Lockout - The placement of a key-operated lock on an energy isolating device to secure it in the locked, safe position and to ensure against unauthorized or unintentional operation or engagement. A. The two types of locks used within the Department are as follows: 1. Personal Lock - The designated lock for the use of individual or group lockout within Lake County. This lock is a standard issue Master name brand, orange-colored, plastic body lock. These locks shall not be used for any other purposes. All affected and authorized employees are issued one personal lock and tag. Maintenance employees are issued six (6) personal locks and tags. 2. Job Lock This lock is designed to be used when there are multiple points of energy to be controlled. This lock can easily be identified as a blue Abus named brand, facility-specific, laser engraved aluminum Page 3

4 body lock. These locks must be signed out from each facility s lockout center. Each facility has a different amount of job locks based on demand. Aquarius has twenty (20), Bacon Road has fourteen (14), GLK has seventy-five (75) and Madison has twenty-five (25). XIV. Lockout Device - A device that utilizes a positive means such as a lock, or chain/lock combination, to hold an energy isolating device in a safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds. XV. LOTO - This is an acronym that defines locking out and tagging out pieces of equipment (Lock Out / Tag Out). XVI. Multiple Lockout Devices - A tong/clasp device, which allows more than one individual lock to be applied to an energy isolating device, thus assuring that each exposed employee has individual lockout protection. XVII. Qualified Electrical Employee This term refers to Department employees who have been trained and authorized to perform electrical work. These employees are not classified as State certified electricians. These designated employees are also referred to as qualified personnel, qualified electricians, an electrical contractor or a contracted electrician. XVIII. Qualified Personnel - Employee assigned to perform tasks that require training in and compliance with OSHA regulations for Electrical Related Safety Work Practices. XIX. Residual Energy - Stored Energy that remains in a system even when the system is shut down. This energy must be drained or released before beginning work on a system. XX. Responsible Person - The authorized person for a LOTO situation. This person: A. Must be familiar with the isolation points involved in the lockout. These isolation points must be identifiable (i.e., numbered and labeled). B. Must be trained by a competent person on the equipment in question prior to enacting the LOTO procedure. C. Must be familiar with all activities involved under the LOTO situation. XXI. Safety Disconnect - A knife-type or equivalent electrical disconnect switch where the handle can be verified to be in the open or off position. XXII. Tag - A means of providing identification concerning a lockout device. Tags are not to be used in lieu of a positive means to isolate energy, such as a lock or chain/lock combination. A. Two types of tags are used in the Department LOTO Program: 1. Personal Lockout Tag - A designated tag for use with individual lockout as an identification tag. This tag must be used for all lockout situations. This tag states, Danger. Do Not Operate. My Life Is on the Line. and can be identified by the employee s photo as well as their signature and phone number. 2. Job Lockout Tag A tag designed to increase the awareness of a job lockout. Job lockout tags must only be used with job locks. XXIII. Zero Energy State (ZES) - The state of a piece of equipment or a process in which the possibility of unexpected or unwanted activation or movement has been completely eliminated. Page 4

5 PROCEDURE: I. Machine or Equipment Shutdown and Isolation A. Stop the equipment using the Department s LOTO checklist and sequential shut down procedures. 1. If the equipment was shutdown because of control failures, energy source interruption, emergency stop procedures or unknown reasons, all operating controls should be placed in the off, neutral or normal shutdown position. a. This step will help prevent the unexpected equipment startup when locks and tags are removed. B. Install or actuate the appropriate energy isolation devices. C. Lock and tag each energy isolating device. 1. Each energy isolating device must be positioned to isolate the energy source from the equipment. 2. Once the device is positioned, the lockout device must prevent the energy isolating device from being repositioned. a. This step is intended to place equipment in a Zero Energy State so that unexpected energization, startup motion, or release of stored energy will not occur. b. Lockout shall be performed only by authorized employees who are performing the maintenance or service. D. Each employee working on a piece of equipment must place his/her own personal lock on each energy isolating device. 1. Multiple lockout devices will be used when more than one employee is working on a piece of equipment. 2. Job locks and tags and group lockout boxes, in conjunction with personal locks and tags, will be used when multiple points of isolation are required. 3. Employees are not permitted to work under the protection of another employee s personal lock or solely under the use of a job lock. a. Personal locks and tags must be applied in all lockout situations. 4. Locks may be removed O LY by the individuals applying them (except when following the Lock Removal Form in this program). 5. Employees should consider the necessity and feasibility of locking and tagging equipment immediately adjacent to the work area that could cause a hazard. 6. Where the use of an electrical disconnect is feasible to isolate electrical energy, an alternate method may be used. a. This method is to remove a fuse to interrupt the energy source. i. If this method is used, the fuse shall be removed only by a qualified employee or contractor. ii. The fuses shall be removed from the holders and enclosures. iii. Access to the electrical box housing the fuse holders shall be locked and tagged to prohibit reinsertion. Page 5

6 7. Where computer controlled equipment is involved, additional steps may be needed to ensure that all energy sources are effectively isolated. Note: The Department has equipment that may be remotely or process controlled. E. A tag must be securely attached to each lock. 1. If tags need replaced or extra tags are needed, contact the Department s Safety Manager. F. Vendors or contractors performing work on LCDU property must use tags showing the individual s name and the company or contractor of the individual applying the lockout as well as the date applied. G. When an employee is relieved on a job, the oncoming employee must review the lockout in effect, complete a new LOTO checklist and then place his/her personal lock(s) and tag(s) on each energy isolating device. 1. The employee who is relieved must not remove their personal lock and tag until the lockout has been reviewed and the oncoming employee s lock is in place. H. Equipment that is under repair or out of service during multiple shifts must be locked and tagged using a job lock to ensure the safety of the employees in the area. I. If work ends and equipment must still be out of service, the key to these locks must be placed in the lockout center at each respective facility. 1. The current plant assigned operator is required to install their personal lock and tag to the lockout center during their shift. a. The departing assigned shift operator will not remove his/her lock and tag until the oncoming assigned operator applies their lock and tag to the lockout center. J. Specific energy isolation guidelines include: a. Manually operated electrical circuit breakers or disconnect switches must be placed in the OFF position and locked to isolate electrical energy sources. b. Locking of control buttons, switches or key controls is not an acceptable means of isolating electrical energy sources. 2. Manually operated blocking valves must be fully closed and locked, or pipeline blinds installed to isolate hydraulic, pneumatic or chemical energy sources. a. Remote actuated valves are not an acceptable means of isolating hydraulic, pneumatic or chemical energy sources unless they can be deenergized and mechanically locked closed. 3. Braces, blocking pins, chain falls or other similar blocking devices must be locked in place by chains and locks or other means to isolate mechanical systems that might move. 4. Air, fluid or other stored energy pressure must be closed, locked in place and energy dissipated to achieve a zero energy state. K. Verification of Isolation 1. After verifying that all employees are clear of the equipment, try to start the equipment using the normal startup control buttons or switches. a. This helps ensure that all the proper energy sources have been isolated and that stored energy is released before work is started. Page 6

7 2. If electrical work is to be done, appropriate electrical test equipment must be used to verify that all electrical energy has been isolated and discharged from the equipment. a. A visual inspection to ensure that all phases of the electrical energy supply have been disconnected should be used to verify proper isolation. i. This testing should only be performed by a Department Electrician or a designated on-site contract electrician. 3. If the equipment unexpectedly starts up, is energized, or moves when you try it, stop the equipment immediately and review the LOTO checklist. a. If you cannot correct the problem by using the correct energy isolating devices or if the devices do not adequately isolate the equipment (such as a valve that leaks), contact the maintenance department and the supervisor. 4. Some equipment may be interlocked through control power devices. a. In this situation, the equipment may not start up or energize during the try step even though the proper energy isolating device(s) may be properly positioned. i. Questions regarding the possibility of the status of interlocked equipment must be resolved before the equipment is worked on. 5. DO NOT CONTINUE OR BEGIN WORKING ON EQUIPMENT WHICH UNEXPECTEDLY STARTED, WAS ENERGIZED, OR MOVED, UNTIL THE PROBLEM HAS BEEN FOUND AND CORRECTED. THE EQUIPMENT MUST BE RESTORED TO A ZERO ENERGY STATE BEFORE WORK CAN CONTINUE OR BEGIN. 6. After you try to start the equipment, return all operating controls to the off, neutral or normal shutdown position. a. This step will help prevent unexpected startup, energization or movement when the equipment is energized after the work is complete. L. Restoring Equipment to ormal Operation 1. Upon completion of the job or when released from the job, each employee will remove his/her own lock(s) and tag(s). 2. The employee, who then is to start up the equipment, will inspect the area to ensure that all personnel are clear of any hazard. a. If the equipment being started has a jog or slow start feature, the equipment will first be jogged, allowing sufficient time for any personnel to escape potential danger, before going to full speed operation. M. Removal of Locks 1. When an employee is finished working on a particular system or at the end of his/her work shift (whichever comes first), they must remove his/her personal lock and tag. 2. No employee will remove the lock and tag of another employee except in the following instances: i. CAUTION: Removing the locks and tags of another employee or company could cause serious injuries, even death and therefore is prohibited. Refer to Responsibilities for further clarification. ii. The individual removing the locks shall ensure that all requirements of the following paragraphs are followed and that the safety ramifications of the removal are not compromised. Page 7

8 b. If an employee leaves the plant site and fails to properly remove their locks and tags, the following steps must be taken: i. A superintendent or designee will attempt to contact the employee by phone and have them come back and remove it. ii. If the person cannot be contacted, the lock should be removed by following the Lock Removal Form and documenting all actions. 1) The site superintendent or supervisor must be notified before any lock is removed. 2) A copy of the documentation must be given to the site superintendent and the Department safety manager. c. The lock must be removed with bolt cutters once it has been verified the area is clear and safe. d. Upon the employees return to work, the employee must be notified their lock had to be removed. 3. If the lock to be removed (under the above conditions) is a contractor lock, the following guidelines shall apply: a. The supervisor shall initially make every reasonable effort to contact the site project leader and the contractor s supervisor, normally by phone. i. If communication is established, they will discuss the status of the lockout and determine whether or not the locks and tags can be safely removed. ii. If they can be removed, the contractor will be called in to remove the locks and tags. iii. If communication cannot be established, the supervisor will discuss the status of the lockout with the employees affected by the work and determine whether or not the locks and tags can be safely removed. b. When it has been determined that the locks and tags can be safely removed, and the contractor cannot be contacted the supervisor will notify effected personnel and remove the locks. c. The lock removal shall be documented using the Lock Removal Form. i. A copy of this form shall be given to the site superintendent and the Department safety manager.. Special Rules for Electrical Protective Devices volt or lower electrical circuit breakers may be operated by anyone, in order to proceed with a LOTO procedure, provided that the door to the circuit breaker compartment is securely closed and the operating handle is in good condition. a. A Department electrician will be called to operate the breaker if the door and/or handle are faulty, as severe burns and injury can result if this is not done properly. 2. Tripped electrical circuit breakers should be reset only by a Department electrician or designated electrical contractors with the following exception: a. Any authorized or affected person can reset 115 volt dead-front panel board circuit breakers. b. Any employee can push externally accessible overload reset buttons to attempt to restart equipment. Page 8

9 i. Note: Only qualified electrical employees and designated electrical contractors may reset internally accessible overload devices. 3. Verify that the door or cover of the starter is closed and securely fastened. 4. Verify that the circuit breaker is NOT in the TRIPPED position. a. If there is any doubt, call a qualified electrical employee. 5. Move the circuit breaker operating handle to the OFF/OPEN position. 6. Stand to the side of the starter, facing away from the device, and press the overload reset device. 7. While standing to the side, move the circuit breaker operating handle to the ON/CLOSED position. a. Should the motor fail to start, call a qualified electrical employee. 8. NOTE: Circuit breakers are overcurrent devices and may only be reset from a tripped condition by a qualified electrician except as permitted by this procedure. 9. When 120 volt panel board breakers are required to be locked open and the padlocking capability for that breaker is not installed or is not available, the wire to the terminal on the breakers must be disconnected, taped and tagged by a qualified electrical employee. 10. A second DANGER tag (tag only) must be placed on the circuit breaker handle. O. Specific Requirements Thermal, Hydraulic, Pneumatic and Mechanical Potential Energy 1. Energy in systems containing fluids, gases or solid material may be controlled by any of the following methods: a. Physically closing the valve, gate, etc., and locking the handle in the closed position. b. Physically separating the pipe or duct work to prevent transfer of fluids of materials. c. Installation of a solid blank or blind flange to prevent transfer of fluids of materials. d. Disconnecting electrical energy serving as the prime mover (e.g., lockout of an air compressor and bleeding residual pressure). i. The release of stored pressure or loss of hydraulic fluid may create a mechanical potential energy source. ii. Members shall be secured or supported where necessary prior to relieving stored pressure or draining hydraulic fluid. 2. Tags may be used without locks to isolate fire protection systems under the following conditions: a. Work is being performed on piping, valves or related components, and b. There is no back-up or secondary fire protection system. i. Example: A tag would be permissible to change a sprinkler head or repair a sprinkler system. 1) A tag would not be permissible to repair an electric fire pump. 3. Mechanical potential energy sources shall be isolated by any of the following methods: a. Installing a block or blocks to support a suspended member; or Page 9

10 b. Securing a moving member with a pin, chain, bar or other method to prohibit movement; or c. Removal of a suspended or movable member; or d. Removal or dissipation of energy contained in springs. 4. Whenever possible, a lock shall be used to secure a mechanical potential energy isolating device. a. All employees working under the protection of block, pin, chain, etc., used to secure a source of mechanical potential energy shall tag the energy isolating device. P. Labeling of Energy Isolation Points 1. All energy isolation points which are involved in shutdown or startup operations must be legibly labeled. a. This includes electrical disconnects, circuit breakers, stop/start buttons and other appropriate control switches. 2. The label must clearly identify the function of the isolation point using names familiar to the authorized employees. 3. Lake County has established a standard for identifying the energy source and is as follows: a. The first set of characters on the procedure indicates the building or building letter. b. The second set of characters indicates the floor level. c. The third series of characters will indicate the panel or valve identifier. d. The last series of characters will be the circuit breaker number. Q. Development and Maintenance of Energy Control Procedures 1. Written energy control procedures shall be developed for all equipment and processes. 2. Procedures shall list specific steps to isolate energy sources and verify control. 3. The minimum information required for an energy control procedure includes: a. Identification of the type and magnitude of all energy sources associated with the equipment or process. b. Location and corresponding identification of energy isolating devices. c. Specific and sequential procedure(s) to safely bring the equipment or process to zero energy state. d. Methods for verifying control of hazardous energies (e.g., attempting to start using local switch or button). 4. Procedures shall be readily accessible to all employees. 5. Posting procedures at the equipment or an equivalent means of access may be used. 6. Procedures shall be maintained in a master file in the site superintendent s office. 7. When performing a LOTO in a situation where procedures have not been established, employees must complete a LOTO Development Form. a. Completed forms must be sent to the Department safety manager so that a written procedure and checklist can be developed. R. Training 1. All employees will be trained in the requirements of this program. Page 10

11 2. The Department safety manager will provide a general overview of this program during new-hire employee orientation. a. Specific training will be provided on the job and refresher training will be provided annually. 3. Affected, authorized and qualified employees shall be evaluated by a competent person to ensure that the employee is aware of all of the requirements to carry out the LOTO program. a. This training must be documented and remain on file as long as the employee remains affected by the program. S. Auditing 1. To ensure that the LOTO program is thoroughly understood and properly used, its application shall be regularly reviewed during normal self-auditing activities. a. These audits must be documented. b. The audit shall identify that the energy control procedure was being utilized, the date of the audit, the employees included in the audit and the person(s) performing the audit. T. Documentation 1. Training and demonstration of proficiency will be documented annually. 2. Reviews of LOTO procedures will be documented annually. U. Approval, Issue and Review 1. This procedure will be reviewed annually and revised on an as needed basis. 2. This procedure will be made available to all employees whenever changes occur. 3. It will be reviewed and approved by the Executive Safety Committee before being distributed. Page 11