LOCKOUT-TAGOUT PROGRAM

Transcription

1 LOCKOUT-TAGOUT PROGRAM Please Note: This material, or any other material used to inform employers/employees of compliance requirements of OSHA standards through simplification of the regulations should not be considered a substitute for any provisions of the OSHA Act or for any standards issued by OSHA. The information in this course is intended for classroom training use only

2 Introduction When it s time for maintenance, repairs or retooling of a machine, simply turning the machine off or unplugging it while it is being worked on does not give enough protection for workers. Many serious accidents have happened when someone thought the machine or all of the energy was safely turned off.

3 Introduction THUS: The Occupational Safety and Health Administration (OSHA) has a standard for locking and tagging out equipment. It is known as 29 CFR , and it presents a minimum performance standard for the control of hazardous energy.

4 Introduction This introductory class takes us through the various required sections of an effective written lockout/tagout program from beginning to end. As we look at each section we ll discuss related requirements, definitions, and procedures. If you re new to lockout/tagout this class will give you the basics you need to know to get your program running. And, for those who are familiar with lockout/tagout, the class will serve as a valuable review.

5 Objectives 1. Gain a greater awareness of the requirements detailed in 29 CFR , Control of Hazardous Energy. 2. Understand the responsibilities of the employer, authorized employee, and the affected employee. 3. Understand lockout/tagout procedures for shutting down, testing, and returning machinery and equipment to operation.

6 Part I: Scope and Application 29 CFR , 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.

7 Scope: The lockout/tagout rule covers the following employees: The standard details lockout/tagout responsibilities of authorized, affected, and other employees.

8 Scope: Authorized Employee: Person who services or performs maintenance on machines or equipment. Affected Employee: Person who operates or uses a machine or equipment which is being serviced or has maintenance being performed. Other Employee: Person who works in an area where lockout/tagout procedures are being used.

9 Application: Procedures must be followed when......servicing and/or maintenance is being done when Possible energization, start-up or release of stored energy could cause injury.

10 Servicing or maintenance Some workplace activities considered to be Servicing and/or maintenance of machinery and equipment include: Adjusting... inspecting... modifying... constructing... retooling... lubricating... removing jams... cleaning...

11 Sources of Energy Sources of energy as possible that could cause injury: Pneumatic Hydraulic Mechanical Kinetic Thermal Radiation Nuclear Electrical

12 Scope: The standard does apply to:

13 Scope: The standard does not apply to:

14 Scope:

15 Scope:

16 Scope:

17 Scope:

18 Scope:

19 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. See appendix for a sample written plan.

20 The Written Energy Control Plan 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.

21 The Written Energy Control Plan If any of the conditions below exist, the employer must include the machine or equipment in the written program: 1. The machine or equipment has potential for unexpected energizing or start up, or release of stored energy after shutdown which could endanger employees; or 2. The machine or equipment has more than a single energy source; or 3. The isolation and locking out of any single energy source will not be able to de-energize and deactivate the machine or equipment; or

22 The Written Energy Control Plan 4. The lockout device is not under direct control of an authorized employee performing the servicing or maintenance; or 5. The servicing or maintenance of the machinery or equipment creates hazard/danger for other employees; or 6. The employer has had knowledge involving the unexpected activation or re-energizing of the machine or equipment during servicing or maintenance.

23 Lockout/Tagout Procedures Step 1 - Prepare for Lockout. The first step in the lockout/tagout procedure is to make preparation to shut down the equipment or machinery to be worked on. 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.

24 Lockout/Tagout Procedures 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.

25 Lockout/Tagout Procedures Step 2 - Shutdown and Isolation 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.

26 Lockout/Tagout Procedures Step 3 Isolation All energy isolation devices should be located and operated to completely de-energize and isolate the equipment. The authorized employee, or team leader will verify operation of each energy isolation device.

27 Lockout/Tagout Procedures Step 4 Lockout or 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.

28 Lockout/Tagout Procedures Step 4 Lockout or Tagout Application Some facilities have special Lock-Out/Tag-Out devices Sign In/Sign Out procedures. With this system you must: Obtain devices from central locations. Sign Out the devices being obtained. Return devices to the location from which they were obtained. Sign In the devices returned.

29 Lockout/Tagout Procedures Before applying and after removing lockout/tagout devices, the authorized employee...must notify all affected employees. A lockout device must use a positive means such as a lock, either key or combination type, to hold an energy isolating device

30 Lockout/Tagout Procedures Tagout Devices 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...

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

32 Lockout/Tagout Procedures Step 5 Controlling Stored Energy Stored Energy. 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 rendered safe.

33 Lockout/Tagout Procedures Step 5 Controlling Stored Energy If Capacitors are present, special care should be taken. Capacitors can store electrical charges. They can present serious hazards. As a result, capacitors must be grounded before starting work on any machine that contains them.

34 Lockout/Tagout Procedures Step 5 Controlling Stored Energy Hydraulic and Pneumatic systems have their own characteristics. They must be treated differently from electrical systems. These systems usually involve pipes and valves. The hazards encountered when working with these systems are usually pressure releases (steam, hydraulic fluid, etc.).

35 Lockout/Tagout Procedures Step 5 Controlling Stored Energy Additional precautions should be taken to protect against the slippage of major moving parts in these systems also. You need to: Use blocks, brackets or pins to immobilize the parts. Isolate equipment from vibrations of nearby traffic and other machines. Shut down adjacent machines, if necessary.

36 Lockout/Tagout Procedures Step 5 Controlling Stored Energy Once initial Lock-Out/Tag-Out procedures are completed, you may need to dissipate stored energy. There are a number of ways to do this, depending on the equipment you are working on. They include: Attaching grounds to electrical systems. Adjusting valves on hydraulic/pneumatic systems. Using blanks in piping systems. Bleeding or draining systems. Releasing spring tension. Dissipating extreme cold or heat.

37 Lockout/Tagout Procedures Step 5 Controlling Stored Energy Once energy dissipation and additional Lock-Out/Tag- Out is completed, Verification should be performed. To do this, you need to: Clear personnel from the surrounding area. Make sure switches, valves and other mechanisms can be turned on. Check electrical systems with a volt meter. Press all start buttons. Throw all switches and levers that would activate equipment. Return switches and buttons to the off position.

38 Lockout/Tagout Procedures 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

39 Lockout/Tagout Procedures Step 6 Verifying Isolation Verification of Isolation. 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-energized.

40 Lockout/Tagout Procedures Step 7. Release from Lockout/Tagout The authorized employee should follow the procedures below prior to removing lockout/tagout devices and restoring energy Equipment. Make sure machinery or equipment is properly reassembled. Inspect machinery or equipment to make sure nonessential items have been removed.

41 Lockout/Tagout Procedures Authorized employee should: 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.

42 Lockout/Tagout Procedures Removing lockout/tagout devices. Only the authorized employee who applied the lockout/tagout device may remove that device. Exception - When the authorized employee is not at the facility and all reasonable efforts have been taken to inform him/her that the lockout/tagout device has been removed written procedures must be in place to remove lockout/tagout devices.

43 Lockout/Tagout Procedures 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.

44 Lockout/Tagout Testing 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.

45 Lockout/Tagout Testing 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.

46 Lockout/Tagout Testing Two Types of Safety Training Type One: Safety Instruction Presents "nice to know" education and training Knowledge and skills are not measured at the end of training in the learning environment Write goals for students. Instructional objectives are not required All you have to do is attend to get a certificate

47 Lockout/Tagout Testing Type Two: Technical Safety Training Describes "must know" general/specific policies, procedures, practices Write goals and operational learning objectives for students Knowledge and skills are measured immediately after training in the learning environment You must "pass a test" in class to get a certificate Measurement tools - oral/written exam, skill demonstration This level is required for most safety training!

48 Lockout/Tagout Testing Training on Tagout Devices If tagout devices are used, further training on tagout systems need to emphasize that: Tags are warning devices only and do not provide a physical restraint that lockout devices provide. Tags must not be removed without the authorized employee s approval, and should never be bypassed, ignored, or otherwise defeated

49 Lockout/Tagout Testing Tags must be legible, and understandable by all employees. Tags must be able to withstand environmental conditions in the workplace. Tags may give employees a false sense of security. Tags must be securely attached to prevent being accidentally detached during use.

50 Lockout/Tagout Testing Retraining When should employees be retrained? Employees should be retrained in all of the following situations, except: a. Change in job assignment b. Change in machinery or equipment c. Evidence of deficiency in knowledge or skills

51 Lockout/Tagout Annual Inspections Annual inspection 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. The inspector and authorized employee will review responsibilities under the energy control procedure. 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

52 Let's review Lockout/tagout is used for service and maintenance when energization, start-up or release of stored energy is expected: a. True b. False

53 Review According to the text, lockout/tagout training is required for all of the following, except: a. OSHA inspectors b. Other employees c. Affected employees d. Authorized employees

54 Review Circuit breakers, valves, fuses, and blocks are all examples of: a. Tagout devices b. Lockout devices c. Energy isolation devices d. Lockout controls

55 Review This term is used to describe the procedure to indicate that the energy isolating device may not be operated: a. Lockout b. Tagout c. Energy isolation d. Tryout

56 Review According to the text, employees should be retrained in all of the following situations, except: a. Change in job assignment b. Change in machinery or equipment c. Evidence of deficiency in knowledge or skills d. Evidence of non-compliance

57 Review Authorized employees must know the types of energy sources and their : a. ratings b. magnitudes c. frequency d. locations

58 Review Servicing or maintenance includes all of the following, except: a. adjusting b. installing c. lubricating d. evaluating

59 Review According to the lockout/tagout rule, which of the following is not one of the three things the authorized employee must know before shutting down? a. Types and magnitudes of energy b. Identity of affected employees c. Hazards posed by that energy d. Methods to effectively control energy

60 Review An energy isolation device physically prevents the: a. transmission or re-accumulation of energy b. defeat logout/tagout devices c. modification of energy accumulation d. involvement of unauthorized individuals

61 Review If it isn't in writing it didn't get done! Make sure documentation is sufficient. Most safety training teaches employees how to perform a procedure or practice. As a result, employees must demonstrate adequate knowledge and skills in the learning environment before exposure to hazards. Test should be a written exam and skills demonstration. It s also a good idea to evaluate performance in the actual work environment some time after training has been completed

62 Review Training Subject Date Location Trainee certification. I have received on-the-job training on those subjects listed (see other side of this sheet): This training has provided me adequate opportunity to ask questions and practice procedures to determine and correct skill deficiencies. I understand that performing these procedures/practices safely is a condition of employment. I fully intend to comply with all safety and operational requirements discussed. I understand that failure to comply with these requirements may result in progressive discipline (or corrective actions) up to and including termination. Employee Name Signature Date Trainer certification. I have conducted orientation/on-the-job training to the employees(s) listed above. I have explained related procedures, practices and policies. Employees were each given opportunity to ask questions and practice procedures taught under my supervision. Based on each student's performance, I have determined that each employee trained has adequate knowledge and skills to safely perform these procedures/practices. Trainer Name Signature Date

63 Energy Control Program Communication and working together are the keys to good Lock-Out/Tag-Out procedures!

64 Energy Control Program Each facilities supervisor will be responsible for setting up their Energy Control Program from Energy Control Manual (on CD) provided them. This manual is an easy how to set up energy Control Program with all needed record keeping forms that can be copied for additional forms.

65 Energy Control Program THE END