Lockout/Tagout Training Overview Safety Fest 2013
Purpose of Lockout/Tagout The standard covers the servicing and maintenance of machine and equipment in which the unexpected energization or start up of the machines or equipment, or release of stored energy could harm employees. 2
Work Exclusions 3
Work Exclusions The procedure applies to operational activities, except as follows: 1. Work on cord and plug connected electrical equipment for which exposure to the hazards of unexpected energization or startup of the equipment is controlled by the unplugging of the equipment from the energy source and by the plug being under the exclusive control of the personnel performing the servicing or maintenance. Exclusive Control? 4
Work Exclusions 2. Hot tap operations involving transmission and distribution systems for substances such as gas, steam, water or petroleum products when they are performed on pressurized pipelines, provided that the employer demonstrates that: continuity of service is essential; shutdown of the system is impractical; and documented procedures are followed, and special equipment is used which will provide proven effective protection for employees. 5
Work Exclusions 3. Work involving minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations, are not covered if they are routine, repetitive, and integral to the use of the equipment for production, provided that the work is performed using alternative measures which provide effective protection. 4. Electrical equipment whose maximum voltage is less than 50 volts and if there is no increased exposure to electrical burns or to explosion due to electrical arcs. 6
Definitions 7
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. 8
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. An affected employee becomes an authorized employee when that employee s duties include performing servicing or maintenance. 9
Capable of being locked out An energy isolating device is capable of being locked out if it has a hasp or other means of attachment to which, or through which, a lock can be affixed, or it has a locking mechanism built into it. Other energy isolating devices are capable of being locked out if lockout can be achieved without the need to dismantle, rebuild, or replace the energy isolating device or permanently alter its energy control capability. 10
Energized Connected to an energy source or containing residual or stored energy. 11
Energy Control Program A program established by the employer 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, startup or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from the energy source and rendered inoperative. 12
Energy Isolating Device A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following: A manually operated electrical circuit breaker; a disconnect switch; a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors and, in addition, no pole can be operated independently; a line valve; a block; and any similar device used to block or isolate energy. Push buttons, selector switches, safety interlocks, and other control circuit type devices are NOT energy isolating devices. 13
Energy Source Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal or other energy. 14
Exclusive Control Exclusive control means that the authorized person has the authority to and is continuously in a position to prevent other individuals from re-energizing the machine or equipment during his/her servicing or maintenance activity. 15
Independent Verification The act of checking, by a separate qualified person, separated by time and distance, that a given operation, or the position of a component, conforms to established criteria. 16
Lockbox A lockbox into which all of the keys and tabs from the Lockout/Tagout devices securing the machines or equipment are placed and which would be secured by individual authorized personnel locks and by a Supervisor lock. 17
Lockout Device A device that utilizes a positive means such as a lock (key or combination type) to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment. 18
Tagout Device A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed. NEVER remove a tagout unless authorized NOTE: The use of tags without locks* 19
Verification of Isolation Authorized employees shall take the means necessary to test the machine or equipment to reliably verify that isolation and de-energization of the equipment has been accomplished before starting servicing or maintenance work on equipment that has been locked out and/or tagged out. 20
Types and Magnitudes of Energy Sources 1. Electrical Distribution Systems 2. Pressurized Systems 3. Mechanical Systems or Equipment 21
Energy Isolation and Control Methods Administrative Controls Procedures Double isolation (typically for systems with >200 F or >500 psi) Use of lock boxes 22
Energy Isolation and Control Physical Controls Methods Locking components (may require use of chains, lock bars, etc.) Release of stored energy (venting, draining, etc.) 23
Equipment Shutdown and Isolation Review the proposed work to clearly understand what equipment will be involved All energy isolation devices needed to control the energy to the equipment must be physically located and operated in such a manner that will isolate the equipment from the energy source(s) This includes a review of related system schematics, piping and instrument diagrams, electrical diagrams, electrical panel schedules, or as-built drawings, as applicable, for hazardous energy sources 24
Equipment Shutdown and Isolation Before turning off equipment, the employee must understand the: type and magnitude of the energy hazards of the energy to be controlled method or means to control the energy Affected Employees shall be notified of the Lockout/Tagout application before these controls are applied 25
Energy Isolation and Control Methods Safety tags and administrative locks are NOT used as a means of personnel protection from exposure to hazardous energy during servicing or maintenance and are NOT to be used as a substitute for a LO/TO The use of safety tags and administrative locks are restricted to those situations in which a component or system is functional, but when a precaution or other information is necessary prior to operation 26
Single Source Criteria 27
Single-Source Criteria 1. The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees; 2. The machine or equipment has a single energy source which can be readily identified and isolated; 3. The isolation and locking out of that energy source will completely de-energize and deactivate the machine or equipment; 28
Single-Source Criteria 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 lockedout condition for the entire machine or equipment; 6. The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; 29
Single-Source Criteria 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 servicing or maintenance. IF all responses are True, THEN a LO/TO permit is not required. IF any response is False, THEN a LO/TO permit is required. 30
Machine or Equipment Shutdown Where possible, blank lines or double block and vent when working with equipment that contains hazardous materials The equipment may require shutdown using an orderly method to avoid any additional or increased hazards to employees 31
Lockout/Tagout Devices and Application Electrical Lockout Devices There are different manufacturers and types of molded case circuit breaker LO devices Some devices are made to be applied on specific kinds of breakers (Westinghouse, GE, single phase, three phase, single pole, double pole) Be sure the device will meet the same substantial protection requirements as a lock If unsure that the correct device is being used, ask your supervisor for guidance 32
Lockout/Tagout Devices and Application What do you do if a lockout device does not fit the isolation point? 33
Lockout/Tagout Devices and Application Each authorized employee performing work on equipment to be locked out shall have a personal lock(s) exclusively for his/her use Personal lock(s) shall be applied to the applicable device (energy isolation device, multi-lock hasp, or lockbox) before work begins on the equipment and removed when work is complete Only the employee who installed the personal lock has authority to remove it* 34
LO/TO Tags Complete a "Danger - Do Not Operate" tag for each isolation point 35
Equipment Shutdown Authorized Employee Notify affected personnel of the equipment to be locked out Verify the LO/TO device description on the tag(s) matches the description of the equipment being locked/tagged out 36
Equipment Shutdown Shut down the equipment Isolate, and lock out the affected equipment by placing it into the desired configuration When performing shutdown and isolation, all requirements should be completed for each item before moving to the next item 37
Machine or Equipment Isolation Authorized persons place each energy isolation device into the required position 38
Lockout or Tagout Device Application Authorized person applies the assigned Lockout lock and associated "Danger - Do Not Operate" tag, and, if applicable, an energy isolation device for each energy isolation point, and controls the key for each lock. 39
Relieve Stored Energy After the equipment has been locked/tagged, all stored or residual energy must be released. Methods for the release of stored energy include, but not limited to, the following: Discharge and grounding of capacitors Bleeding pressure from vessels and lines Releasing mechanical sources of energy to engage blocks Inform nearby personnel of the expected energy release (e.g., noise) 40
Relieve Stored Energy Release stored energy in a controlled, appropriate manner (e.g., make provisions to collect liquids and minimize spray or splash if depressurizing a liquid service line) If stored energy is re-accumulating, stop work and notify the supervisor to reevaluate for appropriate corrective action 41
Independent Verification The supervisor assigns another Authorized Person to perform an Independent Verification of the LO/TO The assigned Independent Verifier verifies the LO/TO has been correctly implemented 42
Independent Verification Verify the following: The device description recorded on the LO/TO tag matches the description of the equipment being locked out Each LO/TO lock and tag is installed on the correct component Each component is in the required position listed on the permit 43
Independent Verification If an inconsistency is discovered, stop and notify the supervisor The supervisor, or designee, resolves the issue (e.g., by physically verifying the position of the component in question) If repositioning is required, the supervisor will approve After independent verification steps are completed, perform verification of isolation 44
Verification of Isolation The authorized employee must verify that the machine or equipment has been properly isolated and de-energized; including performing a zero-energy check to verify the effectiveness of the lockout by attempting to operate the equipment, inspecting mechanical blocks/chocks, or ensuring that vent valves are open/unobstructed 45
Application of Individual and/or Group Lockouts The Supervisor or Designee: Places a supervisor lock on a single energy source isolation device using a multi-lock hasp, or places the keys for multiple energy isolation device locks in a lockbox and places a supervisor lock on the lockbox The Supervisor: Retains control of all supervisor lock keys 46
Application of Individual and/or Group Lockouts Authorized Personnel: Place a personal lock and tag on the multi-lock hasp or over-lock the lockbox Retain control of the key to personal locks Perform, or ensure a representative of the organization performing the work has performed, a zero-energy check to verify that all hazardous energy associated with the equipment are properly locked out and effectively isolated 47
Removal of Lockout Ensure all personnel, tools, loose parts, etc., are clear of the equipment Replace safety guards Remove locks and tags Notify affected employees of the lockout removal 48
Temporary Suspension 49
Temporary Suspension In situations in which lockout or tagout devices must be temporarily removed from the energy isolating device and the machine or equipment energized to test or position the machine, equipment or component thereof, the following sequence of actions shall be followed: 50
Temporary Suspension Clear the machine or equipment of all tools and materials Remove employees from the machine or equipment area Remove the lockout or tagout devices as specified Energize and proceed with testing or positioning De-energize all systems and reapply energy control measures following the same requirements of the initial LO/TO to continue the servicing and/or maintenance 51
Temporary Suspension Inspect the work area and review other work on the same system to determine if it is safe to remove the necessary LO/TO device(s) The supervisor authorizes the temporary suspension Remove the necessary locks/tags Position the device(s) in the required position for testing, inspecting, or temporary service 52
Temporary Suspension Return the locks, keys, and tags to the supervisor The supervisor retains the locks, keys, and tags for re-use if the protection is to be reapplied If test or inspection indicate the LO/TO protection is no longer required, notify the supervisor and obtain approval to place the equipment back in service Authorized personnel remove remaining locks and notify affected employees that the equipment is back in service 53
Temporary Suspension If further maintenance or service is required, the supervisor authorizes the LO/TO protection to be re-applied Authorized personnel reapply the LO/TO protection by positioning the device(s) in the required position The supervisor places the keys in the lockbox and over-locks the lockbox; then, authorized personnel apply a personal lock to the lockbox 54
Temporary Suspension Perform Independent Verification Verify the correct device(s) have been placed in the required position Verify locks/tags are properly applied and secured Perform applicable zero-energy checks 55
Shift Changes Oncoming and off-going supervisor(s) review new LO/TO work and any changes to current LO/TO status The keys and responsibility for the supervisor(s) lock on current LO/TOs are transferred to the on-coming supervisor 56
Failure to Clear Personal Lock Document lock removal If an authorized employee fails to remove his/her personal lock at the end of the shift, the supervisor: Verifies that the employee who applied the lock is not on site Makes all reasonable efforts to contact the person who applied the lock to inform them that the lock needs to be removed Documents the phone calls/pager calls *This form is attached to the applicable LO/TO Permit package 57
Failure to Clear Personal Lock If the authorized person cannot be contacted, investigate the situation and verify that removal of the lock will not create a hazard in the work zone If no hazards in the work zone will be created, the supervisor authorizes the lock to be cut and to restore energy to the equipment The supervisor ensures that the authorized employee is informed that their lock has been removed as soon as the employee returns to work 58
Failure to Clear Personal Lock When the authorized employee who applied the lockout or tagout device is not available to remove it, that device may be removed under the direction of the employer, provided that specific procedures and training for such removal have been developed, documented and incorporated into the employer's energy control program. 59
Failure to Clear Personal Lock The employer shall demonstrate that the specific procedure provides equivalent safety for the removal of the device by the authorized employee who applied it. 60
Failure to Clear Personal Lock The specific procedure shall include: Verification by the employer that the authorized employee who applied the device is not at the facility Making all reasonable efforts to contact the authorized employee to inform him/her that his/her lockout or tagout device has been removed; and Ensuring that the authorized employee has this knowledge before he/she resumes work at that facility 61
Periodic Inspections The employer shall conduct an inspection of the Energy Control Program at least annually to ensure it is being followed Shall be performed by an authorized employee other than the one(s) utilizing the energy control procedure being inspected Where lockout is used for energy control, the inspection shall include a review between the inspector and each authorized employee of that employee s responsibilities under the energy control procedure being inspected* 62
Periodic Inspections The inspection is recorded in a written report that includes the following information: Date of the inspection Machine or equipment involved in the LO/TO Names of authorized personnel performing the LO/TO Names of authorized personnel conducting the inspection Observations and findings noted during the inspection, both positive and negative 63
Training Requirements Training shall be provided 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. 64
Training Requirements Training shall include the following: Each Authorized Employee shall receive training in the recognition of hazardous energy sources, the type and magnitude of the energy 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 the energy control procedures All training shall be documented and include the employee s name and date of training. 65
Training Requirements Retraining shall be: Provided for Authorized and Affected Employees whenever there is a change in job assignments, a change in machines, equipment or processes that presents a new hazard, or when there is a change in the energy control procedure Performed whenever the periodic inspection reveals that there are deviations from or inadequacies of the employee s knowledge of the energy control procedure 66
Summary All personnel completing this training are Authorized Personnel for LO/TOs Energy Source Identification resources include: Drawing reviews Walkdowns Hands-on check of equipment Historical process knowledge Energy Sources Include: Electrical Pressurized Systems Mechanical 67
Summary Isolation Methods Include: Positive physical component locking Release of stored energy Double isolation of high energy systems Use of locks and lock boxes Human Performance: Self-Check Procedure Adherence Independent Verification Questioning Attitude Know Your Limits Good Communication Skills 68
Questions 69