The Proper Procedure
Lockout Lockout is used to prevent the release of hazardous energy or equipment from starting by applying a lockout device and lock A padlock is placed on the appropriate energy isolating device that secures equipment in the off or closed position
Tagout Tagout is the placement of a tag on the lockout device that identifies: The person who placed the lock The date of lockout
The Fatal Five Causes of Lockout/Tagout Injuries Failure to stop equipment Failure to disconnect from power source Failure to dissipate (bleed, neutralize) residual energy Accidental restarting of equipment Failure to clear work areas before restarting
Definitions Authorized Employee one who is trained in the procedures to lockout the specific machines or equipment in order to perform the adjustments or maintenance Affected Employee one whose job duties are interrelated to the operation of the equipment being locked out. Example: a person that feeds product to the equipment being shut down
Definitions (continued) Energy Isolating Device A mechanical device that physically prevents the equipment from being turned on and/or the transmission or release of energy
Electrical Energy Isolating Devices Circuit Breaker Lockout Plug Lockout Multiple Lockout Device
Other Energy Isolating Chemical Hydraulic Pneumatic Devices Pressure Temperature or chemical Gate or wheel valve lockout Ball or lever valve lockout Pancake / blind
Energy Isolating Devices Gravity Isolation Blocks or other locking mechanisms supplied from the equipment manufacturer must be used
Hazardous Energy Sources Found in the Workplace Electrical Generated AC from electric company Static (stored) Batteries Capacitors
Hazardous Energy Sources Found in the Workplace Mechanical Transitional Rotational
Hazardous Energy Sources Found in the Workplace Chemical Ammonia Nitrogen Hydrogen Propane Caustics Acids
Hazardous Energy Sources Found in the Workplace Potential Pressure Hydraulic Pneumatic Vacuum Springs Gravity
Hazardous Energy Sources Found in the Workplace Thermal Machines or Equipment Steam Hot liquids
6-Step Lockout Procedure Alert all affected employees that equipment is being locked out. Properly shutdown and deactivate equipment Dissipate any stored energy Properly isolate ALL energy sources Apply lockout devices and tags VERIFY LOCKOUT
Lockout Procedure (continued) EACH ENERGY SOURCE MUST BE ISOLATED May require more than one lock per person EACH EMPLOYEE MUST INSTALL THEIR OWN LOCK
Lockout Procedure (continued) ONLY POWER DISCONNECTS MAY BE USED FOR ELECTRICAL LOCKOUT Field start/stop switches are not to be used Equipment limit switches are not suitable for electrical energy isolation
Electrical Disconnect
Restart Procedure Remove all tools and loose items Reinstall guards Alert all affected employees that equipment is being turned back on Remove lockout devices Restart using proper startup procedures
Special Situations #1 When servicing lasts longer than one shift You and your relief exchange locks at shift change time. OR Your supervisor locks the equipment in the interim. NO EQUIPMENT SHOULD BE LEFT UNLOCKED IN AN UNSAFE CONDITION
Special Situations #2 When contractors are performing service or maintenance at your workplace There should be a company representative overseeing the contractor s project who will coordinate all lockouts with the Contractor s Representative
Special Situations #3 When the equipment has more than one energy source. OSHA wants to see a written procedure for proper lockout fir each piece of equipment The starter or disconnect should indicate that the equipment is Multiple Energy Source Consider developing a master MES form to be completed and made available to employees to use for reference during the lockout process
Special Situations #4 The employee is required to take a copy of the form with him/her unless: The lockout procedure is posted on the equipment or The lockout process is redundant, (i.e. the employee locks this equipment out numerous times and is familiar with the specific lockout requirements)
Special Situations #5 When the number of employees placing locks makes it impractical for each to lockout all energy sources GROUP LOCKOUT is performed
Special Situations #5 GROUP LOCKOUT THREE STEP PROCEDURE Supervisor performs the lockout of each energy source Supervisor and employees attempt to restart the equipment
Special Situations #5 GROUP LOCKOUT Keys are placed in a lockbox and each employee places a lock on the box
Tidbits Locks and keys are provided by the company Only keyed locks are permitted Never loan or share your lock or key with anybody else If you misplace your lock or key, see your supervisor to get a new one
Tidbits (continued) Identify all energy sources that need to be locked out. For equipment with multiple types of energy develop a written lockout procedure and post it for that equipment on the local disconnect and/or on the equipment.
Tidbits (continued) If a piece of equipment is to be removed from service for an extended period or permanently (NIU), the starter should be tagged accordingly and the fuses pulled. (Normally a maintenance activity) Plugged in equipment does not need a plug lock IF the plug is in your sight and control during your work on the equipment. It need only be unplugged.
Tidbits (continued) A common thing missed by many is failure to conduct a periodic inspection of several lockout to ensure the process is being done correctly. OSHA will ask if you have certified your workers lockout.
Tidbits (continued) As with any other sign around the plant, OBEY IT If you happen on a situation that you do not understand (i.e. why the equipment is locked out) ask your supervisor
Accident Statistics 1992 2002 2,942 work related fatalities Average 267/year Every 36 hours an electrical related death at home Electrocution and fires
Reasons for Electrical Accidents 95% Unsafe Practices People becoming part of the circuit 5% Unsafe Conditions
Question If the AC current required to light a 15 watt, 120 V bulb passed through your chest for 1 second, could it kill you? Volts V = 120 V Current I =??? Wattage P = 15 W
Electricity Review I = P / V = (15 W) / (120 V) =.125 amp = 125 milliamps Volts V = 120 V Current I =??? Wattage P = 15 W
Electrocution Threshold
Answer If the AC current required to light a 15 watt, 120 V bulb passed through your chest for 1 second, could it kill you? YES! Most people have a natural fear of electricity because they cannot see it and usually don t understand it. The fear helps protect them.
Class II Application Those areas of a facility made hazardous by the presence of combustible dust Grain elevators; Flour and feed mills; Producers of starch or candies; Spice grinding plants, sugar plants and cocoa plants.
A Class II, Division 1 location is a location: (a) In which combustible dust is or may be in suspension in the air under normal operating conditions, in quantities sufficient to produce explosive or ignitable mixtures; or (a) where mechanical failure or abnormal operation of machinery or equipment might cause such explosive or ignitable mixtures to be produced, and might also provide a source of ignition through simultaneous failure of electric equipment, operation of protection devices, or from other causes,...
Class II, Division 1 May apply to: Head houses Bin floors (top of bins with open conveyors) Open transfer points Tunnels with open conveyors Milling operations with dust normally in air
A Class II, Division 2 location is a location in which: (a) combustible dust will not normally be in suspension in the air in quantities sufficient to produce explosive or ignitable mixtures, and dust accumulations are normally insufficient to interfere with the normal operation of electrical equipment or other apparatus; or (b) dust may be in suspension in the air as a result of infrequent malfunctioning of handling or processing equipment, and dust accumulations resulting therefrom may be ignitable by abnormal operation or failure of electrical equipment or other apparatus.
Class II, Division 2 May apply to: Totally enclosed conveyor areas Milling equipment the is totally enclosed Good exhaust ventilation and dust control Areas adjacent to Class II, Division 1 areas
Final Consideration Electrical Equipment should also be rated for Group G (Flour, starch, grain, combustible plastic or chemical dust (explosive) Therefore equipment should be rated as: Class II, Division 1, Group G normally dusty areas Class II, Division 2, Group G not normally dusty areas
Many citations are about the obvious. Everyone should be on the look out for the obvious. Examples: Junction box with no cover plate. Cover left off a conduit elbow. Disconnect boxes being left open and full of dust. Wires hanging out of junctions. Frayed wires.
Many citations are about the obvious. Improper use of extension cords, not appropriate for a hazardous area, repaired with tape poorly done Unapproved equipment brought in hazardous areas: radios, heater, hot plates Knockout holes left open in an electrical box
Many citations are about the obvious. Light bulbs with no globes or protection cage to help keep them from being hit when in low areas Take the challenge look for these and have your workers look. Catch your own problems
Any Questions?