University of Illinois Chicago Lockout/Tagout - The Control of - - PowerPoint PPT Presentation

University of Illinois Chicago Lockout/Tagout - The Control of Hazardous Energy

29 CFR 1910.147

Why Lockout Tagout ?

♦ Worker injuries, illnesses and fatalities

5,190 workers were killed on the job in 2016 on average, more than 99 a week or more than 14 deaths every day

♦ Lockout Tagout is the 5th most cited

standard that OSHA issues citations

Video – LOTO Accident

Requirements for LOTO

The OSHA standard covers the “servicing and maintenance

• f

machines and equipment in which the unexpected energization or start-up of the machines or equipment, or release of stored energy, could harm employees. This standard establishes minimum performance requirements for the control

• f

such hazardous energy.”

When is LOTO required?

Servicing or Maintenance activities that require any of the following:

♦ Removal of a guard or other safety

device

– A panel or a door is included in this list

♦ An employee is required to place any

part of the body into a danger zone on a piece of equipment (point of operation, machine operating cycle)

Video – LOTO Overview

Exception – Cord and Plug

OSHA allows for some exceptions:

– Cord and plug connected equipment where the cord is in the exclusive control of the employee performing the servicing, when electricity is the ONLY form of hazardous energy to which employees may be exposed.

Exceptions – Hot Tap

Hot tap operations involving transmission and distribution systems for substances such as gas, steam, or oil, when they are performed on pressurized pipe lines, provided that the employer demonstrates the following: – Continuity of service is essential – Shutdown of system is impractical; and – Documented procedures are followed, and special equipment is used which will provide proven effective protection for employees (NEC 70E is followed)

• Steam
• Hot Water
• Electrical

Exception – Minor Tool Changes

♦ Lockout/Tagout is not required for minor

tool changes or other minor servicing activities that are routine, repetitive, and integral to production, and that occur during normal production operations when employees have effective, alternative protection.

Employee Involvement - LOTO

♦ 3 types of employees under LOTO

– Authorized - An employee who is qualified, through training, to lockout and tagout a machine or equipment in order to perform service or maintenance on the machine or equipment. – Affected - An employee who normally works on or near a machine that must be locked out for maintenance. – Other - An employee, other than the authorized or affected employee, whose work operations are, or may be, in an area where energy control procedures may be utilized.

Employee Involvement at UIC – LOTO (cont ntinue nued) d)

♦ Authorized Employees – Building

Engineers, Utilities, Electrical, Plumbing and others

♦ Affected/Other –Building Occupants,

Faculty, Management/Supervisors

Controlling Energy Sources

Energy sources that require lockout/tagout

♦ Electrical ♦ Mechanical ♦ Pneumatic ♦ Hydraulic ♦ Chemical ♦ Thermal ♦ Water under pressure ♦ Gravity ♦ Potential

Controlling Energy Sources

Some problems of hazardous energy: – Accidental start-ups – Electric shock – Release of stored, residual, potential energy

The Lockout/Tagout Procedure

♦ The scope and purpose of lockout/tagout ♦ How to perform a shutdown

– Isolating – Blocking – Securing machines – Equipment

♦ How to place, remove, and transfer locks ♦ How to test the machine and make sure it’s

locked out

Magnitude of energy

♦ What voltages are present in

mechanical rooms?

♦ What pressures are steam, hot water,

and oxygen lines at?

♦ Other?

Methods and Means for Isolation

♦ How are electrical feeds shut down? ♦ How are pressurized lines shut down or

isolated?

♦ Other?

RULES – LOTO EQUIPMENT

LOTO Devices (locks and tags) must:

♦ be unique to the individual using the device. The

devices shall only be utilized for lockout purposes;

♦ clearly identify the individual who applied the device; ♦ be sturdy, durable, and able to withstand the

environment they will be used in, and to prevent accidental removal;

♦ Be standardized according to shape, color, and size.

Tags must be legible and understandable to all

• employees. They must warn employees about the

hazards if the machine is energized, and offer employees clear instruction such as “DO NOT START, DO NOT OPEN, DO NOT ENERGIZE”

Built-in Locks

– If an isolating device has a built-in locking mechanism, such as a Kirk-key lock, then it can be used as a locking device and it is not necessary to affix an additional padlock. – A personal tag properly dated, signed with name of authorized employee and department or company must be attached to the built-in lock to indicate that work is being done

• n the circuit or equipment.

– If there is more than one person involved, the group lockout tagout procedures should be used.

Keys

♦ Each lock has two keys, primary and

emergency.

– primary key with authorized employee – emergency key must be kept in a secured area (e.g. a lock box) with access limited to the authorized employee only.

Prohibitions

UNDER NO CIRCUMSTANCES SHOULD ANY EMPLOYEE ATTEMPT TO RESTART OR REENERGIZE MACHINES OR EQUIPMENT WHICH ARE LOCKED AND/OR TAGGED OUT.

Tags Only - PROHIBITED

IF YOU ENCOUNTER EQUIPMENT THAT CANNOT BE LOCKED OUT, REPORT TO YOUR Chief Engineer, Manager: DO NOT PROCEED WITH WORK

♦ Limitations – Tags are warning devices only; they 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 can only be removed by the authorized person that installed it

♦ Tags must be made of material that can withstand the

environment they’re in

♦ Tags must be secured well ♦ Tags evoke a false sense of security; their meaning

must be understood.

Sequence of LOTO

• 1. Prepare for Shutdown
• 2. Shut down machine with

normal stopping procedure

• 3. Disconnect or isolate the machine from

the energy source

• 4. Apply the lockout and tagout device
• 5. Release or restrain all potential forms of

hazardous or stored energy

• 6. Verify

Preparing for a Shutdown

Before turning off machines you must know:

♦The type and magnitude of energy

involved

♦Associated hazards ♦Control methods

Performing a Shutdown

• 1. Notify affected employees of lockout

procedure

• 2. Locate all energy sources
• 3. Follow procedures to shut down

machine

Isolating Equipment and Applying Lockout Devices

Every power source has its own procedure

♦ Lockout

– Accomplished by pulling a plug – Opening a disconnect switch – Closing a valve – Bleeding a line – Placing a block in the equipment

Isolating Equipment and Applying Lockout Devices

♦ After completing the shutdown, turn off the

energy at the main power source

♦ Using a designated lock, lock out all

energy sources involved

♦ Attempt to restart the

machine to guarantee power is shut off

♦ RETURN THE CONTROL

KNOB TO THE OFF POSITION

Isolating Equipment and Applying Lockout Devices

If several people are needed a MULTIPLE LOCKOUT DEVICE is used to accommodate several locks at once (see Group Lockout Procedures) AUTHORIZED EMPLOYEES MAY NEVER USE ANOTHER EMPLOYEE’S LOCK AND NEVER LEND THEIRS

Safe Release of Stored Energy

Before servicing or maintenance begins

♦ Equipment must be at “Zero energy

state”

– Drain all valves – Bleed off air from system – Eliminate stored hydraulic pressure – Test the machine to make sure all energy was disconnected or released – Lower raised parts – Place blocks where needed

Restoring Power

All tools removed Replace all machine guards Employees are clear of machine Notify affected employees the that the

lockout has been removed

Machine can be restarted

Lockout Tagout Device Removal

♦ Each lock and tag should be removed only by the employee that

placed the lock. – WHY?

♦ EXCEPTION: when an employee that placed the lock is not

available to remove the lock and tag, it may be removed under supervisor/manager control, with the following steps in place: – All attempts have been made to locate employee on site (check break areas) – The employee’s personal /home phone has been called – It is confirmed that the employee is no longer on site (badge, time clock, etc…) – The employee is notified that the lock/tag have been removed prior to resuming work at the facility. – ALL OF THIS MUST BE DOCUMENTED

Testing or Positioning of Machines

If lockout or tagout devices must be temporarily removed to test or position the machine, the following sequence will be followed:

• 1. Clear the equipment of tools
• 2. Remove employees from the equipment
• 3. Remove the LOTO devices
• 4. Energize and proceed with testing
• 5. De-energize and follow LOTO

procedures

Group LOTO or Procedures Involving More Than One Person:

If more than one individual is required to lockout and tagout equipment:

♦ Each employee must be properly trained ♦ Each authorized employee must place his/her own

personal lockout device and tagout device on the energy isolating device(s)

♦ Group LOTO and shift or personnel changes must be

documented in Shop Log.

Group LOTO (continued)

When an energy isolating device cannot accept multiple locks or tags, a multiple lockout or tagout device (such as a hasp) may be used. If you encounter a piece of equipment that cannot accept a hasp, notify your supervisor prior to beginning work

Employee Retraining

♦ For all authorized and affected

employees whenever there is a change in job assignment, change in machines, equipment or processes that present a new hazard, or when there is a change in LOTO procedures

♦ When there are deviations from the

employee’s knowledge or use of the LOTO procedure

♦ Must establish employee proficiency

Contractors/Vendors

♦ Coordinate LOTO activities with Project Engineers

– Pre-work visual inspection and approval

♦ Participate in required training. ♦ Perform LOTO procedures in accordance with the UIC

Hazardous Energy Control Program requirements.

♦ Perform LOTO procedures in accordance with

Equipment Specific Lockout Procedure (ESLP).

♦ Contractors will use their own LOTO equipment

Shift Change

♦ Shift and Personnel Changes

– When a LOTO is being performed and it goes longer than one shift, the first employee’s lock must stay on the machine until the second employee comes to apply their lock. OR – When an employee is leaving for the day, and the LOTO work is not complete, the employee will apply an “OUT OF SERVICE” lock and tag. This will stay

• n the equipment until the employee returns to

continue the work. Before continuing work, the employee must confirm that the LOTO (de- energizing) remains in tact.

Shift Change (continued)

– If this does not occur, the entire lockout sequence must be re-performed. NEVER ASSUME EQUIPMENT IS DE- ENERGIZED IF LOCKS AND TAGS HAVE BEEN REMOVED.

DOCUMENTATION

Group LOTO and shift

• r

personnel changes must be documented in Shop Log by Utilities or Building Engineers

Training and Audit Requirements

TRAINING

• Authorized employees
• Recognize hazardous energy sources
• Type and magnitude
• How to perform lockout/tagout
• Affected employees
• Trained in the purpose and use of

lockout/tagout

• Others: instructed on purpose of use

Training and Audit Requirements

♦ Inspections and audits

– Performed on authorized employee

♦ Retraining must be done

– Changes in equipment – Job assignment – Audit shows deficiencies with procedure

Energy Control Procedure – Purpose and Use

Energy Control Procedure – Purpose and Use

Electrical

Hydraulic

Natural Gas

Chilled Water

Hot Water

Chemical

Transfer Switch

Stored Energy

Lockout / Tagout It’s your Right and Your Life

CONCLUSION

• Write your name on Locks, Tags, and

Bag

• If you need more locks or devices see

you supervisor or EHSO

• Fill out the Survey
• Sign form you received a lock kit
• Test

♦ All Authorized Employees will have a

hands on demonstration later