control of hazardous energy welcome osha 29 cfr 1910.147 lockout/tagout

CONTROL OF HAZARDOUS ENERGY

WELCOME

OSHA 29 CFR 1910.147

LOCKOUT/TAGOUT

COURSE OBJECTIVES

Teach The Student to Recognize Where Lockout/Tagout Is

Needed. Allow the Student to Develop an Understanding of the the

Local Lockout/Tagout Policy. Introduce Techniques Needed to Select the Appropriate

Lockout/Tagout Devices. Teach the Student to Successfully Conduct Lockout/Tagout

Operations. Introduce the Rules for Safe Lockout/Tagout.

29CFR - Safety and Health Standards

1910 - General Industry

147 - Lockout Tagout Standard

REGULATORY STANDARDCONTROL OF HAZARDOUS ENERGY

29CFR - 1910 - 147

Title - Control of Hazardous Energy

September 1, 1989 - Final Rule Issued January 2, 1990 - Final Rule Took Effect

REGULATORY STANDARD29CFR 1910.147

CIRCUMSTANCES OF INJURY

Injured by Moving Machinery Part. Made Contact With Energized Part. Injured by Physical Hazard (Heat, Chemicals). Injured by Falling Machine Part.

HOW MOST INJURIES OCCURIN ORDER OF OCCURRENCE


1. Unjamming Object(S) From Equipment

2. Cleaning Equipment

3. Repairing Equipment

4. Performing Routine Maintenance

5. Installing Equipment

ACTIVITY AT TIME OF ACCIDENTFREQUENCY OF OCCURRENCE

6. Adjusting Equipment

7. Doing Set-up Work

8. Performing Electrical Work

9. Inspecting Equipment

10. Testing Materials


ACTIVITY AT TIME OF ACCIDENTFREQUENCY OF OCCURRENCE


Afraid of Slow Down in Production. Afraid It Would Take Too Long. Not Required by Company Procedure. Worker Didn't Know Power Was on. Worker Didn't Know How to Turn Off. Did Not Think It Was Necessary. Task Could Not Be Done With Power Off.

REASONS FOR EQUIPMENT NOT BEING TURNED OFF

ON OFF

SYSTEMCONTROLSWITCH


Accidentally Turned on by Injured Employee Co-Worker Accidentally Turned Equipment On Equipment Moved When Jam-up Cleared Equipment Unexpectedly "Cycled" Parts Still in Motion (Coasting)

REASONS FOR EQUIPMENT BEING TURNED ON

ON OFF

SYSTEMCONTROLSWITCH

CASE STUDY #1KILLED BY THE MOVING PARTS OF A SAW

Citation: Failure to Shutdown or Turn off Equipment To

Perform Maintenance.

Narrative: An Employee Was Cleaning the Unguarded Side of

an Operating Granite Saw. The Employee Was

Caught in the Moving Parts Of The Saw and Pulled

Into a Nip Point Between The Saw Blade and the

Idler Wheel, Resulting In Fatal Injuries.

CASE STUDY #2DECAPITATED BY SHEARING MACHINE

Narrative: An Employee Was Removing Scrap From Beneath

a Large Shear When a Fellow Employee Hit the

Control Button Activating The Blade. The Blade

Cycled and Decapitated The Employee Cleaning

Scrap.

Citation: Failure to Shutdown or Turn off Equipment To

Perform Maintenance.

CASE STUDY #3KILLED BY PNEUMATIC DOOR

Citation: Failure to Isolate Equipment From Energy Sources Before Attempting Any Repair, Maintenance or Servicing.

Narrative: An Employee Was Partially Inside of an Asphalt Mixing Machine Changing Its Paddles. Another Employee, While Dusting in The Control Room, Accidentally Hit a Toggle Switch Which Caused the Door of the Mixer to Close, Striking the First Employee on the Head and Killing Him.

Authorized Employee

The Person Who Locks or Tags Out Machines To Perform Servicing or Maintenance.

Affected EmployeeAn Employee Whose Job Requires Him or Her To Operate or Use a Machine or Piece of Equipment On Which Servicing or Maintenance Is Being Performed.

DEFINITION OF EMPLOYEES

Designated Inspector

DEFINITION OF EMPLOYEES

Does Not Utilize the Specific Procedure. The Person Who Inspects the LO/TO Procedure. Is an Authorized Employee.

Authorized Employee

Recognition of Hazardous Energy Sources. Type and Magnitude Energy Sources. Energy Isolation and Control Methods.

TRAINING REQUIREMENTS


Affected Employee

Purpose and Use of The Energy Control Program.


All Other Employees

Procedures and Prohibitions Relating To Attempts to Restart or Reenergize Machines or Equipment Which Are Locked Out or Tagged Out..

Authorized and Affected Employees

Retraining Provided When There Is a: Change in Job Assignment.

Change in Machines, Equipment or Processes.

Change in Energy Control Procedures.

Close-Call Event.

Failure in the Procedures.

Reason to Doubt Employee Proficiency.

RETRAINING REQUIREMENTS

ENERGY CONTROL PROGRAM

1. ENERGY CONTROL PROCEDURES

2. EMPLOYEE TRAINING

3. PERIODIC INSPECTIONS

THREE ELEMENTS TO THE PROGRAM:

DEFINITION OF LOCKOUT

Lockout Is Defined as:

The Placement of a Lockout Device on an Energy Isolating

Device, in Accordance With an Established Procedure,

Ensuring That the Energy Isolating Device and the Equipment

Being Controlled Cannot Be Operated Until the Lockout

Device Is Removed.

DEFINITION OF ENERGY ISOLATING DEVICE

Block Line Valve Disconnecting Switch Manually Operated Switch Any Other Device That Isolates Energy

TYPES OF ENERGY SOURCES

HYDRAULIC

PNEUMATIC

MECHANICAL

RADIOACTIVE

THERMAL

ELECTRICAL

CHEMICAL

TYPES OF ENERGY STATES

STORED ENERGYACTIVE ENERGY

HOT SURFACE110 VOLTS AC

ACTIVE ENERGY

VOLTAGES EXTERNAL PRESSURIZED LINE FEEDS TO THE MACHINE


STORED ENERGY

INTERNAL LINE PRESSURES CAPACITORS SURFACE TEMPERATURES MECHANICAL TENSION (SPRINGS, ETC.) COASTING OF PARTS CHEMICAL (OPPOSING pH) GRAVITY


THE SCOPE OF LOCKOUT/TAGOUT

AREAS REGULATED BY 29 CFR 1910.147:

SERVICING OF MACHINES AND EQUIPMENT MAINTENANCE OF MACHINES AND EQUIPMENT

AREAS NOT REGULATED:

CONSTRUCTION, AGRICULTURE AND MARITIME WORK CONTROLLED BY ELECTRIC UTILITIES ELECTRIC UTILITY INSTALLATIONS OIL AND GAS WELL DRILLING AND SERVICING

ACTIVITIES COVERED

1. Covered If an Employee Must Remove or Bypass Guards or Devices

2. Covered Where Employees Are Required to Put A Body Part in a Machine Process Area

3. Covered Where Employees Are Required to Put A Body Part in a Machine Having a Danger Zone

NORMAL OPERATIONS:

TAGOUT REQUIREMENTS

LOCKEDOUT

This Lock/Tag mayonly be removed by

NAME: _______________DEPT : _______________EXPECTED COMPLETIONDATE: ________________TIME: _________________

DO NOT OPERATE

DANGER

Tags Are Only Warning Devices! Tags Must Be Securely Attached! May Evoke False Sense of Security! Tags Do Not Provide Physical Restraint! Tags Must Never Be Defeated or Ignored! Must Withstand Environmental Conditions! Tags Must Be Legible and Understandable! Tags Are Only Removed by the Responsible Person.

REQUIREMENTS IF TAGOUT IS USED

SOME KEY POINTS ABOUT TAGS:

LOCKEDOUT



DO NOT OPERATE

DANGER

LOCK OUT SEQUENCE OF EVENTS

1. Preparation for Shutdown

2. Shutdown

3. Machine or Equipment Isolation

4. Application of Lockout/Tagout Devices

5. Testing of LO/TO

6. Servicing or Maintenance

7. Removal of LO/TO Devices

8. Reenergization

9. Equipment Reactivation

LOCKEDOUT



DO NOT OPERATE

DANGER

WRITTEN PROGRAM REQUIREMENTS

Maintain a Written Program. Review the Program on an Annual Basis. Develop Detailed Energy Control Procedures. Review Individual LO/TO Procedures Annually. Make the Written Program Available to All Affected

Employees During Each Work Shift.

ALL EMPLOYERS MUST:

ENERGY CONTROL PROCEDURES

29CFR 1910.147 REQUIRES THAT:

Procedures Be Developed, Documented and Utilized for Control of Potentially Hazardous Energy When Employees Are Engaged in the Activities Covered by the Standard.


1. Statement of Intended Use.

2. Steps for Shut-Down and Energy Control.

3. Steps for LO/TO Device Placement, Transfer and Removal.

4. Determination of Responsibility.

5. Steps for Testing LO/TO.

PROCEDURES MUST CONTAIN:

EXCEPTIONS TO THE REQUIREMENTTO HAVE WRITTEN LOTO PROCEDURES

ALL OF THE FOLLOWING EIGHT CONDITIONS MUST EXIST:

1. No Potential for Residual, Stored or Reaccumulation of Energy.

2. Contains Only One Energy Source Which Is Readily Identified

and Isolated.

3. Isolating & Locking Out Results in Complete De-Energization.

4. The Machine or Equipment Is Isolated or Locked Out During

Maintenance.

5. One Lockout Device Will Achieve Complete Lockout.

6. The Lockout Device Is Under Exclusive Control Of An

Authorized Employee

7. Servicing/Maintenance Does Not Produce Hazards For Other

Employees

8. No Previous Energy Control Accident History Exists for the

Employer

EXCEPTIONS TO THE REQUIREMENTTO HAVE WRITTEN LOTO PROCEDURES

ALL OF THE FOLLOWING EIGHT CONDITIONS MUST EXIST:


PROCEDURES INSPECTED ANNUALLY

INSPECTIONS PERFORMED BY - “AUTHORIZED EMPLOYEES” OTHER THAN PRIMARY

LOCKOUT REVIEWED BETWEEN - INSPECTOR AND AUTHORIZED EMPLOYEES

TAGOUT REVIEWED BETWEEN - INSPECTOR AND AUTHORIZED/AFFECTED EMPLOYEES

DATE OF INSPECTION

IDENTIFICATION OF MACHINE OR EQUIPMENT

EMPLOYEES INCLUDED IN INSPECTION

PERSON PERFORMING INSPECTION


ANNUAL INSPECTIONS MUST INCLUDE:

RELEASE FROM LOCKOUT/TAGOUT

1. INSPECT WORK AREA FOR HAZARDS

2. CLEAR ALL EMPLOYEES

3. NOTIFY ALL AFFECTED EMPLOYEES

4. REMOVE ENERGY ISOLATING DEVICES

THE AUTHORIZED EMPLOYEE MUST:

IMPORTANT POINTS TO REMEMBER

WHERE LOCKOUT CANNOT BE USED:

TAGOUT PROCEDURES MUST BE INITIATED

*(Unless It Can Be Demonstrated That Full Protection Can Be Achieved by Other Means)

WHERE LOCKOUT CAN BE USED:

IT MUST BE*

1. Responsibility Vested in a Single Authorized Employee.

2. The Authorized Employee Must Have the Authority To Determine Exposure Status of Group Members.

3. With Multiple Crews the Authorized Employee Must Be Assigned the Responsibility of The Overall Job.

4. The Authorized Employee Shall Affix an Individual LO/TO Device at the Beginning of Work and Remove It at Completion of the Work.

GROUP LOCKOUT/TAGOUT

FOUR SPECIFIC REQUIREMENTS

WHEN THE AUTHORIZED EMPLOYEE IS UNAVAILABLE PROCEDURES MUST INCLUDE, AS A MINIMUM:

GROUP LOCKOUT/TAGOUT

1. Proof That the Employee Who Applied the Device Is Unavailable.

2. A Valid Attempt to Inform the Employee Who Applied the Device, That It Has Been Removed.

3. Adequate Notice to the Employee Who Applied The Device, of the Removal of the Device Before That Employee Returns to Work.

CONTRACTOR SAFETY REQUIREMENTS

OUTSIDE CONTRACTORS MUST:

Inform Representatives of the Facility Of Their LO/TO Procedures and Devices.

COMPANY REPRESENTATIVES MUST:

Inform the Contractor of Internal LO/TO Procedures and Devices.

Ensure That the Contractor(S) Are Following LOTO Procedures.

Remember, You Control Your Facility! Review Their Procedures With Them Before Starting the Job! Determine Their Safety Performance Record! Determine Who Is in Charge of Their People! Determine How They Will Affect Your Employees! Ensure Your Data on Your Facility Is Accurate!

TIPS FOR USING CONTRACTORS

1. Develop and Strictly Adhere to LO/TO Procedures.

2. Establish and Enforce Safe Work Practices.

3. Ensure Proper Training and Supervision.

4. Strengthen and Modify Present Policies.

5. Understand the Relationship Between 29 CFR 1910.147 And

the Business or Industry Involved.

KEY ELEMENTS TO AN EFFECTIVE PROGRAM

EQUIPMENT REQUIREMENTS

1. Durable2. Standardized3. Identifiable4. Substantial

DEVICES AND TAGS MUST BE:

1. Designed to Prevent Accidental Energization.2. Not Designed As a Substitution for Security.

DEVICES AND TAGS ARE:

CASE STUDY #1WORKER KILLED BY MIXING MACHINE

NARRATIVE: An employee was assigned the task of cleaning the inside of a sand mixer. The task was conducted during a break in the production cycle, caused by routine maintenance work. He did this without anyone else’s knowledge. While he was engaged in this, out of sight and hearing of the others, an electrician started the machine, killing the man inside. This plant had a written lockout procedure, training had been given, and all affected employees (including the deceased), were issued keys and locks.

What caused the death of the worker? Do you believe there are multiple causes? Are multiple OSHA Standard violations involved? What could upper management have done? What could the supervisor have done? What could the co-workers have done? To what extent was attitude responsible? To what extent is a lack of written policy responsible? To what extent is a lack of training responsible? Do you believe there is a single cause to this accident that,

if removed would have prevented it?

QUESTIONS TO BE CONSIDERED

LOCKEDOUT



DO NOT OPERATE

DANGER

CASE STUDY #2WORKER KILLED BY HIGH VOLTAGE

NARRATIVE: A 13,800-volt main circuit breaker was under routine inspection. A test instrument was used to check for electrical energy. No electrical energy was detected at the primary power contacts in the circuit breaker. To verify the operation of the tester, the sensitivity was readjusted and checked against a known 120-volt receptacle. The tester was found to be operable. As the journeyman electrician approached one of the contacts with a shop towel, an explosion, engulfed him in flames. The power from the public utility company to the main circuit breaker had not been shut off.




LOCKEDOUT



DO NOT OPERATE

DANGER

CASE STUDY #3WORKER KILLED BY STORAGE MECHANISM

NARRATIVE: A stock handler entered a computer controlled storage and retrieval area apparently to perform stock inventory. While performing this work he was crushed between the robot retrieval vehicle and a third level post, when the vehicle responded to an electronic command. It was found that even though there were a number of disconnect switches on the vehicle and main console none had been used. The plant had no written lockout procedure and workers had not been trained or advised regarding entry into this area.




LOCKEDOUT



DO NOT OPERATE

DANGER

CASE STUDY #4WORKER KILLED BY PARTS UNLOADER

NARRATIVE: The part presence switch to an unloading fixture was sticking on an automatic transfer line. The jobsetter removed a guard and was standing at the side of the line to observe the operation of the switch. He apparently leaned forward just as the unloader actuated; it caught his right side and crushed him between the moving unloader and the support post for the guard. The company had a written lockout program and the employee had attended operator awareness training for control of hazardous energy.




LOCKEDOUT



DO NOT OPERATE

DANGER

CASE STUDY #5DECAPITATED BY SHEARING MACHINE

NARRATIVE: An employee was removing scrap from beneath a large shear when a fellow employee hit the control button activating The blade. The blade cycled and decapitated the employee cleaning scrap. The company had no written lockout procedure and workers had not been trained or advised regarding the hazards associated with machinery.




LOCKEDOUT



DO NOT OPERATE

DANGER

ENERGY CONTROL PROGRAMREVIEW

1. ENERGY CONTROL PROCEDURES

2. EMPLOYEE TRAINING

3. PERIODIC INSPECTIONS

THREE ELEMENTS TO THE PROGRAM:

control of hazardous energy welcome osha 29 cfr 1910.147 lockout/tagout

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