nwacc business & industry workforce development institute j- 1 control of hazardous energy...

NWACC Business & Industry Workforce Development Institute

J- 1

CONTROL OF HAZARDOUS CONTROL OF HAZARDOUS ENERGY ENERGY

(LOCKOUT/TAGOUT) FOR (LOCKOUT/TAGOUT) FOR GENERAL INDUSTRYGENERAL INDUSTRY


J- 2

COMMON QUESTIONS ABOUT LOCKOUT/TAGOUT

WHAT IS LOCKOUT/TAGOUT? IS IT NECESSARY?

WHAT ARE LOCKS AND TAGS AND HOW ARE THEY USED? WHO IS RESPONSIBLE FOR THEM?

ARE WRITTEN PROCEDURES REQUIRED?

WHAT ABOUT TRAINING?

WHAT IS THE PROCEDURE FOR LOCKOUT/TAGOUT?


J- 3

LOCKOUT/TAGOUT IS THE CONTROL OF HAZARDOUS ENERGY DURING SERVICING AND MAINTENANCE OF OF MACHINES AND EQUIPMENT.

UNEXPECTED ENERGIZATION OR RELEASE OF STORED ENERGY CAN INJURE AND KILL.

29 CFR 1910.147(c) requires the employer to establish an energy control program if the danger of unexpected releaseof energy exists


J- 4

HUNDREDS OF WORKERS ARE KILLED AND HURTEACH YEAR MAINTAINING EQUIPMENT!

CASE STUDY: An employee cleaning scrap from beneath a large shear is is decapitated when another employee pushes the control button. There is no procedure for lockout of the shear.

CASE STUDY: An electrician is electrocuted while performing maintenance on a motor control circuit. A procedure existed but the electrician wanted to save time, and did not follow it.


J- 5

LOCKS: IN LOCKOUT/TAGOUT, A LOCK IS USEDFOR HOLDING AN ENERGY ISOLATING DEVICE SUCH AS A VALVE OR SWITCH, IN A POSITION THAT WILL PREVENT ACTIVATION.

LOCKS MUST USE KEYS OR COMBINATION LOCKS

LOCKS AND TAGS ARE UNDER THE EXCLUSIVECONTROL OF THE EMPLOYEES PERFORMING THE WORK !


J- 6

TAGS: IN LOCKOUT TAGOUT, A TAG IS A WARNINGPLACED ON OR NEAR THE ENERGY ISOLATING DEVICETO ALERT OTHERS NOT TO OPERATE THE DEVICE.

DO NOT STARTDO NOT OPENDO NOT CLOSEDO NOT ENERGIZEDO NOT OPERATE

DO NOTSTART

DANGER


J- 7

TAGS CANNOT BE USED WITHOUT LOCKS UNLESS IT IS INFEASIBLE OR HAZARDOUS TO LOCKOUT AN ISOLATING DEVICE.

SOME POINTS ABOUT TAGS

TAGS MUST BE STANDARDIZED AS TO AT LEASTONE OF THE FOLLOWING: FORMAT, COLOR, SHAPE,SIZE, TYPE.TAGS MUST BE CLEARLY VISIBLE AND DISTINCTIVE.

TAGS MUST BE DESIGNED TO DETER UNAUTHORIZED REMOVAL.ATTACHMENT MEANS MUST BE NON-REUSABLE.


J- 8

IF A LOCK CANNOT BE USED DUE TO INFEASIBILITY OR INCREASED HAZARD,ONE ADDITIONAL SAFETY MEASUREMUST BE USED.

EXAMPLES:REMOVE AN UPSTREAM DISCONNECT.BLOCK AN UPSTREAM DISCONNECT.LOCK OUT AND TAG UPSTREAM DISCONNECT.GROUND A CIRCUIT BEING WORKED ON.


J- 9

Are Written Procedures Are Written Procedures Required?Required?

Written procedures are generally required. Written procedures are generally required. 1910.147 (c)1910.147 (c)

Procedures must include scope, purpose, Procedures must include scope, purpose, authorization, techniques, rules, responsibilities authorization, techniques, rules, responsibilities and training. and training.

Annual audits and inspections are required to Annual audits and inspections are required to verify the effectiveness of the procedures unless verify the effectiveness of the procedures unless they are used. they are used. 1910.147(c)(6)1910.147(c)(6)


J- 10

EXCEPTIONS TO THE RULE:All the following must be true

•No potential for stored energy exists.•There is a single readily identifiable energy source.•Isolating and lockout completely deenergizes the equipment.•A single lock will lockout the equipment.•The equipment is isolated during the work performed.•The lock is controlled by the person doing the work.•No hazard is created for others.•No history of unexpected startup for the equipment exists.


J- 11

DEFINITION: AN AUTHORIZED EMPLOYEE IS ANEMPLOYEE WHO PERFORMS OR PARTICIPATES IN THE LOCKOUT/TAGOUT OPERATION

DEFINITION: AN AFFECTED EMPLOYEE IS AN EMPLOYEE WHO MUST OPERATE THE EQUIPMENTDURING LOCKOUT/TAGOUT OR WHO IS IN THE VICINITY

BOTH AUTHORIZED AND AFFECTED EMPLOYEES MUST BE APPROPRIATELY TRAINED.


J- 12

TRAINING AND COMMUNICATION1910.147(c)(10)

Training and communication must take place before Lockout/Tagout can begin.

All employees involved must have necessary skills.

Other employees in the area may require some training.

Training must cover: required parts of energy control program,elements of applicable procedures, applicable Safety RelatedWork Practices.


J- 13

LOCKOUT/ TAGOUT LOCKOUT/ TAGOUT PROCEDUREPROCEDURE

29 CFR 1910.147(c)


J- 14

Preplanning

Isolation & Control Procedure

Restart Procedure

GENERAL LOCKOUT/TAGOUT PROCEDURE

Step 1

Step 2

Step 3


J- 15

IDENTIFY TYPES & AMOUNTS OF ENERGY SOURCES

IDENTIFY INDIVIDUAL EQUIPMENT & LOCATION

LOCATE & IDENTIFY DISCONNECT & ISOLATING DEVICES

VERIFY/DETERMINE POWER SHUTDOWN & POWER UP PROCEDURES

NOTIFY ALL AFFECTED EMPLOYEES

PREPLANNINGBLOCK DIAGRAM

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5


J- 16

STEP 1 IDENTIFY TYPES & AMOUNT OF ENERGY SOURCES

TYPES OF ENERGY: MECHANICAL, ELECTRICAL, HYDRAULIC, THERMAL, AIR, CHEMICAL, ETC.

STEP 2 IDENTIFY INDIVIDUAL EQUIPMENT & LOCATION

ELECTRICAL MOTORS, MACHINES, CONTROLLERS, DISTRIBUTION PANELS, ETC.


J- 17

STEP 3 LOCATE AND IDENTIFY DISCONNECTS AND ISOLATING DEVICES

CIRCUIT BREAKERS, SWITCHES, VALVES, BLOCKS, GATES, ETC.

STEP 4 POWER SHUTDOWN AND POWER UPPROCEDURES

SEQUENCE PROCEDURES, PROCESS CONTROL DIAGRAMS, SINGLE ELECTRICAL ONE LINE DIAGRAMS, ETC.


J- 18

STEP 5 NOTIFY ALL AFFECTED EMPLOYEES

ENSURE ALL PERSONNEL AND UNNECESSARY EQUIPMENT ARE REMOVED.


J- 19 SHUTDOWN, ISOLATION & CONTROL

PROCEDURE BLOCK DIAGRAM

PREPARATION FOR SHUTDOWN

EQUIPMENT SHUTDOWN

ISOLATE EQUIPMENT

APPLY LOTO DEVICES

CONTROL STORED ENERGY

VERIFY ISOLATION

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

STEP 6


J- 20

STEP 1 PREPARE FOR SHUTDOWNAUTHORIZED EMPLOYEE TO DIRECT EQUIPMENT SHUTDOWN

STEP 2 EQUIPMENT SHUTDOWN AUTHORIZED EMPLOYEE DIRECTS EQUIPMENT SHUTDOWNWITH AUTHORIZED PROCEDURES.

STEP 3 ISOLATE EQUIPMENTUSE THE DISCONNECTING MEANS TO REMOVE ENERGY SOURCES.

STEP 4 APPLY LOCKOUT/TAGOUT DEVICES

FOLLOW PROCEDURES FOR INDIVIDUAL, GROUP, OR CONTRACTOR LOCKOUT. WATCH FOR SHIFT CHANGES.


J- 21

STEP 5 CONTROL STORED ENERGY

DISCHARGE CAPACITORS, RELEASE PRESS FLYWHEELS,DOUBLE BLOCK & BLEED LINES, ETC.

STEP 6 VERIFY ISOLATIONACTIVATE CONTROLS, MAKE CIRCUIT MEASUREMENTS, ETC.


J- 22

FOLLOW PROCEDURES FOR RELEASE FROM LOCKOUT/TAGOUT

INSPECT AREA TO ENSURE NON-ESSENTIALS REMOVED & EQUIPMENT INTACT & EMPLOYEES IN “SAFE ZONES”.

NOTIFY AFFECTED EMPLOYEES.

INDIVIDUALS REMOVE THEIR LOCKS & TAGS.

TEST & POSITION EQUIPMENT AS REQUIRED BY PROCEDURES

INFORM REQUIRED PERSONNEL AND RELEASE EQUIPMENT FOR USE.

nwacc business & industry workforce development institute j- 1 control of hazardous energy...

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