THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT).
-
Upload
madlyn-green -
Category
Documents
-
view
220 -
download
4
Transcript of THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT).
THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT)
THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT)
Lockout/Tagout OverviewLockout/Tagout Overview
Covers the servicing and maintenance of equipment where the unexpected energization or start up of equipment, or release of stored energy could cause injury
Establishes minimum performance requirements for controlling hazardous energy
All new equipment installed after January 2, 1990, must be designed to accept lockout of its energy-isolating device
Lockout/Tagout Overview (continued)Lockout/Tagout Overview (continued)
Promulgated January 2, 1990 Covers 39 million workers Standard intended to
Save 122 lives Reduce 28,400 lost-workday injuries Reduce 31,900 non-lost workday injuries
HistoryHistory
More citations More costly fines 95% of all lockout/tagout citations involve the failure to
have a formal Energy Control Program in place Remains near the top of OSHA’s list of most frequently
violated standard
Related ReferencesRelated References
29 CFR 1910.147, The Control of Hazardous Energy (Lockout/Tagout)
29 CFR 1910.146, Permit-Required Confined Spaces 29 CFR 1910.331-335, Safety-Related Work Practices 29 CFR 1910.269, Electric Power Generation, Transmission, and
Distribution 29 CFR 1926.417, Lockout and Tagging of Circuits
PurposePurpose
Requires employers to train “authorized” employees When and how to shut down machinery Drain and isolate all energy sources Verify the absence of energy Safely restart equipment when maintenance or repair is
complete
Mandated awareness training of “affected” workers (equipment operators, etc.)
ExemptionsExemptions
Construction Agriculture Maritime Installation under the exclusive control of electric utilities
for the purpose of power generation, transmission and distribution, including related equipment for communication or metering
Oil and gas well drilling services
Exemptions (continued)Exemptions (continued)
Servicing and/or maintenance during normal production unless the employee: Is required to remove or bypass a guard or other safety device Is required to place any part of his/her body into an area on a
machine or piece of equipment where:– Work is actually performed upon the material being processed (point of
operation)– An associated danger zone exists during a machine operating cycle
Exemptions (continued)Exemptions (continued)
If work is routine, repetitive, and integral to the use of the equipment for production Minor tool changes Adjustments Other minor servicing activities
Work on cord and plug Must be able to disconnect cord Must be under the exclusive control of the employee
Additional ExceptionsAdditional Exceptions
Machine has no potential for stored or residual energy, or reaccumulation of stored after shutdown
Has a single source that can be easily identified and isolated
Isolating and locking out the energy source will completely de-energize and deactivate the equipment
The equipment is isolated from an energy source and locked out during maintenance
Additional Exceptions (continued)Additional Exceptions (continued)
A single lockout device will achieve a lock condition The lockout is under the exclusive control of and in the view of
the authorized employee performing the servicing and maintenance
The servicing or maintenance does not create hazards for other employees
There have been no accidents involving unexpected energization of the equipment while taking advantage of this exception
DefinitionsDefinitions
Authorized Employee: A person who locks or tags out equipment in order to perform
servicing or maintenance
Definitions (continued)Definitions (continued)
Affected employee: Job requires employee to operate or use equipment on which
servicing or maintenance is being performed under lockout and tagout conditions
Job requires the employee to work in an area in which such servicing or maintenance is being performed
Note: Becomes an authorized employee when that employee'sduties include performing servicing or maintenance
Definitions (continued)Definitions (continued)
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
Energized: Connected to an energy source or containing residual or
stored energy
Definitions (continued)Definitions (continued)
Energy isolating device: A mechanical device that physically prevents the transmission
or release of energy: – Manually operated electrical circuit breaker– A disconnect switch– Line valve– A block– Any similar device used to block or isolate energy
Note: Push button, selector switches and other control devices are not energy isolating devices
Definitions (continued) Definitions (continued)
Energy Sources: Mechanical Hydraulic Electrical Gas Pneumatic Water Chemical Thermal Other stored energy (Springs, capacitors, etc)
Definitions (continued) Definitions (continued)
Lockout/Tagout: The placement of a lock/tag on an energy isolating device, in
accordance with an established procedure, to ensure that the energy isolating device and the equipment being controlled cannot be operated until the lock and tag is removed
Definitions (continued)Definitions (continued)
Lockout device: A device that utilizes a positive means such as a lock either
key or combination type, to hold an energy isolating device in the safe position and prevents the energizing of a equipment
Included are blank flanges and bolted slip blinds
Definitions (continued)Definitions (continued)
Servicing/maintenance activities Constructing Installing Setting up Adjusting Inspecting Modifying Lubricating Cleaning or unjamming equipment Making adjustments or tool changes
Definitions (continued)Definitions (continued)
Tagout device: A warning device, such as a tag and a means of attachment 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 can not be operated until the tag is removed
Energy Control ProgramEnergy Control Program
Must clearly and specifically outline the: Scope Purpose Authorization Rules Techniques to be utilized for lockout/tagout, and means to
enforce compliance
Energy Control Program (continued)Energy Control Program (continued)
Must include: A statement of the intended used of the procedure Specific steps for shutting down, isolating, blocking, and
securing equipment to control hazardous energy Specific steps for the placement, removal and transfer of
lockout devices or tagout devices and the responsibility for them
Requirements for testing equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures
Where to Begin Where to Begin
Conduct a hazard assessment by identifying each piece of equipment that is used, serviced, or maintained Include broken or stored equipment
Determine the requirements for lockout If there is more than one primary energy source to the
equipment, document each source
Where to Begin (continued) Where to Begin (continued)
Document all energy sources Hidden Direct
The hazard posed The magnitude or measurable degree of danger Special or unusual conditions Proper isolations and devices
Hardware and LimitationsHardware and Limitations
Lockout/Tagout DevicesLockout/Tagout Devices
Durable All devices must be capable of withstanding the workplace
environment. All tags and their means of attachment must be sturdy enough
to prevent inadvertent removal
Lockout/Tagout Devices (continued)Lockout/Tagout Devices (continued)
Standardized Lockout/tagout devices must be
– Singularly identified– The only device(s) used for controlling energy– Not be used for other purposes
Devices must have the same color, shape, or size. The format and print of tags should be standardized
Lockout/Tagout Devices (continued)Lockout/Tagout Devices (continued)
Substantial Removal of lockout devices should be extremely difficult to
remove, requiring the use of excessive force and the help of tools such as bolt cutters
Tagout devices and their attachments must be tough enough so that they can’t be accidentally removed
Lockout Lockout
Lockout is a more appropriate means of ensuring deenergization of equipment than tagout
If an energy-isolating device can’t be locked out, tagout may be used Tagout may be used in place of lockout if it can be
demonstrated that it will offer equivalent protection to that offered by lockout
TagoutTagout
When only a tag is used because equipment cannot be locked out, the following steps must be taken: Removing an isolating circuit element (fuses) Block machine (control switch, die) Opening an extra disconnecting device Other means of isolation
Tagout (continued)Tagout (continued)
Tags must be placed where the lockout device would have been placed
A legend must be used such as: Do not start Do not open Do not close Do not energize Do not operate
Tagout LimitationsTagout Limitations
Tags are attached to energy isolation devices, but they are only warning.
They do not provide the protection offered by a lockout procedure
A tag is never to be bypassed or ignored, and it may not be removed without the specific authorization of person responsible for it
Tagout Limitations (continued)Tagout Limitations (continued)
Tags must be clearly visible and easily understandable by any employee who may be in the area
Tags and their attaching materials must be able to withstand any adverse environmental conditions in the workplace
Tagout Limitations (continued)Tagout Limitations (continued)
Tags must be clearly understood and respected to be effective Workers should guard against false sense of security
Tags must be carefully secured to the energy-controlling devices so that they can’t easily be detached by accident during use
Safety AuditSafety Audit
Annual InspectionsAnnual Inspections
Certain circumstances lend themselves to the opportunity for an inspection Construction of new equipment Installation of new equipment Modification or adjustment of equipment Routinely scheduled cleaning and maintenance Major repairs
Designating an InspectorDesignating an Inspector
Periodic inspections must be performed by an authorized employee other than the one(s) using the energy control procedure
Who can inspect Department manager Plant management Safety manager Others
Employee ReviewsEmployee Reviews
Lockout Must include a review between the inspector and each
authorized employee
Tagout Must be a review between the inspector and each authorized
and affected employee Review should cover each employee's responsibility under the
procedure being inspected, as well as the limitations of tags
Certifying InspectionsCertifying Inspections
Must certify that the required periodic inspections have been performed
Certification must identify the following: The equipment on which the energy control procedure was
used The date of the inspection The employee included in the inspection The name of the person performing the inspection
Follow-up auditFollow-up audit
A follow-up audit must be conducted to ensure that all deficiencies noted have been corrected
Documentation must identify: The equipment on which the lockout procedure is being
utilized The date of the inspection Employees interviewed Employee(s) performing the inspection
TrainingTraining
Specific RequirementsSpecific Requirements
A training program must consist of: Effective initial training Periodic retraining as necessary Certification that training has been given to all employees
covered by the standard
Certification must become part of employee record and contain Employee's name Date of training
Specific Requirements (continued) Specific Requirements (continued)
Training must be provided to ensure that the purpose and function of the energy control program are understood by employees
That the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees
Type of TrainingType of Training
The amount and kind of training is based upon The relationship of each employee’s job to the equipment
being locked or tagged out The degree of knowledge relevant to hazardous energy that
he/she must possess – Need to know
Authorized EmployeeAuthorized Employee
Each authorized employee must receive the following training:
The purpose of the procedure Ability to recognize applicable hazardous energy sources in the
workplace The type and magnitude of the energy available in the workplace Understanding the means and methods of isolating and/or
controlling the various types of energy sources Ways to verify that energy isolation is effective
Affected EmployeesAffected Employees
All affected employees must be instructed in the purpose and use of the lockout/tagout system
Create awareness
Other EmployeesOther Employees
All other employees (including new hires) whose work operations are or may be in an area where lockout/tagout may be utilized
These employees must be instructed: About the procedure That they are prohibited from starting up or reenergizing any
locked-out or tagged-out equipment they encounter
RetrainingRetraining
Must be conducted for all authorized and affected employees whenever: There is a change in job assignment Change in equipment, machinery, or processes that presents
a new hazard A change in the lockout/tagout procedure
Retraining (continued)Retraining (continued)
Must be conducted whenever a periodic inspection reveals or whenever the authorized employee has reason to believe that there are deviations from or inadequacies in the employee's knowledge or use of the lockout/tagout procedures
Group Lockout/TagoutGroup Lockout/Tagout
When servicing and/or maintenance is performed by a crew, craft, department or other group, they must utilize a procedure that affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout/tagout device
Group Lockout/Tagout (continued)Group Lockout/Tagout (continued)
Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device
Provision for the authorized employee to ascertain the exposure status of individual group members with regard to the lockout/tagout of the equipment
Group Lockout/Tagout (continued)Group Lockout/Tagout (continued)
Lockout/tagout control responsibility is designated to an authorized employee to coordinate affected work forces and ensure continuity of protection
Each authorized employee must affix a personal lockout/tagout device to the group lockout device, group lock box, or comparable mechanism when he/she begins work, and must remove those devices when he/she stops working on the equipment being serviced or maintained
Shift or personnel changes occurShift or personnel changes occur
Continuity of lockout/tagout protection must be ensured by following specific procedures for shift and personnel changes, including the orderly hand-off of lockout of lockout/tagout devices
Unusual ConditionsUnusual Conditions
Machines need to be tested or repositioned during servicing When necessary, under special condition, OSHA allows
the temporary removal of locks or tags and the reenergization of the equipment– Example, when power is needed for the testing or positioning of
equipment
Unusual Conditions (continued)Unusual Conditions (continued)
Subject to the follow restrictions: Equipment must be cleared of tools and material Employees must vacate the equipment areas The lockout/tagout device must be removed only by the
authorized employee who applied it
Unusual Conditions (continued)Unusual Conditions (continued)
Energization may then be allowed by testing or positioning All systems must be de-energized, the employee or equipment
must be isolated from energy source, and the lockout/tagout devices reapplied
ContractorsContractors
Must inform each other of all applicable lockout/tagout procedures.
Both employer and contractor must ensue that their employees understand and will respect the others Energy Control Program
Typical Shutdown ProcedureTypical Shutdown Procedure
Notify affected employees Use the specific procedures as outlined for the
appropriate situation Shut off energy source(s) to affected equipment
Use normal stopping or running procedures for the machine
Isolate the equipment from the energy source
Shutdown Procedures (continued)Shutdown Procedures (continued)
Affix lock(s) and tag(s) to each energy source controlling device
Relieve all stored energy from capacitor banks, springs, compressed air, hydraulics, steam, etc.
Verify isolation of energy has occurred by trying equipment
Removal of Lockout/Tagout and Start-Up ProceduresRemoval of Lockout/Tagout and Start-Up Procedures
Ensure that nonessential items are removed from equipment Ensure that equipment components are intact Check area to ensure that all affected employees are safely
positioned or removed from the area Notify all affected employees and site supervisor before
reenergizing the equipment Remove lockout/tagout device Reenergize equipment to ensure safe operation
Summary Summary
Accidents will happen Equipment will occasionally malfunction People will still make mistakes
There is no excuse for serious injury that results from ignorance, carelessness, complacency, or lack of an Energy Control Program