LockoutTagout Awareness Training

1
Lockout/TagoutAwareness Training

• 29 CFR 1910.147
• By Chaizong Lor, Safety Coordinator

2
Training Objectives

• Definitions
• Responsibilities
• General Procedures
• Device Requirements
• Shut Down Procedures
• Group Lockout/Tagout Procedures
• Shift/Personnel Change Procedures
• Outside Personnel (Contractors)
• Equipment Return to service
• Special Exceptions
• Specific Energy Control Procedures
• Summary

3
Definitions

• Lockout device
• Use to hold an energy isolating device in
  the safe position and prevents the energizing
  of an equipment
• Tag-out device
• Use along with lockout devices as an additional
  warning or information.
• This tag can only be removed by the person
  originally installing it or a qualified
  electrician.

Note FPM uses both lockout/tag-out devices.
4
Responsibilities

• Supervisors
• Identify machinery and equipment that
  requires lockout/tagout before servicing.
• Develop machine specific procedures
  for each type of machine or equipment.
• Approve lockout devices to be used
  for each type of equipment that
  may need to be
  serviced.
• Provide individual tags and key
  locks to each employee who will
  need to de-energize equipment.
• Coordinate with outside contractors
  when servicing of equipment is done
  by them, or will affect them.

5
Responsibilities Cont.

• Authorized Employees
• Understand the intended use of
  each type of lockout/tagout hardware.
• Understand specific procedures for machinery,
  equipment and processes, including
• The hazards involved with working on electrical
  circuit and/or machinery or
  equipment.
• Use the proper procedure for locking/tagging
  out an electrical source or piece of
  equipment.
• Ensure the devices are kept in such a
  manner as to prevent use by other employees.
• Notify any affected employees prior to the
  application of lockout/tagout devices and after
  they are removed.

6
Responsibilities Cont.

• Affected Employee - An employee whose job
  requires him/her to work in an area in which such
  servicing or maintenance is being performed.
• Comply with restrictions and limitation imposed
  upon them during lockout/tagout of equipment or
  machinery.
• Do not attempt to move lockout/tagout devices or
  start, energize or use equipment that have been
  locked or tagged out.

7
General Procedures

• Electrical Procedures
• Shut off power on machine and disconnect.
• Lockout/tagout on disconnect sources.
• Press start button to ensure that energy
  source has been locked.
• Remember the keys points
• If a machine or piece of equipment contains
  capacitors, they must be drained of stored
  energy.
• Possible disconnecting sources include the power
  cord, power panels (look for primary secondary
  voltage), breakers, the operators station, motor
  circuit, relays, limit switches, electrical
  interlocks.

8
General Procedures Cont.

• Hydraulic/Pneumatic Procedures
• Shut off all energy sources (pumps
  compressors).
• Lockout/tagout the valve on the pumps and
  compressors that supply energy to more than one
  piece of equipment.
• Drain or bleed stored pressure from
  hydraulic/pneumatic lines during lockout/tagout
  procedures.
• Make sure controls are returned to their safest
  position (off, stop, neutral, etc.).

9
General Procedures Cont.

• Fluids and Gases
• Identify the type of fluid or gas properly.
• Close valves to prevent flow during
  lockout/tagout.
• Determine the isolating device, close and
  lockout/tagout.
• Drain and bleed lines to zero energy state.
• Check for zero energy state on the equipment.

10
General Procedures Cont.

• Mechanical Energy Procedures
• Block out or use die ram safety chain.
• Lockout or tagout safety device.
• Shut off, lockout or tagout electrical system.
• Check for zero energy state on equipment.
• Return controls to safest position.
• Extra precaution
• Know equipment and systems
• Understand equipment hazards
• Isolation points
• Procedures for lockout

11
Device Requirements

• Use only lockout/tagout devices that have been
  approved by FPM.
• Locks/tags must clearly identify the employees
  who applied them.

Note Key differently.
12
Shutdown Procedures

• Prepare for Shutdown
• Identify lockout points
• Locate and identify all energy
  isolating
  devices that apply
  to the machine/equipment
  to be
  locked out.
• Refer to the manufacturers control
  diagram detailing the location of all
  isolating points for complex equipment.
• Determine the magnitude of the energy,
  the hazards of the energy to be
  controlled, and the methods to
  control the energy.
• If authorized employees are unable to determine
  each form of energy, they must
  consult their supervisors before starting work.

13
Shutdown Procedures Cont.

• Notification
• Notify all affected employees that a
  lockout/tagout is about to take place.
• The reason for the lockout/tagout.
• The specific machinery or equipment affected.
• Shutdown
• Shut Off Equipment
• If the equipment is operating, employees shall
  shut it down by the normal stopping procedures
  (depress the stop button, open the switch, close
  valve, etc.)

14
Shutdown Procedures Cont.

• Deactivate Energy
• Disconnect the device
  from ALL energy sources
• Inspect the equipment to
  ensure ALL energy sources
  are disconnected.
• Release of Stored or Residual Energy
• Release the stored or residual energy such as
  that in capacitors, springs, elevated machine
  members, rotating flywheels, hydraulic systems
  and pressurized systems such as air, gas, steam,
  or water.

15
Shutdown Procedures Cont.

• Attach Locking and Tagging Devices
• Locks and tags should be standardized.
• Locks shall be attached to energy
  isolating devices so that they cannot
  be accidentally detached
  during maintenance.
• Tags shall be attached to
  all points where equipment
  or
  circuits can be energized.
• A multiple lock plate shall
  be used when more than
  one employees attach
  their own
  lock on the same equipment.

16
Shutdown Procedures Cont.

• Tryout
• Test the deactivation of the equipment to ensure
  that equipment cannot be energized.
• Checking that no personnel are exposed.
• Verifying the isolation of equipment by operating
  the push button or other normal operating
  controls.
• Checking pressure gauges to ensure
  de-pressurization of lines.
• Inspecting electrical circuits to confirm zero
  voltage.
• Testing equipment by pushing start buttons or
  other controls to make certain the equipment will
  not run.
• Returning the operating control(s) to NEUTRAL
  or OFF position after the test.
• Ensuring equipment is now locked out/tagged out.

Note If equipment DOES energize on tryout, push
the stop button contact immediate supervisor
immediately for further instruction.
17
Group Lockout/Tagout Procedures

• The primary authorized employee applies a
  multi-lock accepting device to the energy
  isolating device and attaches
  his/her lock.
• One authorized employee in the group is
  allowed to function as the lockout/tagout
  coordinator to ensure that all control
  methods are applied and there is
  continuity of
  protection for the group.
• Each authorized employee shall affix a
  personal lockout/tagout device to the
  multi-lock accepting
  device when they begin
  work and shall remove those
  devices when they stop work.
• The primary authorized employee
  removes his/her lock and the
  multi-lock accepting device
  when all work
  has been completed.

18
Shift/Personnel Change Procedures

• Either on the same shift or on the next shift,
  the following procedures should be followed
• The on-coming personnel shall notify the
  off-going personnel that they are ready to begin
  work on the machine or equipment.
• All lockout/tagout devices attached to the
  machine or equipment by the off-going personnel
  shall be removed and immediately replaced with
  like devices by the on-coming authorized
  personnel.
• The primary authorized employee shall ensure that
  all pertinent coordination between off-going and
  on-coming personnel has been completed before the
  on-coming authorized personnel begins work on the
  machine or equipment.

19
Outside Personnel (Contractors)

• The following procedures should be followed if
  work activities are performed by contractors
• FPM supervisor and contractor shall inform each
  other of their respective lockout/tagout
  procedures.
• FPM supervisor shall ensure that his/her
  employees understand and comply with the
  restrictions and prohibitions of the outside
  employers energy control program.
• Contractors failing to adhere to lockout/tagout
  procedures acceptable to FPM will be asked to
  terminate their work until they employ acceptable
  energy control procedures.

20
Equipment Return to Service

• Inspect the machine and work area to ensure that
• Non-essential materials
  have been removed.
• Tools and equipment are removed.
• Blocks, pins and chain (used during
  the lockout) are removed.
• Secured safe guards are in place.
• All equipment components are
  fully assembled and operational.
• Ensure that all employees have
  left the area or are safely positioned.

21
Equipment Return to Service Cont.

• Verify that controls are in neutral or the OFF
  position.
• Remove all locking/tagging devices
• Each lock shall be removed by
  authorized employee that applied
  it or under his/her
  direct supervision.
• Notify affected employees
  that the servicing or
  maintenance is completed
  and the machine/equipment
  is ready for use.

22
Equipment Return to Service Cont.

• If the authorized employee who placed a
  lockout/tagout is absent from the workplace, when
  necessary, the immediate supervisor of that
  employee may remove the lock/tag device after
  completing ALL of the following specific
  procedures
• Verify that the employee is not present and
  therefore unable to remove the lock.
• Obtain approval to remove the lock from one of
  the following Director, Associate Director,
  and/or Assistant Director.
• With the assistance of one of the above, get the
  Second Key from the lock box in the vault.
• Remove lock/tag device (if supervisor is an
  authorized person) or supervise the removal by a
  person authorized to do so.
• Ensure that the authorized employee who place it
  lockout/tagout device has been removed before
  they resume work at the facility.

23
Special Exceptions

• Minor, low risk, repetitive, routine
  equipment adjustments which
  take place during production
  operations which are integral
  to the use of the equipment.
• Work on cord or plug connected
  electrical equipment when it is
  unplugged, and the employee working
  on the equipment has complete control
  over the plug.
• Hot tap operations on transmission
  and distribution systems in which
  continuity or service is essential.

24
Specific Energy Control Procedures

• A written procedure is required for piece of
  equipment or machinery that utilizes multiple
  power sources. Each case must outline
• ALL energy sources lockout points
  for the equipment or process.
• Specific steps to shut down,
  isolate, block and secure the
  machine or equipment to
  control
  the hazardous energy.
• Steps for the placement, removal
  and transfer of the lockout
  devices and the
  responsibility for the devices.
• Specific requirements for testing the equipment
  or machine to ensure the effectiveness of the
  lockout devices and other energy control devices.

25
Specific Energy Procedures Cont.

• Exceptions to Requirement for Specific Energy
  Control Procedures.
• Specific documentation if not required for
  equipment when all of the following element
  exist
• Machine/equipment has no potential for stored
  energy after shut down which could endanger
  employees.
• Machine/equipment has a single energy source
  that can be readily identified and
  isolated.
• Isolation/locking out of that energy
  and source will
  completely de-energize
  de-active the machine or equipment.
• Machine/equipment is isolated from that
  energy source during servicing or
  maintenance.
• Single lockout device will achieve a locked out
  condition.

26
Summary

• Only authorized personnel may perform
  lockout/tagout using only the prescribed
  procedures.
• Identify ALL energy sources and establish a zero
  energy prior to servicing equipment.
• Take your time and do it RIGHT!!!
  (Lockout, Tagout, Tryout)
• IF YOU DO NOT KNOW, ASK!!!

27

• Any Questions

??
Please visit FPM Website
(www.uwec.edu/facmgt./index.htm)
for additional information.