Facilities Management

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Lockout/TagoutAwareness Training

• 29 CFR 1910.147
• By Chaizong Lor, Safety Coordinator

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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
• The placement of a lockout device in accordance
  with established procedures, ensuring that the
  energy-isolating device and the equipment being
  controlled may not be operated until the lockout
  is removed.
• Tagout
• The placement of a tagout device in accordance
  with an established procedure to indicate that
  the energy-isolating device and the equipment
  being controlled may not be operated until the
  tagout is removed.

Note FM uses both lockout/tagout devices.
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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.

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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.

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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.

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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.

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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.).

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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.

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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

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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.
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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.

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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.)

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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.

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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.

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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.
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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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.

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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!!!

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• Any Questions

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