PSU Lockout/Tagout Training for Authorized Employees (Note: This training is intended to be presented by EHS)

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1 PSU Lockout/Tagout Training for Authorized Employees (Note: This training is intended to be presented by EHS)

2 Objectives Clarify requirements of PSU Lockout/Tagout (LOTO) Program Ensure everyone is aware of their role within LOTO Program Provide an opportunity to discuss concerns related to LOTO Program

3 Training Outline I. How Do Injuries Occur During Servicing? II. What is LOTO? Types of hazardous energy When should LOTO be applied? Energy isolation devices III. LOTO Basics IV. General LOTO procedure at PSU V. Special Situations VI. Energy Isolation Device Video Review VII. Safe or Unsafe? Exercise

4 I. How Injuries Occur During the Servicing BLS study on injuries while servicing equipment revealed: 80% failed to turn off equipment 10% equipment activated by someone else 5% failed to control potential energy Most of remaining 5% disconnected power but failed to verify effectiveness of Equipment?

5 II. What is LOTO? LOTO is a technique used to prevent energy from being released during the servicing of equipment. This is accomplished by placing locks on energy isolation devices prior to starting work.

6 Types of Hazardous Energy What types of hazardous energy are subject to LOTO?

7 Types of Hazardous Energy Electrical Pneumatic Hydraulic Mechanical Thermal Chemical Radiation Steam Spring-Driven Suspended Parts Some energy sources can be turned on/off. Others can only be dissipated or controlled.

8 Potential Energy vs. Kinetic Energy Potential energy can be converted to kinetic! Goal of LOTO is to achieve Zero Energy State

9 When is LOTO applied? during the servicing of equipment. Adjusting Inspecting Modifying Replacing parts Tool changes Clearing jams Lubricating Cleaning There are some situations where LOTO is not required

10 Exceptions to LOTO Cord & plug connected equipment Plug is only source of energy Plug is under continuous control of one person

11 Exceptions to LOTO Minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations, if they are routine, repetitive and integral to the use of the equipment for production, provided that the work is performed without the removal or bypassing of machine guards. Alternative measures for protection are used. Body part not placed in the point of operation or other dangerous area during machine cycle.

12 Energy Isolation Devices accomplished by placing locks on energy isolation devices Device that physically prevents the transmission or release of energy Examples: Electrical disconnect switch Electrical breaker switch Hydraulic valve Pneumatic valve Line valve Pushbuttons, selector switches, and other control circuit devices are NOT energy isolation devices.

13 Review of LOTO Definition LOTO is a technique used to prevent energy from being released during the servicing of equipment. This is accomplished by placing locks on energy isolation devices prior to starting work.

14 III. LOTO Basics All employees fit into one of the following LOTO roles: Authorized employee Services equipment & authorized to apply LOTO. Affected employee Operates or uses equipment being serviced under LOTO. Other employee Works in an area where LOTO being used.

15 Preferred means of controlling hazardous energy at PSU is LOCKOUT IN CONJUNCTION WITH TAGOUT. Each isolation point must have both a lock and a tag attached to it. Locks must be standardized & used only for LOTO. Tags must indicate lock holder & date of application. LOTO Basics

16 IV. General PSU LOTO Procedure STEP 1 ID Energy Sources STEP 2 Notify Others STEP 3 Shutdown Equipment STEP 4 Isolate Equipment STEP 5 LOTO Equipment STEP 6 Release Stored Energy STEP 7 Verify Isolation STEP 8 Perform Servicing STEP 9 Release from LOTO

17 Step 1: ID All Energy Sources Know types & magnitude of energy associated with equipment. ID all energy sources feeding the equipment (including potential energy). Gather appropriate control devices. Clarify any questionable identification of energy sources before proceeding.

18 Step 2: Notify Others Verbally notify all affected and other employees of impending shutdown. Not all equipment will have someone assigned to it.

19 Step 3: Shut Down Equipment Use normal stopping procedures to shut down equipment. Push Stop button Off/On toggle switch etc.

20 Step 4: Isolate Equipment After shutdown, operate all energy isolation devices so equipment is disconnected from energy sources. Turn electrical disconnect to OFF position Open circuit breaker Close valve Etc.

21 Step 5: LOTO the Equipment Attach locks & devices to each isolation point. Tag must accompany each lock. Good idea to also tag point of operation if located remotely from isolation points. What if equipment won t accept a lock?

22 Step 6: Release Stored Energy Ensure all potential or residual energy is controlled. Block elevated parts. Block/release springs. Relieve system pressure. Drain fluids. Vent gases. Allow system to cool. Discharge capacitors. Stop rotating flywheels.

23 Step 7: Verify Isolation Before any servicing begins, verify effectiveness of LOTO. Use normal starting procedure or otherwise verify Zero Energy State. Return controls to OFF position after testing. Verification is the step which is most frequently skipped during evaluations.

24 Step 8: Perform Servicing Complete required service work. Avoid doing anything that could potentially reactivate the equipment. OK to interrupt LOTO, but must be reapplied if servicing is to continue.

25 Step 9: LOTO Release All locks, tags, & devices removed by same person who applied. Remove all tools from equipment area. Replace all machine guards. Verbally inform all affected & other employees that LOTO is complete. Ensure area is clear prior to restart.

26 IV. General PSU LOTO Procedure STEP 1 ID Energy Sources STEP 2 Notify Others STEP 3 Shutdown Equipment STEP 4 Isolate Equipment STEP 5 LOTO Equipment STEP 6 Release Stored Energy STEP 7 Verify Isolation STEP 8 Perform Servicing STEP 9 Release from LOTO

27 V. Special Situations Shift changes Oncoming employee attaches locks/tags prior to outgoing employee removing theirs. EHS must OK alternative procedures. Vehicle hazardous energy control Alternative vehicle control methods are permitted in circumstances where removal of the key fully ensures employee protection. The authorized employee performing the maintenance would need to retain sole control of the key. If removal of the key does not fully ensure employee protection additional measures are needed. (removal of battery cable, chock wheels, etc)

28 Lock removal procedure Supervisor must be notified if lock owner is not present. Use Appendix C of program to document removal.

29 V. Special Situations Group LOTO Each employee applies own locks/tags to each isolation point. OR A designated person locks out each of the energy sources and puts the keys into a group lockbox. The authorized employees place their lock on the group lockbox before they begin work. After each worker finishes, the worker removes his lock from the box. EHS must OK alternative procedures.

30 Summary All hazardous energy sources must be controlled (kinetic & potential). Control via energy isolation device (do not rely on control circuit). Only use designated lock for LOTO. Tags must accompany all locks. Nine-step general procedure remember to verify isolation. Protection must be ensured during special situations.

31 Any Questions?

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