Rockwell Automation Lockout-Tagout Service

Transcription

1 Rockwell Automation Lockout-Tagout Service

2 The Solution To remain competitive in a global race toward efficiency and safety, you need a company known for implementing lockout-tagout services worldwide that have a clear purpose - to efficiently keep people safe. Rockwell Automation seeks to understand each company s unique lockout-tagout needs and custom tailor a solution that is not only guaranteed to meet all applicable state and federal regulations, but more importantly establishes what is recognized by hundreds of companies around the world as the most efficient way to keep their employees safe. YOUR ADVANTAGE OPTIMIZED AUDITS AND LOCKOUTS Employee and procedure audits up to 85% faster Access equipment lockout status real time from any device Identify lockout-tagout trends to focus efforts on problem areas FUTURE PROOF AND FAMILIAR SOFTWARE Customized template specifically tailored to your specific needs All machine-specific lockout-tagout procedures created in MS Excel Templates, source files and training provided to enable in-house updates COMPLIANCY GUARANTEED Solutions are customized to account for production value and employee time All essential elements required to establish and maintain compliancy are provided All solutions help to meet or exceed OSHA requirements OUR PHILOSOPHY ALL INCLUSIVE AND COMPREHENSIVE Modern lockout-tagout program created with all essential elements addressed: Unique machine-specific procedures created for every required piece of equipment Ruggedized placards included for applicable areas Training for all employees Authorized, Affected, and Contractors Corporate policy designed for optimization and compliancy Annual audit solution plan developed with training module Custom tailored lock and device architecture established All energy isolation and related machine control points graphically identified with industry leading technology All source files and program modules customized and delivered to ensure future modifications can be easily prepared by your employees.

3 Why Choose Rockwell Automation Efficiency and Safety do not have to be mutually exclusive OUR COMPANY has decades of experience and a brand name you can trust will be here to serve you tomorrow when you need us. OUR PROGRAMS provide industry leading value that can be measured and proven to pay you back. OUR PEOPLE are the top trained people in the world that specialize in lockouttagout program implementation. OUR SYSTEMS work in tandem with our services to provide you a truly comprehensive solution that is compliant, safe, and efficient. COMPLIANCY CHECKLIST 1:5 - POLICY A good corporate policy should be clear and easy to understand for authorized employees. Like the procedures, this should remain dynamic, change with conditions and be used by authorized employees to ensure they fully understand how and when to properly apply lockout-tagout. 2:5 - PROCEDURES This is perhaps the most difficult part of the regulation to comply with and notoriously the most cited part of the regulation. All equipment must meet eight criteria to be exempt from LOTO. Unless all eight criteria are met, it needs a procedure. In general over 95% of all equipment in a facility will need a LOTO procedure (think water heaters, air handler units, exhaust fans, etc.). OSHA can cite a company up to $70,000 for each occurrence of a missing LOTO procedure. 3:5 EMPLOYEE TRAINING Special training is required for all groups of employees who are present at a company s workplace. Authorized employee training for those applying the locks Affected training to operators and administrative staff Contractor training for temporary workers or those brought in for special tasks 4:5 ANNUAL AUDITING AND RE-TRAINING The following procedures must be audited every year: Check to ensure equipment hasn t changed Ensure every procedure is still readily available and accurate Training authorized and affected employees: By giving annual training to all authorized employees you will help ensure you are compliant Affected employee training can be condensed and should focus on awareness only to be most effective 5:5 - DEVICES: LOTO DEVICES (MORE THAN JUST LOCKS) Locking out equipment isn t always as easy as just applying a lock. At times a specialized device will be needed in addition to the lock to ensure the energy source isn t inadvertently reactivated. When it comes to selecting the right products and solutions to fit your needs, Rockwell Automation knows best. We evaluate hundreds of options from various manufacturers and custom tailors a non- biased device order and recommend lock architecture that fits your production needs without compromising safety or compliancy. With efficiency as our focus you can rest assured knowing you have the most optimized solution for your specific needs.

4 OSHA S 8 Criteria OSHA defines 8 required criteria in order for a piece of equipment to not need a machine-specific lockout-tagout procedure Below is an excerpt taken directly from OSHA s website: Energy control procedure (c)(4)(i). Procedures shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section. Note: Exception: The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist: 1: The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees; 2: the machine or equipment has a single energy source which can be readily identified and isolated; 3: the isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment; 4: the machine or equipment is isolated from that energy source and locked out during servicing or maintenance; 5: a single lockout device will achieve a locked-out condition; 6: the lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; 7: the servicing or maintenance does not create hazards for other employees; 8: the employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance. IMPORTANT NOTE: ALL eight criteria must be met in order to be exempt from requiring a machine specific procedure. EQUIPMENT TYPES Exhaust Fans Air Handler Units Unit Heaters because it has electrical and kinetic energy. This particular equipment setup also does not have a local electrical disconnect (criteria 2) that can be readily identified and isolated. This equipment type typically does not meet criteria numbers 1, 2, 3, 5, and possibly 4, 6, and 7. Clothing Washer Dishwasher because it has electrical and water. Because of these two sources, it does not meet criteria numbers 1, 2, 3, 5, and possibly 4, 6, and 7. In this example pictured, the washer has electricity, hot water, and two cold water inlets in addition to thermal energy. It has five sources total, but OSHA requires anything over two sources have a machine specific procedure. Grinders Mills Lathes Drill Press because it has electrical and kinetic energy. Because of these two sources, it does not meet criteria numbers 1, 2, 3, 5, and possibly 4, 6, and 7. Even though the picture shows one of the simplest pieces of shop equipment, OSHA requires a lockouttagout procedure due to the residual energy from the grinding disks. Welders Plasma Cutters Gas Cutter because it has electrical, Gas, and thermal. Because of these three sources, it does not meet criteria numbers 1, 2, 3, 5, and possibly 4, 6, and 7. Welders are often overlooked when companies are assessing their LOTO compliancy; this can lead to a separate OSHA citation for each unit that does not have a specific procedure. Boiler Systems Condensate Return Pumps & Tanks because it has electrical, water, steam, natural gas and/or fuel oil, thermal energy and kinetic energy. Because of the multiple energy sources, it does not meet criteria numbers 1, 2, 3, 5, and possibly 4, 6, and 7. Boilers can use electrical, gas, or fuel oil to change water into high pressure steam. Boiler systems need procedures due to the inherent hazards of such high temperatures and pressures. A proper lockout-tagout procedure for a boiler will completely isolate all incoming sources, identify and address any internal heat and pressure, and address the steam output valves so no feedback from the other boilers could possibly occur. Due to the high heat and high pressure, any steam-condensate tank or pump will also need a written lockout-tagout procedure. Chiller Systems Cooling Towers because they contain electrical energy, chilled water lines, glycol lines and kinetic energy from fan blades. Because of the multiple number of energy sources, it does not meet criteria numbers 1, 2, 3, 5, and possibly 4, 6, and 7. Depending on the chiller system it may also contain a refrigeration loop. The complexity of the chiller systems and cooling towers water system results in having to lock out multiple valves. A detailed lockout procedure assists in the safe maintenance and repair of these systems. Supply Pumps Return Pumps Booster Pumps because it has electrical and water/product/chemical liquids. Because of these three sources, it does not meet criteria numbers 1, 2, 3, 5, and possibly 4, 6, and 7. All types of pumps required lockout-tagout procedures so safe preventative maintenance or repairs can be conducted. In addition to the electrical isolation, the suction and discharge of each pump needs to be locked out. The fluids that are being transported by the pump (hot water or chemicals) may be hazardous to the mechanic. Proper lockout of the suction and discharge lines can help prevent property damage from occurring if the lines remained open while another machine introduces pressurized fluid into the system.

5 GLOBAL REACH, LOCAL REPRESENTATION QUICK FACTS In the manufacturing industry, the #1 most cited regulation by OSHA is Lockout-Tagout (#5 most cited for all industries). The most common reason for non-compliancy is missing or inadequate lockout-tagout procedures. Lockout-Tagout has been in the top 10 most cited regulations for over 15 years straight. Repeat violations within 5 years carry 10x the fine amount. Large companies have a bigger burden with lockout-tagout because any company they acquire or own under the parent company name is subjected to repeat and willful violations if there is a record of citation in the last 5 years. The second most common reason for lockout-tagout citations is not auditing the program correctly. Most companies fail to audit every procedure on a 12 month cycle. Rockwell Automation, Inc. (NYSE:ROK), the world s largest company dedicated to industrial automation, makes its customers more productive and the world more sustainable. Throughout the world, our flagship Allen-Bradley and Rockwell Software product brands are recognized for innovation and excellence. Follow ROKAutomation on Facebook & Twitter. Connect with us on Linkedin. Contact us: Rockwell Automation Safety Solutions Safety Automation Forum Group Allen-Bradley, Rockwell Automation, LISTEN. THINK. SOLVE, are registered trademarks of Rockwell Automation, Inc. All other registered trademarks and trademarks are property of their respective companies. Publication GMSN-BR001A-EN-P September 2013 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.