Lock out / Tag out The Best Practices 29 CFR

Transcription

1 Lock out / Tag out The Best Practices 29 CFR

2 Presenters John Hartman

3 Outline Introduction OSHA Standards Implementation Steps in a Typical LO/TO Procedure Phase I Locks, Blocks or Releases Energy Phase II- Returning the machine to service LO/TO Risk Assessment

4 The Importance of Lockout/Tagout: Situation Analysis Machines inevitably break down and need to be serviced. It s not enough to just shut them off and make repairs. According to theoccupational Safety and Health Administration (OSHA), machines need to have power sources removed and be locked out, tagged out(lo/to) and isolated from the source to prevent serious injury.

5 The Importance of Lockout/Tagout: Situation Analysis

6 The Importance of Lockout/Tagout: Situation Analysis LO/TO violations cost US companies nearly $8million every year from both state and federal OSHA citations combined. Compliance with the LO/TO standard (29 CFR ) prevents an estimated 120 fatalities and 50,000 injuries each year. Workers injured on the job from exposure to hazardous energy lose an average of 24 workdays for recuperation.

7 The Importance of Lockout/Tagout: Situation Analysis Five Main Causes of LO/TO Injuries, according to the Oklahoma State Univeristy EHA: Failure to stop equipment Failure to disconnect from power source Failure to dissipate residual energy Accidental restarting of equipment Failure to clear work areas before restarting

8 OSHA To comply with OSHA standards, companies must draft a written LO/TO plan which includes the scope and purpose of the techniques to be used to control hazardous energy

9 OSHA Disconnecting the equipment involves removing energy sources. There are four steps necessary to isolate the equipment included in the LO/TO procedure. 1 Identifying the energy source 2 Isolating the energy source 3 Locking and/or tagging the energy source 4 Proving that the isolation is effective

10 OSHA What is stored Energy All machines employ the use of one or more types of energy to work. Electrical, chemical, hydraulic, thermal and hydraulic are the five most common forms. These energies exist in one of two conditions active or stored(kinetic or potential). Both active and stored energy cause problems in the workplace.

11 OSHA Affected Individual A person who works in an area where servicing or maintenance operations are performed. This person does not perform servicing or maintenance on machines or equipment and is not responsible for implementing lockout/tagout procedures. An authorized individual and an affected individual may be the same person when the affected individual s duties also involve performing maintenance or service. An affected individual becomes an authorized individual whenever he or she performs servicing or maintenance functions.

12 OSHA Authorized Individual This is the person that performs servicing or maintenance on equipment and machinery. This person implements lockout/tagout procedures to guarantee his or her own protection. Tags, padlocks, and other lockout items may designate this person as the authority should someone wish to restore a machine to operability.

13 OSHA Steps to Equipment Lockout 1. Notify affected employee that equipment is being locked out for maintenance. 2. Safely shut down equipment. 3. Isolate hazardous energy sources by placing switches,breakers and valves in position and applying locks/tags as appropriate. 4. Block/Jack/Pin raised components and other potential mechanical energy sources.

14 OSHA Steps to Equipment Lockout 5. Release stored energy by draining, bleeding down and applying grounds. 6. Test for zero energy by attempting to start the equipment.

15 OSHA Steps to Remove Lockout 1. Search equipment for personnel, tools and loose parts. Remove if necessary. 2. Replace safety guards. 3. Remove locks and tags. 4. Notify affected employees that lockout has been removed.

16 OSHA Steps to Reposition Locked-out Equipment 1. Follow steps to remove lockout. 2. Keep personnel clear. Perform test or repositioning. 3. Follow steps to equipment lockout.

17 OSHA What Must Employers do to Protect Employees? Develop, implement, and enforce an energy control program. Use lockout devices for equipment that can be locked out. Tagout devices may be used in lieu of lockout devices only if the tagout program provides employee protection equivalent to that provided through a lockout program.

18 OSHA Ensure that new or overhauled equipment is capable of being locked out. Develop, implement, and enforce an effective tagout program if machines or equipment are not capable of being locked out. Develop, document, implement, and enforce energy control procedures.

19 OSHA Use only LO/TO devices authorized for the particular equipment or machinery and ensure that they are durable, standardized and substantial. Ensure that LO/TO devices identify individual users. Establish a policy that permits only the employee who applied a LO/TO device to remove it. Inspect energy control procedures at least annually.

20 OSHA Provide effective training as mandated for all employees covered by the standard. Comply with additional energy control provisions in OSHA standards when machines or equipment must be tested or repositioned, when outside contractors work at the site, in group lockout situations, and during shift changes.

21 OSHA What do Employees Need to Know? Employees need to be trained to ensure that they know, understand, and follow the applicable provisions of the hazardous energy control procedures. The training must cover at least three areas: aspects of the employer s energy control program; elements of the energy control procedure relevant to the employee s duties or assignment; and the requirements of the OSHA standards related to LO/TO.

22 Implementation Steps in a Typical LO/TO Procedure What are you locking out? How many switches and machines need locking out? How many people will be affected by the lockout? What is the duration of the lockout? What is the application? Is there a shift rotation to consider? Is there an existing permit system in place?

23 Implementation Phase I- Locks, Blocks or Released Energy 1. The authorized employee notifies all affected employees that a LO/TO procedure is ready to begin. 2. Machinery is de-energized. 3. Authorized employee releases or restrains all stored energy. 4. Locks and tags are checked for defects; if found, they are discarded and replaced.

24 Implementation 5. Authorized employee places a personalized lock or tag on the energy isolating device; if multiple persons are involved in the equipment maintenance or service, group lockout is permitted. 6. Authorized employee tries starting machine to ensure that it s been isolated from energy source; machine is de-energized after this test. 7. Machine is now ready to be serviced.

25 Definitions Lockout- The placement of a lockout device on an energy isolating device, in accordance with an established procedure, ensuring that the device and equipment being controlled cannot be operated until the lockout device is removed. Lockout Device- A device that utilizes a positive means to hold an energy isolating device in a safe position and prevent energizing.

26 Definitions Tagout- Placement of a tagout device on an energy isolating device to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed. Tagout Device- a prominent warning device which can be securely fastened to an energy isolating device to indicate that the equipment being controlled may not be operated until the tagout device is removed.

27 Requirements for Devices Durable Lockout and tagout devices shall be capable of withstanding the environment for the maximum period of time exposure is expected. Tagout devices shall be constructed and printed so that exposure to weather conditions or wet and damp locations will not cause the tag to deteriorate Tags shall not deteriorate when used in corrosive environments such as areas where acid and alkali chemicals are handled and stored.

28 Requirements for Devices Standardized Lockout and tagout devices shall be standardized wiithin the facility in at least one of the following criteria: Color, Shape, or Size. In the case of tagout devices, Print and Format shall be standardized

29 Requirements for Devices Substantial Lockout devices shall be substantial enough to prevent removal without the use of excessive force Tagout devices, including there means of attachment, shall be substantial enough to prevent inadvertant or accidential removal.

30 Requirements for Devices Identifiable Lockout and Tagout Devices shall indicate the identity of the employee applying the device. Tagout devices shall warn against hazardous conditions if the machine or equipment is energized and shall include but not limited to: DO NOT START, DO NOT OPEN, DO NOT CLOSE, DO NOT ENERGIZE, and DO NOT OPERATE.

31 Lockout vs. Tagout When tagout is used on equipment which is capable of being locked out. Tags should be attached where lockout devices would be and the employer must demonstrate the tagout will provide safety equivalent to lockout

32 Lockout

33 Tagout

34 Implementation Phase II- Returning Machine to Production 1. Authorized employee checks machine to be certain no tools have been left behind. 2. Safety guards are checked to be sure they ve been properly replaced. 3. Verify that machine/equipment controls are off or in a neutral position. 4. All appropriate employees are notified that the machine is about to go back into production.

35 Implementation 5. Authorized employee conducts secondary check of the area to ensure that no one is exposed to danger. 6. Authorized employee removes locks and/or tags from the energy isolating device and restores energy to the machine. 7. Machine is re-energized

36 LO/TO Training After implementing your program, ensure its longevity by training and auditing your employees and procedures. Conduct a drill to identify shortcomings. Test for practicality. One reason LO/TO requirements exist is because workers tend to take shortcuts to make their jobs easier. Consider the following:

37 Do s Do conduct an annual procedural audit as required by OSHA. Do know the difference in servicing and maintenance requiring LO/TO and basic minor routine adjustments and normal production operations like changing a light bulb, a drill bit, grinding stone or the speed of the belt on a drill press which do not expose workers to unexpected releases of hazardous energy.

38 Don t s Don t assume that your energy control policy works just fine. Don t rely on duplicate keys. Bolt cutters may encourage employees to follow proper procedures to remove locks.

39 LOTO Procedures

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41 Lock Out Program

42 Lock Out Program

43 Lock Out Program

44 Lock Out Program

45 Lock Out Program