X394-LOTO Safety Congress 2009-Roll.ppt

1910.147Lockout/TagoutWhat your plan is probably missing!Lockout/Tagout:What your plan is probablymissingDave Roll – OSHA OnOn-Site Consultation419 295 0040419.295.0040david.roll@bwc.state.oh.usMarch 31, 2009Session SCH394Presented by Dave Roll2LOTOExclusionsz OSHA’s statistics show that failure to controlhazardous energy has resulted in:z10% of Serious industrial accidents– 28,000 lost work days/year– Loss of 120120 lives/yearz–Normal production operations (See SubpartO)Work on cord and plug connected equipmentprovided that:The hazards must be controlled solely byunplugging the equipment from its energy sourcez The plug must be under the exclusive control ofthe employee performing the maintenancezz Remember: These accidents are usually a result ofsomeone taking a short cut or when the employeedoesn’t understand the hazards of the equipmentor the job at hand, or from poor/improperprocedures.1910.147(a)(2)(ii) & (iii)Scope4Applicationz Coversservicing and maintenanceof machines when UNEXPECTEDp or release of storedstart--upstartenergy could cause injury1910.147(a)(1)(i)5zStandard applies to control of energy duringservicing and/or maintenance of machines andequipment.1910.147(a)(2)(i)61

Controlling Energy SourcesDefinitionszz Sources which require LOTO:Servicing and/or maintenance - Includeslubrication, cleaning or unjamming,unjamming, makingadjustments and tool changes, whereemployees may be exposed tounexpected energizationenergization,, startstart-up, orrelease of hazardous monly Cited Hazards gasesThermalWater under pressureSpringsGravityOthersRequirements for LOTO devicesNot locking equipment outLack of employee trainingNo or insufficient LOTO procedures (MSP’s)No periodic inspectionszWhichever devices are used, they must besingularly identified and must be the ONLYdevices used for LOTO;z Whatdoes singularly identified mean? Recognized as a LOTO lock compared to others.10Requirements – con’tzRequirements – con’tStandardized – Both LOTO devices mustbe standardized according to either color,shape, or size;zz Tagoutdevices must also be standardizedaccording to print and format.Substantial – LOTO devices must besubstantial enough to minimize early oraccidental removal;z Locksmust be substantial to prevent removalexcept by excessive force of special tools suchas bolt cutters;z No breakbreak--away locks!11122

Requirements – con’tNormal Production OperationsIdentifiable – Locks and tags must clearlyidentify the employee who applies them,z What system do you have?zzThe LOTO rule may apply during normalproduction operations in some instances1314Normal Production OperationszEnergy Control ProgramIf a servicing activity such as lubricating, cleaning orunjamming the equipment takes place DURINGproduction, employees performing the servicing arecovered by LOTO when any of the following conditionsoccur:The employee must either remove or bypass machineguards or other safety devices,z The employee places any part of his or her body into thepoint of operation or other pinch point;z The employee is required to place any part of his or herbody into a danger zone associated with a machine oroperating cycle;zzIn the above situations, the equipment must be lockedout.15z Consists of the following:– Documented energy control procedures;– Employee training program;– Periodic inspections of the procedures;– Other proceduresz Employers have the flexibility to develop aprogram that meets the needs of theirparticular workplace.Lockout ProceduresEnergy Control ProgramLockout ProceduresECP – con’tz At a minimum, the ECP includes, but is notlimited to the following:––A statement on how the procedure will be used;The procedural steps needed to shut down, isolate,block, and secure machines or equipment;z The magnitude of each energy source (voltage, psi, etc.)––The steps designating safe placement, removal andtransfer of LOTO devices and who hasresponsibility for them;The specific requirements for testing machines orequipment to determine and verify the effectivenessof locks, tags, and other energy control measures.z LOTO procedures must include thefollowing steps:z Preparationpfor shutdown – Notifyy affectedemployeesz Shut down the machinez Isolate the energy sources–Must physically locate and isolate themz Attach locks/tags to the devices.3

ECP – con’tECP – con’tz Eliminate stored energy hazards;– All potentially hazards stored energy must berelieved, disconnected, restrained or otherwiserendered safe;z Verify the isolation– The authorized person must verify that theisolation and dede-energization has beenaccomplished;z Can be done by clearing the equipment areaz Attempt to start the equipmentz Check for residual voltage in electrical componentsz Release from LOTO – Steps to follow whenreleasing machinery from LOTO after service iscompleted:z Inspect the work area to ensure that all nonnonessential items have been removed and that theequipment components are operationally intact;z Ensure that all employees are safely positioned;z Notify affected employees that the LOTOdevices will be removed (before next step)z ReRe--energize equipment.Group LOTOTesting of Machineszz When servicing and/or maintenance isWhen lockout/tagout devices musttemporarily be removed for testing/positioning:performed by a crew, craft, department orother group, they shall utilize a procedurewhich affords the employees a level ofprotection equivalentpqto that pprovided byy theimplementation of a personal LOTO device.z Clearmachine of toolsemployees, notify affected ee’sz Remove lockout/tagout devicez Energize and testz Notify affected ee’see’s,, dede-energize and reapplyenergy control measuresz Remove1910.147(f)(1)21Group LOTO – con’tGroup LOTO – con’tz Group LOTO devices shall be used inz When more than one crew, craft, department, etc isaccordance with the procedures as specifiedincluding, but not necessarily limited to thefollowing requirements:z Primaryy responsibilitypy is vested in an authorizedemployee for a set number of employeesworking under the protection of a group LOTOdevice;z Provision for the authorized employee toascertain the exposure status of individual groupmembers with regard to the lockout or tagout ofthe machine; andinvolved, assignment of overall jobjob-associatedlockout or tagout control responsibility shall be giveto an authorized employee designated tocoordinate affected work forces and ensurecontin it of protectioncontinuityprotection; andz Each authorized employee shall affix a personallockout device to the group LOTO device, grouplockbox, and shall remove those devices when heor she stops working on the machine or equipmentbeing serviced–The last person removing his/her lock shall beresponsible for following “Release from LOTO”procedures.4

Special Lock Removal ConditionszSpecial Lock Removal ConditionsLock removal of employees that are notpresent when the work is complete (i.e.absent the following day (s), left in ahurry while working on the equipment dueto an emergency, or not present for someother reason when the equipment is readyto be placed back into service.zThe maintenance manager or applicablesupervisor shall verify that the authorizedemployee who applied the device is not at thefacility.zThe applicable manager shall make allreasonable efforts to contact the authorizedemployee. If the job status is unknown, thisperson will obtain the status from thisauthorized employee and will inform him/herthat his/her lockout or tagout device(s) will beremoved (via use of bolt cutters).2526Special Lock Removal ConditionsShift/Personnel ChangesIf the employee cannot be reached, a noteshall be placed on the employee’s timecard to let him/her know that his/herlock(s)/tag(s) have been removed;z In addition, the equipment shall bereviewed to determine the status of therepair/maintenance;z The locks/tags shall be removed by theapplicable manager.zzzz27 On-site employer and outside employer shallinform each other of their respective procedures;On-site employer shall ensure that his/heremployeesp yunderstand and complyp y withcontractor’s procedures;Employer to ensure that contractor’s program iscompliant if allowing them to use their program;Determine WHO will notify YOUR affectedemployees.1910.147(f)(2)i.e. Supervisory locks1910.147(f)(4)28Employee TrainingOutside Personnel (Contractors) Specific procedures needed to ensure continuityof lockout/tagout protection, including provisionfor the orderly transfer of lockout/tagout devicesbetween offoff-- going and oncoming employees.Other procedures may be followed as long asthe employer can assure that the equipmentcannot be started or rere-energized between shiftszzThe employer MUST provide effective initialtraining and retraining as necessary and MUSTcertify that such training has been given to allemployees covered by the standard;This certification must contain each employee’sname and dates of training;It is recommended that you alsoinclude who gave the training and howlong it lasted;z Also, you should develop an outline whichportrays the details of the training program(agenda, lecture, video, handouts, etc.).z305

Employee TrainingzEmployee TrainingEvery training program must ensure thatALL employees understand the purpose,function and restrictions of the energycontrol program and that the authorizedemployees possess the knowledge andskills necessary for the safe application,use, and removal of energy controls.zTraining programs used for compliancewith this standard must deal with theequipment, type(s) of energy, and hazardsspecific to the workplace being coveredz i.e.Make the training SITE SPECIFIC3132Employee TrainingAffected / OtherEmployee TrainingAuthorized EmployeeszThe employer’s training program for authorizedemployees must cover, at a minimum, thefollowing areas:zRecognition of applicable hazardous energysourcesDetails about the type and magnitude of thehazardous energy sources present in theirworkplace; andThe methods and means necessary to isolateand control those energy sourceszzzi.e. the elements of your ECPWe like to group these two types togetherfor training as the training is limited and canbe done in about 1 minute.z The ability to recognize when the LOTO isbeing implemented;z Understand the purpose of the procedureand the importance of NOT attempting tostart up or use locked out equipment; andz The limitations of tagout only (if applicable).z3334Employee TrainingzzzzzzLockoutPeriodic InspectionsRetraining must be provided when:Whenever there is a change in job assignmentswhich presents new hazards;Whenever a change in machines occurs;Wherever equipment or processes that present anew hazard are introduced;A change occurs in any of the energy controlprocedures;Periodic inspection reveals, or employer hasreason to believe, there are deviations inemployee knowledge of procedureszPI’s are performed to assure that the energycontrol procedures are being implementedproperly. EACH authorized employee and toshow that EACH authorized employeep y is familiarwith their responsibilities under thoseprocedures;zThe PI shall be performed by an authorizedemployee other than the one utilizing the ECPbeing inspected.356