Control of Hazardous EnergyControl of Hazardous Energy

Lockout/TagoutLockout/Tagout

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Why bother with Why bother with lockout/tagout?lockout/tagout?

Lockout and tagout procedures areLockout and tagout procedures are

designed and implemented to protect designed and implemented to protect

you from an accidental release of you from an accidental release of

energy. energy.

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What is an “energy source?”What is an “energy source?”

Energy sources include:Energy sources include: ElectricalElectrical MechanicalMechanical PneumaticPneumatic HydraulicHydraulic ChemicalChemical

Thermal

Pressurized water or steam

Gravity

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Hazardous EnergyHazardous Energy

Problems associated with hazardous Problems associated with hazardous energy include:energy include:

Accidental start-upsAccidental start-ups Electrical shockElectrical shock Release of stored or residual energyRelease of stored or residual energy

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Control of Hazardous EnergyControl of Hazardous Energy

The following slides demonstrate The following slides demonstrate

some of the potential hazards some of the potential hazards

associated with energy sources.associated with energy sources.

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Swift justice for aSwift justice for a Texas Shoplifter Texas Shoplifter

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Curly finds himself in Curly finds himself in trouble (again)… trouble (again)…

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Rick Smith (as a child) Rick Smith (as a child)

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What is the difference What is the difference between lockout and tagout?between lockout and tagout?

Lockout – a padlock and locking Lockout – a padlock and locking

device are used to physically “hold” an device are used to physically “hold” an

energy control point, such as a switch, energy control point, such as a switch,

lever or valve handle. This makes it lever or valve handle. This makes it

impossible for energy to be released.impossible for energy to be released.

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Types of lockout devicesTypes of lockout devices

Plug LocksPlug Locks Ball Valve LockoutBall Valve Lockout Gate Valve LockoutGate Valve Lockout Group HaspGroup Hasp ElectricalElectrical Hydraulic, pneumatic, Hydraulic, pneumatic,

and other pressurized and other pressurized systems.systems.

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What is the difference What is the difference between lockout and tagout?between lockout and tagout?Tagout – a written warning that tells Tagout – a written warning that tells

operators not to operate a switch, operators not to operate a switch,

lever or valve that could release lever or valve that could release

hazardous energy. Tagouts hazardous energy. Tagouts DO NOT DO NOT

physically prevent someone from physically prevent someone from

releasing potentially hazardous releasing potentially hazardous

energy.energy.

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Examples of TagsExamples of Tags

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When should you lockout?When should you lockout?

A lockout should be used when A lockout should be used when

working around systems where an working around systems where an

unexpected release of energy could unexpected release of energy could

occur, causing injury or equipment occur, causing injury or equipment

damage.damage.

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Common examples of when Common examples of when lockouts should be used:lockouts should be used:

Clearing jammed or blocked Clearing jammed or blocked mechanismsmechanisms

Preventive MaintenancePreventive Maintenance Working in confined spacesWorking in confined spaces Repairs on electrical circuitsRepairs on electrical circuits

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Isolate Isolate ALL ALL energy sourcesenergy sources

Prior to starting a job, all energy Prior to starting a job, all energy

sources must be identified sources must be identified

(mechanical, electrical, etc.). Each (mechanical, electrical, etc.). Each

energy source must be locked out.energy source must be locked out.

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Multiple or Group LockoutMultiple or Group LockoutLockout boxes are frequently used so Lockout boxes are frequently used so

that multiple employees can install their that multiple employees can install their

personal safety locks. These boxes are personal safety locks. These boxes are

typically stored in close proximity to typically stored in close proximity to

the associated piece of equipment. the associated piece of equipment.

Boxes are usually labeled to identify the Boxes are usually labeled to identify the

corresponding plant system.corresponding plant system.

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Multiple LockoutMultiple Lockout

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Group LockGroup Lock

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Prepare for shutdownPrepare for shutdown Shut down the machine or equipmentShut down the machine or equipment Safely release all stored or residual energy Safely release all stored or residual energy Isolate the machine or equipment from Isolate the machine or equipment from ALLALL

energy sourcesenergy sources Apply the Lockout or Tagout Device(s) to Apply the Lockout or Tagout Device(s) to

the Energy Isolating Device(s)the Energy Isolating Device(s) Verify isolation by physically attempting to Verify isolation by physically attempting to

“run” the machine or equipment. “run” the machine or equipment.

How to de-energize How to de-energize equipmentequipment

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Repairman attempted to lockout raw mill Repairman attempted to lockout raw mill separatorseparator

Repairman properly installed lock on Repairman properly installed lock on associated MCC breakerassociated MCC breaker

Repairman properly attempted to start Repairman properly attempted to start equipment to verify lockoutequipment to verify lockout

Equipment started because breaker was Equipment started because breaker was still energized (although it appeared to be still energized (although it appeared to be open)open)

““Real World” ExampleReal World” Example

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Clinker Sample Bldg MCC

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Clinker Sample Bldg MCC

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High Voltage SwitchgearHigh Voltage Switchgear

When de-energizing a high voltage switchgear, employees must contact a qualified electrician. Only qualified electricians are authorized to work on these systems.

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High Voltage SwitchgearHigh Voltage Switchgear

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Every employee working in the plantEvery employee working in the plant has been issued his or her own lock. has been issued his or her own lock. A specific lock color is assigned to each A specific lock color is assigned to each

department. department. Locks Locks SHOULDSHOULD NOTNOT be used to secure be used to secure

personal lockers, tool boxes, etc.personal lockers, tool boxes, etc. An individual should An individual should NEVERNEVER ask a co- ask a co-

worker to install or remove his or her worker to install or remove his or her personal lock.personal lock.

Lock & Lockout ProtocolLock & Lockout Protocol

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Plant Lockout Policy Plant Lockout Policy (taken from Plant Manager’s memo (taken from Plant Manager’s memo

dated 13 June 2002)dated 13 June 2002)“In lieu of these issues I want to make sure every employee understands that if they leave their lock, for any reason, on a piece of equipment and leave the plant site and that lock has to be removed either by getting the employee back to remove it, or cutting the lock off, disciplinary action will be taken against that employee. Further, that employee will be responsible to purchase the new lock after it has been cut off.”

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Lockout/Tagout StandardsLockout/Tagout Standards

OSHA regulates lockout/tagout OSHA regulates lockout/tagout

through the “Control of Hazardous through the “Control of Hazardous

Energy” standard, 29 CFR 1910.147.Energy” standard, 29 CFR 1910.147. MSHA regulates lockout/tagout MSHA regulates lockout/tagout

through 30 CRF 56.12016, .12017. through 30 CRF 56.12016, .12017.

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Employer responsibilities Employer responsibilities under the “Control of under the “Control of

Hazardous Energy” standardHazardous Energy” standard Establish an energy control programEstablish an energy control program Establish energy control procedures Establish energy control procedures

for machines and equipmentfor machines and equipment Provide employee trainingProvide employee training Conduct periodic inspections or Conduct periodic inspections or

audits of the energy control programaudits of the energy control program

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When the standard appliesWhen the standard applies An employee is required to remove or bypass a An employee is required to remove or bypass a

guard or other safety device.guard or other safety device. An employee is required to place any part of An employee is required to place any part of

their body in contact with the point of their body in contact with the point of operation of an operational machine or piece of operation of an operational machine or piece of equipment.equipment.

An employee is required to place any part of An employee is required to place any part of their body into a “Danger Zone” associated their body into a “Danger Zone” associated with a machine operating cycle.with a machine operating cycle.

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Work on electric equipment controlled Work on electric equipment controlled by plugging in or unplugging the by plugging in or unplugging the equipment. The plug is under equipment. The plug is under exclusive control of the employee exclusive control of the employee performing maintenance.performing maintenance.

““Hot Tap” operations involving Hot Tap” operations involving transmission and distribution systems transmission and distribution systems for gas, steam, water, petroleum for gas, steam, water, petroleum products, etc.products, etc.

Exceptions to the standardExceptions to the standard

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Minor Servicing TasksMinor Servicing Tasks

Employees performing minor tool changesEmployees performing minor tool changesand adjustments that are rand adjustments that are routine, repetitive, outine, repetitive, and integraland integral to the use of the equipment and to the use of the equipment and that occur during normal operations are that occur during normal operations are not covered by the Lockout/Tagout not covered by the Lockout/Tagout Standard, provided the work is performed Standard, provided the work is performed using alternative measures that provide using alternative measures that provide effective protection.effective protection.

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Outside ContractorsOutside Contractors

Whenever outside contractors are Whenever outside contractors are engaged in activities covered by engaged in activities covered by Lockout/Tagout, the on-site Lockout/Tagout, the on-site employer and the outside contractor employer and the outside contractor shall inform each other of their shall inform each other of their respective Lockout or Tagout respective Lockout or Tagout procedures.procedures.

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““FATAL FIVE” FATAL FIVE” (main causes of injury)(main causes of injury)

Failure to stop equipment.Failure to stop equipment. Failure to disconnect from power source.Failure to disconnect from power source. Failure to dissipate (bleed, neutralize) Failure to dissipate (bleed, neutralize)

residual energy.residual energy. Accidental restarting of equipment.Accidental restarting of equipment. Failure to clear work areas before Failure to clear work areas before

restarting.restarting.

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Electrical Energy HazardsElectrical Energy Hazards

Arc flash

Arc flash light

Arc blast

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Arc flashArc flashTemperature can escalate rapidly near the center of an arc flash, reaching 35,000 F. Copper melts at 1,981 F.

The skin is very sensitive to temperature; while sitting in the sun for only six hours at 110 F, cell structure will start to break down. At 158 F, cell destruction occurs in one second. At 200 F, incurable third degree burns are incurred in one-tenth of a second.

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Arc flashArc flash

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Arc Flash LightArc Flash Light

At 35,000 degrees Fahrenheit, an arc flash can generate enough light to cause serious injury to the eyes. It is not uncommon for an electrician to develop cataracts three years after visual exposure to an arc flash.

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Arc flashArc flash

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Arc BlastArc Blast

Arc blast is a force caused by the rapid expansion of air due to the transition of solid conducting material into vapor. This rapid expansion can occupy 67,000 times the initial volume of the transitioning material. The blast can easily knock a person across a room, and the sound from the explosion can destroy a person’s ability to hear.

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Arc BlastArc Blast

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Plugging in ElectricalPlugging in ElectricalEquipmentEquipment

When “plugging in” or “disconnecting” 480 volt electrical equipment,

THE DISCONNECT SWITCH MUST BE OPENED.

The following pictures will demonstrate the reasons why!!

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Electrical BurnsElectrical Burns

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Site specific electrical hazardsSite specific electrical hazards

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Site specific electrical hazardsSite specific electrical hazards

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Site specific electrical hazardsSite specific electrical hazards

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Site specific electrical hazardsSite specific electrical hazards

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ANY QUESTIONS?ANY QUESTIONS?

THANKS FOR YOUR ATTENTION!THANKS FOR YOUR ATTENTION!