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1.
MODULE 20 Lockout/Tagout
2.
1910.147(a)(1) Scope Covers
servicing and maintenance of machines and equipment in which Unexpected energization or start up or Release of stored energy could cause Injury to employees Normal operation is covered in 1910 Subpart O 2 ©2006 TEEX
3.
1910.147(a)(1)(ii) Exemptions Construction,
agriculture and maritime employment; Electrical Utilities; Electrical equipment (covered by Subpart S) Oil and gas well drilling and servicing So why comply? 3 ©2006 TEEX
4.
Control of Hazardous
Energy Why use lockout/tagout? Protects maintenance personnel from power being reapplied by mistake Recommended by API RP 54 for electrical systems in drilling and servicing operations Recognized hazard 4 ©2006 TEEX
5.
1910.147(a)(2) Application Service
and maintenance: Employee required to remove or bypass a guard or safety device Employee required to place part of body into area that would be a danger zone during machine operation cycle 5 ©2006 TEEX
6.
1910.147(a)(2) Application Exception:
Minor adjustments and servicing activities during normal production if Routine Repetitive Integral to production Provided that alternative measures provide effective protection 6 ©2006 TEEX
7.
1910.147(a)(2) Application Does
not apply to cord and plug connected equipment for which Exposure to hazard is controlled by unplugging and Plug under exclusive control of employee performing service or maintenance 7 ©2006 TEEX
8.
1910.147(a)(2) Application Does
not apply to hot tap operations in transmission and distribution operations in pressurized pipelines provided that: Continuity of service is essential, Shutdown of system is impractical, and Documented procedures and special equipment provide proven effective protection for employees 8 ©2006 TEEX
9.
1910.147(a)(3) Purpose Establish
a program and utilize procedures for affixing appropriate lockout devices or tagout devices to energy isolating devices Prevent unexpected energization, start up or release of stored energy in order to prevent injury to employees Training and procedural requirements for other sections’ LO/TO requirements 9 ©2006 TEEX
10.
1910.147(b) Definitions
11.
Affected employee Job
requires employee to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or work in an area in which such servicing or maintenance is being performed 11 ©2006 TEEX
12.
Authorized employee Locks
out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment Affected employee whose duties include servicing or maintenance under this section 12 ©2006 TEEX
13.
Energized Connected to
an energy source OR Containing residual or stored energy 13 ©2006 TEEX
14.
Energy isolating device
A mechanical device that physically prevents the transmission or release or energy 14 Circuit breakers included NOT push buttons NOT selector switches NOT control circuits ©2006 TEEX
15.
Energy source Any
source of: 15 Electrical, Mechanical, Hydraulic, Pneumatic, Chemical, Thermal, or Other energy What kind of energy did the rock have? ©2006 TEEX
16.
Lockout Placement of
a lockout device on an energy isolating device, in accordance with an established procedure, ensuring that energy isolating device and equipment being controlled cannot be operated until lockout device is removed 16 ©2006 TEEX
17.
Lockout device Device
that uses a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment Blank flanges and bolted slip blinds included 17 ©2006 TEEX
18.
Servicing and/or maintenance
Workplace activities such as: 18 Constructing, Installing, Setting up, Adjusting, Inspecting, Modifying, and Maintaining and/or servicing machines or equipment ©2006 TEEX
19.
Tagout Placement of
tagout device on an energy isolating device, in accordance with an established procedure, to indicate that energy isolating device and equipment being controlled may not be operated until tagout device is removed 19 ©2006 TEEX
20.
1910.147(c) General Requirements
21.
Energy control program 21 Energy
control procedures Employee training Periodic inspections Any employee who services/maintains any equipment where unexpected energizing or stored energy release could cause injury isolates and renders it inoperative first. ©2006 TEEX
22.
1910.147(c)(ii) General Requirements If
an energy isolating device is capable of being locked out, the employer's energy control program shall utilize lockout, unless the employer can demonstrate that the utilization of a tagout system will provide full employee protection 22 ©2006 TEEX
23.
1910.147(c)(iii) General Requirements Energy
isolating devices designed to accept lockout devices whenever: Replacement or major repair, renovation or modification of equipment is performed or New machines or equipment are installed 23 ©2006 TEEX
24.
1910.147(c)(3) Full employee protection
When tagout device used on energy isolation device capable of being locked out: Same location as potential lockout device Demonstrably equivalent program May require additional safety elements 24 ©2006 TEEX
25.
1910.147(c)(4) Energy control procedure
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. Exception with all 8 elements listed in standard 25 ©2006 TEEX
26.
1910.147(c)(4) Energy control procedure
Outline scope, purpose, authorization, rules, techniques for control of hazardous energy, including: Specific intended use of the procedure; Specific steps for shutting down, isolating, blocking and securing equipment Specific steps for placement, removal, transfer of lockout/tagout devices and responsibility for them Specific requirements for testing equipment to verify effectiveness of lockout devices, tagout devices, and other energy control measures 26 ©2006 TEEX
27.
1910.147(c)(5) Protective materials and
hardware Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware shall be provided by the employer for isolating, securing or blocking of equipment from energy sources 27 ©2006 TEEX
28.
1910.147(c)(5) Protective materials and
hardware Lockout and tagout devices must be: Singularly identified The only device(s) used for controlling energy Not used for other purposes And shall meet the following requirements: 28 ©2006 TEEX
29.
1910.147(c)(5) Protective materials and
hardware Capable of withstanding environment for maximum time period Moisture or corrosives must not make tag deteriorate Standardized: 29 Color Shape Size Print/Format ©2006 TEEX
30.
1910.147(c)(5) Protective materials and
hardware Lockout devices: Substantial enough to prevent removal without excessive force or unusual techniques such as bolt cutters Tagout devices: Substantial enough to prevent inadvertent or accidental removal Non-reusable attachment means Attachable by hand, self-lockable At least equivalent to nylon cable tie 30 ©2006 TEEX
31.
1910.147(c)(5) Protective materials and
hardware Lockout and tagout devices indicate identity of employee applying devices 31 ©2006 TEEX
32.
1910.147(c)(6) Periodic Inspection Energy
control procedure inspected at least annually: By authorized employee not using the procedure being inspected Correct any deviations Review employee responsibilities with: each authorized employee – lockout each affected or authorized employee – tagout 32 ©2006 TEEX
33.
1910.147 (c)(7) Training
and communication Ensure employees understand purpose and function of energy control program Ensure employees acquire skills required for safe application, usage, removal of energy controls 33 ©2006 TEEX
34.
Employee Training Requirements Authorized
employee: Recognition of hazardous energy sources Type and amount of energy in workplace Methods and means for energy isolation Affected employee: Purpose and use of procedure Other employees in area: Procedure and prohibition on restarting 34 ©2006 TEEX
35.
Employee Training Requirements for
Tagout Train on limitations of tags: Warning devices do not provide physical restraint that a lock would Tag not to be removed without owner’s authorization, bypassed, ignored, defeated Must be legible / understandable to work Must withstand environmental conditions False sense of security Attach securely: avoid accidental removal 35 ©2006 TEEX
36.
Employee Retraining For
all authorized or affected employees when: Job assignment changes Equipment or processes present new hazard Energy control procedure changes Knowledge / use of program is inadequate Certify employee training up to date 36 ©2006 TEEX
37.
1910.147(c)(8) Energy Isolation
Only the authorized employees performing the servicing or maintenance may apply lockout/tagout 37 ©2006 TEEX
38.
1910.147(c)(9) Notification of Employees
Affected employees must be notified By employer or authorized employee Of application and removal of lockout and tagout devices Before controls are applied After controls are removed 38 ©2006 TEEX
39.
1910.147(d) Application of Control
40.
Order of Operation
for Application of Control 1. 2. 3. 4. 5. Preparation for shutdown Equipment shutdown – orderly Equipment isolation Lockout or tagout device application Stored energy relieved; continue while reaccumulating 6. Verification of isolation 40 Test and return to “off” position ©2006 TEEX
41.
1910.147(e) Release from Lockout/Tagout
42.
1910.147(e) Release from Lockout
Before lockout or tagout devices removed and energy restored, ensure: Machine or equipment: Inspect area; remove nonessential items Ensure equipment components intact Employees: Ensure all employees safe or removed Before restart, notify affected employees of removal 42 ©2006 TEEX
43.
1910.147(e) Release from Lockout
Each lockout/tagout device removed by employee who applied the device If not available, removed under employer direction Specific procedures and training from energy control program must be in use! Verify that applying employee is not at facility Make all reasonable efforts to contact/notify Ensure authorized employee knows of removal before resuming work at facility 43 ©2006 TEEX
44.
1910.147(f) Additional Requirements
45.
1910.147(f)(1) Testing or Positioning
Temporary removal of lockout/tagout devices for testing/positioning: 45 Clear tools and materials Remove employees from equipment area Remove lockout/tagout devices (as in (e)) Energize and test or position Deenergize systems and reapply energy control measures to continue servicing ©2006 TEEX
46.
1910.147(f)(2) Outside Personnel
Contractors and other outside personnel: On-site employer and outside employer inform each other of lockout/tagout procedures On-site employer complies with outside employer’s energy control program 46 ©2006 TEEX
47.
1910.147(f)(3) Group Lockout
or Tagout Procedure must provide protection equivalent to personal lockout/tagout device Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device (such as an operations lock); 47 ©2006 TEEX
48.
1910.147(f)(3) Group Lockout
or Tagout When more than one crew, craft, department, etc. is involved: Designated authorized employee takes lockout/tagout control responsibility Coordinates affected work forces Ensures continuity of protection 48 ©2006 TEEX
49.
1910.147(f)(3) Group Lockout
or Tagout Each authorized employee affixes personal lockout/tagout device to group lockout device when beginning work Each removes personal device when stopping work on this equipment 49 ©2006 TEEX
50.
1910.147(f)(4) Shift or
Personnel Changes Specific procedures in energy control plan Ensure continuity of lockout/tagout protection Orderly transfer of lockout/tagout device protection between shifts Minimize exposure to hazards from unexpected energization or release 50 ©2006 TEEX
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