Control of Hazardous EnergyControl of Hazardous EnergyLLOCKOCKOOUT/UT/TTAGAGOOUTUT

Plant Asset ProtectionPlant Asset Protection

Lockout/TagoutLockout/Tagout

If you have any questions If you have any questions about the presentation, about the presentation, please contact:please contact:

Plant Asset Protection (PAP)Plant Asset Protection (PAP) Local 388 - Plant Shift-in-ChargeLocal 388 - Plant Shift-in-Charge Local 375 - PAP ManagerLocal 375 - PAP Manager

Lockout/TagoutLockout/Tagout Purpose of Lockout/TagoutPurpose of Lockout/Tagout

ScopeScope

DefinitionsDefinitions

Step by Step InstructionStep by Step Instruction

Lockout/Tagout – Common ExcusesLockout/Tagout – Common Excuses This job will only take a few minutes. I don’t need to

lock it out.

I’ve done this work for 20 years. I know what I’m doing. I don’t need to lock it out.

I’m in a hurry. I’ve locked the equipment out. I’m sure it’s okay. I don’t need to verify it.

There are two of us working on the equipment. There is no need for both of us to lock it out. I’ll work under my partner’s lock.

Lockout/Tagout – Top 5 ReasonsLockout/Tagout – Top 5 Reasons1.1. Your life is on the lineYour life is on the line

2.2. Your family and friends love and need youYour family and friends love and need you

3.3. Your co-workers depend on you being aroundYour co-workers depend on you being around

4.4. It’s a company requirementIt’s a company requirement

5.5. It’s a regulatory requirementIt’s a regulatory requirement

Lockout/Tagout – PurposeLockout/Tagout – PurposeThe Concentrate Plant has established The Concentrate Plant has established

requirements for Lockout/Tagout of requirements for Lockout/Tagout of equipment during servicing and equipment during servicing and maintenance to ensure:maintenance to ensure:

equipment is isolated & locked or tagged equipment is isolated & locked or tagged out from all potentially hazardous energyout from all potentially hazardous energy

where the unexpected energization or where the unexpected energization or release of such energy could cause injury.release of such energy could cause injury.

Lockout/Tagout – ScopeLockout/Tagout – Scope

Lockout/Tagout covers:Lockout/Tagout covers:

SERVICING and MAINTENANCESERVICING and MAINTENANCE of of machines and equipment in which machines and equipment in which the unexpected energization, start-the unexpected energization, start-up or release of energy could cause up or release of energy could cause injury to employees.injury to employees.

Lockout/Tagout – ScopeLockout/Tagout – Scope

SERVICING and MAINTENANCESERVICING and MAINTENANCE includes: includes:•Constructing

•Installing

•Setting upSetting up

•AdjustingAdjusting

•Inspecting

•Modifying

•ServicingServicing

•MaintenanceMaintenance

Lockout/Tagout – Scope Lockout/Tagout – Scope Lockout/Tagout is not required Lockout/Tagout is not required

for maintenance or servicing for maintenance or servicing performed during normal performed during normal production production unlessunless it it requires:requires:

Removal of a guardRemoval of a guard Bypass of a safety deviceBypass of a safety device Placement of any part of the Placement of any part of the

body in point of operation or body in point of operation or other danger zone other danger zone

Lockout/Tagout – Definitions Lockout/Tagout – Definitions

LOCKOUTLOCKOUT Placement of a lockout Placement of a lockout

device on an energy device on an energy isolating device, in isolating device, in accordance with an accordance with an established procedure.established procedure.

Lockout/Tagout – Definitions Lockout/Tagout – Definitions

TAGOUTTAGOUT Placement of a tagout Placement of a tagout

device on an energy device on an energy isolating device, in isolating device, in accordance with an accordance with an established procedure.established procedure.

Lockout/Tagout – Definitions Lockout/Tagout – Definitions

AUTHORIZED PERSONAUTHORIZED PERSONA duly trained personnel A duly trained personnel

who locks or tags who locks or tags machines or equipment machines or equipment to perform maintenance to perform maintenance or servicingor servicing

Lockout/Tagout – Definitions Lockout/Tagout – Definitions

AFFECTED PERSONAFFECTED PERSONA person whose job A person whose job

requires him/her to requires him/her to operate or work in an operate or work in an area where servicing is area where servicing is being performed under being performed under Lockout/Tagout.Lockout/Tagout.

Lockout/Tagout – Definitions Lockout/Tagout – Definitions SOURCES OF ENERGYSOURCES OF ENERGYEnergy needed to operate Energy needed to operate

the machine or equipmentthe machine or equipment

ElectricalElectrical HydraulicHydraulic PneumaticPneumatic MechanicalMechanical Process PipingProcess Piping ThermalThermal StoredStored

Lockout/Tagout – Definitions Lockout/Tagout – Definitions ENERGY ISOLATING DEVICEENERGY ISOLATING DEVICEMechanical device that prevents the Mechanical device that prevents the

transmission or release of energytransmission or release of energy

Electrical circuit breakerElectrical circuit breaker Disconnect switch Disconnect switch Line valveLine valve Slip blindSlip blind

Note: Push button, selector switches, emergency Note: Push button, selector switches, emergency stops and other control devices are NOT stops and other control devices are NOT energy isolating devicesenergy isolating devices

Lockout/Tagout – Definitions Lockout/Tagout – Definitions

Lockout/Tagout Devices must Lockout/Tagout Devices must be:be:

DurableDurable

StandardizedStandardized

SubstantialSubstantial

IdentifiableIdentifiable

Lockout/Tagout – Instructions Lockout/Tagout – Instructions 1.1. Know the EquipmentKnow the Equipment

2.2. Notify Affected PersonsNotify Affected Persons

3.3. Shutdown equipment by Shutdown equipment by normal procedures (If normal procedures (If possible)possible)

4.4. Isolate Equipment by Isolate Equipment by operating energy isolating operating energy isolating devices.devices.

Lockout/Tagout – Instructions Lockout/Tagout – Instructions

5.5. Apply locks to devicesApply locks to devices

6.6. Dissipate stored energyDissipate stored energy

7.7. VERIFY Lockout is VERIFY Lockout is effectiveeffective

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

The next step after locking out the The next step after locking out the energy sources & dissipating the energy sources & dissipating the stored energy is:stored energy is:

a)a) Take a coffee breakTake a coffee breakb)b) Perform servicing/maintenancePerform servicing/maintenancec)c) Verify the LockoutVerify the Lockoutd)d) None of the aboveNone of the above

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

VERY GOOD! VERY GOOD! C. IS THE CORRECT C. IS THE CORRECT

ANSWER!ANSWER!

Always verify if Always verify if lockout/tagout lockout/tagout performed is performed is effective.effective.

Lockout/Tagout – Instructions Lockout/Tagout – Instructions Verification of Lockout includes:Verification of Lockout includes:

Push controls buttons, turn knobs, Push controls buttons, turn knobs, etc.etc.

Use voltage meter for electrical Use voltage meter for electrical work (If the employee could be work (If the employee could be exposed to live circuits)exposed to live circuits)

(For circuits above 600 volts, check (For circuits above 600 volts, check meter against a known source, meter against a known source, before & after use)before & after use)

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

When performing maintenance where When performing maintenance where the employee could be exposed to the employee could be exposed to live electrical circuits, verification is live electrical circuits, verification is accomplished by turning/pushing accomplished by turning/pushing control knobs/buttons.control knobs/buttons.

TRUETRUE

FALSEFALSE

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

VERY GOOD! VERY GOOD! The answer is The answer is FalseFalse

Verification is Verification is accomplished by accomplished by using a voltmeter. using a voltmeter. This must be This must be performed by a performed by a qualified person.qualified person.

Lockout/Tagout – Instructions Lockout/Tagout – Instructions ENERGY RESTORATIONENERGY RESTORATION

1.1. Check that tools/parts are Check that tools/parts are removedremoved

2.2. Check for people in hazardous Check for people in hazardous locationslocations

3.3. Replace guards & safety devicesReplace guards & safety devices

4.4. Notify all Affected employeesNotify all Affected employees

Lockout/Tagout – Instructions Lockout/Tagout – Instructions ENERGY RESTORATIONENERGY RESTORATION

5.5. Ensure all controls are in the Ensure all controls are in the “OFF” position“OFF” position

6.6. Remove Locks & TagsRemove Locks & Tags

7.7. Restore EnergyRestore Energy

8.8. Ensure Equipment is Ensure Equipment is operationaloperational

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW During energy restoration the authorized person During energy restoration the authorized person

should:should:

a.a. Check that tools and people are clearedCheck that tools and people are cleared

b.b. Guards and safety devices have been replaced aGuards and safety devices have been replaced and are operationalnd are operational

c.c. All controls are in the “OFF” PositionAll controls are in the “OFF” Position

d.d. All of the aboveAll of the above

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

VERY GOOD! VERY GOOD! D is the correct D is the correct

answeranswer

Lockout/Tagout – Instructions Lockout/Tagout – Instructions IMPORTANT POINTS TO CONSIDERIMPORTANT POINTS TO CONSIDER

Lockout/Tagout is the required Lockout/Tagout is the required method of isolating machines method of isolating machines from the energy sourcefrom the energy source

Only Authorized Employees Only Authorized Employees may lock/tag out equipment.may lock/tag out equipment.

DO NOT ATTEMPT TO OPERATE DO NOT ATTEMPT TO OPERATE ANY ENERGY ISOLATING DEVICE ANY ENERGY ISOLATING DEVICE

WHERE IT IS LOCKED AND WHERE IT IS LOCKED AND TAGGED OUT.TAGGED OUT.

Lockout/Tagout – Instructions Lockout/Tagout – Instructions IMPORTANT POINTS TO CONSIDERIMPORTANT POINTS TO CONSIDER

All equipment must be locked All equipment must be locked and tagged out to protect and tagged out to protect against accidental or against accidental or inadvertent operation which inadvertent operation which could cause injury to personnel.could cause injury to personnel.

Lockout/Tagout – Instructions Lockout/Tagout – Instructions CONTRACTORSCONTRACTORS

TCCEC and the contractor must inform each TCCEC and the contractor must inform each other of their respective lockout/tagout other of their respective lockout/tagout procedures.procedures.

The two parties must coordinate the The two parties must coordinate the implementation of the procedures.implementation of the procedures.

The contractor’s employees and TCCEC The contractor’s employees and TCCEC engineering personnel must perform the engineering personnel must perform the lockout/tagout and verificationlockout/tagout and verification

Lockout/Tagout – Instructions Lockout/Tagout – Instructions

SHIFT CHANGESHIFT CHANGE

There must be a procedure or method There must be a procedure or method to ensure the continuity of the to ensure the continuity of the Lockout during shift or personnel Lockout during shift or personnel changes.changes.

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW When an outside contractor’s work requires a When an outside contractor’s work requires a

lockout/tagout:lockout/tagout:

a.a. TCCEC and the contractor must inform each TCCEC and the contractor must inform each other of their Lockout/Tagout proceduresother of their Lockout/Tagout procedures

b.b. The two parties must coordinate the The two parties must coordinate the implementation of the procedures.implementation of the procedures.

c.c. Both a and bBoth a and b

d.d. None of the aboveNone of the above

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

VERY GOOD! VERY GOOD! C is the correct C is the correct

answeranswer

Lockout/Tagout – Instructions Lockout/Tagout – Instructions ABANDONED LOCKABANDONED LOCK

In general, only the person who applied the In general, only the person who applied the lock should remove it.lock should remove it.

The PAP Manager may have the lock The PAP Manager may have the lock removed by another authorized person, removed by another authorized person, under the following conditions:under the following conditions:

All reasonable attempts have been All reasonable attempts have been made to contact the person who made to contact the person who abandoned the lockabandoned the lock

It has been determined that the It has been determined that the equipment is safe to operateequipment is safe to operate

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW Who should normally remove the lock of an Who should normally remove the lock of an

authorized employee?authorized employee?

a.a. The Plant Asset Protection ManagerThe Plant Asset Protection Manager

b.b. The authorized employee performing The authorized employee performing lockoutlockout

c.c. Another Authorized employeeAnother Authorized employee

d.d. All of the aboveAll of the above

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW

VERY GOOD! VERY GOOD! B is the correct B is the correct

answeranswer

Under normal Under normal conditions, only the conditions, only the person who applied person who applied the lock should the lock should remove it.remove it.

Lockout/TagoutLockout/Tagout

LOCK ITLOCK ITTAG ITTAG IT

VERIFY ITVERIFY IT

Lockout/TagoutLockout/Tagout

QUESTIONS?QUESTIONS?

COMMENTS?COMMENTS?

SUGGESTIONS?SUGGESTIONS?

VIOLENT REACTIONS?VIOLENT REACTIONS?

Safety is Everyone’s Responsibility!Safety is Everyone’s Responsibility!

Safety

Safety