Control of Hazardous Energy

OSHA Standard 29CFR1910.147

MIOSHA PART 85 - The Control of Hazardous

Energy Sources

An employee was cleaning the unguarded side of an operating granite saw. The employee was caught in the moving parts of the saw and pulled into a nip point between the saw blade and the idler wheel resulting in fatal injuries.

Case Study #1

A trainee employee was cleaning a flour batch mixer. The employee was reaching into the machine when another worker activated the wrong switch turning the machine on. The employee cleaning the mixer suffered fatal crushing injuries to his neck. There was an unwritten company procedure for locking out during all maintenance. The procedure was not followed.

Case Study #2

An employee was cleaning scrap from beneath a large shear when a fellow employee hit the control button activating the blade. The blade came down and decapitated the employee cleaning the scrap.

Case Study #3

WHAT DO WHAT DO

ALLALL

OF THESE LOSSES OF THESE LOSSES HAVE IN COMMON?HAVE IN COMMON?

FAILURE TO

You will learn…

Four E’s of LOTO

Purpose of LOTO

Requirements for LOTO

Types of Hazardous Energy

Procedures for LOTO

Four E’s of LOTO

Energy

Engineering

Education

Enforcement

EE

EEEEEE

Energy

More than just switching a machine on/off

Energy is dangerous when it is strong enough to injure your body

Types of energy include:• Kinetic

• Potential

Types of Energy

Electrical

Mechanical

Thermal

Hydraulic

Pneumatic

Mechanical Energy Hazards

2 Types Kinetic - In Motion

Potential - Stored

Kinetic Energy Hazards

Energy of moving machinery can cause:

Amputations

Lacerations

Fractures

Loss of life

Potential Energy Hazards

Energy stored in machinery

• Weights & Springs

• Pistons under pressure

• Hydraulic controls

Stored potential energy can be released during work causing injury or death

Chemical Hazards

Some chemicals can:Start fires

Cause skin burns

Generate harmful gases, vapors, or fumes

Before working – release, drain, or vent chemicals safely

Thermal Energy Hazards

Hazards of Heat and Cold Hot equipment and fluids can burn you Very cold fluids can cause injury Quick release of compressed gases can

freeze your skin Allow equipment to reach a safe

temperature before starting work

Hydraulic Energy

Energy of Liquids Under Pressure Pressure can cause equipment to move Rapid release can cause injury Rapid release can also cause the

ejection of system parts

Relieve pressure slowly into a proper container

Pneumatic Energy Hazards

Energy of Compressed Gases Uncontrolled release can cause injury

Rapid depressurization can create extremely low temperatures

Properly vent all systems before starting work

Engineering

Do not bypass safety devices - they are designed for your protection!

Engineered mechanisms built into machines for your safety include:• Mechanical guards

• Mechanical stops (pins, valves)

• Point-of-Operation guards

• Interlocks

• Light curtains

Education

Know all places hazardous energy releases might occur on each machine you are working on.

Make sure people in the area know were all energy sources are located.

Review and follow the written OCC Lockout/Tagout Program.

First Step In LOTO

Know your equipment and systems • Hazards

• Isolation points

• Machine-specific procedures for lockout / tagout

Working on unfamiliar machinery is a hazard

When is LOTO necessary?

To prevent unexpected start-up during service/maintenance

There is the potential for the hazardous release of stored energy

Safety devices are bypassed for service Body is exposed to hazardous energy Clearing jams Electrical repairs

Energy Isolation

Machine specific LOTO instructions• Required if more than one power source

involved

• Identifies isolation points

• Many different scenarios possible

LOTO devices are assigned to specific affected employees

Use Safe Electrical Practices

Use non-conducting tools

Check that circuits are dead before working

Lock & Tag source breakers, not switches

Ensure all control power is de-energized

Discharge all capacitors after Lockout

L o c k o u t / T a g o u t I s o l a t i o n P o i n t s

M A C H I N E / P R O C E S S : U - C e l l 1 A p p r o v e d : N . S a i z D a t e : 3 / 1 2 / 9 9D E S C R I P T I O N : R o b o t M a c h i n i n g C e l l

E n e r g y S o u r c e L o c a t i o n M e t h o d C h e c kR o b o t M a i nP r i m a r y - E l e c t r i c a lD i s c o n n e c t 4 8 0 V

D i s c o n n e c t r i g h t s i d e o fc o n v e y o r

P u l l l e v e r d o w n t o o f fp o s i t i o n . A p p l y L O / T O .

D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .

R o b o t S e r v oS e c o n d a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V

C o n t r o l p a n e l , r i g h t o fc o n v e y o r .

T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .

D e p r e s s s t a r t b u t t o n . R o b o t w i l l n o to p e r a t e .

M o r i - S e k iP r i m a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V

B u s b a r – c e i l i n g . P u l l d i s c o n n e c t . D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .

M o r i - S e k iS e c o n d a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V

D i s c o n n e c t r e a r o fm a c h i n e a d j a c e n t t oc o n v e y o r .

T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .

D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .

E m c oP r i m a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V

D i s c o n n e c t r e a r o fm a c h i n e .

T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .

D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .

O k u m aP r i m a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V

D i s c o n n e c t s i d e o fm a c h i n e , a d j a c e n t t oE m c o .

T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .

D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .

L o a d / U n l o a d C o n v e y o rP r i m a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V

C o n t r o l p a n e l c o n n e c t e dt o l o a d c o n v e y o r .

T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .

D e p r e s s s t a r t b u t t o n . C o n v e y o r w i l ln o t o p e r a t e .

R o b o tP r i m a r y - A i r 1 1 0 p s i

B a l l v a l v e n e x t t o l o a dc o n v e y o r – i n s i d e f e n c e .

C l o s e v a l v e – a p p l yL O / T O d e v i c e .

B l e e d a l l a c c u m u l a t e d a i r p r e s s u r e .

M o r i - S e k iP r i m a r y – A i r 1 1 0 p s i

B a l l v a l v e s i d e o fm a c h i n e a d j . t o E m c o .

C l o s e v a l v e – a p p l yL O / T O d e v i c e .

B l e e d a l l a c c u m u l a t e d a i r p r e s s u r e .

E m c oP r i m a r y – A i r 1 1 0 p s i

B a l l v a l v e a b o v e m a i nd i s c o n n e c t .

C l o s e v a l v e – a p p l yL O / T O d e v i c e .

B l e e d a l l a c c u m u l a t e d a i r p r e s s u r e .

O k u m aP r i m a r y – A i r 1 1 0 p s i

B a l l v a l v e , s i d e o fm a c h i n e a d j . , E a s t s i d e .

C l o s e v a l v e – a p p l yL O / T O d e v i c e .

B l e e d a l l a c c u m u l a t e d a i r p r e s s u r e .

R E M E M B E R L o c k o u t / T a g o u t B e f o r e L O / T O , n o t i f y a l l a f f e c t e d e m p lo y e e s . I f m a c h in e is o p e r a t in g , s h u t d o w n u s in g n o r m a l

p r o c e d u r e . L O / T O n e c e s s a r y p o w e r s o u r c e s – d e p e n d in g o n t a s k

p e r f o r m e d . T e s t e q u ip m e n t t o e n s u r e d e e n e r g iz e d . A s s u r e R e le a s e o f a l l S t o r e d E n e r g y R e t u r n c o n t r o ls t o o f f p o s i t io n a f t e r t e s t in g . R e t u r n t o o p e r a t io n o r r e m o v a l o f L O / T O f o r t e s t in g .1 . C h e c k m a c h in e t o e n s u r e a l l s a f e g u a r d s a r e in p la c e ,

m a c h in e c o m p o n e n t s in t a c t a n d e m p lo y e e s c le a r e d .2 . A s s u r e c o n t r o ls a r e in t h e o f f p o s i t io n3 . R e m o v e L O / T O d e v ic e a n d r e e n e r g iz e d e v ic e .4 . N o t i f y a f f e c t e d e m p lo y e e s t h a t m a in t e n a n c e is c o m p le t e

a n d m a c h in e is r e a d y f o r u s e .5 . D e e n e r g iz e a n d r e a p p ly L O / T O d e v ic e a s r e q u i r e d . O n ly W o r k U n d e r Y o u r O W N L o c k

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Energy Isolation Identify potential sources of

hazardous energy release

Identify method(s) for isolating the energy

Document procedures for each piece of equipment

Enforcement

Know the results of tampering with or not following complete LOTO procedures:

LOTO procedures have been established to protect OCC employees from serious injury or death.

Failure to comply with OCC LOTO policies and procedures can result in disciplinary actions up to, and including, dismissal.

Who Can Lockout Equipment?

Employees who have been trained

and authorized by management

ONLY!

Contractors

All contract employees

must follow OCC LOTO

procedures!

Items Needed for LOTO

Written LOTO schedule Locks & Tags - specific to the worker Hasps - for placing locks & tags Breaker Clips - for electrical LOTO Blank Flanges (Pancakes) - for fluid lines Valve Covers - for LOTO of valves Plug Buckets - for electrical plugs

Use of Locks and Tags

• Use only those issued to you

• Never use another worker’s lock or tag

• Ask your supervisor if you need more LOTO equipment

Who Can Remove Locks and Tags?

The employee who placed the tag

or

A supervisor, after obtaining permission from the worker who placed the tag

NO EXCEPTIONS!

Q: A piece of equipment already has a lock and tag.  Do I have to place my own locks and tags?

A: YES.  Each person working on the equipment must place their own locks and tags to ensure their safety.

Frequently Asked Questions

Procedures for Lockout / Tagout

Remember Know your equipment and systems before

proceeding

• Hazards

• Isolation points

• Procedures for Lockout

Working on unfamiliar machinery is a hazard!

6 Step LOTO Procedure

1. Prepare for shutdown

2. Shut down equipment

3. Isolate all energy sources

4. Place Locks and Tags

5. Release stored energy

6. Verify equipment isolation

1  Prepare for Shutdown

Understand equipment hazards

Notify other workers of shutdown

2  Shutdown Equipment

Use normal shutdown procedures

Turn all switches to OFF

Shut all control valves

Disable all sources of energy

3  Isolate All Energy Sources

Shut valves

Open breakers and disconnects

4 Place Locks & Tags On

Shut off and lock valves

Deactivate and lock breakers / electrical disconnects

Block or disconnect all lines

Lock and tag blank flanges

5  Release or Block All Stored Energy

• Discharge capacitors • Block or release springs • Block elevated parts • Stop rotating flywheels • Relieve system pressure • Drain fluids • Vent gases • Allow system to cool

6  Verify Equipment Isolation

• Ensure that all other workers are clear

• Check that locking devices are securely placed

• Check isolation

• Attempt normal startup (should fail!)

• Return controls to OFF/Neutral

Release from Locked Out / Tagged Out Status• Inspect area and equipment • Ensure all machine guards are in place • Move tools away from equipment • Inform others of startup • Restore system connections • Remove Locks & Tags • Restore equipment to normal operating

parameters• Conduct normal startup

Lockout / Tagout Protects YOU!

Use Proper Lockout /

Tagout Procedures