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Lockout/TagoutMODULE 20
2 ©2006 TEEX
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 iscovered in 1910 Subpart O
3 ©2006 TEEX
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?
4 ©2006 TEEX
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
5 ©2006 TEEX
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
6 ©2006 TEEX
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
7 ©2006 TEEX
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
8 ©2006 TEEX
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
9 ©2006 TEEX
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
Definitions1910.147(b)
11 ©2006 TEEX
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
12 ©2006 TEEX
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
13 ©2006 TEEX
Energized
Connected to an energy source OR Containing residual or stored energy
14 ©2006 TEEX
Energy isolating device
A mechanical device that physically prevents the transmission or release or energy Circuit breakers included NOT push buttons NOT selector switches NOT control circuits
15 ©2006 TEEX
Energy source
Any source of: Electrical, Mechanical, Hydraulic, Pneumatic, Chemical, Thermal, or Other energy
What kind of energydid the rock have?
16 ©2006 TEEX
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
17 ©2006 TEEX
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
18 ©2006 TEEX
Servicing and/or maintenance
Workplace activities such as: Constructing, Installing, Setting up, Adjusting, Inspecting, Modifying, and Maintaining and/or servicing machines or
equipment
19 ©2006 TEEX
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
General Requirements1910.147(c)
21 ©2006 TEEX
Energy control program
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.
22 ©2006 TEEX
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
23 ©2006 TEEX
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
24 ©2006 TEEX
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
25 ©2006 TEEX
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
26 ©2006 TEEX
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
27 ©2006 TEEX
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
28 ©2006 TEEX
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:
29 ©2006 TEEX
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: Color Shape Size Print/Format
30 ©2006 TEEX
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
31 ©2006 TEEX
1910.147(c)(5) Protective materials and hardware
Lockout and tagout devices indicate identity of employee applying devices
32 ©2006 TEEX
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
33 ©2006 TEEX
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
34 ©2006 TEEX
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
35 ©2006 TEEX
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
36 ©2006 TEEX
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
37 ©2006 TEEX
1910.147(c)(8) Energy Isolation
Only the authorized employees performing the servicing or maintenance may apply lockout/tagout
38 ©2006 TEEX
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
Application of Control1910.147(d)
40 ©2006 TEEX
Order of Operation for Application of Control
1. Preparation for shutdown2. Equipment shutdown – orderly3. Equipment isolation 4. Lockout or tagout device application5. Stored energy relieved; continue while
reaccumulating6. Verification of isolation
Test and return to “off” position
Release from Lockout/Tagout1910.147(e)
42 ©2006 TEEX
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
43 ©2006 TEEX
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
Additional Requirements1910.147(f)
45 ©2006 TEEX
1910.147(f)(1) Testing or Positioning
Temporary removal of lockout/tagout devices for testing/positioning: 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
46 ©2006 TEEX
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
47 ©2006 TEEX
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);
48 ©2006 TEEX
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
49 ©2006 TEEX
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
50 ©2006 TEEX
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