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UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program Training
UNC-CH Chilled Water Department
Control of Hazardous Energy Policy
and Procedure Training Module
UNC Chilled Water Energy Control Policy-
Class Objectives
The objectives of this safety training module is to instruct UNC Energy Services Chilled Water Employees on Policy with regards to:
1) The Energy Control Procedure (Lock Out/Tag Out; (LOTO)) for Chilled Water Services
2) Understand causes of accidents related to lack of Energy Control (LockOut/TagOut) Programs
Note: In addition to this training, additional training covering the individual procedures and hands on training will be performed at your work unit.
UNC Chilled Water Energy Control Policy-
Purpose of the Policy
The purpose of the Chilled Water Energy Control Procedure is to establish minimum requirements for the manual isolation and securing of energy sources for the purpose of service and/or maintenance for Chilled Water Systems Department equipment.
UNC Chilled Water Energy Control Policy-
Purpose of the Policy
This policy will ensure that machines/equipment are isolated from all potentially hazardous energy which may include electrical, mechanical, hydraulic, pneumatic, chemical and thermal, and are locked out and tagged out before individuals perform any servicing or maintenance during which an unexpected energizing, start-up or release of stored energy could cause an injury.
To view the Original Chilled Water Department Energy Control Procedure, Click on This Link…..
UNC Chilled Water Energy Control Policy-
Purpose of the Policy
Why Do these Procedures exist and what are the Regulations?The Occupational Safety and Health Administration (OSHA) regulates lockout/tag out through the Control of Hazardous Energy Standard, found at 29 CFR 1910.147. This standard mandates training, audits, and recordkeeping to ensure that workers will not be injured by unintentionally energized equipment.
UNC-CH incorporates OSHA requirements for the University Energy Control Requirements.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
Lockout/Tagout Applies to:
Servicing and maintenance of machines and equipment in which unexpected energization and/or start up or release of energy could cause injury.
There are many sources of equipment at Chilled Water Services that could cause injury if energy control procedures are not followed.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
Types of Energy Hazards at Chilled Water
Services Physical Plants:
- Electrical
- Mechanical
- Pressure (Hydraulic and Pneumatic)
- Thermal (e.g. Water, Steam)
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
Types of Energy Hazards:
Plant Chiller Systems
Pumps and Motors, Pipeline, and Electrical
Systems (e.g. Switches) that require Lock
Out/Tag Out.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
Types of Energy Hazards:
• Mechanical, Pressure, and Electrical Hazards
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Valves/
Pressure
Hazard
Electrical
Components/
Electrical
Hazard
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
Who’s Covered Under Lockout/Tagout Procedure?
Affected employees are those employees whose job requires them to operate equipment or a machine subject to Lockout/Tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed.
Authorized employees are those employees whophysically locks and tags out equipment or machinery in order to perform servicing and/or maintenance on that machine or equipment.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/ Tagout
Lock Out/Tag Out is the control of energizing, starting,
or stored energy in machinery or equipment which could
cause injury to employees.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/ Tagout
Lockout is the placement of a lockout device on an
energy isolating device, in accordance with an
established procedure, ensuring that the energy isolating
device and the equipment being controlled cannot be
operated until the lockout device is removed.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/ Tagout
A Lockout device is a lock that keeps a switch, valve, or
lever in the off position this providing a “physical
restriction”.
Locks are provided by your Department and can only be
used for lockout purposes. They should never be used to
lock tool boxes, storage sheds, or other devices.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/Tagout
An Example of a Lockout Station at Chilled Water
Services:
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/Tagout
Tagout is the placement of a tagout device on an
energy isolating device, in accordance with an
established procedure, to indicate that the energy
isolating device and the equipment being controlled
may not be operated until the tagout device is
removed.
Note: The above valve is both locked and tagged out
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/Tagout
Tagout is accomplished by placing a tag on the power source. The tag acts as a warning not to restore energy-it is not a physical restraint.
Tagout shall only be used when an energy isolating device is not capable of being locked out.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/Tagout
The preferred method of isolation is Lockout/Tagout, using department issued locks and tags.
Both locks and tags must be strong enough to prevent unauthorized removal and to withstand various environmental conditions.
A Chilled Water Supervisor must provide writtenapproval of the use of Tagout alone instead of the preferred Lockout/Tagout.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/Tagout
Locks used for locking out energy isolating devices under this procedure will be issued by the Chilled Water Department and will be red in color.
Locks must be accompanied by a department issued tag that is dated, signed legibly in dark ink by the employee who applied it and be understandable by employees whose work operations are or may be in the area.
Tags used for locking out energy isolating devices under this procedure will read:
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/Tagout
“Locked Out” “Do Not Operate” :
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/Tagout
The employee will use a Department issued label to apply to the tag where the date is indicated. This label can then be replaced or covered with a new label with a new date.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
What is Lockout/Tagout
Department
issued label which
can be replaced or
covered with a
new label with a
new date.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
When a Lockout/Tagout or Tagout device is attached to an energy-isolating device,
1) it is not to be removed without authorization of the individual who signed it, and..
2) it is not to be bypassed, ignored or otherwise defeated.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
Each employee must apply his own personal Lockout/Tagout or Tagout device on the energy isolating device. No one can apply another employee’s Lockout/Tagout or Tagout device.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure
Only the employee who attached the Lockout/Tagout or Tagout device or the employer, in the employee’s absence and upon completion of this procedure’s Absentee Tagout or Lockout/TagoutRemoval Report may remove an employee’s Lockout/Tagout device.
Link to Absentee Tagout or Lockout/Tagout Removal Report
UNC Chilled Water Energy Control Procedure
Twelve Elements to the Energy Control
Procedure
The 12 elements to the Chilled Water Energy Control
Procedure
UNC Chilled Water Energy Control Procedure
Twelve Elements
The 12 elements to the Chilled Water Energy Control
Procedure consist of: 1) Preparation for Shutdown
2) Machine or Equipment Shutdown
3) Machine or Equipment Isolation
4) Notification of employees
5) Lockout/Tagout or Tagout Device Application
6) Release of Stored Energy
7) Verification of Isolation
8) Shift or Personnel Changes
9) Release From Lockout/Tagout or Tagout
10) Lockout/Tagout or Tagout Device Removal
11) Removal of Lockout/Tagout or Tagout When Individual Is Not Available
12) Testing or Positioning of Machines, Equipment, or Components
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step1 - Preparation for Shutdown
Before an authorized employee turns off a machine
or piece of equipment, they shall have knowledge
of:
1) type and magnitude of the energy,
2) the hazards of the energy to be controlled, and
3) the method or means to control the energy.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step2 – Shutdown of Equipment
The machine or equipment shall be turned off or shut
down using the procedures established for the
machine or equipment. An orderly shutdown must be
utilized to avoid any additional or increased
hazard(s) to employees as a result of equipment de-
energization.
If the machine is in operation, follow proper or
normal stopping procedures. (Press STOP button,
move switch or lever to OFF).
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step3 – Equipment Isolation
All energy- isolation devices that are needed to control the energy to the machine or equipment shall be physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s).
Operate the switch, valve, or other energy-isolating device so that each energy source (electrical, mechanical, hydraulic, etc.) is disconnected or isolated from the equipment. Stored energy such as capacitors, springs, elevator machine members, rotating flywheels, hydraulic systems and air, gas, steam or water pressure, etc. must also be dissipated or restrained by methods such as grounding, blocking, repositioning, bleeding down, etc.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 4 – Notification of employees
Affected employees shall be notified by Chilled Water Operations Control Room and the authorized employee of the application and removal of energy control devices. Notification shall be given before the controls are applied, and after they are removed from the machine or equipment.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 5 - Application of Lock-Out / Tag-Out Devices
Lockout devices shall be affixed to each energy-
isolating means by authorized individuals and shall be
affixed in a manner that will hold the energy in a
“safe” or “off” position. Attach with the lockout device
an approved lockout tag containing the name, date
and contact information for the person performing the
lockout/tagout. Locks shall not be attached without
tags.
Video clip for applying lockout/tagout device
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 5 - Application of Lock-Out / Tag-Out Devices
Tagout shall only be used when an energy isolating
device is not capable of being locked.
A Chilled Water Supervisor must complete a Tagout
Authorization form to provide his approval of the use of
Tagout alone instead of the preferred Lockout/Tagout.
Tags are essentially warning devices and do not
provide the physical restraint on energy-isolating
devices that are provided by lockout. They therefore
may evoke a false sense of security.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 5 - Application of Lock-Out / Tag-Out Devices
Attach locks in a manner that will hold that same valve,
switch or lever in that "Open" or "Off" position. Attach
tags to the same point as you would a lock, or as close as
possible and clearly state that removal is prohibited.
Video Clip for applying lockout/tag out device
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 6 – Release of Stored Energy
Following the application of Lockout/Tagout or Tagout
devices to energy-isolating devices, all potentially
hazardous stored energy shall be relieved,
disconnected, restrained, and otherwise rendered safe.
If there is a possibility of re-accumulation of stored
energy to a hazardous level, verification of isolation
shall be continued until the servicing or maintenance is
completed, or until the possibility of such accumulation
no longer exists.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 6 – Release of Stored Energy
Make hazardous energy safe: Release trapped
pressure, Bleed lines, Disconnect circuits, or
Block/Support pressured driven parts.
When a re-buildup of energy is possible, employees
must monitor that area until the maintenance is
complete.
Make sure all moving parts have stopped – Install
ground wires to isolate live circuits, discharge
capacitors, and prevent static electricity buildup.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 6 – Release of Stored Energy
Following the application of Lockout/Tagout or Tagout
devices to energy-isolating devices, all potentially
hazardous stored energy shall be relieved,
disconnected, restrained, and otherwise rendered safe.
If there is a possibility of re-accumulation of stored
energy to a hazardous level, verification of isolation
shall be continued until the servicing or maintenance is
completed, or until the possibility of such accumulation
no longer exists.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 7 – Verification of Isolation
Prior to starting work on machines or equipment that
have been isolated and de-energized using
Lockout/Tagout or Tagout, the authorized employee will
verify that isolation and de-energization of the machine
or equipment has been accomplished. After ensuring that
no personnel are exposed, test the system to make
certain it can’t operate.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 7 (Cont’d) - Verification of Isolation
Prior to starting work, authorized employees will
verify that energy isolation was accomplished.
Double-check previous steps.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 7 (Cont’d) - Verification of Isolation
Double-check previous steps:
1. Clear personnel – Test system to ensure it can’t operate.
2. Try to move main disconnect to ON.
3. Press START button.
4. Make sure you have correct system locked out.
5. Push STOP button – Return start switches to neutral or OFF.
CAUTION: Return operating control(s) to ‘neutral’ or off position
after the test.
To confirm Verification of Isolation consult with Chilled Water
Operations Control Room!
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 8 – Shift or Personnel Changes
In the case of shift or personnel changes, a
changeover period will be established so that
individuals may exchange their assigned energy
control devices. Individuals assuming control of
the Lockout/Tagout of equipment shall be fully
briefed in the scope and strategy of the work by
those who are being relieved.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 9 – Release From Lockout/Tagout or Tagout
Before start-up of equipment after servicing, complete
the following steps as per Chilled Water’s Energy Control
Procedure:
1) Make sure machine/equipment is in good working order,
including the reinstallation of all removed
equipment/machine guards.
2) Check for and retrieve all loose tools, equipment/machine
parts.
3) Ensure all employees are in a safe position or removed
from the area.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 10 – Lockout/Tagout or Tagout Device Removal
Each energy control device shall be removed from each
energy-isolated means by the individual who applied it.
Before a machine or equipment is started, affected
individuals shall be notified that the device(s) have been
removed.
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 11 – Removal of Lockout/Tagout device when
individual is absent.
The supervisor removing the device will initiate an
Absentee Lockout/Tagout or Tagout Removal Report.
Before removing, the supervisor will make all
reasonable effects to contact the individual.
Once the employee returns, the supervisor will
immediately assure the individual signs off indicating
he is aware that his device has been removed.
Attach PDF link of Absentee LO/TO Removal Report
UNC Chilled Water Energy Control Procedure
Twelve Elements
Step 12 – Testing or Positioning of Machines,
Equipment, or Components
When energy control devices must be temporarily
removed to test or position the equipment or
component:
Follow the procedures for release and removal from
Lockout/Tagout or Tagout.
Follow procedure as described above in Lockout/Tagout or
Tagout Device Removal.
Energize and proceed with testing or positioning.
De-energize all systems and reapply energy control devices as
outlined to continue the servicing and/or maintenance.
UNC Chilled Water Energy Control Procedure
Twelve Elements- Equipment that Applies
The Energy Control twelve element Procedure would
be utilized when maintenance is required on the
following equipment:
Plant Chillers (Pumps, Motors, Valves)
Pipelines (Pumps, Motors, Valves)
Electrical Systems (Switches, Open Starter or Breaker)
UNC Chilled Water Energy Control
Types of Lockout/Tagout
There are several different types of Lockout pertaining to Chilled Water Services.
1) Individual Lockout
2) Group Lockout
3) Group Lockout with a Lockbox
4) Contractor Lockout
UNC Chilled Water Energy Control
Types of Lockout/Tagout
1) Individual Lockout/Tagout is..
The placement of a lockout device on an energy
isolating device by an employee, in accordance with
an established procedure, ensuring that the energy
isolating device and the equipment being controlled
cannot be operated until the lockout device is
removed.
Individual lockout/tagout applies to all Lockout/
Tag Out Procedures performed at Chilled Water
Services including: Pipeline, Electrical, and Pump
and Motor Lockout/Tagout Procedures.
UNC Chilled Water Energy Control
Types of Lockout/Tagout
The following illustration is of an individual Pipeline
Lockout/Tagout after employee has:
1. Notified all affected personnel
2. Identified and Isolated energy sources (e.g.
hazard: water, steam, or other).
3. And is in the process of Installing lockout devices.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual Lockout
•This video illustrates a Chilled Water Services Employee performing an
individual lockout/tagout by placing a LO/TO device on a Plant Valve:
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual Lockout•Below are Illustrations of a Chilled Water Services Employee performing an
individual lockout by installing a Lockout/Tagout device on a valve.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual Lockout
• Employee places his assigned Lock and tag device on the valve securely.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual Lockout
•Employee removes key from lock and verifies Lockout/Tagout Device is
in place and is visible to other employees in the work area.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual Lockout
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual Lockout
Next is another example of an employee
performing an individual lockout on a electrical
switch to a Variable Frequency Drive for a pump:Electrical
Switch
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual Lockout
The following illustration is after:
1) Notification of affected personnel (operators of
equipment, etc) that LOTO procedures will be in
effect.
2) Identified and Isolated energy sources.
3) Verified “Zero Energy State” and
4) In the process of Installing Lockout device.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual LockoutEmployee places Lockout/Tagout Device onto electrical switch to
ensure equipment may not be energized while performing
assigned work task.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual Lockout
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Individual Lockout Before start-up of equipment after servicing, complete the following steps as
per Chilled Water’s Energy Control Procedure:
1) Make sure machine/equipment is in good working order to include the
reinstallation of all removed equipment/machine guards.
2) Check for and retrieve all loose tools, equipment/machine parts.
3) Notify all affected personnel that LOTO devices are being removed from
equipment/machinery.
4) Remove all LOTO devices from energy isolating devices.
5) Assure that all personnel are safely positioned away from the
equipment/machinery.
6) Operate the energy isolating devices to restore energy to the
equipment/machine.
7) If possible and practical, start equipment to assure that if functions properly.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Group Lockout
Group Lockout is used when servicing and/ormaintenance is performed by a crew, craft,department or other group. This procedure affordsthe individuals a level of protection equivalent tothat provided by a personal lockout/tagout device.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Group Lockout
In a Group Lockout one primary authorized employee of a work crew, or a supervisor with the knowledge of the crew, can lock out equipment for the whole crew. In such cases it shall be the responsibility of that individual to carry out all twelve steps of the lockout/tagout procedure and inform the crew when it is safe to work on the equipment. This individual will attach his lockout/tagout device to a multi-lock accepting device.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Group Lockout
Group Lockout: Each affected and authorized individual, once satisfied that the equipment has been properly isolated from all potentially hazardous energy, shall affix a personal lockout/tagout device to the multi-lock accepting device when they begin work, and shall remove those devices when they stop working on the machine or equipment being serviced or maintained.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Group Lockout
Group Lockout:
The next slides provide examples of employees performing a Group Lockout/Tagout procedure at one of the Chilled Water Plants.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Group Lockout
The following illustration is for a ‘Group’ Lock
Out/Tag Out (LOTO) after employees have:
1. Notified all affected personnel
2. Identified and Isolated energy sources (e.g.
hazard: water, steam, or other).
3. In process of installing lockout devices.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-Group Lockout
Lock out of a Pipeline with Pumps, Valves,
Motors Requiring Multiple Locks and Tags
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Group Lockout
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Group Lockout with a Lockbox
Group Lockout with LockBox: If multiple pieces of equipment are being locked out, multiple lockout/tagout devices may be used to lockout the machine or equipment with the keys being placed in a lockout box that allows the use of multiple locks to secure it.
Each individual will then use his Lockout/Tagout device to secure the box. As each person no longer needs to maintain his lockout protection, that person will remove his Lockout/Tagout device from the box.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Group Lockout with a Lockbox
The Primary Authorized Individual shall remove
his lockout/tagout device and the multi-lock
accepting device when all service or
maintenance has been completed.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Group Lockout
Video Clip: Of Group Lockout of South Chiller PlantPipeline (e.g. Pump, motor, valve)
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Group Lockout with a LockboxNote: No one can get to the Keys in the Lockbox unless all
authorized persons Locks are removed
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure-
Group Lockout with a Lockbox Before start-up of equipment after servicing, complete the following steps as
per Chilled Water’s Energy Control Procedure:
1) Make sure machine/equipment is in good working order to include the
reinstallation of all removed equipment/machine guards.
2) Check for and retrieve all loose tools, equipment/machine parts.
3) Notify all affected personnel that LOTO devices are being removed from
equipment/machinery.
4) Remove all LOTO devices from energy isolating devices.
5) Assure that all personnel are safely positioned away from the
equipment/machinery.
6) Operate the energy isolating devices to restore energy to the
equipment/machine.
7) If possible and practical, start equipment to assure that if functions properly.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Contractors
Contractors: Whenever Contractor personnel are to be engaged in activities covered by the scope and application of this standard, Energy Services Chilled Water and the Contractor shall inform each other of their respective energy control procedures.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Contractors
Contractors(cont’d): Energy Services Chilled Water shall ensure that Contractors understand and comply with the restrictions and prohibitions of the Chilled Water Services Energy Control Program.
If the Contractors has no documented energy control procedures, or if their procedure allows tagout in lieu of lockout/tagout, they shall ensure that their personnel understand and comply with the procedures established in the Chilled Water Services Program.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Contractors
The contractor shall contact the Chilled Water Supervisor and Chilled Water Operations to coordinate the work activities. Chilled Water personnel will initially isolate and lockout the appropriate.
The contractor shall then install his lockout device.
UNC Chilled Water Energy Control
(Lock Out/Tag Out) Procedure- Contractors
Once work is completed, the contractor will remove his lockout device and inform the Chilled Water Supervisor and Chilled Water Operations of its. At this time, if no other work is to be preformed on the equipment, Chilled Water personnel will remove their lockout devices.
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
What are some types of accidents that have occurred due to poor LO/TO procedures?
Injured by:
1) Moving machinery part
2) Contact with energized part
3) Physical hazard (chemicals, heat)
4) Falling Machine Part
5) In some cases fatalities have occured.
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
Activities at Time of Accident?-Unjamming object(s)
-Cleaning equipment
-Repairing equipment
-Performing routine maintenance
-Installing equipment
-Adjusting equipment
-Doing set-up work
-Performing electrical work
-Testing materials
Note: These activities often required a worker to place all or part of their body into the machine’s hazard zone.
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
Contributing Causes?-Afraid of production slow down
-Afraid it would take too long
-Not required by company policy
-Worker didn’t know power was on
-Worker didn’t know power was off
-Did not think it was necessary
-Task could not be done with power off
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
Reasons Equipment was Turned On?
-Accidentally turned on by injured employee
-Co-worker accidentally turned equipment On
-Equipment moved when jam-up cleared
-Equipment unexpectedly “cycled”
-Parts still in motion (coasting)
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
The following is a National Institute for Occupational
Safety and Health (NIOSH) Case Studies.
The Investigations were conducted as part of NIOSH
Fatality Assessment and Control Evaluation (FACE)
Program to help educate employers and employees
on the hazards associated with hazardous energy.
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
NIOSH Case No. 1- Uncontrolled Kinetic Energy
A 25-year old male worker at a concrete pipe manufacturing facility died from injuries he
received while cleaning a ribbon-type concrete mixer. The victim’s daily tasks included cleaning
out the concrete mixer at the end of the shift. The clean-out procedure was to shut off the power
at the breaker panel (approximately 35 feet from the mixer), push the toggle switch by the
mixer to make sure that the power was off, and then enter the mixer to clean it.
No one witnessed the event, but investigators concluded that the mixer operator had shut off the
main breaker and then made a telephone call instead of following the normal procedure for
checking the mixer before anyone entered it. The victim did not know that the operator had de-
energized the mixer at the breaker. Thinking he was turning the mixer off, he activated the
breaker switch and energized the mixer. The victim then entered the mixer and began cleaning
without first pushing the toggle switch to make sure that the equipment was de-energized. The
mixer operator returned from making his telephone call and pushed the toggle switch to check
that the mixer was de-energized. The mixer started, and the operator heard the victim scream.
He went immediately to the main breaker panel and shut off the mixer.
Within 30 minutes, the emergency medical service (EMS) transported the victim to a local
hospital and then to a local trauma center. He died approximately 4 hours later [NIOSH 1995].
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
NIOSH Case No. 1- Uncontrolled Kinetic Energy
What do you think were some contributing causes of
this accident (Please Type Below)?
Answers: Poor Communication, Not following proper
LO/TO procedures, Improper Training of Safety
Guidelines for work process, etc.
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
NIOSH Case No. 2- Uncontrolled Electrical Energy
A 53 year-old journeyman wireman was electrocuted when he contacted two energized, 6.9-kilovolt buss terminals. The victim and two coworkers (all contract employees) were installing electrical components of a sulfur dioxide emission control system in a 14-compartment switch house.
The Circuit breaker protecting the internal buss within the switch house had been tripped out and marked with a tag- but it had not been secured by locking. This procedure was consistent with the hazardous energy control procedures of the power plant.
The victim and his coworkers were wiping down the individual compartments before a prestart up inspection by power plant personnel. Without the knowledge of the victim and his coworkers, power plant personnel had energized the internal buss in the switch house. When the victim began to wipe down one of the compartments at the south end of the switch house, he contacted the A-phase buss terminal with his right hand and the C-phase buss terminal with his left hand. This act completed a path between phases, and the victim was electrocuted.
A coworker walking past the victim during the incident was blown backward by the arcing and received first-degree flash burns on his face and neck. A second coworker at the north end of the switch house heard the explosion and came to help. He notified the contractor’s safety coordinator by radio and requested EMS. The EMS responded in about 15 minutes and transported the victim to a local hospital emergency room where he was pronounced dead [NIOSH 1994}.
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
NIOSH Case No. 2- Uncontrolled Electrical Energy
What do you think were some contributing causes of
this accident (Please Type Below)?
Answers: Poor Communication,
Failure to de energize energy,
Failure to dissipate stored energy.
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
NIOSH Case No. 3- Uncontrolled Kinetic Energy
A 38-year-old worker at a county sanitary landfill died after falling into a large trash compactor used to bale cardboard for recycling. The cardboard was lifted 20 feet by a belt conveyer and fed through a 20-by 44-inch opening into a hopper. The hopper had automatic controls that activated the baler when enough material collected in the baling chamber. When the baler was activated, material in the chamber was compressed by a ram that entered the chamber from the side. Excess material above the chamber was trimmed by a shearer.
On the day of the incident, cardboard jammed at the conveyer discharge opening. Without stopping, de-energizing, or locking out the equipment, the victim rode the conveyer up to the discharge opening to clear the jam. He fell into the hopper and the bailing cycle was automatically activated, amputating his legs. The victim bled to death before he could be removed from the machine [ Colorado Department of Public Health and Environment 1994].
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
NIOSH Case No. 3- Uncontrolled Kinetic Energy
What do you think were some contributing causes of
this accident (Please Type Below)?
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
Review of the NIOSH FACE data indicates that three related factors contribute to injuries and deaths that occur when workers perform installation, maintenance, service, or repair work near hazardous energy sources.
Let’s Review the three related factors.
1. Failure to completely de-energize, isolate, block, and/or dissipate the hazardous energy source.
2. Failure to lockout and tagout energy control devices and isolation points after the hazardous energy source has been de-energized.
3. Failure to verify that the hazardous energy source was de-energized before beginning work.
Note: The fatalities that occurred could have been prevented if comprehensive hazardous energy control procedures had been implemented and followed.
Types of Accidents in General Industry-
Due to Poor Energy Control Procedures
The 5- fatal errors noted by NC OSHA include:
1) Failure to stop equipment
2) Failure to disconnect from power source
3) Failure to dissipated residual energy
4) Accidental Start up of equipment/machine
5) Failure to clear area before starting equipment.
Conclusion and Post Test