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UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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ONLINE SELF-STUDY UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program Training
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Page 1: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

ONLINE SELF-STUDY

UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program Training

Page 2: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC-CH Chilled Water Department

Control of Hazardous Energy Policy

and Procedure Training Module

Page 3: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 4: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 5: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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…..

Page 6: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 7: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure

Page 8: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure

Page 9: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 10: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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)

Page 11: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 12: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure

Types of Energy Hazards:

• Mechanical, Pressure, and Electrical Hazards

Page 13: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure-

Valves/

Pressure

Hazard

Electrical

Components/

Electrical

Hazard

Page 14: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 15: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 16: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 17: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 18: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure

What is Lockout/Tagout

An Example of a Lockout Station at Chilled Water

Services:

Page 19: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 20: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 21: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 22: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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:

Page 23: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure

What is Lockout/Tagout

“Locked Out” “Do Not Operate” :

Page 24: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 25: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 26: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 27: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 28: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 29: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control Procedure

Twelve Elements to the Energy Control

Procedure

The 12 elements to the Chilled Water Energy Control

Procedure

Page 30: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 31: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 32: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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).

Page 33: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 34: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 35: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 36: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 37: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 38: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 39: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 40: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 41: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 42: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 43: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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!

Page 44: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 45: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 46: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 47: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 48: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 49: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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)

Page 50: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 51: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 52: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 53: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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:

Page 54: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 55: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure-

Individual Lockout

• Employee places his assigned Lock and tag device on the valve securely.

Page 56: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 57: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure-

Individual Lockout

Page 58: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 59: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 60: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 61: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure-

Individual Lockout

Page 62: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 63: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 64: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 65: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 66: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 67: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 68: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 69: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

UNC Chilled Water Energy Control

(Lock Out/Tag Out) Procedure- Group Lockout

Page 70: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 71: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 72: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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)

Page 73: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 74: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 75: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 76: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 77: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety 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.

Page 78: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 79: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

Types of Accidents in General Industry-

Due to Poor Energy Control Procedures

Types of Accidents in General Industry-

Due to Poor Energy Control Procedures

Page 80: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 81: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 82: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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

Page 83: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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)

Page 84: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 85: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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].

Page 86: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 87: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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}.

Page 88: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 89: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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].

Page 90: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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)?

Page 91: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 92: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

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.

Page 93: UNC-CH Energy Services Chilled Water Department Control of Hazardous Energy Safety Program

Conclusion and Post Test


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