Energy Control Procedures Lockout/Tagout 29 CFR 1910.147
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Transcript of Energy Control Procedures Lockout/Tagout 29 CFR 1910.147
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Energy Control Procedures
Lockout/Tagout29 CFR 1910.147
Georgia Tech Research Institute
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2
Most Frequently Cited Serious Violations in General Industry FY 2006
1418
1155
733
689
645
589
572
564
556
522
212(a)(1) - O
1200(e)(1) - Z
212(a)(3)(ii) - O
23(c)(1) - D
1200(h)(1) - Z
151(c) - K
147(c)(1) - J
215(b)(9) - O
147(c)(4)(i) - J
305(b)(1) - SStan
dard
& S
ubpa
rt:
1910
.
Machine Guards - General
Eye & Body Flushing Facilities
Point of OperationOpen-Sided Floors
Conductors Entering Cabinets/Boxes/Fittings Protected from Abrasion
Lockout/Tagout - Program
Grinders-Tongue Guards
Hazard Communication – Information & Training
Note: There were also 1222 Section 5(a)(1) General Duty Clause violations cited for all inspections during this period.
Lockout/Tagout - Procedures
Hazard Communication – Written Program
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3
Subpart J - General Environmental Controls (1910.141 - 147)
572
556
448
342
188
147(c)(1)
147(c)(4)(i)
147(c)(7)(i)
147(c)(6)(i)
147(c)(4)(ii)
Lockout/Tagout - Program
Lockout/Tagout - Training
Lockout/Tagout - Procedures
Lockout/Tagout - Content of energy control procedures
Stan
dard
: 191
0. Lockout/Tagout procedure - Periodic inspection
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What is covered?
Servicing and maintenance Normal production operations where:
Employees by-pass guard(s) Employees place any part of their body in a hazardous
area
When you are training it is important to cover the relationship between Subpart O-Machine Guarding and Lockout Tagout!!
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What is not covered?
Construction, agriculture, and maritime Normal production operations (subpart O) Cord-and-plug under the control of
employee (written procedure still required) Exposure to electrical conductors (subpart
S and electrical safety-related work practices)
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Locked Out?????????
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Energy types
Electrical Mechanical Hydraulic Pneumatic Chemical Thermal Other
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Lockout vs. Tagout
If capable of being locked out:Prefer lockoutTags allowed, if employer can demonstrate FULL
EMPLOYEE PROTECTION
Machine Modifications If you alter a machine you must make the machine
capable of accepting a lock.
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Full employee protection?
Tags attached at the same location as locks
Full compliance with all tagout provisions in 29 CFR 1910.147
Additional means when necessary (e.g. removal of a valve handle)
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Definitions
Affected employee Authorized employee Capable of being locked out Energy isolating device Servicing and/or maintenance
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Servicing and maintenance includes:
Setting up Adjusting Inspecting Modifying Installing
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Lockout/tagout requirements
Written program which includes specific written procedures
Training of employees (not just maintenance!)
Periodic review of procedures
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Written lockout/tagout procedure
(Equipment Specific Procedures) Clearly and specifically outline
ScopePurposeAuthorizationRules, techniques for control of energy
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Lockout procedure (cont.)
Clearly and specifically outline:
Means to enforce compliance including:
Intended use of procedure Specific procedural steps Specific testing requirements
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Documentation exceptions:
Machine has no potential for stored energy Machine has a single energy source Isolation of that source will completely de-
energize Machine is isolated and locked out during
maintenance
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Documentation exceptions (cont.) A single lockout device will achieve locked-
out condition Lockout device under exclusive control of
employee Maintenance does not create hazard to others No previous accidents involving unexpected
energization on this equipment
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Energy control procedure Notification of employees Preparation for shutdown Machine or equipment shutdown Machine or equipment isolation Lockout/tagout device application Stored energy Verification of isolation Release from lockout/tagout
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Equipment Specific Procedures
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Lockout procedure – Step 1
NOTIFICATION OF EMPLOYEES
Before controls are applied, and before they are removed
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Lockout procedure – Step 2
PREPARATION FOR SHUTDOWN
Knowledge of the type and magnitude of energy and methods to control energy
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Lockout procedure – Step 3
MACHINE OR EQUIPMENT SHUTDOWN
Orderly shutdown to avoid increased hazard
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Lockout procedure – Step 4
MACHINE OR EQUIPMENT ISOLATION
All energy isolation devices located and operated to isolate machine
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Line breaking:
Means the intentional opening of a pipe, line, or duct that is or has been carrying flammable, corrosive, or toxic material, an inert gas, or any fluid at a volume, pressure, or temperature capable of causing injury
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Line blanking or blinding:
Means the absolute closure of a pipe, line, or duct by fastening of a solid plate that completely covers the bore and that is capable of withstanding the maximum pressure of the pipe, line, or duct with no leakage beyond the plate.
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Double block and bleed:
Means the closure of a line, duct, or pipe by closing and locking or tagging two in-line valves and by opening and locking or tagging a drain or vent valve in the line between the two closed valves.
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Lockout procedure – Step 5
LOCKOUT OR TAGOUT DEVICE APPLICATION
Affixed by authorized employee holding energy isolating device in the safe or off position
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Lockout procedure – Step 6
STORED ENERGY
Relieve all stored energy and continue to verify if there is a chance of re-accumulation
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Stored energy examples
Batteries and capacitors Pressure differential
HydraulicPneumaticVacuum
Springs Gravity
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Lockout procedure – Step 7
VERIFICATION OF ISOLATION
Prior to servicing or maintenance, authorized employee must verify machine has been de-energized
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Lockout procedure – Step 8
RELEASE FROM LOCKOUT OR TAGOUT
Inspect work area to ensure removal of non-essentials
Employees safely positioned and notified Lockout/tagout removal (by employee who applied)
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Lock/tag removal if authorized employee is not available?
Verify that authorized employee is not at facility Make reasonable efforts to inform him or her Ensure that he/she knows of removal upon re-
entering
MUST INCLUDE THIS PROCEDURE IN WRITTEN PROGRAM
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Hardware requirements
Durable Standardized Substantial Identifiable
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Hardware must be:
Provided by the employer Singularly identified Only devices used for control Not used for other purposes
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Hardware must be (cont.):
Durable – be able to withstand environment Standardized – color, size, etc.
Tags : print and format Substantial – no accidental removal
Tag attachment means: Withstand at least 50 pounds of force Not re-usable Self locking Attachable by hand
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Durable…
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Hardware must be (cont.):
Identifiable – identify the employee who applied
Tags must include legend such as DO NOT START
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Locked Out Tagged Out of Service
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Hmmm?
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Allows for identification
Disconnect
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Periodic Inspection
Performed at least annually Lockout – include review with authorized employees Tagout – include review with authorized and
affected employees Certification record kept:
Identify machine or equipment Date of inspection Employees performing and included in inspection
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Training and re-training Authorized employees
Recognition of hazardous energyType and magnitude of hazardous energyMethods of isolating energyHow to verify isolation
Affected – Purpose and use of procedure Other – Procedure and Prohibition from tampering Tagout provisions
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Re-training is required when:
Change in job assignment Change in machine or process Change in lockout/tagout procedure Inadequacies revealed in periodic review
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Training certification
Certify that the training has been conducted and kept up to date:
Employee namesDate(s) of training
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Other requirements
Contractors? Personnel or shift changes?
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Testing or positioning machines
Clear the machine of tools and materials Remove employees from the area Remove lockout/tagout devices Energize and proceed with
testing/positioning De-energize and re-apply energy control
measures
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Group lockout
Personal lock or tag (usually) Lockbox or master tag system with principal
authorized employee
“Shall utilize a procedure which affords a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device”
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Group Lockout
Each exposed employee must be provided the same level of protection…Each person must be protected by their own lock!
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TRAINING
GeneralOperationSteps to:
Change Set up Clean
Second Nature Feedback from Employees
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Training (cont.)
InspectionsHazard Assessment (Training of Operators) Incorrect Procedures (Training of Supervisors)
DocumentationTrainingRetraining
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Minor Servicing Exemption Activities which are routine, repetitive, and
integral to the use of the equipment for production are not covered by this standard if alternative measures provide effective protection.
Activity must be conducted during normal production operations
Activity must be routine (regular course of procedure in accordance with established practices), repetitive (regularly repeated as part of production), and integral (essential to the production process).
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SUMMARY
Written program including written procedures for each machine
Training of employees Periodic review of program ENFORCEMENT