Presentation on theme: "Energy Control Procedures Lockout/Tagout 29 CFR"— Presentation transcript:
1 Energy Control Procedures Lockout/Tagout 29 CFR 1910.147 Georgia Tech Research Institute
2 Most Frequently Cited Serious Violations in General Industry FY 2006 Machine Guards - GeneralHazard Communication – Written ProgramPoint of OperationOpen-Sided FloorsHazard Communication – Information & TrainingEye & Body Flushing FacilitiesLockout/Tagout - ProgramGrinders-Tongue GuardsLockout/Tagout - ProceduresConductors Entering Cabinets/Boxes/Fittings Protected from AbrasionNote: There were also 1222 Section 5(a)(1) General Duty Clause violations cited for all inspections during this period.
3 Subpart J - General Environmental Controls (1910.141 - 147) Lockout/Tagout - ProgramLockout/Tagout - ProceduresLockout/Tagout - TrainingLockout/Tagout procedure - Periodic inspectionStandard: 1910.Lockout/Tagout - Content of energy control procedures
4 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 areaWhen you are training it is important to cover the relationship between Subpart O-Machine Guarding and Lockout Tagout!!
5 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)
7 Energy types Electrical Mechanical Hydraulic Pneumatic Chemical ThermalOther
8 Lockout vs. Tagout If capable of being locked out: Prefer lockoutTags allowed, if employer can demonstrate FULL EMPLOYEE PROTECTIONMachine ModificationsIf you alter a machine you must make the machine capable of accepting a lock.
9 Full employee protection? Tags attached at the same location as locksFull compliance with all tagout provisions in 29 CFRAdditional means when necessary (e.g. removal of a valve handle)
10 Definitions Affected employee Authorized employee Capable of being locked outEnergy isolating deviceServicing and/or maintenance
11 Servicing and maintenance includes: Setting upAdjustingInspectingModifyingInstalling
12 Lockout/tagout requirements Written program which includes specific written proceduresTraining of employees (not just maintenance!)Periodic review of procedures
13 Written lockout/tagout procedure (Equipment Specific Procedures) Clearly and specifically outlineScopePurposeAuthorizationRules, techniques for control of energy
14 Lockout procedure (cont.) Clearly and specifically outline:Means to enforce compliance including:Intended use of procedureSpecific procedural stepsSpecific testing requirements
15 Documentation exceptions: Machine has no potential for stored energyMachine has a single energy sourceIsolation of that source will completely de-energizeMachine is isolated and locked out during maintenance
16 Documentation exceptions (cont.) A single lockout device will achieve locked-out conditionLockout device under exclusive control of employeeMaintenance does not create hazard to othersNo previous accidents involving unexpected energization on this equipment
17 Energy control procedure Notification of employeesPreparation for shutdownMachine or equipment shutdownMachine or equipment isolationLockout/tagout device applicationStored energyVerification of isolationRelease from lockout/tagout
19 Lockout procedure – Step 1 NOTIFICATION OF EMPLOYEESBefore controls are applied, and before they are removed
20 Lockout procedure – Step 2 PREPARATION FOR SHUTDOWNKnowledge of the type and magnitude of energy and methods to control energy
21 Lockout procedure – Step 3 MACHINE OR EQUIPMENT SHUTDOWNOrderly shutdown to avoid increased hazard
22 Lockout procedure – Step 4 MACHINE OR EQUIPMENT ISOLATIONAll energy isolation devices located and operated to isolate machine
23 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
24 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.
25 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.
26 Lockout procedure – Step 5 LOCKOUT OR TAGOUT DEVICE APPLICATIONAffixed by authorized employee holding energy isolating device in the safe or off position
28 Lockout procedure – Step 6 STORED ENERGYRelieve all stored energy and continue to verify if there is a chance of re-accumulation
29 Stored energy examples Batteries and capacitorsPressure differentialHydraulicPneumaticVacuumSpringsGravity
30 Lockout procedure – Step 7 VERIFICATION OF ISOLATIONPrior to servicing or maintenance, authorized employee must verify machine has been de-energized
31 Lockout procedure – Step 8 RELEASE FROM LOCKOUT OR TAGOUTInspect work area to ensure removal of non-essentialsEmployees safely positioned and notifiedLockout/tagout removal (by employee who applied)
32 Lock/tag removal if authorized employee is not available? Verify that authorized employee is not at facilityMake reasonable efforts to inform him or herEnsure that he/she knows of removal upon re-enteringMUST INCLUDE THIS PROCEDURE IN WRITTEN PROGRAM
34 Hardware must be: Provided by the employer Singularly identified Only devices used for controlNot used for other purposes
35 Hardware must be (cont.): Durable – be able to withstand environmentStandardized – color, size, etc.Tags : print and formatSubstantial – no accidental removalTag attachment means:Withstand at least 50 pounds of forceNot re-usableSelf lockingAttachable by hand
44 Periodic Inspection Performed at least annually Lockout – include review with authorized employeesTagout – include review with authorized and affected employeesCertification record kept:Identify machine or equipmentDate of inspectionEmployees performing and included in inspection
45 Training and re-training Authorized employeesRecognition of hazardous energyType and magnitude of hazardous energyMethods of isolating energyHow to verify isolationAffected – Purpose and use of procedureOther – Procedure and Prohibition from tamperingTagout provisions
46 Re-training is required when: Change in job assignmentChange in machine or processChange in lockout/tagout procedureInadequacies revealed in periodic review
47 Training certification Certify that the training has been conducted and kept up to date:Employee namesDate(s) of training
48 Other requirementsContractors?Personnel or shift changes?
49 Testing or positioning machines Clear the machine of tools and materialsRemove employees from the areaRemove lockout/tagout devicesEnergize and proceed with testing/positioningDe-energize and re-apply energy control measures
50 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”
51 Group LockoutEach exposed employee must be provided the same level of protection…Each person must be protected by their own lock!
52 TRAINING General Second Nature Feedback from Employees Operation Steps to:ChangeSet upCleanSecond NatureFeedback from Employees
53 Training (cont.) Inspections Documentation Hazard Assessment (Training of Operators)Incorrect Procedures (Training of Supervisors)DocumentationTrainingRetraining
54 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 operationsActivity 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).