NWACC Business & Industry Workforce Development Institute J- 1 CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT) FOR GENERAL INDUSTRY

NWACC Business & Industry Workforce Development Institute J- 2 COMMON QUESTIONS ABOUT LOCKOUT/TAGOUT WHAT IS LOCKOUT/TAGOUT? IS IT NECESSARY? WHAT ARE LOCKS AND TAGS AND HOW ARE THEY USED? WHO IS RESPONSIBLE FOR THEM? ARE WRITTEN PROCEDURES REQUIRED? WHAT ABOUT TRAINING? WHAT IS THE PROCEDURE FOR LOCKOUT/TAGOUT?

NWACC Business & Industry Workforce Development Institute J- 3 LOCKOUT/TAGOUT IS THE CONTROL OF HAZARDOUS ENERGY DURING SERVICING AND MAINTENANCE OF OF MACHINES AND EQUIPMENT. UNEXPECTED ENERGIZATION OR RELEASE OF STORED ENERGY CAN INJURE AND KILL. 29 CFR (c) requires the employer to establish an energy control program if the danger of unexpected release of energy exists

NWACC Business & Industry Workforce Development Institute J- 4 HUNDREDS OF WORKERS ARE KILLED AND HURT EACH YEAR MAINTAINING EQUIPMENT! CASE STUDY: An employee cleaning scrap from beneath a large shear is is decapitated when another employee pushes the control button. There is no procedure for lockout of the shear. CASE STUDY: An electrician is electrocuted while performing maintenance on a motor control circuit. A procedure existed but the electrician wanted to save time, and did not follow it.

NWACC Business & Industry Workforce Development Institute J- 5 LOCKS: IN LOCKOUT/TAGOUT, A LOCK IS USED FOR HOLDING AN ENERGY ISOLATING DEVICE SUCH AS A VALVE OR SWITCH, IN A POSITION THAT WILL PREVENT ACTIVATION. LOCKS MUST USE KEYS OR COMBINATION LOCKS LOCKS AND TAGS ARE UNDER THE EXCLUSIVE CONTROL OF THE EMPLOYEES PERFORMING THE WORK !

NWACC Business & Industry Workforce Development Institute J- 6 TAGS: IN LOCKOUT TAGOUT, A TAG IS A WARNING PLACED ON OR NEAR THE ENERGY ISOLATING DEVICE TO ALERT OTHERS NOT TO OPERATE THE DEVICE. DO NOT START DO NOT OPEN DO NOT CLOSE DO NOT ENERGIZE DO NOT OPERATE DO NOT START DANGER

NWACC Business & Industry Workforce Development Institute J- 7 TAGS CANNOT BE USED WITHOUT LOCKS UNLESS IT IS INFEASIBLE OR HAZARDOUS TO LOCKOUT AN ISOLATING DEVICE. SOME POINTS ABOUT TAGS TAGS MUST BE STANDARDIZED AS TO AT LEAST ONE OF THE FOLLOWING: FORMAT, COLOR, SHAPE, SIZE, TYPE. TAGS MUST BE CLEARLY VISIBLE AND DISTINCTIVE. TAGS MUST BE DESIGNED TO DETER UNAUTHORIZED REMOVAL. ATTACHMENT MEANS MUST BE NON-REUSABLE.

NWACC Business & Industry Workforce Development Institute J- 8 IF A LOCK CANNOT BE USED DUE TO INFEASIBILITY OR INCREASED HAZARD, ONE ADDITIONAL SAFETY MEASURE MUST BE USED. EXAMPLES: REMOVE AN UPSTREAM DISCONNECT. BLOCK AN UPSTREAM DISCONNECT. LOCK OUT AND TAG UPSTREAM DISCONNECT. GROUND A CIRCUIT BEING WORKED ON.

NWACC Business & Industry Workforce Development Institute J- 9 Are Written Procedures Required? n Written procedures are generally required (c) n Procedures must include scope, purpose, authorization, techniques, rules, responsibilities and training. n Annual audits and inspections are required to verify the effectiveness of the procedures unless they are used (c)(6)

NWACC Business & Industry Workforce Development Institute J- 10 EXCEPTIONS TO THE RULE: All the following must be true No potential for stored energy exists. There is a single readily identifiable energy source. Isolating and lockout completely deenergizes the equipment. A single lock will lockout the equipment. The equipment is isolated during the work performed. The lock is controlled by the person doing the work. No hazard is created for others. No history of unexpected startup for the equipment exists.

NWACC Business & Industry Workforce Development Institute J- 11 DEFINITION: AN AUTHORIZED EMPLOYEE IS AN EMPLOYEE WHO PERFORMS OR PARTICIPATES IN THE LOCKOUT/TAGOUT OPERATION DEFINITION: AN AFFECTED EMPLOYEE IS AN EMPLOYEE WHO MUST OPERATE THE EQUIPMENT DURING LOCKOUT/TAGOUT OR WHO IS IN THE VICINITY BOTH AUTHORIZED AND AFFECTED EMPLOYEES MUST BE APPROPRIATELY TRAINED.

NWACC Business & Industry Workforce Development Institute J- 12 TRAINING AND COMMUNICATION (c)(10) Training and communication must take place before Lockout/Tagout can begin. All employees involved must have necessary skills. Other employees in the area may require some training. Training must cover: required parts of energy control program, elements of applicable procedures, applicable Safety Related Work Practices.

NWACC Business & Industry Workforce Development Institute J- 13 LOCKOUT/ TAGOUT PROCEDURE 29 CFR (c)

NWACC Business & Industry Workforce Development Institute J- 14 Preplanning Isolation & Control Procedure Restart Procedure GENERAL LOCKOUT/TAGOUT PROCEDURE Step 1 Step 2 Step 3

NWACC Business & Industry Workforce Development Institute J- 15 IDENTIFY TYPES & AMOUNTS OF ENERGY SOURCES IDENTIFY INDIVIDUAL EQUIPMENT & LOCATION LOCATE & IDENTIFY DISCONNECT & ISOLATING DEVICES VERIFY/DETERMINE POWER SHUTDOWN & POWER UP PROCEDURES NOTIFY ALL AFFECTED EMPLOYEES PREPLANNING BLOCK DIAGRAM STEP 1 STEP 2 STEP 3 STEP 4 STEP 5

NWACC Business & Industry Workforce Development Institute J- 16 STEP 1 IDENTIFY TYPES & AMOUNT OF ENERGY SOURCES TYPES OF ENERGY: MECHANICAL, ELECTRICAL, HYDRAULIC, THERMAL, AIR, CHEMICAL, ETC. STEP 2 IDENTIFY INDIVIDUAL EQUIPMENT & LOCATION ELECTRICAL MOTORS, MACHINES, CONTROLLERS, DISTRIBUTION PANELS, ETC.

NWACC Business & Industry Workforce Development Institute J- 17 STEP 3 LOCATE AND IDENTIFY DISCONNECTS AND ISOLATING DEVICES CIRCUIT BREAKERS, SWITCHES, VALVES, BLOCKS, GATES, ETC. STEP 4 POWER SHUTDOWN AND POWER UP PROCEDURES SEQUENCE PROCEDURES, PROCESS CONTROL DIAGRAMS, SINGLE ELECTRICAL ONE LINE DIAGRAMS, ETC.

NWACC Business & Industry Workforce Development Institute J- 18 STEP 5 NOTIFY ALL AFFECTED EMPLOYEES ENSURE ALL PERSONNEL AND UNNECESSARY EQUIPMENT ARE REMOVED.

NWACC Business & Industry Workforce Development Institute J- 19 SHUTDOWN, ISOLATION & CONTROL PROCEDURE BLOCK DIAGRAM PREPARATION FOR SHUTDOWN EQUIPMENT SHUTDOWN ISOLATE EQUIPMENT APPLY LOTO DEVICES CONTROL STORED ENERGY VERIFY ISOLATION STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

NWACC Business & Industry Workforce Development Institute J- 20 STEP 1 PREPARE FOR SHUTDOWN AUTHORIZED EMPLOYEE TO DIRECT EQUIPMENT SHUTDOWN STEP 2 EQUIPMENT SHUTDOWN AUTHORIZED EMPLOYEE DIRECTS EQUIPMENT SHUTDOWN WITH AUTHORIZED PROCEDURES. STEP 3 ISOLATE EQUIPMENT USE THE DISCONNECTING MEANS TO REMOVE ENERGY SOURCES. STEP 4 APPLY LOCKOUT/TAGOUT DEVICES FOLLOW PROCEDURES FOR INDIVIDUAL, GROUP, OR CONTRACTOR LOCKOUT. WATCH FOR SHIFT CHANGES.

NWACC Business & Industry Workforce Development Institute J- 21 STEP 5 CONTROL STORED ENERGY DISCHARGE CAPACITORS, RELEASE PRESS FLYWHEELS, DOUBLE BLOCK & BLEED LINES, ETC. STEP 6 VERIFY ISOLATION ACTIVATE CONTROLS, MAKE CIRCUIT MEASUREMENTS, ETC.

NWACC Business & Industry Workforce Development Institute J- 22 FOLLOW PROCEDURES FOR RELEASE FROM LOCKOUT/TAGOUT INSPECT AREA TO ENSURE NON-ESSENTIALS REMOVED & EQUIPMENT INTACT & EMPLOYEES IN “SAFE ZONES”. NOTIFY AFFECTED EMPLOYEES. INDIVIDUALS REMOVE THEIR LOCKS & TAGS. TEST & POSITION EQUIPMENT AS REQUIRED BY PROCEDURES INFORM REQUIRED PERSONNEL AND RELEASE EQUIPMENT FOR USE.