2 Disclaimer This training material presents very important information. Your organization must do an evaluation of all exposures, applicable codes and regulations, and establish proper controls, training, and protective measures to effectively control exposures and assure compliance.This program is neither a determination that the conditions and practices of your organization are safe nor a warranty that reliance upon this program will prevent accidents and losses or satisfy local, state or federal regulations.All procedures and training, whether required by law or not, should be implemented and reviewed by safety and risk management professionals, and legal counsel to ensure that all local, state and federal requirements are satisfied.Explains program disclaimer.
3 Course Outline – Lockout and Tagout Why Take Lockout and Tagout Training?DefinitionsTypes of Hazardous EnergyEnergy Control ProcedureStart-up ProceduresAdditional Lockout/Tagout RequirementsSummaryOutlines presentation:Purpose of Lockout and Tagout:Why lockout/tagout is necessarywhat are the ramifications for failure to comply?Requirements for Lockout and Tagout:Outline specific requirements as defined in OSHA 29CFR and ANSI Z244.1.Types of Hazardous Energy.Define specific energy sources found within a facility.Understand that these sources are process and facility specific.Procedures for Lockout and Tagout.List in procedural steps implementation of energy control procedures.
4 Why Take Lockout and Tagout Training? It is important for everyone’s safety!The lockout/tagout standard:Requires organizations to establish a program and utilize procedures for affixing appropriate lockout or tagout devices to energy isolating devices.To otherwise disable machines or equipment to prevent unexpected energization, start up or release of stored energy in order to prevent injury to employees.This slide outlines the lockout/tagout standard.Lockout/ tagout programs are both organization and facility specific.It is important that programs such as this one are customized according to the equipment and conditions that are specific to each individual site.This is an example of a lockout and tagout training program. It can be used as a basis for designing a program that is applicable to your specific facility.
5 DefinitionsAffected employee: An employee whose job requires him or her to operate or use a machine or equipment, which needs servicing or maintenance.Authorized employee: A person who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment.Hardware: A device that is attached to the energy isolating device to physically prevent it from being moved from the OFF position.Definitions used throughout the presentation:To put it more simply:An Affected Employee is one whose job is affected by lockout/tagout (such as a machine operator).An Authorized Employee is the person who performs the lockout/tagout.Hardware (such as for a gate valve or circuit breaker) is affixed to energy isolating device in it’s off position.
6 DefinitionsEnergy isolating device: A mechanical device that physically prevents the transmission or release of energy when in the OFF position such as a gate valve or a circuit breaker.DOES NOT include:On/off switchesPush buttonsControl circuit devicesZero energy state: All stored or residual energy has been released, restrained or dissipated.Equipment can’t be energized or turned on.An Energy Isolating Device is not the same as an on/off switch.It is the point where energy is isolated during lockout procedures.Zero Energy State means there is no energy present which can injure the worker.
7 Types of Hazardous Energy There are several types of hazardous energy which can injure an employee.These include but are not limited to:ElectricalMechanicalChemicalThermalHydraulicPneumaticSeveral types of hazardous energy sources exist.This will vary by facility and the processes that take place there.
8 Types of Hazardous Energy Electrical energy:Most common energy type.Electrical storage devices such as batteries & capacitors.Panelboards house circuit breakers for distribution of electricity.Panelboards are also energy isolating devices and provide overcurrent protection.This slide outlines electrical energy as a source of hazardous energy.Lists common types of stored electrical energy including batteries and capacitors.Defines panelboards and disconnects as common electrical energy isolating devices.
9 Types of Hazardous Energy Electrical energy (continued):Disconnects are common electrical energy isolating devices.Injuries:ElectrocutionElectric shockBurnsThis slide outlines potential injuries associate with electrical hazards.
10 Types of Hazardous Energy Mechanical energy:Energy is manifested through motion and energy is associated with moving parts of a mechanical system:Power transmission apparatusFly wheelsBeltsPulleysContact with moving parts can crush, fracture, cut, or amputate a body part.This slide outlines and defines mechanical energy as a source of hazardous energy.Lists common types of mechanical energy.Lists potential injuries associate with mechanical hazards.
11 Types of Hazardous Energy Potential energy:Potential energy is stored energy that can be hazardous if released. Some examples of potential energy include:GravitySpringsThermal energyStored energyCapacitorsThis slide outlines and defines potential energy as a source of hazardous energy.Lists common types of potential energy.
12 Types of Hazardous Energy Pneumatic energy:Pneumatic lines and vessels can retain energy in the form of stored pressure which may have to be relieved prior to servicing or maintenance.This may be encountered in:Pressurized systemsCompressorsHouse airAir powered toolsOther gasesThis slide outlines and defines pneumatic energy as a source of hazardous energy.Lists common types of pneumatic energy.
13 Energy Control Procedure A written procedure, developed to protect employees who perform maintenance on machines, equipment and processes where hazardous energy sources are present.This slide defines purpose and requirements of energy control procedure.
14 Energy Control Procedure Energy control procedure (continued):A hazardous energy control procedure shall be developed and utilized by the employer when employees are engaged in the cleaning, repairing, servicing, setting-up or adjusting of:Prime moversMachineryEquipment
15 Energy Control Procedure Process of energy control procedure implementation:There are six steps:Prepare for shutdownShutdownIsolate energy sourcesApply locks & tagsControl residual energyVerify energy control methodsBriefly describe methods for energy control procedure implementation.The six step procedure is detailed in the slides that follow.
16 Energy Control Procedure Step 1 - Prepare for shutdown:Notify affected employees of activities.Use energy control procedure data to prepare for shutdown:Identify shutdown procedures.Identify energy sources.Identify energy isolation devices.Determine quantity and type of lockout and tagout devices required.The first step in energy control procedure implementation is to Prepare for Shutdown. This includes the use of energy control procedure data for shutdown including:Identify shutdown proceduresIdentify energy sourcesIdentify energy isolation devicesDetermine quantity and type of lockout and tagout devices required
17 Energy Control Procedure Step 2 - Shutdown:Shut equipment down by its normal stop/start method.This can include an on/off switch, a toggle switch, or typical machine start/stop method.The second step in energy control procedure implementation is to shut down equipment by its normal start/stop method.Equipment toggle switches and on/off buttons are common.
18 Energy Control Procedure Step 3 - Isolate energy sources:Isolate all energy sources from the machinery or equipment.This may include using energy isolating devices, i.e., circuit breakers, valves, etc.The third step is to isolate the energy at the energy isolating device.Common energy isolating devices include circuit breakers and electrical disconnects.
19 Energy Control Procedure Step 4 – Apply locks and tags:Apply locks, tags and hardware to energy isolating devices in OFF position.Signs, tags, padlocks, and seals shall have means by which they can be readily secured to the controls.The fourth step is to actually apply the locks and tags.
20 Energy Control Procedure Step 4 – Apply locks and tags: (continued):Group lockout:One lock/tag per individual per energy isolating device!Each person who enters a danger zone must apply his or her own lock/tag!In a group lockout situation all staff (authorized level) must place their individual lock and tag on each energy isolating device(i.e., if there are two circuit breakers and two people working on equipment there will be a total of 4 locks; two on each circuit breaker).
21 Energy Control Procedure Step 4 – Apply locks and tags: (continued):Group lockout (continued):Must provide the same level of protection as individual lockout/tagout through the use of hasps, group lockout boxes, or other equivalent devices.Locks will be placed inside a lock box or hasp, an additional lock will be placed on the outside of lock box or hasp.
22 Energy Control Procedure Step 5 – Control residual energy:This is accomplished by releasing, restraining, or dissipating all residual energy, i.e., bleeding, blocking, or discharging all sources of energy.The fifth step is to control all residual energy.This can include electrical energy, stored pneumatic or hydraulic energy.
23 Energy Control Procedure Step 6 – Verify energy control methods:Verify that energy control measures are effective:Ensure that switches, valves and other mechanisms can not be turned on.Use a meter to ensure that electrical energy is not present.Activate equipment control switches and levers, and depressing start buttons to ensure power is isolated. Then return switches, levers and buttons to the off position.THE MOST IMPORTANT is the sixth and final step of Verification!The authorized employee must ensure that equipment will not start prior to starting servicing and maintenance.
24 Start-up Procedures Once repairs/maintenance have been completed: Inspect area and remove all tools, rags and other materials.Ensure that equipment/machinery is operationally intact and all guards and other safety devices are replaced, if applicable.Notify affected employees that equipment will be restarting.Check work area to ensure all employees are safely positioned.Verify all controls are in the neutral or “OFF” position.Remove lockout/tagout devices.Notify affected employees that lockout/tagout devices have been removed and the equipment or machinery is ready for useThis slide outlines the Start-up procedures in step by step in order from start to finish.
25 Additional Lockout/Tagout Requirements Auditing:The audit of the Lockout/Tagout Program must be performed by an authorized employee [other than the ones(s) utilizing the energy control procedure].The audit must be conducted annually.A review is also to be performed if a weakness or issue is noted associated with the Lockout/Tagout Program .Explains lockout auditing requirements.Each energy control procedure must be inspected to make sure lockout/tagout procedures were carried out correctlyEnergy control procedures must be annually audited.They may be grouped by similar equipment.All employees in the area must be trained.
26 Additional Lockout/Tagout Requirements Training requirements:Affected employees need to be informed of the procedures and prohibitions relating to attempts to:Perform work on equipmentRestart or re-energize machines or equipment which are locked out or tagged out.Who is authorized to perform work on equipment.This slide explains training requirements for authorized vs. affected employees.
27 Additional Lockout/Tagout Requirements Important instructions for authorized employees:Recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace.The methods and means necessary for energy isolation and control.The purpose and use of the energy control procedure.Initial training on the energy control program, the steps and requirements.Periodic training as necessary.This slide explains training requirements for authorized vs. affected employees.
28 Additional Lockout/Tagout Requirements Re-training must be done when:There has been a change in an employee’s job assignments.There has been a change in machines, equipment or processes that present a new hazard.There has been a change in the energy control procedures.A periodic inspection reveals, or the employer has reason to believe, that there are deviations from or inadequacies in the employee's knowledge or use of the energy control procedures.This slide explains re-training requirements.
29 Additional Lockout/Tagout Requirements Contractors:Review work to be done and assure they have and follow controls at least as effective as your organization's procedures, and in compliance with all codes.Cross-communicate re the Lockout processes with all affected people.Audit contractors prior to allowing and periodically to assure adherence to needed controls.This slide explains re-training requirements.
30 SummaryThere are several types of hazardous energy which can injure an employee. Lockout and tagout procedures are important to keep everyone safe!Ensure your organization is following the correct guidelines for lockout/tagout, including:Start up and group lockout proceduresAuditingTraining and retraining
31 Summary Follow the six steps for energy control procedure: Prepare for shutdownShutdownIsolate energyApply locks and tagsControl residual energyVerify energy control methods
32 Lockout and TagoutThis form documents that the training specified above was presented to the listed participants. By signing below, each participant acknowledges receiving this training.Organization:Trainer: Trainer’s Signature:Class Participants:Name: Signature: Date:Please write your name, sign your name and include today's date.Documentation SummaryThe Risk Management Center is to be used to document all information including the following:DocumentsRisk Management Center LocationWritten ProgramMy ContentTraining Documentation including:- Classroom training and training course completed- sign-in sheets- Quizzes- Skills evaluations- Operator CertificatesTraining Track applicationPre-shift Inspection ChecklistsSafety ObservationsJob Hazard Analysis- Safety Observation ToolNear missesIncident TrackAccidents and claimsSupplier and manufacturer COIsCOI TrackMaterial Safety Data Sheets for fuels and other PIT chemical suppliesMSDS Track