Best Practices for Control of Hazardous Energy (Lockout/Tagout) · 2019-02-26 · 2018-11-29 EHS...
Transcript of Best Practices for Control of Hazardous Energy (Lockout/Tagout) · 2019-02-26 · 2018-11-29 EHS...
2018-11-29EHSBestPractice-ControlofHazardousEnergy
BestPracticesforControlofHazardousEnergy(Lockout/Tagout)
Scope
ThescopeofthisbestpracticecoverstheControlofHazardousEnergy,commonlyreferredto
asLockout/Tagout.ThisactivityisregulatedbyOSHAunder29CFR1910.147andthereader
mustbethoroughlyfamiliarwiththisregulation.Althoughthisbestpracticeprovides
commentaryoncertainaspectsoftheregulation,itisnotintendedtobeusedinlieuofthe
regulation.Controlofhazardousenergyiscriticaltoprotectingworkersfrompotentiallyfatal
orseriousinjuries,andaneffectiveprogramwillprotectemployeesfrominjuryduetothe
unexpectedenergizationofequipment.
KeyPoints
• WebelieveyouwillfindtheEnergyControlProcedureattheendofthisdocumentfar
moreusefulthantheEnergyControlProceduresampleprovidedinAppendixAofthe
regulation.
• Whenapplyinglockoutdevicesonvalves,makesurethevalvecannotbeoperated.
• Audityourfacilitytoensurethatpersonallockoutlocksandenergyisolation
locks/devicesareONLYusedforthispurpose.Agoodplacetostartonanauditare
locksonpersonallockers.
• Formultiple-daylockouts,bestpracticeistoremovepersonallocksattheendofthe
shiftandtoreapplythemwhentheemployeesreturnthefollowingday.Thisminimizes
thechancethatwhenthejobiscompleted,personallocksremainforworkerswhoare
noton-site.
• Insituationswheregrouplockoutboxesareemployed,itiscriticalthatthegrouplock
boxesbeclearlylabeledandrecordedontheEnergyControlProcedure.Nearmisses
haveoccurredwhenamechanicorcontractorhasappliedtheirpersonallocktothe
wronglockbox.Thisissueshouldbeaddressedduringpre-taskbriefingswhenmultiple
grouplockoutboxesareinuse.
• Commerciallyavailablegrouplockoutboxesvaryinquality.Ensurethattheboxes
cannotbeeasilytamperedwithtoimproperlyremovekeys.
• Tagoutinsteadoflockoutisstronglydiscouraged.
• Requiredperiodic(atleastannual)inspectionsofEnergyControlProcedurescanbe
streamlinedbygroupingenergycontrolproceduresforsimilarequipmentand
magnitudesofenergy.
• AnannualreviewofthewrittenEnergyControlProgramisrecommendedinadditionto
therequiredannualperiodicinspection(audit)oftheEnergyControlProcedures.
• Annualrecurringtrainingisstronglyrecommended.
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TypesofHazardousEnergy
Hazardousenergycomesinmanyforms.Theseinclude,butarenotlimitedtoelectrical,
mechanical,hydraulic,pneumatic,chemical,thermal,gravity(suspendedloads)andradiation.
Insomecases,theenergymaybestoredandmustbeaddressedandrenderedsafe.Examples
ofstoredenergyincluderesidualgasorliquidpressureinapipeline,springenergy,stored
electricityinacapacitororbattery,etc.
EnergyControlProgram
EveryfacilityisrequiredtohaveadocumentedEnergyControlProgram.Thisistypicallyinthe
formofadocumentedsafeworkpracticespecifictothissubject.OSHArequiresthefollowing
threeelements:EstablishedEnergyControlProcedures,employeetrainingandannualprogram
reviews.Bestpracticerequiresthefollowing:
• Establishrolesandresponsibilities
• Definethescopeoftheprogramandanyexceptionsthatmayapplytotroubleshooting
andnormalproductionoperationactivities(e.g.,openingvalves/hatchestoaddraw
materials)
• Specifywhatpersonallocksthatmaybeusedandprovisionsforuseof“grouplockout
boxes”(discussedbelow)
• Defineanyspecialprovisionsrequiredforlockoutduringconfinedspaceentry
• DevelopablankchecklistfortheannualreviewsofEnergyControlProcedures.
• Setproceduresforremovalofapersonallockbysomeoneotherthantheindividualwho
installedit.
• ReviewtheEnergyControlProgramperiodically,butnolessthanonceeachyear.
EnergyControlProcedures
Foreachspecificequipmentitemtobeisolated,developanEnergyControlProcedure,
sometimescalledanenergycontrolchecklist,equipmentisolationchecklistorsomeother
similarname.Thisdocumentidentifieseachisolationpointinchecklistformtorecordwho
appliedthelockateachlocation,whoindependentlyverifiedthelockapplication,andwhenit
wasremoved.Thesearetypicallypreparedwellinadvance(thelistingofisolationpoints)and
keptonfileuntilneeded.Foruniquelockoutsthatcan’tbeanticipated,ablankEnergyControl
Procedurecanbeusedandfilledinbyhandimmediatelypriortoequipmentlockout.
OSHAstatesthefollowingasregardsEnergyControlProcedures:
“Theenergy-controlproceduresmustoutlinethescope,purpose,authorization,rules,and
techniquesthatemployeeswillusetocontrolhazardousenergysources,aswellasthemeans
thatwillbeusedtoenforcecompliance.Theseproceduresmustprovideemployeesatleastthe
followinginformation:
• Astatementonhowtousetheprocedures;
• Specificproceduralstepstoshutdown,isolate,block,andsecuremachines;
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• Specificstepsdesignatingthesafeplacement,removal,andtransferoflockout/tagout
devicesandidentifyingwhohasresponsibilityforthelockout/tagoutdevices;and
• Specificrequirementsfortestingmachinestodetermineandverifytheeffectivenessof
lockoutdevices,tagoutdevices,andotherenergy-controlmeasures.”
Regardingthelastbulleteditemontestingmachinestoverifytheeffectivenessofthelockout,
therearesomekeypointsregardingelectricalmotors.Electricalmotorscanpresentunique
riskswhentestingtoverifythattheyareproperlylockedout.Forexample,amotorthatwas
notproperlyisolatedmaynotstartwhentestedduetoaninterlockortimerunrelatedtothe
lockout,givingfalseindicationthatthelockoutwaseffective.Thisriskcanbeaddressedby
havingaqualifiedelectricianinstallatestbuttonthatbypassesalltimersandinterlocks.
Anotherwaytoaddresstheriskofanimproperelectricalmotorlockoutistohaveaqualified
electricianparticipateinthetesting/verificationsteptoensurethatthelockoutiseffective.
Energycontrolproceduresaretobeinspectedperiodically,atleastannually.OSHAhas
clarifiedinaletterofinterpretationtoallowgroupingofenergycontrolproceduresforsimilar
equipmentandmagnitudesofenergyforthepurposesofperiodicinspections.Thisstreamlines
theperiodicinspectionprocess.Ensuretheseinspectionsaredocumented.
EnergyIsolationDevicesandLockoutDevices
OSHAdefinesanEnergyIsolationDeviceas“amechanicaldevicethatphysicallypreventsthe
transmissionorreleaseofenergy,includingbutnotlimitedtothefollowing:Amanually
operatedelectricalcircuitbreaker;adisconnectswitch;amanuallyoperatedswitchbywhich
theconductorsofacircuitcanbedisconnectedfromallungroundedsupplyconductors,and,in
addition,nopolecanbeoperatedindependently;alinevalve;ablock;andanysimilardevice
usedtoblockorisolateenergy.Pushbuttons,selectorswitchesandothercontrolcircuittype
devicesarenotenergyisolatingdevices.”
OSHAdefinesaLockoutDeviceas“adevicethatutilizesapositivemeanssuchasalock,either
keyorcombinationtype,toholdanenergyisolatingdeviceinasafepositionandpreventthe
energizingofamachineorequipment.Includedareblankflangesandboltedslipblinds.”Per
OSHA,lockoutdevicesmustbe:
• Standardizedbycolor,shape,orsizeandonlyusedforthispurpose.
• Substantial
• Identifiable
Someenergyisolationdevicesareeasiertoapplyalockoutdevicethanothers,buttherearea
remarkablenumberofdevicescommerciallyavailabletolockoutalmostanything.Valvesare typicallylockedoutwithchainsorthevalvemayhavealigningholestoapplyalockwhenthe
valveisintheclosedposition.Whenlockingvalves,ensurethatthevalvecan’tbeoperated.
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Whenremovingisolationdevices,itisgoodpracticetohaveaknowledgeableemployee
completeafieldinspectiontoassurealldevicesareremovedpriortostartup.
PersonalLockoutDevices
Locksappliedbyindividualsmustidentifyindividualusers.Thiscanbedonebyaffixingatagto
thelockwiththisinformationorwritingthisinformationdirectlyonthelock,ifthelockis
designedtodoso.PerOSHA,personallocksforlockoutmustbe:
• Standardizedbycolor,shape,orsizeandonlyusedforthispurpose.
• Substantial
• Identifiable
Thefacility’sEnergyControlProgramshoulddocumentthespecificlocktobeused.Itishighly
recommendedthatthefacilityaudititselftoensurethatthislockisn’tbeingusedforanyother
purpose.Agoodplacetostarttheinspectioniswithlocksappliedtopersonallockers.
Personallocksmustberemovedonlybythepersonwhoinstalledit.Bestpracticeistoremove
personallockseachdayandreapplythemthefollowingday.Thisminimizesthechancethat
whenthejobiscompleted,personallocksremainforworkerswhoarenoton-site.
EnsureyourEnergyControlProgramhasaproceduretoremovealockforanindividualwho
hasleftthefacility.Thistypicallyinvolvesattemptingtocontacttheindividual,involvingthe
SafetyDepartment,documentingremoval/cuttingofthelock,andcommunicationtothe
individual.It’sveryimportanttocommunicatetotheworkerofthelockremoval.Thiswill
preventtheworkerfromresumingworkuponhisorherreturn,assumingthatthepersonallock
isstillinplace.Ifpersonnelareissuedabadgetoenterthefacility,considershuttingoffaccess
tothefacilityuntilthiscommunicationcanoccur.
GroupLockoutBoxes
Theregulationallowsforthefacility’sEnergyControlProgramtoincludeprovisionsforagroup
lockoutsystem,aslongasthesamelevelofprotectionisprovidedtopersonnel.Thegroup
lockoutboxcanmakeequipmentisolationmoreefficientandequallyeffectivewhenthereare
multipleusersandmultiplelockoutdevicekeysbeingused.Individualpersonallocksarethen
appliedtothegrouplockoutbox.
Onlargeturnarounds,theremaybemultiplegrouplockoutboxesemployedfordifferent
processequipment.Nearmisseshaveoccurredwhentheemployeeaffixeshisorherpersonal
locktothewronggrouplockoutbox.Communicationmustbeclear,andapre-taskbriefingisa
goodwaytodothis.Anotherlevelofprotectionistoclearlyidentifyontheenergyisolation
procedurethenameornumberoftheapplicablegrouplockoutbox.
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Commerciallyavailablegrouplockoutboxesvarysignificantlyinquality.Examinetheseto
ensurethatkeyscan’tfalloutorthattheboxcan’tbeeasilytamperedwithtoimproperly
removekeys.Ideally,agrouplockoutboxhasatransparentcoverwithhookstodisplaythe
keysforthelockoutdevices.
Tagout
AlthoughOSHAallowstheuseoftagoutinlieuoflockout,thetagoutmustprovidethesame
levelofprotectionaslocks.Bestpracticeistocompletelyavoiduseofatagout-onlysystem.
DeviceswithaSingleIsolationPoint
“CordandPlug”Devices
PerOSHA,thesedevicesareexemptfromthelockoutstandard.However,ifthereisa
secondisolationpoint,suchasacompressedairline,theexemptionwouldnotapply.
OSHAstates:“Workoncordandplugconnectedelectricequipmentforwhichexposure
tothehazardsofunexpectedenergizationorstartupoftheequipmentiscontrolledby
theunpluggingoftheequipmentfromtheenergysourceandbytheplugbeingunder
theexclusivecontroloftheemployeeperformingtheservicingormaintenance.”
OtherEquipmentIsolatedbyaSingleIsolationPoint
Thesedevicesfallundertheregulation,butarenotrequiredtohaveanEnergycontrol
procedure.
EmployeeTraining
OSHArequiresinitialemployeetrainingandrecurringtraining.OSHAstatesthatrecurring
trainingshouldoccurwhenwheneverthereisachangeintheirjobassignments,achangein
machines,equipmentorprocessesthatpresentanewhazard,whenthereisachangeinthe
energycontrolprocedures,orwhentheperiodic(annual)inspectionrevealsdeviationsor
deficiencies.Bestpracticeforrecurringtrainingistodothisonascheduledbasis(e.g.every
year,everyotheryear)andalsotoconsiderincidentandnearmisshistorywhenestablishinga
frequency.
Disclaimer: The statements contained in this publication are suggestions to enhance performance of certain activities. There is no warranty or guarantee that following these suggestions will prevent each and every incidence of personal injury or property damage. Neither Pine Chemicals Association International nor any of its agents, officers, employees, consultants or contractors, warrants the accuracy, reliability, completeness or timeliness of any information published here and shall not be liable for any losses caused by such reliance on the accuracy, reliability, completeness or timeliness of this information, including, but not limited to, incidental or consequential damages. This publication is provided without warranty of any kind, either express or implied, including, but not limited to, an implied warranty of merchantability, fitness for a particular purpose, compliance or non-infringement. The recipient of this information is responsible for compliance with all applicable restrictions, regulations, statutes or other standards or conditions.
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SAMPLEENERGYCONTROLPROCEDURE
Date:__________________EquipmenttobeIsolated: Reasonforisolation: WorkOrderNumber(s):
Equipment
(DescriptionorLocation)Example:T-1AgitatorMotor
Note1
DescribeActionTaken
KeyNumber
InitialsofPerson(s)Isolating
Equipment
InitialsofPerson(s)
TestingandVerifying
InitialsofPerson(s)UnlockingEquipment
InitialsofPerson(s)ConfirmingUnlocking
(OptionalColumn)
Comments
open/close/dis-connect,etc.
Addmorerowsasneeded.
Note 1. Magnitude of energy being isolated is ≤ 150 psig and ≤ 480 volts and ≤ 212°F unless specified otherwise in this column.
2018-11-29EHSBestPractice-ControlofHazardousEnergy
AdditionalNotesorComments_________________________________________________________________________________________________
_________________________________________________________________________________________________
NameandInitialsofPersonsInitialingBoxesinAboveProcedures:Name(Print): Initials: Disclaimer: The statements contained in this publication are suggestions to enhance performance of certain activities. There is no warranty or guarantee that following these suggestions will prevent each and every incidence of personal injury or property damage. Neither Pine Chemicals Association International nor any of its agents, officers, employees, consultants or contractors, warrants the accuracy, reliability, completeness or timeliness of any information published here and shall not be liable for any losses caused by such reliance on the accuracy, reliability, completeness or timeliness of this information, including, but not limited to, incidental or consequential damages. This publication is provided without warranty of any kind, either express or implied, including, but not limited to, an implied warranty of merchantability, fitness for a particular purpose, compliance or non-infringement. The recipient of this information is responsible for compliance with all applicable restrictions, regulations, statutes or other standards or conditions.