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Transcript of Control of Hazardous Energy OSHA Standard 29CFR1910.147 MIOSHA PART 85 - The Control of Hazardous...
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Control of Hazardous Energy
OSHA Standard 29CFR1910.147
MIOSHA PART 85 - The Control of Hazardous
Energy Sources
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An employee was cleaning the unguarded side of an operating granite saw. The employee was caught in the moving parts of the saw and pulled into a nip point between the saw blade and the idler wheel resulting in fatal injuries.
Case Study #1
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A trainee employee was cleaning a flour batch mixer. The employee was reaching into the machine when another worker activated the wrong switch turning the machine on. The employee cleaning the mixer suffered fatal crushing injuries to his neck. There was an unwritten company procedure for locking out during all maintenance. The procedure was not followed.
Case Study #2
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An employee was cleaning scrap from beneath a large shear when a fellow employee hit the control button activating the blade. The blade came down and decapitated the employee cleaning the scrap.
Case Study #3
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WHAT DO WHAT DO
ALLALL
OF THESE LOSSES OF THESE LOSSES HAVE IN COMMON?HAVE IN COMMON?
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FAILURE TO
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You will learn…
Four E’s of LOTO
Purpose of LOTO
Requirements for LOTO
Types of Hazardous Energy
Procedures for LOTO
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Four E’s of LOTO
Energy
Engineering
Education
Enforcement
EE
EEEEEE
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Energy
More than just switching a machine on/off
Energy is dangerous when it is strong enough to injure your body
Types of energy include:• Kinetic
• Potential
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Types of Energy
Electrical
Mechanical
Thermal
Hydraulic
Pneumatic
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Mechanical Energy Hazards
2 Types Kinetic - In Motion
Potential - Stored
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Kinetic Energy Hazards
Energy of moving machinery can cause:
Amputations
Lacerations
Fractures
Loss of life
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Potential Energy Hazards
Energy stored in machinery
• Weights & Springs
• Pistons under pressure
• Hydraulic controls
Stored potential energy can be released during work causing injury or death
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Chemical Hazards
Some chemicals can:Start fires
Cause skin burns
Generate harmful gases, vapors, or fumes
Before working – release, drain, or vent chemicals safely
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Thermal Energy Hazards
Hazards of Heat and Cold Hot equipment and fluids can burn you Very cold fluids can cause injury Quick release of compressed gases can
freeze your skin Allow equipment to reach a safe
temperature before starting work
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Hydraulic Energy
Energy of Liquids Under Pressure Pressure can cause equipment to move Rapid release can cause injury Rapid release can also cause the
ejection of system parts
Relieve pressure slowly into a proper container
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Pneumatic Energy Hazards
Energy of Compressed Gases Uncontrolled release can cause injury
Rapid depressurization can create extremely low temperatures
Properly vent all systems before starting work
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Engineering
Do not bypass safety devices - they are designed for your protection!
Engineered mechanisms built into machines for your safety include:• Mechanical guards
• Mechanical stops (pins, valves)
• Point-of-Operation guards
• Interlocks
• Light curtains
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Education
Know all places hazardous energy releases might occur on each machine you are working on.
Make sure people in the area know were all energy sources are located.
Review and follow the written OCC Lockout/Tagout Program.
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First Step In LOTO
Know your equipment and systems • Hazards
• Isolation points
• Machine-specific procedures for lockout / tagout
Working on unfamiliar machinery is a hazard
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When is LOTO necessary?
To prevent unexpected start-up during service/maintenance
There is the potential for the hazardous release of stored energy
Safety devices are bypassed for service Body is exposed to hazardous energy Clearing jams Electrical repairs
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Energy Isolation
Machine specific LOTO instructions• Required if more than one power source
involved
• Identifies isolation points
• Many different scenarios possible
LOTO devices are assigned to specific affected employees
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Use Safe Electrical Practices
Use non-conducting tools
Check that circuits are dead before working
Lock & Tag source breakers, not switches
Ensure all control power is de-energized
Discharge all capacitors after Lockout
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L o c k o u t / T a g o u t I s o l a t i o n P o i n t s
M A C H I N E / P R O C E S S : U - C e l l 1 A p p r o v e d : N . S a i z D a t e : 3 / 1 2 / 9 9D E S C R I P T I O N : R o b o t M a c h i n i n g C e l l
E n e r g y S o u r c e L o c a t i o n M e t h o d C h e c kR o b o t M a i nP r i m a r y - E l e c t r i c a lD i s c o n n e c t 4 8 0 V
D i s c o n n e c t r i g h t s i d e o fc o n v e y o r
P u l l l e v e r d o w n t o o f fp o s i t i o n . A p p l y L O / T O .
D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .
R o b o t S e r v oS e c o n d a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V
C o n t r o l p a n e l , r i g h t o fc o n v e y o r .
T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .
D e p r e s s s t a r t b u t t o n . R o b o t w i l l n o to p e r a t e .
M o r i - S e k iP r i m a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V
B u s b a r – c e i l i n g . P u l l d i s c o n n e c t . D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .
M o r i - S e k iS e c o n d a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V
D i s c o n n e c t r e a r o fm a c h i n e a d j a c e n t t oc o n v e y o r .
T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .
D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .
E m c oP r i m a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V
D i s c o n n e c t r e a r o fm a c h i n e .
T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .
D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .
O k u m aP r i m a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V
D i s c o n n e c t s i d e o fm a c h i n e , a d j a c e n t t oE m c o .
T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .
D e p r e s s s t a r t b u t t o n . M a c h i n e w i l ln o t o p e r a t e .
L o a d / U n l o a d C o n v e y o rP r i m a r y – E l e c t r i c a lD i s c o n n e c t 4 8 0 V
C o n t r o l p a n e l c o n n e c t e dt o l o a d c o n v e y o r .
T u r n d i s c o n n e c t c o u n t e r -c l o c k w i s e . A p p l yL O / T O .
D e p r e s s s t a r t b u t t o n . C o n v e y o r w i l ln o t o p e r a t e .
R o b o tP r i m a r y - A i r 1 1 0 p s i
B a l l v a l v e n e x t t o l o a dc o n v e y o r – i n s i d e f e n c e .
C l o s e v a l v e – a p p l yL O / T O d e v i c e .
B l e e d a l l a c c u m u l a t e d a i r p r e s s u r e .
M o r i - S e k iP r i m a r y – A i r 1 1 0 p s i
B a l l v a l v e s i d e o fm a c h i n e a d j . t o E m c o .
C l o s e v a l v e – a p p l yL O / T O d e v i c e .
B l e e d a l l a c c u m u l a t e d a i r p r e s s u r e .
E m c oP r i m a r y – A i r 1 1 0 p s i
B a l l v a l v e a b o v e m a i nd i s c o n n e c t .
C l o s e v a l v e – a p p l yL O / T O d e v i c e .
B l e e d a l l a c c u m u l a t e d a i r p r e s s u r e .
O k u m aP r i m a r y – A i r 1 1 0 p s i
B a l l v a l v e , s i d e o fm a c h i n e a d j . , E a s t s i d e .
C l o s e v a l v e – a p p l yL O / T O d e v i c e .
B l e e d a l l a c c u m u l a t e d a i r p r e s s u r e .
R E M E M B E R L o c k o u t / T a g o u t B e f o r e L O / T O , n o t i f y a l l a f f e c t e d e m p lo y e e s . I f m a c h in e is o p e r a t in g , s h u t d o w n u s in g n o r m a l
p r o c e d u r e . L O / T O n e c e s s a r y p o w e r s o u r c e s – d e p e n d in g o n t a s k
p e r f o r m e d . T e s t e q u ip m e n t t o e n s u r e d e e n e r g iz e d . A s s u r e R e le a s e o f a l l S t o r e d E n e r g y R e t u r n c o n t r o ls t o o f f p o s i t io n a f t e r t e s t in g . R e t u r n t o o p e r a t io n o r r e m o v a l o f L O / T O f o r t e s t in g .1 . C h e c k m a c h in e t o e n s u r e a l l s a f e g u a r d s a r e in p la c e ,
m a c h in e c o m p o n e n t s in t a c t a n d e m p lo y e e s c le a r e d .2 . A s s u r e c o n t r o ls a r e in t h e o f f p o s i t io n3 . R e m o v e L O / T O d e v ic e a n d r e e n e r g iz e d e v ic e .4 . N o t i f y a f f e c t e d e m p lo y e e s t h a t m a in t e n a n c e is c o m p le t e
a n d m a c h in e is r e a d y f o r u s e .5 . D e e n e r g iz e a n d r e a p p ly L O / T O d e v ic e a s r e q u i r e d . O n ly W o r k U n d e r Y o u r O W N L o c k
E 1
E - S t o p
E - S t o p
E - S t o p
E - S t o p
E - S t o p
I n t e r l o c k
I n t e r l o c k
I n t e r l o c k
I n t e r l o c k
E 2
E 3
E 4
E 4E 5
E 6
E 7
A 1
A 2
A 3
A 4
A 1
A 2
A 3
A 4
E 1 E 2
E 3
E 4
E 5
E 6
E 7
E - S t o p
E
A
= E l e c t r i c 4 8 0 V
= A i r 1 1 0 p s i
Energy Isolation Identify potential sources of
hazardous energy release
Identify method(s) for isolating the energy
Document procedures for each piece of equipment
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Enforcement
Know the results of tampering with or not following complete LOTO procedures:
LOTO procedures have been established to protect OCC employees from serious injury or death.
Failure to comply with OCC LOTO policies and procedures can result in disciplinary actions up to, and including, dismissal.
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Who Can Lockout Equipment?
Employees who have been trained
and authorized by management
ONLY!
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Contractors
All contract employees
must follow OCC LOTO
procedures!
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Items Needed for LOTO
Written LOTO schedule Locks & Tags - specific to the worker Hasps - for placing locks & tags Breaker Clips - for electrical LOTO Blank Flanges (Pancakes) - for fluid lines Valve Covers - for LOTO of valves Plug Buckets - for electrical plugs
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Use of Locks and Tags
• Use only those issued to you
• Never use another worker’s lock or tag
• Ask your supervisor if you need more LOTO equipment
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Who Can Remove Locks and Tags?
The employee who placed the tag
or
A supervisor, after obtaining permission from the worker who placed the tag
NO EXCEPTIONS!
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Q: A piece of equipment already has a lock and tag. Do I have to place my own locks and tags?
A: YES. Each person working on the equipment must place their own locks and tags to ensure their safety.
Frequently Asked Questions
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Procedures for Lockout / Tagout
Remember Know your equipment and systems before
proceeding
• Hazards
• Isolation points
• Procedures for Lockout
Working on unfamiliar machinery is a hazard!
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6 Step LOTO Procedure
1. Prepare for shutdown
2. Shut down equipment
3. Isolate all energy sources
4. Place Locks and Tags
5. Release stored energy
6. Verify equipment isolation
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1 Prepare for Shutdown
Understand equipment hazards
Notify other workers of shutdown
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2 Shutdown Equipment
Use normal shutdown procedures
Turn all switches to OFF
Shut all control valves
Disable all sources of energy
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3 Isolate All Energy Sources
Shut valves
Open breakers and disconnects
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4 Place Locks & Tags On
Shut off and lock valves
Deactivate and lock breakers / electrical disconnects
Block or disconnect all lines
Lock and tag blank flanges
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5 Release or Block All Stored Energy
• Discharge capacitors • Block or release springs • Block elevated parts • Stop rotating flywheels • Relieve system pressure • Drain fluids • Vent gases • Allow system to cool
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6 Verify Equipment Isolation
• Ensure that all other workers are clear
• Check that locking devices are securely placed
• Check isolation
• Attempt normal startup (should fail!)
• Return controls to OFF/Neutral
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Release from Locked Out / Tagged Out Status• Inspect area and equipment • Ensure all machine guards are in place • Move tools away from equipment • Inform others of startup • Restore system connections • Remove Locks & Tags • Restore equipment to normal operating
parameters• Conduct normal startup
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Lockout / Tagout Protects YOU!
Use Proper Lockout /
Tagout Procedures