The Society of the Plastics Industry, Inc. Lockout/Tagout for Extrusion Control of Hazardous Energy...
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Transcript of The Society of the Plastics Industry, Inc. Lockout/Tagout for Extrusion Control of Hazardous Energy...
![Page 1: The Society of the Plastics Industry, Inc. Lockout/Tagout for Extrusion Control of Hazardous Energy A Presentation of the SPI-OSHA Alliance.](https://reader035.fdocuments.us/reader035/viewer/2022081416/56649f325503460f94c4e094/html5/thumbnails/1.jpg)
The Society of the Plastics Industry, Inc.
Lockout/Tagout forExtrusion
Control of Hazardous Energy
A Presentation of the SPI-OSHA Alliance
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The Society of the Plastics Industry, Inc.
1910.147 The Control of Hazardous Energy
a.k.a. Lockout/Tagout (LOTO)
The specific practices and procedures necessary to disable machinery and equipment so that employees performing service and maintenance activities are protected
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The Society of the Plastics Industry, Inc.
The Purpose of LOTO
• Prevent the unexpected start-up or release of stored energy
• Reduce the number of fatalities and injuries
• Establish a program and procedures for controlling hazardous energy
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The Society of the Plastics Industry, Inc.
Where to Begin?
• Job Safety Analysis (JSA)
• Develop Procedures
• Verify
• Train
• Audit
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The Society of the Plastics Industry, Inc.
Preventing Unexpected Start-up or Release of Stored Energy
Energy isolation:
• Minimize potential for inadvertent activation and/or release of stored energy
• Ensure that power to the machine is isolated and locked at control points
• Use a method that cannot readily be removed, bypassed, overridden or otherwise defeated
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The Society of the Plastics Industry, Inc.
Common Types of Energy Used in Extrusion
• Electrical
• Mechanical
• Hydraulic
• Pneumatic
• Thermal
• Gravity
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The Society of the Plastics Industry, Inc.
Definitions
• Servicing and/or maintenance is where employees may be exposed to unexpected start-up or release of hazardous energy– Construction– Installing and setting up– Adjusting, inspecting, modifying– Maintaining and/or servicing equipment– Lubricating, cleaning or unjamming– Tool changes or adjustments
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The Society of the Plastics Industry, Inc.
Definitions (cont’d)
• Set-up - Work to prepare a machine to perform its normal production operation
• Lockout – Placement of lockout device on an energy isolating device
• Lockout device – Device that uses a physical means to prevent energizing of a machine or equipment
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The Society of the Plastics Industry, Inc.
Definitions (cont’d)
• Energized - Connected to an energy source, or containing residual or stored energy
• Energy isolating device - A mechanical device that physically prevents the transmission or release of energy
Push buttons, selector switches and other control circuit devices are not energy isolating devices
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The Society of the Plastics Industry, Inc.
Common Causes of Accidents
• Failure to identify risk
• Employees working outside of job description
• Inadequate training and/or comprehension
• Pressure to meet production goals
• Feeling they can do the task after watching someone else do it
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The Society of the Plastics Industry, Inc.
LOTO applies when:
• Employees are performing servicing and maintenance, and there is a potential for injury from unexpected start-up or release of stored energy
• Service and maintenance that takes place during normal production, if employee:– Must remove or bypass a guard or safety
device; or – Must place any part of their body into the
danger zone
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The Society of the Plastics Industry, Inc.
Exception to LOTO
Minor servicing activities that take place during normal production when alternative effective protection is used
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The Society of the Plastics Industry, Inc.
Minor Servicing During Normal Production Operations
• Routine
• Repetitive
• Integral to the use of the equipment for production
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The Society of the Plastics Industry, Inc.
Alternative effective protection such as:
• Interlocked gates and barriers
• Mechanical blocks, pins, bars, or locking devices
• Remote lubricators or other remote devices
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The Society of the Plastics Industry, Inc.
Changing Slitter Knives
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The Society of the Plastics Industry, Inc.
Trim Knives
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The Society of the Plastics Industry, Inc.
Power-Positioned Trim Knives
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The Society of the Plastics Industry, Inc.
Roll CleaningIs Lockout Required ?
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The Society of the Plastics Industry, Inc.
Roll Cleaning
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The Society of the Plastics Industry, Inc.
Accident #1Crushing Fatality
• Employee was attempting to remove a waste buildup that had accumulated on a roller of a plastic extrusion machine.
• He was pulled into and through the roll stand, and was fatally injured.
• The roll stand had five 8” diameter rollers that were 4” apart and moved at over 300 RPM, and was equipped with emergency stop cord.
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The Society of the Plastics Industry, Inc.
Accident #2Amputation of Fingers
• Employee was troubleshooting a plastic extruder which developed a vacuum loss.
• He opened the feeder pipe from the hopper.
• While checking the 4” diameter nipple he noticed a piece of plastic inside.
• He tried to remove it with his left hand.
• He had several fingers amputated in the pneumatic slide-gate.
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The Society of the Plastics Industry, Inc.
Core Components of an Energy Control Program
• Energy control procedures for each type of machine
• Training and retraining to ensure employees understand the program
• Periodic inspection to ensure procedures are being followed
ABC Co.Energy Control Program
Purpose._______________________________________________________________________
Compliance with this program ______________________________________________________________________________
Sequence of Lockout
(1)__________________________________________________
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The Society of the Plastics Industry, Inc.
Energy Control Procedures
• Must be specific to each type of machine and equipment you are working on
• Must include – Statement of intended use of the procedure – Steps for shutting down and securing machines
and equipment– Steps for placing, removing, and transferring of
lockout devices– Requirements for testing and verifying
effectiveness of lockout devices
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The Society of the Plastics Industry, Inc.
Required Training
• Authorized employees– Recognition of hazardous energy sources– Type and magnitude of energy in the workplace– Methods for energy isolation / control
• Affected employees– Purpose and use of energy control procedures
• Other employees in work area– Procedures related to restarting machines
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The Society of the Plastics Industry, Inc.
Retraining Requirements
• Retraining is required when:– Change in job assignments– Change in machines– Change in energy control procedures– Equipment or processes present new hazards– Inspections reveal deficiencies in employee's
knowledge of energy control procedures
• Retraining must reestablish employee proficiency
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The Society of the Plastics Industry, Inc.
Periodic Inspections
• Performed at least annually
• Conducted by authorized employees
• Intended to correct inadequacies identified in program
• Certified
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The Society of the Plastics Industry, Inc.
Certification Requirements
• Identification of equipment or machinery
• Date of inspection
• Names of employees involved in the inspection
• Name of person(s) performing inspection
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The Society of the Plastics Industry, Inc.
Application of the Energy Control Procedure (Lockout)
1. Prepare for shutdown
2. Shut down equipment
3. Isolate all energy sources
4. Apply locks & tags
5. Release stored energy
6. Verify equipment isolation
7. Perform the task
8. Release from Lockout
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The Society of the Plastics Industry, Inc.
Step 1: Prepare for Shutdown
• Understand equipment hazards
• Notify other workers of shutdown
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The Society of the Plastics Industry, Inc.
Step 2: Shut down equipment
• Use the normal shutdown procedures
• Turn all switches to OFF/Neutral
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The Society of the Plastics Industry, Inc.
Step 3: Isolate all Energy Sources
• Use energy isolation devices in accordance with established procedures to prevent transmission or release of energy
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The Society of the Plastics Industry, Inc.
Step 4: Apply Locks & Tags
Apply locks and tags to:
• Valves
• Breakers/electrical disconnects
• Mechanical blocksValve lockout device
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The Society of the Plastics Industry, Inc.
Step 5: Release or Block all Stored Energy
• Discharge capacitors
• Block/disconnect lines
• Block or release springs
• Block elevated parts• Relieve system
pressure
• Drain fluids• Vent gases• Allow system to cool
(or use PPE)• Apply any additional
locks and tags needed
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The Society of the Plastics Industry, Inc.
Step 6: Verify Equipment Isolation
• Check that other workers are clear of potential hazards
• Check that locking devices are secure
• Attempt normal startup
• Return control to OFF/Neutral
Controls to verifyenergy isolation
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The Society of the Plastics Industry, Inc.
Step 7: Perform the Task
• Perform maintenance or service
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The Society of the Plastics Industry, Inc.
Step 8: Release from Lockout
• Ensure machinery is properly assembled and all tools removed
• Ensure that employees are outside of danger zones and are notified that devices are being removed
• Remove LOTO devices– Must be removed by authorized employee
who applied it
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The Society of the Plastics Industry, Inc.
The Job Safety Analysis Process
The Job Safety Analysis (JSA) process is a very effective means of helping reduce incidents, accidents, and injuries in the workplace. It is a multi-step process.
•Basic Job Steps
•Potential Hazards
•Recommended Safe Job Procedures
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The Society of the Plastics Industry, Inc.
Our sincere thanks to:
• United Southern Industries, Inc.
• SPI Sheet Producer’s Division
• Spartech Plastics, Inc.
• OSHA Regions V & VIII
Michigan OSHA
• The OSHA Office of Education and Training
• OSHA’s Salt Lake Technical Center
• The Society of the Plastics Industry, Inc.
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The Society of the Plastics Industry, Inc.
Do you have anyQuestions?