Lockout/Tagout Awareness Training

1. Lockout/TagoutAwareness Training 29 CFR 1910.147 By: Chaizong Lor, Safety Coordinator Facilities Management UW-Eau Claire

2. Training Objectives: • Definitions • Responsibilities • General Procedures • Device Requirements • Shut Down Procedures • Group Lockout/Tagout Procedures • Shift/Personnel Change Procedures • Outside Personnel (Contractors) • Equipment Return to service • Special Exceptions • Specific Energy Control Procedures • Summary Facilities Management UW-Eau Claire

3. Definitions • Lockout • The placement of a lockout device in accordance with established procedures, ensuring that the energy-isolating device and the equipment being controlled may not be operated until the lockout is removed. • Tagout • The placement of a tagout device in accordance with an established procedure to indicate that the energy-isolating device and the equipment being controlled may not be operated until thetagout is removed. Note:FM uses both lockout/tagout devices. Facilities Management UW-Eau Claire

4. Responsibilities • Supervisors • Identify machinery and equipment that requires lockout/tagout before servicing. • Develop machine specific procedures for each type of machine or equipment. • Approve lockout devices to be used for each type of equipment that may need to be serviced. • Provide individual tags and key locks to each employee who will need to de-energize equipment. • Coordinate with outside contractors when servicing of equipment is done by them, or will affect them. Facilities Management UW-Eau Claire

5. Responsibilities Cont. • Authorized Employees • Understand the intended use of each type of lockout/tagout hardware. • Understand specific procedures for machinery, equipment and processes, including: • The hazards involved with working on electrical circuit and/or machinery or equipment. • Use the proper procedure for locking/tagging out an electrical source or piece of equipment. • Ensure the devices are kept in such a manner as to prevent use by other employees. • Notify any affected employees prior to the application of lockout/tagout devices and after they are removed. Facilities Management UW-Eau Claire

6. Responsibilities Cont. • Affected Employee - An employee whose job requires him/her to work in an area in which such servicing or maintenance is being performed. • Comply with restrictions and limitation imposed upon them during lockout/tagout of equipment or machinery. • Do not attempt to move lockout/tagout devices or start, energize or use equipment that have been locked or tagged out. Facilities Management UW-Eau Claire

7. General Procedures • Electrical Procedures • Shut off power on machine and disconnect. • Lockout/tagout on disconnect sources. • Press start button to ensure that energy source has been locked. • Remember the keys points: • If a machine or piece of equipment contains capacitors, they must be drained of stored energy. • Possible disconnecting sources include the power cord, power panels (look for primary & secondary voltage), breakers, the operator’s station, motor circuit, relays, limit switches, electrical interlocks. Facilities Management UW-Eau Claire

8. General Procedures Cont. • Hydraulic/Pneumatic Procedures • Shut off all energy sources (pumps & compressors). • Lockout/tagout the valve on the pumps and compressors that supply energy to more than one piece of equipment. • Drain or bleed stored pressure from hydraulic/pneumatic lines during lockout/tagout procedures. • Make sure controls are returned to their safest position (off, stop, neutral, etc.). Facilities Management UW-Eau Claire

9. General Procedures Cont. • Fluids and Gases • Identify the type of fluid or gas properly. • Close valves to prevent flow during lockout/tagout. • Determine the isolating device, close and lockout/tagout. • Drain and bleed lines to zero energy state. • Check for zero energy state on the equipment. Facilities Management UW-Eau Claire

10. General Procedures Cont. • Mechanical Energy Procedures • Block out or use die ram safety chain. • Lockout or tagout safety device. • Shut off, lockout or tagout electrical system. • Check for zero energy state on equipment. • Return controls to safest position. • Extra precaution • Know equipment and systems • Understand equipment hazards • Isolation points • Procedures for lockout Facilities Management UW-Eau Claire

11. Device Requirements • Use only lockout/tagout devices that have been approved by FP&M. • Locks/tags must clearly identify the employees who applied them. Note: Key differently. Facilities Management UW-Eau Claire

12. Shutdown Procedures • Prepare for Shutdown • Identify lockout points • Locate and identify all energy isolating devices that apply to the machine/equipment to be locked out. • Refer to the manufacturer’s control diagram detailing the location of all isolating points for complex equipment. • Determine the magnitude of the energy, the hazards of the energy to be controlled, and the methods to control the energy. • If authorized employees are unable to determine each form of energy, they must consult their supervisors before starting work. Facilities Management UW-Eau Claire

13. Shutdown Procedures Cont. • Notification • Notify all affected employees that a lockout/tagout is about to take place. • The reason for the lockout/tagout. • The specific machinery or equipment affected. • Shutdown • Shut Off Equipment • If the equipment is operating, employees shall shut it down by the normal stopping procedures (depress the stop button, open the switch, close valve, etc.) Facilities Management UW-Eau Claire

14. Shutdown Procedures Cont. • Deactivate Energy • Disconnect the device from ALL energy sources • Inspect the equipment to ensure ALL energy sources are disconnected. • Release of Stored or Residual Energy • Release the stored or residual energy such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems and pressurized systems such as air, gas, steam, or water. Facilities Management UW-Eau Claire

15. Shutdown Procedures Cont. • Attach Locking and Tagging Devices • Locks and tags should be standardized. • Locks shall be attached to energy isolating devices so that they cannot be accidentally detached during maintenance. • Tags shall be attached to all points where equipment or circuits can be energized. • A multiple lock plate shall be used when more than one employees attach their own lock on the same equipment. Facilities Management UW-Eau Claire

16. Shutdown Procedures Cont. • Tryout • Test the deactivation of the equipment to ensure that equipment cannot be energized. • Checking that no personnel are exposed. • Verifying the isolation of equipment by operating the push button or other normal operating controls. • Checking pressure gauges to ensure de-pressurization of lines. • Inspecting electrical circuits to confirm zero voltage. • Testing equipment by pushing start buttons or other controls to make certain the equipment will not run. • Returning the operating control(s) to “NEUTRAL” or “OFF” position after the test. • Ensuring equipment is now locked out/tagged out. Note:If equipment DOES energize on tryout, push the stop button & contact immediate supervisor immediately for further instruction. Facilities Management UW-Eau Claire

17. Group Lockout/Tagout Procedures • The primary authorized employee applies a multi-lock accepting device to the energy – isolating device and attaches his/her lock. • One authorized employee in the group is allowed to function as the lockout/tagout coordinator to ensure that all control methods are applied and there is continuity of protection for the group. • Each authorized employee shall affix a personal lockout/tagout device to the multi-lock accepting device when they begin work and shall remove those devices when they stop work. • The primary authorized employee removes his/her lock and the multi-lock accepting device when all work has been completed. Facilities Management UW-Eau Claire

18. Shift/Personnel Change Procedures • Either on the same shift or on the next shift, the following procedures should be followed: • The on-coming personnel shall notify the off-going personnel that they are ready to begin work on the machine or equipment. • All lockout/tagout devices attached to the machine or equipment by the off-going personnel shall be removed and immediately replaced with like devices by the on-coming authorized personnel. • The primary authorized employee shall ensure that all pertinent coordination between off-going and on-coming personnel has been completed before the on-coming authorized personnel begins work on the machine or equipment. Facilities Management UW-Eau Claire

19. Outside Personnel (Contractors) • The following procedures should be followed if work activities are performed by contractors: • FP&M supervisor and contractor shall inform each other of their respective lockout/tagout procedures. • FP&M supervisor shall ensure that his/her employees understand and comply with the restrictions and prohibitions of the outside employer’s energy control program. • Contractors failing to adhere to lockout/tagout procedures acceptable to FP&M will be asked to terminate their work until they employ acceptable energy control procedures. Facilities Management UW-Eau Claire

20. Equipment Return to Service • Inspect the machine and work area to ensure that: • Non-essential materials have been removed. • Tools and equipment are removed. • Blocks, pins and chain (used during the lockout) are removed. • Secured safe guards are in place. • All equipment components are fully assembled and operational. • Ensure that all employees have left the area or are safely positioned. Facilities Management UW-Eau Claire

21. Equipment Return to Service Cont. • Verify that controls are in neutral or the “OFF” position. • Remove all locking/tagging devices • Each lock shall be removed by authorized employee that applied it or under his/her direct supervision. • Notify affected employees that the servicing or maintenance is completed and the machine/equipment is ready for use. Facilities Management UW-Eau Claire

22. Equipment Return to Service Cont. • If the authorized employee who placed a lockout/tagout is absent from the workplace, when necessary, the immediate supervisor of that employee may remove the lock/tag device after completing ALL of the following specific procedures: • Verify that the employee is not present and therefore unable to remove the lock. • Obtain approval to remove the lock from one of the following: Director, Associate Director, and/or Assistant Director. • With the assistance of one of the above, get the “Second Key” from the lock box in the vault. • Remove lock/tag device (if supervisor is an authorized person) or supervise the removal by a person authorized to do so. • Ensure that the authorized employee who place it lockout/tagout device has been removed before they resume work at the facility. Facilities Management UW-Eau Claire

23. Special Exceptions • Minor, low risk, repetitive, routine equipment adjustments which take place during production operations which are integral to the use of the equipment. • Work on cord or plug connected electrical equipment when it is unplugged, and the employee working on the equipment has complete control over the plug. • Hot tap operations on transmission and distribution systems in which continuity or service is essential. Facilities Management UW-Eau Claire

24. Specific Energy Control Procedures • A written procedure is required for piece of equipment or machinery that utilizes multiple power sources. Each case must outline: • ALLenergy sources & lockout points for the equipment or process. • Specific steps to shut down, isolate, block and secure the machine or equipment to control the hazardous energy. • Steps for the placement, removal and transfer of the lockout devices and the responsibility for the devices. • Specific requirements for testing the equipment or machine to ensure the effectiveness of the lockout devices and other energy control devices. Facilities Management UW-Eau Claire

25. Specific Energy Procedures Cont. • Exceptions to Requirement for Specific Energy Control Procedures. • Specific documentation if not required for equipment when all of the following element exist: • Machine/equipment has no potential for stored energy after shut down which could endanger employees. • Machine/equipment has a single energy source that can be readily identified and isolated. • Isolation/locking out of that energy and source will completely de-energize de-active the machine or equipment. • Machine/equipment is isolated from that energy source during servicing or maintenance. • Single lockout device will achieve a locked out condition. Facilities Management UW-Eau Claire

26. Summary • Only authorized personnel may perform lockout/tagout using only the prescribed procedures. • Identify ALL energy sources and establish a zero energy prior to servicing equipment. • Take your time and do it RIGHT!!! (Lockout, Tagout, Tryout) • IF YOU DO NOT KNOW, ASK!!! Facilities Management UW-Eau Claire

27. Any Questions ?? Please visit FP&M Website (www.uwec.edu/facmgt/index.htm) for additional information. Facilities Planning & Management UW-Eau Claire