Control of Hazardous Energy (Lockout/Tagout) Program

Transcription

1 Cntrl f Hazardus Energy (Lckut/Tagut) Prgram 1. Purpse: The purpse f the Hazardus Energy Cntrl Prgram (Lckut/Tagut) is t prevent injury t emplyees caused by the unexpected energizatin, start-up, r release f stred energy. Surces f hazardus energy include radiatin, electrical, mechanical, hydraulic, pneumatic, chemical, thermal, r ther energy. This prgram establishes the minimum perfrmance requirements fund in the Virginia Occupatinal Safety and Health Standard (VOSH) , "The Cntrl f Hazardus Energy (Lckut/Tagut)." 2. Scpe/Applicability: Any emplyee servicing r maintaining machinery r equipment, where the unexpected energizatin, start-up r release f stred energy culd ccur and cause injury, shall islate and make inperative the machinery r equipment befre servicing. The fllwing nrmal prductin peratins are cvered in this prgram: a) An emplyee is required t remve r bypass a guard r ther safety device; r b) An emplyee is required t place his r her bdy r bdy part int an area n a machine r piece f equipment where wrk is perfrmed upn the material being prcessed r where an assciated danger zne exists during an perating cycle. c) Out f scpe: The fllwing are nt cvered in this prgram 1) Supervised crd and plug cnnected equipment; r 2) Ht taps 3. Table f Cntents: Purpse Page 1 Scpe/Applicability 1 Definitins 2 Respnsibilities 3 Devices and Hardware Requirements 4 General Guidelines 5 General Sequence f LOTO Prcedures 5 Equipment Specific Energy Cntrl Prcedures 6 Testing r Re-psitining f Equipment 7 Grup Lckut/Tagut 7 Shift r Persnnel Changes 7 Remval f LOTO Device 8 Peridic Inspectin 8 Page 1 f 13

2 Training and Re-training 8 Recrdkeeping 9 4. Definitins: Affected emplyee - An emplyee whse jb requires him/her t perate r use a machine r equipment n which servicing r maintenance is being perfrmed under lckut r tagut r whse jb requires him/her t wrk in an area in which such servicing r maintenance if being perfrmed. Authrized emplyee - A persn wh lcks r implements a tagut system prcedure n machines r equipment t perfrm the servicing r maintenance n that machine r equipment. The authrized emplyee has been designated t perfrm such duties by the emplyer. The authrized emplyee nt nly attaches the lck and tag but must als perfrm the servicing r maintenance. Capable f being lcked ut - An energy islating device will be cnsidered t be capable f being lcked ut either if it is designed with a hasp r ther attachment r integral part f which, r thrugh which a lck can be attached, r it has a lcking mechanism built int it. Other energy islating devices will als be cnsidered t be capable f being lcked ut, if lckut can be achieved withut the need t dismantle, rebuild, r replace the energy islating device r permanently alter its energy cntrl capability. Energized - Cnnected t energy surce r cntaining residual r stred energy. Energy islating device - A mechanical device that physically prevents the transmissin r release r energy, including but nt limited t the fllwing: A manually perated electrical circuit breaker; a discnnect switch; a manually perated switch by which the cnductrs f a circuit can be discnnected frm all ungrunded supply cnductrs and, in additin, nt ple can be perated independently; a slide gate; a slip blind; a line valve; a blck; and any similar device used t blck r islate energy. The term des nt include a push buttn, selectr switch, and ther cntrl circuit type devices. Energy surce - Any surce f electrical, mechanical, hydraulic, pneumatic, chemical, thermal, r ther energy. Ht tap - A prcedure used in the repair, maintenance and service activities that invlves welding n a piece f equipment (pipelines, vessels r tanks) under pressure, in rder t install cnnectins r appurtenances. It is cmmnly used t replace r add sectins f pipeline withut the interruptin f serve fr air, gas, water, steam, and petrchemical distributin systems. Page 2 f 13

3 Lckut - The placement f a lckut device n an energy islating device, cnsistent with an established prcedure, ensuring that the energy islating device and the equipment being cntrlled cannt be perated until the lckut device is remved. Lckut device - A device that utilizes a psitive means such as a lck, either key r cmbinatin type t hld an energy islating device in the safe psitin and prevent the energizing f a machine r equipment. Nrmal prductin peratins - The use f a machine r equipment t perfrm its intended prductin functin. Servicing and/r maintenance - Wrk place activities such as cnstructing, installing, setting up, adjusting, inspecting, mdifying and maintaining and/r servicing machines r equipment. These activities include lubricatin, cleaning r un-jamming f machines r equipment and making adjustments r tl changes, where the emplyee may be expsed t the unexpected energizatin r start up f the equipment r release f hazardus energy. Setting up - Any wrk perfrmed t prepare a machine r equipment f perfrm its nrmal prductin peratin. Tagut - The placement f a tagut device n an energy islating device, using an established prcedure, t indicate that the energy islating device and the equipment being cntrlled may nt be perated until the tagut device is remved. Tagut device - A prminent warning device, such as a tag and a means f attachment, which can be securely fastened t an energy islating device cnsistent with an established prcedure, t indicate that the energy islating device and the equipment being cntrlled may nt be perated until the tagut device is remved. 5. Respnsibilities: a) Safety and Risk Management (SRM) is respnsible fr: i. Develping and updating basic training and standard guidelines; ii. Maintaining basic LOTO training recrds alng with department supervisrs; iii. Validating Prgram implementatin; and iv. Assisting with revising and updating departmental specific prgrams as necessary. b) Departments invlved in hazardus energy tasks cvered in this prgram are respnsible fr: i. Assigning a Prgram Crdinatr; Page 3 f 13

4 ii. Identifying equipment and energy surces where LOTO is required; iii. Develping equipment-specific energy cntrl prcedures and testing the equipment r machine t verify the effectiveness f the energy cntrlling measure; iv. Maintaining basic LOTO training recrds alng with SRM; v. Prviding LOTO equipment; and vi. Assigning emplyees t authrized r affected status and maintaining a list f current authrized emplyees. c) Prgram Crdinatrs are respnsible fr: i. Prgram implementatin ii. Ensuring all affected emplyees receive apprpriate training n the specific prcedures pertaining t their particular jb duties; iii. Selecting and apprving specific lckut devices fr each type f equipment that may be serviced; iv. Reviewing LOTO prcedures at least annually; v. Pursuing the apprpriate crrective actin fr any emplyee that des nt cmply with this prgram; vi. Ensuring crdinatin and cperatin between emplyees and utside cntractrs; and vii. Remving r apprving the remval f a lckut device if the initial authrized emplyee is unavailable. d) Emplyees invlved in tasks cvered by this Prgram (authrized and affected emplyees) are respnsible fr: i. Cmplying with all aspects f the Prgram; ii. Attending basic LOTO training; and iii. Ntifying their supervisr f any unsafe cnditin 6. Devices and Hardware Requirements: Tags are nly warning devices and are t accmpany lcks, which prvide the physical restraint n energy islating devices. Tags will be accepted nly if lckut cannt be accmplished. Tagut devices are t be attached at the same lcatin that the lckut device wuld have been attached. LOTO devices must be marked by the authrized emplyee, nly used fr cntrlling energy and never used fr ther purpses. Devices must: Indicate the identity f the authrized emplyee applying the device; Be capable f withstanding the envirnment fr the maximum perid f time that expsure is expected, including but nt limited t crrsive envirnments; Page 4 f 13

5 Be cnstructed and printed s that expsure t weather cnditins r wet and damp lcatins will nt cause the tag t deterirate r the message n the tag t becme illegible; as with the use f blt cutters; Be substantial enugh t prevent inadvertent r accidental remval. All attachments are t be f a nn-reusable type, attaches by hand, and a minimum f unlcking strength f n less than 50 punds; Be standardized in at least ne f the fllwing criteria: clr, shape, r size. Tags must be the same print and frmat. Warn against hazardus cnditins if the machine r equipment is energized and shall include a statement such as the fllwing: DO NOT OPERATE, DO NOT START, DOT NOT ENERGIZE ; and Be apprved by the Prgram Crdinatr. 7. General Guidelines Only authrized emplyees shall perfrm LOTO prcedures. Authrized emplyees shall ntify all affected emplyees that a LOTO system is ging t be utilized and why. A LOTO device shall nly be remved by the initial authrized emplyee unless the fllwing is dne: a) Verify the authrized emplyee wh applied the device is nt at the lcatin by making respnsible effrts t cntact the authrized emplyee (inspect area, machine, equipment, r prcess t ensure that emplyee has left the facility, check emplyee time card, attempt t cntact the emplyee at hme); and b) Apprval has been received frm the Prgram Crdinatr t remve the device; and c) The Absentee Lck/Tag Remval Frm is filled ut in its entirety (see Appendix A). The Prgram Crdinatr will ensure that the authrized emplyee has been infrmed that his/her LOTO device has been remved. 8. General Sequence f LOTO Prcedures 1. Ntify all affected emplyees that a LOTO systems is ging t be utilized and the reasn fr LOTO. All authrized emplyees shall have knwledge f the type and magnitude f energy, the hazard t be cntrlled, and the methd r means t cntrl the energy. 2. If the machine r equipment is perating, shut it dwn by the nrmal stpping prcedure. 3. Islate the equipment frm its energy surce(s). Page 5 f 13

6 4. An authrized emplyee will LOTO the energy islating device with assigned individual lcks. Affix a tag with the lck t identify the authrized emplyee wh applied the device. Seek apprval frm Prgram Crdinatr if equipment cannt be lcked ut and a tagut system alne must be used. 5. Dissipate all stred energy (such as that in springs, elevated machine members, rtating flywheels, hydraulic systems, and air, gas steam r water pressure, etc.). Restrain if necessary by methds such as grunds, repsitining, blcking, bleeding dwn, etc. 6. Relieve all ptentially hazardus stred r residual energy by discnnecting, restraining, etc. t render the equipment safe. Prir t wrking n machines r equipment verify that islatin r de-energizatin has been accmplished by perating the push buttn r ther nrmal perating cntrls t make certain the equipment will nt perate. Return the perating cntrl(s) t neutral r ff psitin after the test. 9. Equipment- Specific Energy Cntrl Prcedures The Prgram Crdinatr is respnsible fr inspecting facilities and cnsulting with emplyees and supervisrs assigned t service and maintain equipment in rder t develp equipment-specific energy cntrl prcedures. These specific prcedures are required and must be develped, dcumented, and used when cntrlling hazardus energy during service r maintenance wrk (See Appendix B). If an energy islating device is capable f being lcked ut, equipment-specific LOTO prcedures must be cmpleted and must specify the use f a lckut system. If an energy islating device is nt capable f being lcked ut, equipment-specific LOTO prcedures must specify t use f a tagut system. When equipment cntains a single hazardus energy surce that can be islated with a single lck may be exempt frm equipment-specific prcedures. All exemptin criteria specified under 29 CFR (c)(4)(i) must be met t receive an exemptin. When using a tagut versus lckut system, specific prcedures shall describe the necessary steps taken t prvide an equivalent level f prtectin. In rder t demnstrate full emplyee prtectin when using a tagut system alne, additinal elements shall be cnsidered such as remving an islating circuit element, blcking a cntrlling switch, r the remval f a valve handle t reduce the likelihd f inadvertent energizatin. Whenever deviating frm standard equipment-specific LOTO prcedures, apprval frm the Prgram Crdinatr must be implemented and dcumented. Page 6 f 13

7 10. Testing r Re-psitining f Equipment If a LOTO device must be temprarily remved frm the energy islating device t test r psitin the machine, the fllwing sequence will be fllwed: 1. Clear the machine r equipment f tls and materials; 2. Ntify all emplyees and remve them frm the area; 3. Remve LOTO device(s); 4. Energize and prceed with testing r psitining; and 5. De-energize all systems and reapply energy cntrl measures t cntinue servicing and/r maintenance. 11. Grup Lckut r Tagut When service r maintenance is perfrmed by a crew, craft, department r ther grup, general prcedures shall be fllwed alng with the fllwing specific requirements: One authrized emplyee shall be designated as respnsible fr the grup LOTO; Hazardus energy cntrl prcedures shall be reviewed with each grup member; When mre than ne crew, craft, department, etc. is invlved, assignment f verall jb-assciated LOTO cntrl respnsibility shall be designated t an authrized emplyee t crdinate affected wrk frces and ensure cntinuity f prtectin fr the grup; Each authrized emplyee is t affix a persnal LOTO device t the grup lckut device, grup lck bx, r cmparable mechanism when beginning wrk, and is t remve thse devices when he r she stps wrking; and The equipment cannt be re-energized until all individuals in the grup have remved their LOTO device. 12. Shift r Persnnel Changes Specific prcedures are t be used during shift r persnnel changes t ensure cntinuity f LOTO prtectin, including prvisins fr the rderly transfer f LOTO devices between ff-ging and ncming emplyees. Each emplyee shall be respnsible fr remving his/her wn LOTO device at the cmpletin f his/her shift. If the wrk is t cease until the fllwing day, the supervisr shall place his/her persnal lck and tag n the equipment and the emplyees shall remve their lck and tag. When wrk resumes, Page 7 f 13

8 the emplyees shall affix his/her persnal lck and tag t the equipment and the supervisr shall remve his/her lck and tag. 13. Remval f LOTO Device Each LOTO device shall nly be remved frm an energy islating device by the emplyee wh applied the device. If the authrized emplyee that applied a LOTO device is nt available, the emplyees immediate supervisr, under the apprval f the department Prgram Crdinatr, may remve the device (refer t General Guidelines). Befre LOTO devices can be remved and energy restred t the machine r equipment, the fllwing prcedures are t be fllwed by the authrized emplyee(s): 1. After service and/r maintenance is cmplete and the equipment is ready fr nrmal prductin peratins, check the area arund the machine(s) r equipment t ensure that n ne is expsed and ntify affected emplyees that LOTO devices have been remved; 2. After all tls have been remved frm the machine r equipment, guards have been reinstalled and emplyees are in the clear, all LOTO devices are t be remved by the emplyee wh applied the device; and 3. Operate the energy islating devices t restre energy t the machine r equipment. Check fr prper peratin. 14. Peridic Inspectin: The department respnsible fr the emplyees perfrming LOTO is required t cnduct a peridic inspectin f the energy cntrl prcedures at least annually. The purpse f the peridic inspectins is t crrect any deviatins r inadequacies identified by the inspectr. Inspectins shall be perfrmed while directly bserving authrized individuals (i.e. an authrized emplyee nt participating in the LOTO) participate in the shutdwn using the peridic inspectin frm (See Appendix C). The immediate supervisr shall be ntified and take apprpriate actin t ensure the safety f all affected individuals. Any deficiencies r prblems bserved shall be reprted t the Prgram Crdinatr. Each department is respnsible fr keeping a cpy f these inspectins. 15. Training and Retraining All departments cvered under the Prgram shall maintain a list f all current authrized emplyees. A cpy f this list shall be made accessible t SRM upn request t the Prgram Crdinatr. Page 8 f 13

9 VCU SRM is respnsible fr prviding basic affected emplyee LOTO training fr emplyees t ensure that the purpse and functin f the energy cntrl prgram are understd and that emplyees pssess the basic knwledge and skills required fr the safe applicatin, usage, and remval f energy cntrls. Authrized emplyees shall receive training in the recgnitin f all applicable hazardus energy surces, the type and magnitude f the energy available in the wrkplace, and the methds and means necessary fr energy islatin and cntrl. Authrized emplyees shall als be trained in the fllwing specific limitatins f tags: a) Tags d nt prvide physical restraint n energy islating devices. Tags are essentially warning devices; b) When a tag is attached t an energy islating means, it is nt t be remved withut authrizatin f the authrized persn respnsible. It is never t be bypassed r ignred; c) Tags are required t be legible and understandable by all authrized emplyees, affected emplyees, and all ther emplyees whse wrk peratins are r may be in the area, in rder t be effective; d) Tags and their means f attachment must be made f materials which will withstand envirnmental cnditins cuntered in the wrkplace; e) Tags must be securely attached t energy islating devices s that they cannt be inadvertently r accidently detached r remved during use; f) Tags are t be understd as part f the verall energy cntrl prgram and nt prvke a false sense f security. Supervising departments are respnsible fr equipment-specific LOTO prcedure training fr their emplyees. The supervising department is als respnsible fr validating cmprehensin f these prcedures as well as instructing affected emplyees n the purpse and use f energy cntrl prcedures. Retraining shall be prvided fr all authrized and affected emplyees whenever there is a change in their jb assignment, a change in machine, equipment r prcess that presents a new hazard, r when there is a change in the energy cntrl prcedure. Retraining shall be cnducted if a peridic inspectin reveals, r whenever the supervising department r SRM has reasn t believe, deviatins frm r inadequacies in the emplyee s knwledge r use f the energy cntrl prcedure. Page 9 f 13

10 Retraining is designed t reestablish emplyee prficiency and intrduce new r revised cntrl methds and prcedures. 16. Recrdkeeping a) Each department is respnsible fr verifying that training is current and dcumented. SRM will maintain basic lckut/tagut training recrds. Recrds shall cntain the emplyee name and signature, date f training, and subject and descriptin f training; b) Absentee LOTO device remval frms (Appendix A) shall be maintained by the supervising department fr the lifetime f the applicable machine r equipment; c) Specific energy cntrl prcedures shall be readily accessible in the area f the specific equipment and available t all affected emplyees upn request. Cpies f all energy cntrl prcedures shall be kept by the Prgram Crdinatr. The fllwing are cnsidered an acceptable means fr making prcedures accessible: Electrnic means; Psting prcedures n the equipment; r Prviding a binder in the mechanical rm r wrking space. d) Peridic inspectin dcumentatin shall include the identity f the machine r equipment n which the energy cntrl prcedure was being utilized, the date f the inspectin, any deviatin f inadequacy, any crrective actin taken, the emplyees included in the inspectin, and the persn perfrming the inspectin (Appendix B). 17. References 29 CFR Cntrl f Hazardus Energy Electrical Safety Prgram 18. Appendices Appendix A Absentee Lck/Tag Remval Frm Appendix B Machine/Equipment Specific Lckut/Tagut Frm Appendix C LOTO Peridic Prcedure Inspectin Frm Page 10 f 13

11 Appendix A: Absentee Lck/Tag Remval Frm When an authrized emplyee wh applied a lck r tag device is nt available t remve the lck r tag, then this lck remval prcedure shall be used. The supervisr will apply the fllwing prcedure: Verify that the authrized emplyee wh applied the device is nt at the facility; Make all reasnable effrts t cntact the authrized emplyee t infrm he/she that his/her lckut r tag ut device has been remved. Ensure that the authrized emplyee has this knwledge befre he/she resumes wrk. This can be accmplished by meeting with the emplyee prir t that emplyee beginning wrk activities upn their earliest return t wrk. Cmplete a lck remval frm and submit t the safety manager upn cmpletin f this frm. Owner f Lck: (print) Name f Supervisr Initiating Remval: (print) Lcatin/Name f Equipment: Date f Remval: Time: Type f Energy (e.g. Electric, Pneumatic, Mechanical): Steps taken t cntact Owner f Lck/Tag: Date/Time Cntact was Attempted: Phne number/methd f Cntact: Reasn fr remving Lck r tag: Signature f Supervisr Initiating Remval: Signature f Individual** whse LOTO device was remved: **By signing, the individual whse LOTO device was remved certifies that they have been made aware f the fact that their energy cntrl device identified abve was remved under the supervisin f an authrized supervisr and realize that they n lnger have this equipment under islatin. Page 11 f 13

12 Appendix B: Machine / Equipment Specific Lck Out / Tag Out Machine: Department: Types and Magnitude f Energy Electric: Pneumatic Thermal Other: Hydraulic: Water (Ht/Cld): Gas: Lcatin f energy and islatin means: Affected Emplyees: Specific steps fr shutting dwn machine: Types f stred energy and methd t dissipate: Lck Out methds t be used:. After lcking ut machine, attempt t start the machine using nrmal perating cntrls. Once it has been assured that the machine cannt perate, be sure t return the perating cntrls t the neutral r ff psitin. After the wrk is cmpleted: A. Install and adjust pint f peratin guards and/r ther safety devices. B. Remve all tls, equipment, r ther nn-essential items. C. Infrm apprpriate persnnel. D. Remve Lck Out devices. E. Test cycle the machine t ensure it perates as expected. F. If further wrk is needed, reinstall Lck Out prcedure. G. Remve Lck Out devices and ntify affected emplyees that the equipment is ready fr use. 1

13 Appendix C: Lckut/Tagut Peridic Inspectin Frm Department: Inspectin cnducted by: Equipment lcatin: Inspectin date: Equipment type and ID#: List authrized emplyees using this prcedure. Has the emplyee been trained in the prcedure? Emplyee name: N Emplyee name: N Emplyee name: N Emplyee name: N D authrized emplyees knw the lcatin f the written prcedure? N D authrized emplyees have access t the prcedure? N Are affected emplyees ntified when the prcedure is being used? Have affected emplyees been trained t recgnize when the prcedure is being used and instructed nt t remve lckut/tagut devices r start de-energized equipment? Can energy-islating devices be lcked ut? Nte: When yu replace, renvate, r mdify machines and equipment, ensure that the energy-islating devices will accept lckut devices. New equipment and equipment renvated r mdified after January 2, 1990, must be capable f being lcked ut. N N N Did each authrized emplyee lck ut all energy surces? N Des this prcedure invlve grup lckut/tagut? N Did the authrized emplyees verify that the equipment was deenergized? N Page 12 f 13

14 Did the authrized emplyees fllw the lckut/tagut prcedure? Des the lckut/tagut prcedure adequately prtect emplyees? If nt, list and describe the deficiencies requiring crrective actin N N If this is a lckut prcedure, did the inspectr review with all authrized and emplyees their respnsibilities under the prcedure? Nte: A review can be accmplished by meeting with emplyees individually r in a grup. N Nt applicable If this is a tagut prcedure, did the inspectr review with all authrized and affected emplyees their respnsibilities under the prcedure? Nte: A review can be accmplished by meeting with emplyees individually r in a grup. N Nt applicable Page 13 f 13