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Control of Hazardous EnergyControl of Hazardous EnergyLLOCKOCKOOUT/UT/TTAGAGOOUTUT
Plant Asset ProtectionPlant Asset Protection
Lockout/TagoutLockout/Tagout
If you have any questions If you have any questions about the presentation, about the presentation, please contact:please contact:
Plant Asset Protection (PAP)Plant Asset Protection (PAP) Local 388 - Plant Shift-in-ChargeLocal 388 - Plant Shift-in-Charge Local 375 - PAP ManagerLocal 375 - PAP Manager
Lockout/TagoutLockout/Tagout Purpose of Lockout/TagoutPurpose of Lockout/Tagout
ScopeScope
DefinitionsDefinitions
Step by Step InstructionStep by Step Instruction
Lockout/Tagout – Common ExcusesLockout/Tagout – Common Excuses This job will only take a few minutes. I don’t need to
lock it out.
I’ve done this work for 20 years. I know what I’m doing. I don’t need to lock it out.
I’m in a hurry. I’ve locked the equipment out. I’m sure it’s okay. I don’t need to verify it.
There are two of us working on the equipment. There is no need for both of us to lock it out. I’ll work under my partner’s lock.
Lockout/Tagout – Top 5 ReasonsLockout/Tagout – Top 5 Reasons1.1. Your life is on the lineYour life is on the line
2.2. Your family and friends love and need youYour family and friends love and need you
3.3. Your co-workers depend on you being aroundYour co-workers depend on you being around
4.4. It’s a company requirementIt’s a company requirement
5.5. It’s a regulatory requirementIt’s a regulatory requirement
Lockout/Tagout – PurposeLockout/Tagout – PurposeThe Concentrate Plant has established The Concentrate Plant has established
requirements for Lockout/Tagout of requirements for Lockout/Tagout of equipment during servicing and equipment during servicing and maintenance to ensure:maintenance to ensure:
equipment is isolated & locked or tagged equipment is isolated & locked or tagged out from all potentially hazardous energyout from all potentially hazardous energy
where the unexpected energization or where the unexpected energization or release of such energy could cause injury.release of such energy could cause injury.
Lockout/Tagout – ScopeLockout/Tagout – Scope
Lockout/Tagout covers:Lockout/Tagout covers:
SERVICING and MAINTENANCESERVICING and MAINTENANCE of of machines and equipment in which machines and equipment in which the unexpected energization, start-the unexpected energization, start-up or release of energy could cause up or release of energy could cause injury to employees.injury to employees.
Lockout/Tagout – ScopeLockout/Tagout – Scope
SERVICING and MAINTENANCESERVICING and MAINTENANCE includes: includes:•Constructing
•Installing
•Setting upSetting up
•AdjustingAdjusting
•Inspecting
•Modifying
•ServicingServicing
•MaintenanceMaintenance
Lockout/Tagout – Scope Lockout/Tagout – Scope Lockout/Tagout is not required Lockout/Tagout is not required
for maintenance or servicing for maintenance or servicing performed during normal performed during normal production production unlessunless it it requires:requires:
Removal of a guardRemoval of a guard Bypass of a safety deviceBypass of a safety device Placement of any part of the Placement of any part of the
body in point of operation or body in point of operation or other danger zone other danger zone
Lockout/Tagout – Definitions Lockout/Tagout – Definitions
LOCKOUTLOCKOUT Placement of a lockout Placement of a lockout
device on an energy device on an energy isolating device, in isolating device, in accordance with an accordance with an established procedure.established procedure.
Lockout/Tagout – Definitions Lockout/Tagout – Definitions
TAGOUTTAGOUT Placement of a tagout Placement of a tagout
device on an energy device on an energy isolating device, in isolating device, in accordance with an accordance with an established procedure.established procedure.
Lockout/Tagout – Definitions Lockout/Tagout – Definitions
AUTHORIZED PERSONAUTHORIZED PERSONA duly trained personnel A duly trained personnel
who locks or tags who locks or tags machines or equipment machines or equipment to perform maintenance to perform maintenance or servicingor servicing
Lockout/Tagout – Definitions Lockout/Tagout – Definitions
AFFECTED PERSONAFFECTED PERSONA person whose job A person whose job
requires him/her to requires him/her to operate or work in an operate or work in an area where servicing is area where servicing is being performed under being performed under Lockout/Tagout.Lockout/Tagout.
Lockout/Tagout – Definitions Lockout/Tagout – Definitions SOURCES OF ENERGYSOURCES OF ENERGYEnergy needed to operate Energy needed to operate
the machine or equipmentthe machine or equipment
ElectricalElectrical HydraulicHydraulic PneumaticPneumatic MechanicalMechanical Process PipingProcess Piping ThermalThermal StoredStored
Lockout/Tagout – Definitions Lockout/Tagout – Definitions ENERGY ISOLATING DEVICEENERGY ISOLATING DEVICEMechanical device that prevents the Mechanical device that prevents the
transmission or release of energytransmission or release of energy
Electrical circuit breakerElectrical circuit breaker Disconnect switch Disconnect switch Line valveLine valve Slip blindSlip blind
Note: Push button, selector switches, emergency Note: Push button, selector switches, emergency stops and other control devices are NOT stops and other control devices are NOT energy isolating devicesenergy isolating devices
Lockout/Tagout – Definitions Lockout/Tagout – Definitions
Lockout/Tagout Devices must Lockout/Tagout Devices must be:be:
DurableDurable
StandardizedStandardized
SubstantialSubstantial
IdentifiableIdentifiable
Lockout/Tagout – Instructions Lockout/Tagout – Instructions 1.1. Know the EquipmentKnow the Equipment
2.2. Notify Affected PersonsNotify Affected Persons
3.3. Shutdown equipment by Shutdown equipment by normal procedures (If normal procedures (If possible)possible)
4.4. Isolate Equipment by Isolate Equipment by operating energy isolating operating energy isolating devices.devices.
Lockout/Tagout – Instructions Lockout/Tagout – Instructions
5.5. Apply locks to devicesApply locks to devices
6.6. Dissipate stored energyDissipate stored energy
7.7. VERIFY Lockout is VERIFY Lockout is effectiveeffective
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
The next step after locking out the The next step after locking out the energy sources & dissipating the energy sources & dissipating the stored energy is:stored energy is:
a)a) Take a coffee breakTake a coffee breakb)b) Perform servicing/maintenancePerform servicing/maintenancec)c) Verify the LockoutVerify the Lockoutd)d) None of the aboveNone of the above
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
VERY GOOD! VERY GOOD! C. IS THE CORRECT C. IS THE CORRECT
ANSWER!ANSWER!
Always verify if Always verify if lockout/tagout lockout/tagout performed is performed is effective.effective.
Lockout/Tagout – Instructions Lockout/Tagout – Instructions Verification of Lockout includes:Verification of Lockout includes:
Push controls buttons, turn knobs, Push controls buttons, turn knobs, etc.etc.
Use voltage meter for electrical Use voltage meter for electrical work (If the employee could be work (If the employee could be exposed to live circuits)exposed to live circuits)
(For circuits above 600 volts, check (For circuits above 600 volts, check meter against a known source, meter against a known source, before & after use)before & after use)
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
When performing maintenance where When performing maintenance where the employee could be exposed to the employee could be exposed to live electrical circuits, verification is live electrical circuits, verification is accomplished by turning/pushing accomplished by turning/pushing control knobs/buttons.control knobs/buttons.
TRUETRUE
FALSEFALSE
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
VERY GOOD! VERY GOOD! The answer is The answer is FalseFalse
Verification is Verification is accomplished by accomplished by using a voltmeter. using a voltmeter. This must be This must be performed by a performed by a qualified person.qualified person.
Lockout/Tagout – Instructions Lockout/Tagout – Instructions ENERGY RESTORATIONENERGY RESTORATION
1.1. Check that tools/parts are Check that tools/parts are removedremoved
2.2. Check for people in hazardous Check for people in hazardous locationslocations
3.3. Replace guards & safety devicesReplace guards & safety devices
4.4. Notify all Affected employeesNotify all Affected employees
Lockout/Tagout – Instructions Lockout/Tagout – Instructions ENERGY RESTORATIONENERGY RESTORATION
5.5. Ensure all controls are in the Ensure all controls are in the “OFF” position“OFF” position
6.6. Remove Locks & TagsRemove Locks & Tags
7.7. Restore EnergyRestore Energy
8.8. Ensure Equipment is Ensure Equipment is operationaloperational
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW During energy restoration the authorized person During energy restoration the authorized person
should:should:
a.a. Check that tools and people are clearedCheck that tools and people are cleared
b.b. Guards and safety devices have been replaced aGuards and safety devices have been replaced and are operationalnd are operational
c.c. All controls are in the “OFF” PositionAll controls are in the “OFF” Position
d.d. All of the aboveAll of the above
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
VERY GOOD! VERY GOOD! D is the correct D is the correct
answeranswer
Lockout/Tagout – Instructions Lockout/Tagout – Instructions IMPORTANT POINTS TO CONSIDERIMPORTANT POINTS TO CONSIDER
Lockout/Tagout is the required Lockout/Tagout is the required method of isolating machines method of isolating machines from the energy sourcefrom the energy source
Only Authorized Employees Only Authorized Employees may lock/tag out equipment.may lock/tag out equipment.
DO NOT ATTEMPT TO OPERATE DO NOT ATTEMPT TO OPERATE ANY ENERGY ISOLATING DEVICE ANY ENERGY ISOLATING DEVICE
WHERE IT IS LOCKED AND WHERE IT IS LOCKED AND TAGGED OUT.TAGGED OUT.
Lockout/Tagout – Instructions Lockout/Tagout – Instructions IMPORTANT POINTS TO CONSIDERIMPORTANT POINTS TO CONSIDER
All equipment must be locked All equipment must be locked and tagged out to protect and tagged out to protect against accidental or against accidental or inadvertent operation which inadvertent operation which could cause injury to personnel.could cause injury to personnel.
Lockout/Tagout – Instructions Lockout/Tagout – Instructions CONTRACTORSCONTRACTORS
TCCEC and the contractor must inform each TCCEC and the contractor must inform each other of their respective lockout/tagout other of their respective lockout/tagout procedures.procedures.
The two parties must coordinate the The two parties must coordinate the implementation of the procedures.implementation of the procedures.
The contractor’s employees and TCCEC The contractor’s employees and TCCEC engineering personnel must perform the engineering personnel must perform the lockout/tagout and verificationlockout/tagout and verification
Lockout/Tagout – Instructions Lockout/Tagout – Instructions
SHIFT CHANGESHIFT CHANGE
There must be a procedure or method There must be a procedure or method to ensure the continuity of the to ensure the continuity of the Lockout during shift or personnel Lockout during shift or personnel changes.changes.
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW When an outside contractor’s work requires a When an outside contractor’s work requires a
lockout/tagout:lockout/tagout:
a.a. TCCEC and the contractor must inform each TCCEC and the contractor must inform each other of their Lockout/Tagout proceduresother of their Lockout/Tagout procedures
b.b. The two parties must coordinate the The two parties must coordinate the implementation of the procedures.implementation of the procedures.
c.c. Both a and bBoth a and b
d.d. None of the aboveNone of the above
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
VERY GOOD! VERY GOOD! C is the correct C is the correct
answeranswer
Lockout/Tagout – Instructions Lockout/Tagout – Instructions ABANDONED LOCKABANDONED LOCK
In general, only the person who applied the In general, only the person who applied the lock should remove it.lock should remove it.
The PAP Manager may have the lock The PAP Manager may have the lock removed by another authorized person, removed by another authorized person, under the following conditions:under the following conditions:
All reasonable attempts have been All reasonable attempts have been made to contact the person who made to contact the person who abandoned the lockabandoned the lock
It has been determined that the It has been determined that the equipment is safe to operateequipment is safe to operate
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW Who should normally remove the lock of an Who should normally remove the lock of an
authorized employee?authorized employee?
a.a. The Plant Asset Protection ManagerThe Plant Asset Protection Manager
b.b. The authorized employee performing The authorized employee performing lockoutlockout
c.c. Another Authorized employeeAnother Authorized employee
d.d. All of the aboveAll of the above
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW
Lockout/Tagout – REVIEW Lockout/Tagout – REVIEW
VERY GOOD! VERY GOOD! B is the correct B is the correct
answeranswer
Under normal Under normal conditions, only the conditions, only the person who applied person who applied the lock should the lock should remove it.remove it.
Lockout/TagoutLockout/Tagout
LOCK ITLOCK ITTAG ITTAG IT
VERIFY ITVERIFY IT
Lockout/TagoutLockout/Tagout
QUESTIONS?QUESTIONS?
COMMENTS?COMMENTS?
SUGGESTIONS?SUGGESTIONS?
VIOLENT REACTIONS?VIOLENT REACTIONS?
Safety is Everyone’s Responsibility!Safety is Everyone’s Responsibility!
Safety
Safety