[alex] cohe loto [instructor]
TRANSCRIPT
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CONTROL OF HAZARDOUS ENERGY AND
LOCK-OUT / TAG-OUT/ TRY-OUT
(LOTOTO)
By: ENGR. ALEXANDER B. TRILLANAOSH CONSULTANT
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• Work with machinery, equipment and processsystems where energization or release of storedenergy could result in injury.
• Work involving energy sources:
– Electrical
–
Pneumatic – Hydraulic
– Stored (such as gravity, spring or compressed gas)
– Chemical
– Thermal – Radiation.
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7Nov. 2, 2003 Rig Floor
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Running at 130 rpm
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Don’t
ignore the “LOTOTO”
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Lockout/Tagout
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Electrical LOTO Mechanical LOTO
“NOBODY GETS HURT”
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Lockout/Tagout Devices
• Locks
• Tags
• Lockout Boards
• Multi-Hole Hasp
• Cables
• Blinds/Spades
• Blind Flanges
NOBODY GETS HURT
“ EVERY ONE EVERY DAY EVERY TASK “
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“NOBODY GETS HURT”
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Electrical Lockout Devices
NOBODY GETS HURT
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Valve Lockout Devices
NOBODY GETS HURT
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Mechanical Lockout
WHEN there is a potential to be exposed to rotating equipment or machinery.
NOBODY GETS HURT
“ EVERY ONE , EVERY DAY , EVERY TASK “
“NOBODY GETS HURT”
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Thermal Energy Lockout
WHEN there is the potential to be exposed to
residual heat or high temperatures.
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Chemical Energy Lockout
When the potential exists for chemical exposure
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Physical Blocks
Truck bed Lockout Punch press blocks
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Pneumatic Lockout
These devices prevent compressed air from flowing through lines and movingsome part of the machinery.The locks prevent anyone from hooking up the
lines while maintenance is being done.”
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Pipe Lockout
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Spades And Blinds
A physical block in a pipeline prevents steam, gas or liquids from flowing through the pipe to the area
where work is being done. For example, the pipe to a chemical tank must be blocked or disconnected
before someone goes in to do repair or maintenance.”
Ensure positive isolation of piping systems (Operation , Mechanical )
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Blind Flange or ‘End Blank’
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Spectacle Blind
“ EVERY ONE EVERY DAY EVERY TASK “
“NOBODY GETS HURT”
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Blocks
“ EVERY ONE EVERY DAY EVERY TASK “
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Types of Lockout/Tagout Devices
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LOTOTO BOX
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Types of Lockout Devices
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Types of Lockout Devices
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Types of Lockout Devices
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Types of Lockout Devices
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Types of Lockout Devices
Step 1:
Verify circuit breaker is de-energized.Place PSL-CBL lockout device over
breaker with the handle centered in
lockout opening.
Step 2:
Turn the toggle set screw knob andtighten firmly against the breaker
handle.
Step 3:
Rotate and flip toggle set screw
upwards.
Step 4:
Install lock and tag and test for
security. Verify that the lockout device
secures the disconnect in a safe or off
position.
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Types of Lockout Devices
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Scope
• Applicable to all operations (manufacturing,distribution and offices) worldwide with potential for
work where energization or release of stored energy
can result in injury.
Definitions
• Energy source: any source of electrical, mechanical,
hydraulic, pneumatic, chemical, thermal, or other
energy.
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Definitions
• Energy isolating device: a mechanical device thatphysically prevents the transmission or release of
energy
• Hazardous energy: any electrical, mechanical,
hydraulic, pneumatic, chemical, thermal or other
energy, which if inadvertently applied to a machine or
worker can cause injury.
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Definitions
•Lock-out: the placement of a lock on energy isolatingdevice ensuring the equipment cannot be operated
until the lock is removed
• Tag-out: the placement of a tag on an energy isolating
device ensuring the equipment may not be operated
until the tag is removed.
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1.0 Administrative controls
1.1 Compliance
• Establish local legal regulations and Companyrequirements
• Implement management practices and controlswhichever is stricter of the two.
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1.2 Hazard ID and Risk Assessment
• Conduct and document initial assessment to ID
machinery and equipment in which energization or
release of energy could result to injury to workers
• Part of safety aspects and impacts analysis of theCompany’s Safety Management System
• To be reviewed annually and modified as necessary.
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1.3 Energy Control Procedures
• Document specific procedures for control of hazardous
energy for each piece of machinery and equipment where
energization or release of energy could result in injury
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1.3 Energy Control Procedures
• The machine-specific CoHE procedures must include how
to:
– Shut down the machine and location of controls
– Isolate energy sources and location of energy isolation devices
– Relieve any stored or residual energy
– Place lock-out and tag-out devices
– Verify energy isolation
– Release the machine from lock-out and tag-out.
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Don’t
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1.4 Training
• All employees whose job requires them to operate, use,or be in the area of equipment or process systems during
LOTO activities must receive documented initial training
– A review of energy sources present in facility
– Overview of purpose and use of CoHE
– Types of energy isolating devices they will see in use
– Prohibition of removing locks or tags or trying to start
equipment with LOTO
– Prohibition in using LOTO unless trained.
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S A F E T Y
T A L K S
!
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1.4 Training
• Disciplinary policy for violating CoHE program• Retraining must be conducted when:
– Employees are assigned to a job in which they have not been
trained in CoHE
– Change in equipment with new hazards
– Change in CoHE procedures
– Audits or accidents reveal deficiencies in employees knowledge
or implementation of CoHE procedures.
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1.5 Working with Contractors
• The site is responsible for ensuring Contractors use CoHE
procedures
• Before work, site and contractor, review all applicable
hazardous energy sources and CoHE procedures
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62
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2.0 Scope of Line break processes
• CoHE during line breaks to prevent exposure to hazardous
chemicals causing injury on contact such
– Fluids above 55oC (130oF)
–Compressed air or gas >5.5bar (>80psig)
• These procedures do not apply where written SOPs are in
place e.g., making clean in place (CIP) connections.
2 0 Li b k
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2.0 Line break processes
2.1 Line breaking permit
• The site must establish a permit program to control andmonitor line breaking work
• Minimum information to be documented
–
Date, time and location of work – Description of work to be done
– Date, time and expiration of work
– Required PPE
–
Procedure to clear the line – Potential sources of energy and CoHE
– Signature of authorizer, attendant and people doing the workthat above have been completed and verified.
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65
S A F E T Y
T A L K S
!
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2.2 Control measures
• Use hazard analysis and recognition to identify potentialcontrol measures such as:
– Removal of chemicals from system
– Use of PPE based on MSDS
– Confirm safety equipment appropriate for the hazards
– Review piping flowsheet
– Confirm and physically check LOTO of pumps, blowers,
compressors to prevent inflow of hazmats
– Confirm work area is isolated or guarded with signs and warning
tape to prevent exposure of others not involved in the linebreak
work.
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2.3 Attendant
• Presence of (standby) attendant familiar with the system,its hazards and CoHE procedures who is wearing
appropriate PPE for initial line break
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3 0 Electrical Pneumatic Hydraulic Powered
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3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.1 Lock-out process
– 1. Stop equipment using normal push button
– 2. Isolate each energy source
– 3. LOTO each energy source – 4. Verify each energy source is isolated. Call “Stand
Clear” then attempt to re-start the equipment. Returncontrols to “neutral”, “stop”, or “OFF” positions after
the test – 5. Do the required work.
3 0 Electrical Pneumatic Hydraulic Powered
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3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.2 Tag-out
• If the person who installed a lock-out must leave the site
before it is safe to re-energize the equipment, he must
install a tag-out – “Warning: Do not operate”
– Name and signature of person doing the LOTO
– Reason for the tag
– Date
– Equipment which is de-energized.
3 0 Electrical Pneumatic Hydraulic Powered
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3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.3 Tag-out in lieu of lock-out
• If energy isolating device is not capable of beinglocked-out, a tag-out may be used
• Additional energy control measure must be usedsuch as removal of isolating circuit element, orblocking a controlling switch
•
Sites must upgrade to lockable isolating devices assoon as practicable.
3 0 El t i l P ti H d li P d
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3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.4 Group LOTO
• Some works may require multiple individual isolations
with several people working on the same equipment or
process
• A multiple hasp or lock box can be used so each
individual worker can attach his own LOTO.
3 0 El t i l P ti H d li P d
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3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.5 Release from LOTO
• Once work is complete, procedure to repower:
1. Inspect work area to verify all components are safe to
operate, GHK done, all personnel stay away
2. Remove LOTO. Each person removes his own.
3. Re-energize equipment. Call out “Stand Clear” visually
verifying all personnel are clear. Switch on, standing tothe side of each electrical disconnect (baka sumipa o
sumabog).
3 0 Electrical Pneumatic Hydraulic Powered
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3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.6 Personnel or Shift changes
• One of two procedures is acceptable
– 1. Incoming employee places his LOTO, after which leaving
employee removes his LOTO – 2. Designated Company supervisor places department
LOTO in addition to the LOTO placed by individualemployees. Authorized employees remove their LOTO atend of their shift. The designated supervisor keeps controlof the keys of the department LOTO.
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3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.7 LOTO removal when owner is off-site • No one is authorized to remove another person’s LOTO
while he is on site
•
In exceptional circumstance when he cannot be located: – His supervisor to verify he is not on site
– Attempt to contact the owner before removal of LOTO
– Inform owner his LOTO is removed before he starts work
– A designated employee to verify that removal of LOTO will notendanger anyone before removal.
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3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.7 LOTO removal when owner is off-site
• In exceptional circumstance when he cannot be
located (continuation):
– The employee removing the LOTO to document
the action. Document kept for 1 year.
– Supervisor investigates why employee left
without removing LOTO devices. Appropriate
disciplinary measures.
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3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.8 LOTO Devices
• Standard durable lock hardware throughout the
site
• Tags printed and constructed to be weather
resistant
• Each tag to have secure means of attachment.
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What is Lock Out / Tag Out (LOTO)
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What is Lock-Out / Tag-Out (LOTO)
•Lockout devices can include:
Locks
Blocks
chainsthat are applied to energy isolating devices:
Switches
Valves etc
A ti iti Th t R i L k O t/T O t
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Activities That Require Lock-Out/Tag-Out
•
Machinery and equipment that require...
Lubrication
Cleaning AdjustmentsR etooling
Un-jamming
RepairingServicing
Inspection
Systems that require Lock Out/Tag Out
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Systems that require Lock-Out/Tag-Out
During service and/or repair
Steam Boilers
Air Handlers
Vehicles
Hydraulic
Pneumatic
Electrical
Plumbing
Pumps
Motorized equipment
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• Lockout/Tagout prevents injuries during work
involving:Repairs
Replacements
Modifications to machines or equipment
Maintenance
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During normal operations, Lock-Out/Tag-Out isneeded whenever an employees must:
Remove or bypass a guard or other safety devices.
Place any part of his or her body into a machine’s
point of operation.
Or a danger zone associated with machine’soperation cycle.
• Authori ed employees
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• Authorized employees
can physically lock or tag out machines to
do service or maintenance work asoutlined in lockout/tagout procedures.
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•
Affected employees
either operate equipment that can be locked
or tagged out or work in an area wherelockout/tagout is used. They must understand
and comply with the lockout/tagout program
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Other employees
are those work operations are or may
be in an area where lockout/tagoutmay be used. They must be instructedabout lockout/tagout and know thatthey are never to attempt to restartequipment that has been locked ortagged out.
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Valve Covers
Switch Covers
Plug Covers
Kits
Locks
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Preventing Accidents
Requires
Team Effort