PSU Lockout/Tagout Training for Authorized Employees

(Note: This training is intended to be presented by EHS)

www.ehs.psu.edu

Objectives

• Clarify requirements of PSU Lockout/Tagout (LOTO) Program

• Ensure everyone is aware of their role within LOTO Program

• Provide an opportunity to discuss concerns related to LOTO Program

Training Outline

I. How Do Injuries Occur During Servicing?

II. What is LOTO? – Types of hazardous energy

– When should LOTO be applied?

– Energy isolation devices

III. LOTO Basics

IV. General LOTO procedure at PSU

V. Special Situations

VI. Energy Isolation Device – Video Review

VII. “Safe or Unsafe?” Exercise

I. How Injuries Occur During the Servicing of Equipment?

• BLS study on injuries while servicing equipment revealed: – 80% failed to turn off

equipment

– 10% equipment activated by someone else

– 5% failed to control potential energy

– Most of remaining 5% disconnected power but failed to verify effectiveness

II. What is LOTO?

• “LOTO” is a technique used to prevent energy from being released during the servicing of equipment. This is accomplished by placing locks on energy isolation devices prior to starting work.

Types of Hazardous Energy

• What types of hazardous energy are subject to LOTO?

Types of Hazardous Energy

• Electrical

• Pneumatic

• Hydraulic

• Mechanical

• Thermal

• Chemical

• Radiation

• Steam

• Spring-Driven

• Suspended Parts

Some energy sources can be turned on/off.

Others can only be dissipated or controlled.

Potential Energy vs. Kinetic Energy

Potential energy can be converted to kinetic!

Goal of LOTO is to achieve “Zero Energy State”

When is LOTO applied?

• Adjusting

• Inspecting

• Modifying

• Replacing parts

• Tool changes

• Clearing jams

• Lubricating

• Cleaning

“…during the servicing of equipment”.

There are some situations where LOTO is not required…

Exceptions to LOTO

• Cord & plug connected equipment • Plug is only source of energy

• Plug is under continuous control of one person

Exceptions to LOTO

• Minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations, if they are routine, repetitive and integral to the use of the equipment for production, provided that the work is performed without the removal or bypassing of machine guards.

• Alternative measures for protection are used.

• Body part not placed in the point of operation or other dangerous area during machine cycle.

Energy Isolation Devices

Examples:

• Electrical disconnect switch

• Electrical breaker switch

• Hydraulic valve

• Pneumatic valve

• Line valve

Pushbuttons, selector switches, and other control circuit devices are NOT energy isolation devices.

“…accomplished by placing locks on energy isolation devices…”

Device that physically prevents the

transmission or release of energy

Review of LOTO Definition

• “LOTO” is a technique used to prevent energy from being released during the servicing of equipment. This is accomplished by placing locks on energy isolation devices prior to starting work.

III. LOTO Basics

All employees fit into one of the following

LOTO roles:

“Authorized employee” • Services equipment & authorized to apply LOTO.

“Affected employee” • Operates or uses equipment being serviced under

LOTO.

“Other employee” • Works in an area where LOTO being used.

LOTO Basics

• Preferred means of controlling hazardous energy at PSU is LOCKOUT IN CONJUNCTION WITH TAGOUT.

• Each isolation point must have both a lock and a tag attached to it.

• Locks must be standardized & used only for LOTO.

• Tags must indicate lock holder & date of application.

IV. General PSU LOTO Procedure

STEP 1 ID Energy Sources

STEP 2

Notify

Others

STEP 4

Isolate

Equipment

STEP 5

LOTO

Equipment

STEP 3

Shutdown

Equipment

STEP 6

Release Stored

Energy

STEP 7

Verify

Isolation

STEP 8

Perform

Servicing

STEP 9

Release

from LOTO

Step 1: ID All Energy Sources

• Know types & magnitude of energy associated with equipment.

• ID all energy sources feeding the equipment (including potential energy).

• Gather appropriate control devices.

• Clarify any questionable identification of energy sources before proceeding.

Step 2: Notify Others

• Verbally notify all “affected” and “other” employees of impending shutdown.

• Not all equipment will have someone “assigned” to it.

Step 3: Shut Down Equipment

• Use normal stopping procedures to shut down equipment.

– Push “Stop” button

– Off/On toggle switch

– etc.

Step 4: Isolate Equipment

• After shutdown, operate all energy isolation devices so equipment is disconnected from energy sources. – Turn electrical

disconnect to “OFF” position

– Open circuit breaker – Close valve – Etc.

Step 5: LOTO the Equipment

• Attach locks & devices to each isolation point.

• Tag must accompany each lock.

• Good idea to also tag point of operation if located remotely from isolation points.

• What if equipment won’t accept a lock?

Step 6: Release Stored Energy

• Ensure all potential or residual energy is controlled.

Block elevated parts.

Block/release springs.

Relieve system pressure.

Drain fluids.

Vent gases.

Allow system to cool.

Discharge capacitors.

Stop rotating flywheels.

Step 7: Verify Isolation

• Before any servicing begins, verify effectiveness of LOTO.

• Use normal starting procedure or otherwise verify “Zero Energy State”.

• Return controls to “OFF” position after testing.

• Verification is the step which is most frequently skipped during evaluations.

Step 8: Perform Servicing

• Complete required service work.

• Avoid doing anything that could potentially reactivate the equipment.

• OK to interrupt LOTO, but must be reapplied if servicing is to continue.

Step 9: LOTO Release

• All locks, tags, & devices removed by same person who applied.

• Remove all tools from equipment area.

• Replace all machine guards.

• Verbally inform all “affected” & “other” employees that LOTO is complete.

• Ensure area is clear prior to restart.

IV. General PSU LOTO Procedure

STEP 1 ID Energy Sources

STEP 2

Notify

Others

STEP 4

Isolate

Equipment

STEP 5

LOTO

Equipment

STEP 3

Shutdown

Equipment

STEP 6

Release Stored

Energy

STEP 7

Verify

Isolation

STEP 8

Perform

Servicing

STEP 9

Release

from LOTO

V. Special Situations • Shift changes

– Oncoming employee attaches locks/tags prior to outgoing employee removing theirs.

– EHS must OK alternative procedures.

• Vehicle hazardous energy control – Alternative vehicle control methods are permitted in circumstances

where removal of the key fully ensures employee protection.

– The authorized employee performing the maintenance would need to retain sole control of the key.

– If removal of the key does not fully ensure employee protection additional measures are needed. (removal of battery cable, chock wheels, etc)

Lock removal procedure

Supervisor must be notified if lock owner is not present. Use Appendix C of program to document removal.

V. Special Situations

• Group LOTO – Each employee applies own

locks/tags to each isolation point.

– OR

– A designated person locks out each of the energy sources and puts the keys into a group lockbox. The authorized employees place their lock on the group lockbox before they begin work. After each worker finishes, the worker removes his lock from the box.

– EHS must OK alternative procedures.

Summary

• All hazardous energy sources must be controlled (kinetic & potential).

• Control via energy isolation device (do not rely on control circuit).

• Only use designated lock for LOTO.

• Tags must accompany all locks.

• Nine-step general procedure – remember to verify isolation.

• Protection must be ensured during special situations.

Any Questions?