Control of Hazardous Energy(PSU-DHCmod)

8/12/2019 Control of Hazardous Energy(PSU-DHCmod)

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CONTROL OF

HAZARDOUS ENERGY(LOCK-OUT/TAG-OUT)

Electrical

Hydraulic

Steam

SpringLoaded

Chemical

Gravity


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Developed by

Garold L. Russell

Joseph P. Flick

Mark C. Radomsky

Raja V. Ramani

Department of Energy & Geo-EngineeringThe Pennsylvania State University

126 Hosler Building

University Park, PA 16802(814) 865-7472

June, 2001


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Energy

Weve harnessed it, tamed it and put it to

work for us.

But, energy is always ready to escape.

And if it is not kept under control, it can hurt

you----even kill you


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The objectives of this program is to assist

miner(s) to become more aware of;

Electrical hazards

Types of electrical hazards

MSHA regulations

Prudent safe work procedures


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Consequences of Lock-Out/Tag-Out Incidents

Unexpectedly getting caught in machinery

Unplanned startup of machinery

Unexpected movement of machine parts

Unexpected release of stored energy


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Consequences of Lock-Out/Tag-Out Incidents

Loss of life

Personal injury

Property damage

Loss of production

Loss of jobs


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Types of Hazardous

Energy

Live energy

Stored energy


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Live Energy

Electrical energy

Moving machine parts


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Stored Energy

Hydraulic or pneumatic pressure that could be

released

Electric energy stored in electric components


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Chemicals

Gravitational force that pulls on equipment, parts,or objects


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Common Factors in Lock-Out/Tag-Out Incidents

Accidental start up

Release of stored energy

Working on energized equipment

Removal of guards


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Accidental Start Up

Equipment being accidentally started by someone

who did not know that work was being performed

Electrical energy from an alternative source

providing power for a machine or equipment tostart


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Release of Stored Energy

Hydraulic or pneumatic pressure being released

and allowing a raised component to fall or drift

onto a worker

Electric energy stored in electric components

causing electrical shock or even allowing a machineto start up

Steam pressure being released when a pipeline is

disconnected


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Release of Stored Energy

Spring loaded mechanisms that fly or are projected

and hit a worker

Chemicals in pipelines that flow onto workers

Gravitational pulling force on equipment, parts, or

objects that allows parts or components to roll,

drift, or turn onto a worker


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Working on Energized Equipment

Failing to deenergize and secure equipment against

start up or movement

Failing to deenergize and secure all energy sources-

one energy source was locked out, but the

equipment moved or started from another energy

source


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Removal of Guards

Removing a guard from active machinery for

cleanup or repair and being caught in or by the

unguarded, active machinery


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MSHA Regulations, Part 56 (highlights and overview

only--not complete for all regulations)

Electrically powered equipment shall be deenergizedbefore work is done on such equipment--power switches

shall be locked out or other measures taken which shall

prevent the equipment from being energized without the

knowledge of the individuals working on it--Suitable

warning notices shall be posted at the power switch and

signed by the individuals who are to do the work--such

locks or preventive devices shall be removed only by thepersons who installed them or by authorized personnel


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Power circuits shall be deenergized before work is done onsuch circuits unless hot-line tools are used--suitable

warning signs shall be posted by the individuals who are to

do the work--switches shall be locked out or other

measures taken which shall prevent the power circuits

from being energized without the knowledge of the

individuals working on them--such locks, signs, or

preventative devices shall be removed only by the personswho installed them or by authorized


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Repairs or maintenance of machinery or equipment shallbe performed only after the power is off, and the

machinery or equipment is blocked against hazardous

motion

Persons shall not work on top of, under, or work from

mobile equipment in a raised position until the equipment

has been blocked or mechanically secured to prevent itfrom rolling, falling, or being accidentally lowered


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Factors Affecting Hazardous Energy

Control

Lock-OutProgram

Employee

Training

Types of

Equipment

Types of Work

Performed

Multiple Energy

Sources

k O


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Lock-Out Program

An organized program must be in effect to identify

and control all energy sources

The plan must be consistently used during all types

of work involving the control ofhazardous energy

E l T i i


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Employee Training

MSHA-required task training should address all

parts of hazardous energy control

If you do not know how to perform lock-out/tag-

out--dont attempt to do so until you have beentrained


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T f E i


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Types of EquipmentElectrically powered equipment needs to be properly

deenergized, and locked out prior to work being done

Some electrically powered equipment may have more

than one energy source, if so, all energy sources have to

be identified, deenergized, and locked out

Bucket elevators, crusher counter-weights, truck beds,

and other such parts and components need to be secured

against movement as part of the lock-out procedure


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All feed belts, lines, bins, etc. need to be isolated, locked

out, and secured to prevent any process material from

feeding or falling into the work area

All parts that may be under load, force, or pressure that

could spring out, or fly, need to be secured as part of the

lock out process

H d li d ti ll t d


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Hydraulic and pneumatically supported

components need to be secured against

movement as part of the lock-out procedure

Pipelines need to be bled off and blanked or

disconnected as part of the lock out process

T f W k P f d


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Types of Work Performed

All forms of construction, maintenance, repair, clean up,

adjustment or modification work require control ofhazardous energy

Any type of work that places you in any location or

position where you may be exposed to live or stored energy

requires control of hazardous energy

M j b i th if


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Many jobs require more than one person--if you

are part of the work, you must be part of the lock-

out

Energy control is vitally important in any type of

confined space work, and should also be part of the

confined space entry procedures

M lti l E S


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Multiple Energy Sources

There may be more than one form of hazardous

energy in any type of machine

Do not assume that electricity is the only form of

hazardous energy

Evaluate each work task to identify and control all

forms of hazardous energy

C t l f H d E


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Control of Hazardous Energy

Hazard identification and correction

Notification of impending workIdentification/isolation of all energy sources

Lock-out/tag-out/block-out of all energy sources

Verification/testing of all energy sources

Replacement of all guards and safety devices

Accounting of all personnel following work

Sounding of all appropriate alarms/warning devices prior

to restart

Company-specific procedures

H d Id tifi ti d C ti


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Hazard Identification and Correction

The lock-out process begins before the actual work

starts

All sources of energy and all potential hazards

must be identified and controlled before any workbegins

The lock out process includes a visual inspection mental


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The lock-out process includes a visual inspection, mental

inspection, and physical inspection of the work area

The electrician will be helpful in identifying all electricalenergy sources--you cant see whats going through a wire-

-dont take chances--have all energy sources verified and

confirmed

You cant lock-out an accident after it starts--the time to

take all precautions is before the work begins

Notification of Impending Work


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Notification of Impending Work

Notify any and all employees who may be affected

by the impending shut down of equipment of whatis about to occur--you do not need to cause any

upstream or downstream surprises (or accidents)

Have a team meeting with all other employees

who will be part of the work to standardize and

confirm what is to be done and why

Identification/Isolation of


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Identification/Isolation of

All Energy Sources

All energy sources (both live and stored energy)must be identified, located, and targeted for lock-

out

Lock Out/Tag Out


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Lock-Out/Tag-Out

All Energy Sources

All energy sources must be deenergized andlocked out

Lock electrical energy sources at main sources

If there is more than one energy source, it needs

to be locked-out

All persons participating in the work must attach their


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All persons participating in the work must attach their

own personal lock to all energy sources--that may mean

each person needs more than one lock

Lock-out hasps are a practical and convenient way for

more than one person to attach his/her lock to an energy

source

Each persons lock should have a unique and individual

key--no common keys

Each energy source that is locked out must be


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Each energy source that is locked out, must be

tagged, advising of the work, and the dangers of

trying to start the machine--the tag must be signed

by all persons who have a lock attached

The key(s) to the lock should be kept in the

personal possession and under the personal controlof the person who attached the lock

Verification/Testing of


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Verification/Testing of

All Energy Sources

Verify that all electrical energy is controlled byattempting to start the machine


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Replacement of All Guards


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Replacement of All Guards

and Safety Devices

Replace all guards after work is completed andbefore the equipment is reenergized


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Sounding of All Appropriate Alarms/Warning


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Sounding of All Appropriate Alarms/Warning

Devices Prior to Restart

After all guards have been replaced, all personshave been accounted for, and all upstream and

downstream workers advised of the impending

restart, sound all warning or start-up alarmsbefore actually restarting the equipment

Company-Specific Procedures


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Company-Specific Procedures

The way you obtain your own personal lock is:

Lock-out hasps are located:

The procedure to follow at this facility to prepare

for a lock-out is:

The types of equipment at this facility that require

energy control are:

Equipment at this facility that has more than one


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Equipment at this facility that has more than one

electrical energy source is:

The actual lock-out procedure at this facility is:

The procedure to follow at this facility if you are

relieving someone and that person has a lockattached is:

The procedure to follow at this facility if/whenusing a box-system lock-out is:


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Causes


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Causes

Review of MSHA fatalgram or fatal accident

report involving energy control

Review of company incident reports

Corrections/Lessons Learned


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Corrections/Lessons Learned

Analysis of MSHA fatalgram or fatal accident

reports involving energy control

Review of company incident reports

Prudent Safe Work Practices


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Prudent Safe Work Practices

If you have the slightest doubt, concern, or confusion

about any part of the lock-out process--STOP--do notcontinue--ASK the supervisor--have your issues addressed

to YOUR satisfaction before continuing

Once a piece of machinery has you in its grasp, its verydifficult to start the lock-out process--that is why all

energy must be controlled before starting work

Hazardous energy control is not a gray-area subject--it

is not debatable--it must, and it will, be part of regular

work procedures at this facility because it is literally a

matter of life and death

If you will be part of the work, you must be part of


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If you will be part of the work, you must be part of

the lock-out process

You must have your own personal lock(s) andkey(s)

Never pass your lock or key off to somebody else,

or accept theirs

You and you alone must put on and take off yourown lock

Keep your key(s) in your own personal control and

ossession

Never remove any lock that belongs to anyone


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Never remove any lock that belongs to anyone

else--you are in control of your lock--they are in

control of their lock

Remember that there may be numerous types of

energy to control on one piece of equipment

Consult the electrician to identify all electrical

energy sources

Lock-out and tag-out all electrical energy sources-

-this may mean that you need more than one

personal lock

Have a team meeting with coworkers to review the


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Have a team meeting with coworkers to review the

lock-out procedure before starting the job

Block and support any and all parts andcomponents that could fall, slide, or roll onto you

Test all energy sources to verify that they are

deenergized

Do not remove guards for any reason without

locking out

Replace all guards and sound all warning alarms

before reener izin

Regularly review your company energy control


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Regularly review your company energy control

procedures--always be alert for ways to improve

the program--lives are on the line

Ask questions--get answers--know, understand

and follow energy control procedures at all times

Instead of thinking about the time you may save

by not locking out, think about the time you may

lose--forever is a long, long time

Several possible last words regarding hazardous


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Seve poss b e s wo ds eg d g dous

energy control

I thought someone else locked it out

I never thought it would start

Weve done it before without locking out

Lock out takes too much time


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References


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Florida Department of Environmental Protection, U.S.

Department of Labor. Mine Safety and Health

Administration. Lock out and Tag Out for Safety.Videotape. Cat. No. VC-852. Beckley, WV: National Mine

Health and Safety Academy, 1994.

Title 30 Code of Federal Regulations. Part 56, Subpart C,

Fire Prevention and Control. Washington: U.S.Government Printing Office.

U. S. Department of Health and Human Services. Center

for Disease Control and Prevention. National Institute for

Occupational Safety and Health. Preventing WorkerDeaths From Uncontrolled Release of Electrical,

Mechanical and Other Types of Hazardous Energy.

NIOSH Publications: 99-110. Cincinnati: NIOSH, 1999.

References


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U.S. Department of Labor. Mine Safety and Health Administration.

Electrical Hazards Awareness Program. Cat. No.: IG-65. Beckley,

WV: National Mine Health and Safety Academy, 1988.

U.S. Department of Labor.Occupational Safety and Health

Administration. Control of Hazardous Energy Sources

(Lockout/Tagout). OSHA Factsheet. Washington: OSHA.

U.S. Department of Labor.Occupational Safety and Health

Administration. Control of Hazardous Energy Sources

(Lockout/Tagout). OSHA Publication: Unnumbered. Washington:

OSHA Rev.1997.

GraphicsSafety Services of Texas, Safety Clipart. Austin, TX 2000.

U. S. Department of Labor. Mine Safety and Health Administration.

Documents

Control of Hazardous Energy(PSU-DHCmod)