Lockout Tagout Tryout (LOTO)

A recent incident… An installer was dispatched out on Saturday to deliver a pump to a customer (City of Colfax).  This pump was to replace a pump that the customer said was "worn out".  It is a back up pump to the customers pump that was pumping treated sewage.  The customer met the RFR employee at the jobsite and asked him for assistance in swapping the pump out, so the employee decided to help him.  (the original project was just a delivery)  The customer stated that there should not have been any pressure on the line, but come to find out there was some pressure on the discharge line, so as soon as they took the wrench to the clamp, it sprayed out a small amount of the treated sewage.  The RFR employee got hit in the chest and face.  After a brief spray, the clamp was tightened, closing off hose. 

A recent incident… Teammate grabbed the middle of the hose and another grabbed the end of the hose preparing to place the hose.   In the process the hose slipped from one Teammates  hands, striking the other in the face.  The injury was a laceration to the mouth requiring sutures.

It was one of us, and could have been any of us It was one of us, and could have been any of us. It is about our family, our brothers and sisters, it is about going home safe!

http://www.youtube.com/watch?v=IHgKhOXHIYM

The purpose of the Lockout Tagout Program is to protect you. Rain for Rent incidents include employees being sprayed with untreated sewage, chlorine and other chemicals while working on systems they thought to be under no pressure.

Application of LOTO When an employee is doing any of the following: Remove or bypass a guard or other safety device (i.e. bandsaw blade replacement) Put any part of his or her body into an area on a machine or piece of equipment where work is performed (i.e. pump or engine maintenance) Is in an associated danger zone during a machine operating cycle (i.e. installing or removing a piping system)

When Else to Consider Hazardous Energy The Human Factor What incidents have we had where the human factor was the energy source that caused injury? One person holding a pipe when another lets go We have had several injuries where one person drops the pipe when the other is not prepared Other injuries include pulling a bend on a pipe and accidently letting go Pushing hard on a wrench when it gives out Attempting to lift or move a heavy or awkward load What else can you think of? What is our plan to protect ourselves?

Types of Energy Human Electrical Mechanical Chemical Thermal Hydraulic Pneumatic Gravity Other pressurized systems

Use of Locks & Tags Use only items that have been issued to you Never use another employees lock Your name must be clearly marked on your LOTO Lock. This can be done by Etching your name or employee number in the lock Using a tag that is attached to the lock It is recommended you also put your cell phone number on the lock as well.

6 Step LO-TO-TO Procedure Prepare for Shutdown Shutdown Equipment Isolate all Energy Sources Place Locks & Tags (Lock-out/Tag-out) Release Stored Energy Verify Equipment Isolation (Try Out)

Exceptions to LOTO Cord & plug connected equipment Plug is only source of energy Plug is under continuous control of one person

LOTO Equipment

Kits Fastenal part number 10743-06370

Locks Red Locks are for people. Every person who is working on the equipment or could be exposed to the hazard needs to be locked out using a red lock. Yellow locks are for equipment when using a LOTO Box

Lock labels Every personal lock (Red lock) must be labeled for who is using that lock. This can be done using a tag attached to the lock or by writing/etching on the lock. It is recommended that both a name and Phone number be placed on the lock

Group Lockout/Tagout Frequently more than one person will work on a piece of equipment. In such cases each person should attach his or her lock to the equipment. Hasps can hold several locks at a time. This protects everyone working on the equipment since the equipment can’t be energized until every lock has been removed.

Continued on next slide Group Lockout/Tagout Equipment can be locked out using a yellow equipment lock Equipment keys can then be placed in a LOTO Box Continued on next slide

Group Lockout/Tagout Personal locks can then be placed on the LOTO Box Additional Keys may be added to the LOTO Box as needed End result All employees are locked out on all equipment who’s keys are in the box. Each employee only needs one person lock to lock out several items

Cable System Open device and insert cable in direction of arrow. Note cable can be tightened, but not loosened, with locks applied.

Locking out a Pump OR The picture at bottom allows others to lock out without the need for the first lock to be removed.

Locking out a valve Many valves are designed to be locked out easily.

Locking Out Valves

Locking Out Valves Unable to get a hasp or lock in due to how far the hole is from the edge, a cable will work.

Valve Handle LO It is important that this device slides over the angled part of the valve. If this device will not, another LOTO device needs to be used.

Too big for what was used in the last slide Simple two piece device that slips over the handle

No place to lock out? The cable systems allow for a variety of valves.

Where to lock out

Stored Energy For systems that do not vent to atmosphere: Valves need to be installed to bleed off any residual energy Relief valves need to be installed anywhere pressure can accumulate and is not automatically relieved when the system is secured

Where to lock out

Where to lock out

Release from LOTO Inspect Area & Equipment Ensure all Machine Guards are in place Move tools away from equipment Inform others of pending startup Restore system connections Remove Locks & Tags Conduct normal startup

Lock Removal An employee may leave for the day and accidently leave a lock on; what do we do now? If a lock needs to be removed by anyone other than the owner of that lock Appendix C – Lock removal form MUST be used. (Recommended a copy of this form be kept in each vehicle) The purpose of the form is to contact the employee and ensure their safety prior to removing their lock. (This is why a phone number on each lock is recommended) Next slide has example of form

Lock Removal Form

Contractors ALL contractors on Rain for Rent property must follow LOTO procedures! Rain For Rent Employees must lockout before any contractor and must be the last to remove a lock. This prevents a contractor from disconnecting or energizing systems without Rain for Rent knowledge or presence.

In the back of the policy is a flow chart on how to conduct LOTO

FAQs If I need to reach into a fusion machine to clear out scraps, wipe the surfaces, or for some other reason do I need to lock out the machine? YES LOTO is required if you are going to be reaching into a pinch point on a fusion machine.

FAQs Can I just unplug a piece of electrical equipment? In some cases YES, so long as the power cord is the ONLY source of energy and it is under the direct control of the person doing maintenance. Examples Welder changing disk on 4’’ grinder Changing disk on bench grinder Maintaining portable drill press

FAQs Why cant I just take off the neg. terminal on the battery and stuff it down the battery box? Most equipment (like pumps) is bonded to the metal frame. Any contact with metal parts can re-energize the system. Always disconnect and LOTO the positive terminal with the terminal block. This ensures isolation.

FAQ What if I am the ONLY mechanic to work on a pump? Do I still need to LOTO? YES. All employees must be protected from hazardous energy. Including YOU.

FAQ Is LOTO ONLY for protecting people? That is the primary concern, but LOTO is also useful to protect equipment and the environment. Starting a vehicle or equipment without oil or missing parts Breaking apart a pipeline and causing a spill Starting a pump with pipeline unfinished and valves open

FAQ What does it mean to ‘Verify’ isolation? After following your physical LOTO procedures, try the equipment to ‘verify’ they DO NOT operate. Turn on the switches Try the tools Turn the keys Try the valve handles

Appendix B – LOTO Form & Plan For complex projects Appendix B is a tool to help plan and communicate what is needed for LOTO on that project.

Summary Locking out is a requirement! All hazardous energy sources must be controlled and stored energy released Control via energy isolation device (LOTO) Only use designated locks for LOTO All personal locks need to be labeled for whose lock it is Remember to verify isolation Ensure area is clear before restarting equipment

They are counting on YOU

Additional Resources LOTO hard hat stickers LOTO Posters http://www.grainger.com/Grainger/BRADY-Hard-Hat-Labels-LOTO-Authorized-15Y471?Pid=search LOTO Posters http://www.grainger.com/Grainger/BRADY-Training-Poster-1D302?Pid=search