CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TRYOUT)

LOCKOUT/TRYOUT The OSHA Standard for the Control of Hazardous Energy (Lockout/Tryout) 29 CFR covers the servicing and maintenance of machines and equipment in which the unexpected start-up or the release of stored energy could cause injury to employees or equipment. OSHA says, “…employee shall verify that isolation and de-energization of the machine or equipment have been accomplished.” PCS Safety Policy 227

Common Definitions Stored Energy: Residual energy that needs to be released prior to performing work. May be in the form of: 1) Hydraulic or Pneumatic pressure 2) Pressure below atmospheric such as in vacuum systems 3) Compressed or extended springs 4) Potential energy due to gravity 5) Stored energy as in flywheels 6) Static electricity 7) Stored electrical in batteries or capacitors 8) Thermal energy due to residual heat or low temperatures 9) Residual chemicals in pipes which may cause thermal or pressure build-up.

LOCKOUT LOTOTO(Lockout/Tagout/Tryout or Testout): The placement of a lock and tag on the energy isolating device indicating that the energy isolating device shall not be operated until removal of the lock and tag in accordance with an established procedure. The equipment must be operated in a way as to prove there is no energy source or stored energy still present or, in the case of an electrical installation, an electrical meter is applied to verify the absence of electrical energy.

PCS:227- “Try,Lock,Try” The Try, Lock, Try Program prohibits the operation of a valve, switch or other equipment, that would endanger personnel. This procedure must be followed by all PCS employees and Contractors.

Following are some examples of TRY/LOCK/TRY SIF incidents since Jan 2014 with failure to verify energy isolation.

Workers asked that the pump be uncoupled from the motor. The operator had employees lock on to a Master LOTO for the system assuming the breaker had already been de-energized and verified as part of that LOTO. The outside operator did a worksite visit with the authorized lockout employees and pushed the start button to verify that the motor would not start. We uncoupled the motor from the pump. It was later found that the breaker was still energized. The permissives are what kept the motor from starting when tested. No injuries Did not verify isolation A lock box was in use for the multi location lock out, and the employees had personal locks and tags properly fixed to the lock box. Upon completion of the task, the lock removal process began and it was noted that (1) lock, which should have been in place for the fan was missing. During the shutdown, a lock box was taken "out of service" and the breaker lock for the fan was removed so it could be exercised periodically. The lock box was moved to the Foreman's office and a tag indicating "incomplete lock out" was installed. When the work at the unit resumed, the breaker lock for the fan was missed and a near miss card submitted. Did not verify isolation

What is isolation? Do you know how to isolate the energy sources? How will you verify isolation?

LOCKOUT/TRYOUT Scope and Application Covered Activities Constructing, installing, setting up, adjusting, inspecting, modifying, maintaining and/or servicing machines or equipment where employees could be exposed to the unexpected energization or release of hazardous energy

LOCKOUT/TRYOUT Scope and Application Lockout/Tryout rules apply (the equipment must be de-energized and locks must be applied to the energy- isolation devices) to servicing and maintenance activities when: The employee must either remove or bypass machine guards or other safety devices, resulting in exposure to hazards at the point of operation.

LOCKOUT/TRYOUT Preparation for shutdown Shutting down the equipment Equipment isolation Application of Lockout devices Release of stored energy Verifying equipment isolation

LOCKOUT/TRYOUT Performing the Work Look ahead and avoid doing anything that could reactivate the equipment. Don’t bypass the lockout when installing new piping or wiring.

LOCKOUT/TRYOUT Removing Locks Make sure the equipment is safe to operate by removing all tools from the work area and making sure the system is fully assembled. Safeguard all employees by conducting a head count to make sure everyone is clear of the equipment. Also notify everyone in the work area that lockout is being removed. Remove the locks and devices. Each device must be removed by the person who put it on.

LOCKOUT/TRYOUT Shift Changes If servicing lasts more than one shift, lockout/tryout protection must not be interrupted. Oncoming will hang their lock. Oncoming will then walk through lockout and verify it. Off going will then remove their lock.

LOCKOUT/TRYOUT Scope and Application Activities Not Covered Minor tool changes and adjustments, and other minor servicing activities that take place during normal operating production operations which are routine, repetitive, and integral to the use of that production equipment, as long as workers are effectively protected by alternative measures

LOCKOUT/TRYOUT QUESTIONS LOTO Notes