“Control of Hazardous Energy” 29 CFR 1910.147 Cummins Rocky Mountain Lockout / Tagout “Control of Hazardous Energy” 29 CFR 1910.147 Cummins Rocky Mountain

Purpose of Lockout/Tagout (LOTO) WHY LOCKOUT/TAGOUT? Cummins Rocky Mountain LOTO procedures are designed to prevent accidents, to protect employees and equipment from accidental start-up.

The “Fatal Five” Main Causes of Lockout/Tagout Injuries Failure to stop equipment Failure to disconnect from power source Failure to dissipate (bleed, neutralize) residual energy Accidental restarting of equipment Failure to clear work areas before restarting

Employee Categories AUTHORIZED EMPLOYEES These are employees who are allowed to perform energy control procedures. Training will include company approved energy control procedures, recognition of energy sources, and methods for isolation and energy control. AFFECTED EMPLOYEES These are employees that operate the equipment on which work is being performed. Training will include the purpose and use of the energy control procedures. OTHER EMPLOYEES These are all other employees that may work in an area where energy control procedures may be used. Training will include instruction on the energy control procedures and the restrictions relating to attempting to restart or reenergize equipment that is either locked out or tagged out.

Hazardous Energy Sources CHEMICAL – acids, corrosives, caustics THERMAL – steam, hot, cold HYDRAULIC – water, oil, liquids ELECTRICAL – AC/DC, generator, battery MECHANICAL – coiled springs, raised loads, moving parts PNEUMATIC – pressurized gas, compressed air

Equipment Requiring Lockout/Tagout at our Facility Produced by Hellman and Associates, Inc. 9/13/1999 Equipment Requiring Lockout/Tagout at our Facility 5 Ton Crane Air Compressor Bead Blaster Chassis Dyno Drill Press Fuel Pump Test Stand Hotsy Injector Test Stand As we said earlier, several machines in the plant use a combination of all of the energy sources listed above to perform the tasks they are designed for. (For example, see Slide). I would like to present a few examples of how several sources of energy can be present in one piece of equipment. (Show photographs of the above mentioned units, and describe the different types of energy sources present.) Respirator Training MSA’s SCBA

LOTO Definitions and Requirements LOTO is defined as the process of the authorized placement and administrative control of locks and tags used to ensure the protection of employees, equipment, and the environment. LOTO locks are used for physical control over an energy isolation device.

Energy Isolation Devices Used to control and isolate hazardous energy. They are mechanical devices that physically prevent the transmission or release of energy. circuit breakers disconnect switches valves Energy isolation devices are where we place the locks and tags. They are NOT locks or tags. These are the devices that prevent the transmission of hazardous energy to the equipment that requires work to be performed. ON OFF SYSTEM CONTROL SWITCH

Only individual circuit breakers can be locked out in a circuit breaker. If the whole panel was locked, circuits powering other equipment would be inaccessible.

Locks All our locks and tags for LOTO are standardized by shape, size or color Personally Controlled Lock Owner has only key No master key is allowed

Produced by Hellman and Associates, Inc. Hardware for LOTO 9/13/1999 Locks/Tags Locking plug caps Chains Wedges Blocks Blanks In lockbox, two problems: Key is in box and tag is missing. Respirator Training MSA’s SCBA

Locks vs Tags Locks are used to block the flow of energy. Tags are a warning to all employees not to turn the power on.

Lockout vs Tagout OSHA prefers lockout. If an energy isolation device will accept a lock, you MUST use a lock. In situations where a lock cannot be used, you may use a tag only. A tag does not provide the positive control of a lock. So it is important that we are all aware of the limitations of a tag.

LOCKED OUT This Lock/Tag may only be removed by NAME: _______________ DEPT : _______________ EXPECTED COMPLETION DATE: ________________ TIME: _________________ DO NOT OPERATE DANGER Tagout CAN BE USED in place of lockout if you can demonstrate that it will offer employee protection equivalent to that offered by lockout. Equivalent protection is demonstrated by the following safety measures: Removing an isolating circuit element; Blocking a control switch; Opening an extra disconnecting device; or Removing a valve handle. The tag must be attached at the same spot where the lockout device would have been found.

Examples of tags we use. Tag Characteristics: Withstand at least 50 pounds of force Not re-usable Self locking Attachable by hand

Applying Locks and Tags LOTO devices are to be attached by an authorized employee to each energy-isolating device. When a lockout device is used, it must be attached in such a way that it secures the energy isolating device in the “off” position. When a tagout device is used, it must be attached exactly where the lock would have been on the energy- isolation device-or as close to that point and in as obvious a position as possible. The tag must clearly indicate that the energy-isolation device must not be disturbed. (The tag should read DO NOT START, DO NOT OPEN, or DO NOT ACTIVATE)

LOTO is NOT Required When: Work is performed in cord and plug electrical equipment on which the plug is under EXCLUSIVE CONTROL of the employee performing the service or maintenance. Note: exclusive control means that the plug is: Physically in possession of or within arm’s reach of the person who performs the work, and In that person’s line of sight. Minor tool changes, when the on/off switch is under EXCLUSIVE CONTROL of the operator. For Example…

…Pedestal grinders

However, if you cannot immediately repair the ‘plug and cord’ equipment, it should be LOTO to prevent unintended startup. The above picture shows the plug to a pedestal grinder. Since the employee couldn’t repair it until the parts arrived, a LOTO plug cap placed was used.

LOTO Shutdown Procedure Steps to Apply LOTO Notification of employees involved or in the area and you will be shutting equipment down. Shutdown of all power sources. You may need to stop, block, or bleed the energy sources. Lockout and Tagout all energy sources. Verify the controls do not start machine and check the voltage. Verification among employees once the work has been completed. Inspect work area to ensure removal of non-essentials Employees safely positioned and notified Lockout/tagout removal (by employee who applied)

Produced by Hellman and Associates, Inc. 9/13/1999 Removal of Locks/Tags Only the maintenance employee performing the original repair can remove a lock. If employee is off-site, the supervisor may remove the lock under the following conditions. Verify that authorized employee is not at facility Make reasonable efforts to inform him or her Ensure that he/she knows of removal upon re-entering The only one authorized to remove a lockout and tag is the person who originally performed the lockout. If work goes over one shift or other workers are involved, a changing of locks must be performed with the consent of the original worker. If the original worker is not available, the Human Resources Manager has authorization to remove the lockout device with the consent of the original worker. Respirator Training MSA’s SCBA

Group Lockout Each employee performing LOTO work on equipment will have his/her own lock and tag at the energy isolation devices. When multiple employees are working on the equipment, a hasp may be used.

Produced by Hellman and Associates, Inc. 9/13/1999 Equipment Start-Up Clear equipment of tools and materials Re-install all guards Alert employees to stand clear Remove locks/tags Energize equipment Once the servicing of equipment is completed, the following steps should be followed: 1. Clear the area of tools and equipment and re-install all guards and shields; 2. Alert employees in the area to stand clear of moving machinery and parts; and 3. Start up equipment in order to verify that all sources of energy are being supplied back to the unit. Respirator Training MSA’s SCBA

Remember to re-install all guards after service is complete Remember to re-install all guards after service is complete!!!!! Otherwise, a serious hazard may be created.

Lockout/Tagout All lockout/tagout procedures are found through the link to Lockout / Tagout link on the Cummin’s safety website. If you have any questions on Lockout/Tagout, contact your supervisor or submit a question using the “ASK THE EXPERT” menu selection on this website.