Introduction

Introduction

How to Use This Training Program To navigate through this training program, use your left mouse button to click on the green left or right buttons. Clicking on the left button will take you back one screen, while clicking on the right button will take you forward one screen. A “Review" screen will follow the current screen. Review screens ARE NOT scored, but are designed to help you learn the material being presented so that you will do well on the course test. On some screens you will see yellow words. These words are very important and each is defined so that you will learn the language of lockout, as well as the concepts and practices related to working safely at Spancrete Group, Inc. locations. Finally, you will see some yellow words that are underlined. Click the left mouse button on these items to reference the Spancrete Lockout program or additional information about the underlined word. Take a moment now to explore this page and its links. We hope you enjoy this training course, and good luck. When you are ready, click on the start button. START

What do I need to know? • The Spancrete Lockout/Tagout Safety Policy and Procedures and its intent. • The operations and activities covered. • Who can lockout equipment and machinery • The types of energy sources. • The types of lockout devices that are available and where they are located. • When to lockout. • The sequence of lockout as listed in your location’s procedures. • What to do when machines and equipment cannot be locked out. • The procedure to re-energize machines and equipment. • What to do when more than one person is required to lockout on the same piece of equipment. • The procedure for when and how to remove the lock of another employee.

Why Is Lockout/Tagout Important? • This practice helps safeguard employees from hazardous energy while they are performing service or maintenance on machines and equipment. • The OSHA standard 29 CFR §1910.147, identifies the practices and procedures necessary: • a written program and lockout procedures, • shut down and lockout or tagout of machines and equipment, • employees training in their role in the lockout/tagout program, and • periodic inspections conducted to maintain or enhance the energy control program.

What Is The Purpose Of The Spancrete Lockout Program? • Our procedureis designed to ensure the safety of our employees when working on and/or around equipment and machinery during: • set-ups • corrective maintenance • scheduled maintenance • installation of equipment, and • removal of equipment • The scope of our program covers all Spancrete employees: • full time • part time, or • temporary agency employees • Our program also covers all contractors performing work at all division locations and job sites.

Review • The Spancrete Lockout Program is designed to ensure your safety when working on and/or around equipment and machinery during: • set-ups • corrective maintenance • scheduled maintenance • installation of equipment, and • removal of equipment True False

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Who can perform a lockout? • There are three classes of employees: • Authorized employees: An employee who has responsibility to lock or tag machines or equipment in order to perform servicing or maintenance. • Affected employees: An employee who is required to use machines or equipment on which servicing is performed under the Lockout/Tagout standard or who performs other job responsibilities in an area where such servicing is performed. • Other employees: All employees who are or may be in an area where energy control procedures may be utilized. • At Spancrete facilities, only authorized employees can perform a lockout.

What activities or operations are covered? • Any servicing and/or maintenance of machines or equipment when the source of energy to the machines or equipment is electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy. • Constructing, installing, setting up, adjusting, inspecting, modifying, maintaining and/or servicing machines or equipment, including lubrication, cleaning or unjamming of machines or equipment, and making adjustments or tool changes, where Spancrete’s employees could be exposed to the unexpected energization or startup of the equipment or release of hazardous energy.

Review At Spancrete facilities only authorized employees can lockoutmachines or equipment to perform servicing and/or maintenance. True False

What are the sources of energy? A survey was done at each facility to locate and identify all energy sources and isolating devices. Here are some important definitions to know. Energized: Machines and equipment are energized when they are connected to an energy source or they contain residual or stored energy. Energy source: Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy.

Electrical Mechanical Hydraulic Pneumatic Thermal Chemical Gravity Return to training

What are lockout devices? Lockout device: Any device that uses a positive means, such as a lock, blank flanges and bolted slip blinds, to hold an energy-isolating device in a safe position, thereby preventing the energizing of machinery or equipment. At our facilities, you can find the lockout devices stored in the lockout center.

Plug out Valve Devices Circuit Breaker Device What are Energy-Isolating devices? Energy-isolating device: A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following: A manually operated electrical circuit breaker; a disconnect switch; a line valve; a block; and any similar device used to block or isolate energy. Push buttons, selector switches and other control circuit type devices are not energy isolating devices.

Review Lockout devices and energy-isolating devices should be used on all lockouts to prevent the start-up of machines or equipment and to prevent the unexpected release of energy. True False

When do I lockout? You must lockout before you begin any servicing or maintenance activities where the unexpected energization, (start-up or release of stored energy) could cause injury. Procedures for locking out equipment and machinery are attached at the control panel. Information in the procedure will provide the location of energy sources, the magnitude of energy, the isolation devices, and the sequence required to shut down and restart the machine or equipment. A good rule of thumb is: whenever the guarding is removed, or by-passed, or any part of your body can come in contact with the working parts during service/maintenance lockout must be done! Basic Rules For Using Lockout Or Tagout System Procedure At Spancrete Facilities

What is the shut-down sequence? • If there are employees in the area, inform them that the equipment will be taken off line for maintenance, repair, service, etc. • If the machine is operating, shut it down by the normal stopping procedure (depress stop button, open toggle switch, etc.). • Operate the switch valve, or other energy isolating device(s) so that the equipment is isolated from its energy source(s). Stored energy (such as that in springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, etc. • Lockout and/or tagout the energy isolating devices with assigned individual lock(s) or tag(s). • After ensuring that no personnel are exposed, and as a check on having disconnected the energy sources, operate the push button or other normal operating controls to make certain the equipment will not operate. • CAUTION: Return operating control(s) to "neutral" or "off" position after the test. • The equipment is now locked out or tagged out.

What if I have to leave before service is finished? If you are involved with a lockout procedure and must leave the job before completion you should obtain a department lock, replace your lock with the department lock, and inform your supervisor that you are leaving and have replaced your lock with the department lock. Similar procedures are followed for shift or personnel changes at our facilities. In all cases communication is the key and the rule. You must inform your supervisor that a change of personnel or that you are leaving the facility.

Review After you shut-down and lockout the machine or equipment it is not necessary to test the control switches to see if they will still operate the machine? True False

What if we have to call in an electrician? Periodically, it may be necessary to use contractors and/or outside personnel, such as an electrician, to perform service or maintenance. All necessary information about our program and the contractor’s program must be exchanged. When contractors or outside personnelperform service or maintenance on the grounds of a Spancrete Industries, Inc. or subsidiaries facility or job site, the authorized Spancrete employee, responsible for their work activity. must have the contractor’s representative sign a Safety Lockout/Tagout Outside Contractors Acknowledgement.

What applies when two or more people work on a machine? When more than one person is required to lockout or tagoutequipment, each shall place his/her own personal lockout device or tagout device on the energy isolating device(s). If the energy isolating device(s) can only accept one locking device, then a hasp must be used to insure continuity in protecting everyone on the crew performing the service or maintenance. The employee initiating the lockout (primary employee) should place his/her personal lock in the upper right hand position. All other locks (contractors too) would be placed below the primary lock.

Review When more than one person is needed for a lockout each person must place his/her personal lock and a tag on the energy-isolating device. True False

What’s the Procedure for Removal of Locks and Tags? • Before your lockout or tagout devices are removed and energy is restored to the machine or equipment, you must take the following actions or observe the following procedures: • Inspect the work area to ensure that non-essential items have been removed and that machine or equipment components are intact and capable of operating properly; • Check the area around the machine or equipment to ensure that all employees have been safely positioned or removed, • Make sure that locks or tags are removed ONLY by those employees who attached the locks or tags; and • Notify affected employees after removing locks or tags and before starting equipment or machines.

What happens if a Lockout procedure changes? The rule requires that a periodic inspection or audit of each procedure, be performed at least annually to assure that the lockout procedures continue to be implemented properly and that our employees are familiar with their responsibilities under those procedures. At Spancrete’s facilities, It is the responsibility of the Plant Manager to periodically conduct audits to ensure compliance with the Safety Lockout/Tagout procedure.

The audits are to be performed on a regular basis at least annually. A copy of the audit report shall be forwarded to the Safety Director. • Any deviations to the established procedures found during the audit could result in disciplinary action, up to and including termination. • All deviations or inadequacies shall be reported and the procedures shall be changed or corrected as necessary.

Review The lockout procedure for each piece of Spancrete equipment must be certified annually. True False

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This procedure establishes the requirements for the lockout or tagout of energy isolated devices. It shall be used to ensure that the machine or equipment are isolated from all potentially hazardous energy, and locked out or tagged out before employees perform any servicing or maintenance activities where the unexpected energization, start-up or release of stored energy could cause injury. PURPOSE Return to training

Appropriate employees shall be instructed in the safety significance of the lockout (or tagout) procedure and shall sign a training acknowledgement form (name(s)/job title(s) of employees authorized to lockout or tagout). Each new or transferred affected employee and other employees whose work operations are or may be in the area shall be instructed in the purpose and use of the lockout or tagout procedure. Responsibility Return to training

Make a survey to locate and identify all isolating devices to be certain which switch(s), valve(s) or other energy isolating devices apply to the equipment to be locked or tagged out. More than one energy source (electrical, mechanical, or others) may be involved. Preparation For Lockout Return to training

Notify all affected employees that a lockout or tagout systems is going to be utilized and the reason therefore. The authorized employee shall know the type and magnitude of energy that the machine or equipment utilizes and shall understand the hazards thereof. • If the machine is operating, shut it down by the normal stopping procedure (depress stop button, open toggle switch, etc.). Sequence Of Lockout or Tagout System Procedure More

Operate the switch valve, or other energy isolating device(s) so that the equipment is isolated from its energy source(s). Stored energy (such as that in springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, etc. • Lockout and/or tagout the energy isolating devices with assigned individual lock(s) or tag(s). Sequence Of Lockout or Tagout System Procedure More

After ensuring that no personnel are exposed, and as a check on having disconnected the energy sources, operate the push button or other normal operating controls to make certain the equipment will not operate. CAUTION: Return operating control(s) to "neutral" or "off" position after the test. • The equipment is now locked out or tagged out. Sequence Of Lockout or Tagout System Procedure Return to training

In the preceding steps, if more than one individual is required to lockout or tagout equipment, each shall place his/her own personal lockout device or tagout device on the energy isolating device(s). When an energy isolating device cannot accept multiple locks or tags, a multiple lockout or tagout device (hasp) may be used. If lockout is used, a single lock may be used to lockout the machine or equipment with the key being placed in a lockout box or cabinet which allows the use of multiple locks to secure it. Each employee will then use his/her own lock to secure the box or cabinet. As each person no longer needs to maintain his or her lockout protection, that person will remove his/her lock from the box or cabinet. Procedure Involving More Than One Person Return to training

All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy-isolated device where it is locked or tagged out. Basic Rules For Using Lockout Or Tagout System Procedure More

If a device cannot be locked out due to the unavailability of a lockout handle or shutoff, a tag is affixed at the the point of control utilizing a nylon cable tie requiring a force greater than 50 pounds to cause its removal. • The tag’s positioning should be obvious to anyone attempting to operate the equipment. • The operator's name, time, and date started should be displayed on the tag. • The tags are a warning to others that work is in progress and to leave equipment/energy source control off (i.e., DO NOT START, DO NOT OPERATE, etc.). Basic Rules For Using Lockout Or Tagout System Procedure Return to training

Periodically, it may be necessary to utilize contractors and/or outside personnel to perform service or maintenance. When contractors or outside personnel perform service or maintenance on the grounds of a Spancrete Industries, Inc. or subsidiaries facility or job site, a Safety Lockout/Tagout Outside Contractors Acknowledgement form is signed by the representative of the outside contractor and the authorized Spancrete employee responsible for their work activity. Outside Contractor Lockout/Tagout Guidelines More

The designated Spancrete employee who is responsible for the project ensures the following is adhered to when dealing with contractors or personnel. • Necessary lockout/tagout information is exchanged between ALL the parties involved in the project. • Outside contractor or personnel reviews and signs the Safety Lockout/Tagout Outside Contractors Acknowledgement form. • The signed form indicates all the appropriate lockout/tagout information was exchanged between Spancrete and outside contractor or personnel. • The form is maintained with the project file. • Outside contractor or personnel understand that failure to follow these guidelines could result in their not being permitted to continue working with Spancrete. Outside Contractor Lockout/Tagout Guidelines Return to training

If an authorized employee involved with a lockout procedure must leave the job before completion, because of job reassignment or shift change, the following steps must be taken. • The employee should remove his/her personal lock and replace it with a department lock • If the employee who is leaving will be replaced by another employee, the replacement employee will place his/her lock into correct lockout position. Shift or Personnel Changes Return to training

It is the responsibility of the Plant Manager to periodically conduct audits to ensure compliance with the Safety Lockout/Tagout procedure. • The audits are to be performed on a regular basis at least annually. A copy of the audit report shall be forwarded to the Safety Director. • Any deviations to the established procedures found during the audit could result in disciplinary action, up to and including termination. • All deviations or inadequacies shall be reported and the procedures shall be changed or corrected as necessary. Audit Return to training

Introduction

Introduction

Presentation Transcript

Introduction to introduction to introduction to … Optimization

INTRODUCTION/ INTRODUCTION

Introduction

INTRODUCTION

Introduction

Introduction