Comprehensive Lockout/Tagout Program for Safety Control - Mandatory Training

Control of Hazardous Energy (Lockout/Tagout) Program April 9, 2015 Mandatory Training for Administrative and Supervisory Employees Richard Jolliff, MS, CSP Jenny Fuller, MS, CSP

Video: Accident without Lockout

Examples of Sources and Equipment Energy Sources Equipment Automated machinery Burner motors Compressor motors Dishwashers Electrical equipment/circuits Systems Elevators Heating, ventilation, and air conditioning • Hydraulic systems • Pneumatic lines • Pumps • Steam valves/lines • Vehicles • Water lines/piping • Pneumatic • Steam • Chemical • Thermal • Water • Electrical • Gravity • Hydraulic • Mechanical • Pressurized systems

1. Purpose • Establishes requirements, process, and administrative responsibilities • The Program adheres to applicable federal regulations (9/1/1989) • 29 CFR 1910.147 OSHA Control of Hazardous Energy (Lockout/Tagout) • Prevent Worker Injury • Provide Safe Work Practices

2. Scope • This program applies to personnel who are exposed to, work with, or supervise operations involving work with hazardous energies at West Virginia University main campus, regional campuses, and related WVU facilities and operations. • Employees • Students • Contractors • Others

Roles/Responsibilities Section 4

Responsibilities: Administration • Comply with applicable state and federal OSHA regulations • Provide resources to assure program implementation and continuance

Responsibilities: Department Directors/ Deans/Managers/Supervisors • Includes supervisory staff and academia overseeing students • Supervisors and leads of authorized employees will also have the responsibilities of authorized employees • Communicate to individual departmental employees requirements of the WVU Control of Hazardous Energy Program and ensure compliance

Responsibilities: Department Directors/ Deans/Managers/Supervisors • Attend scheduled LOTO Training • Ensure departmental employees receive applicable training prior to conducting hazardous energy control (LOTO) procedures • Assure Equipment Specific Procedure determinations are conducted and complete procedures for required equipment and processes

Responsibilities: Department Directors/ Deans/Managers/Supervisors • Conduct and/or ensure Periodic Inspections of the LOTO Procedures for compliance • Provide On-the-Job Training (OJT) to department authorized employees using: • Employee On-the-Job Training Checklist • Specific Energy Control LOTO Procedures • Return employee training records to EHS within 24 Hours

Responsibilities: Department Directors/ Deans/Managers/Supervisors • Designate authorized employees • Ensure authorized individuals are provided effective information, resources, and training • Initial Assignment • Upon Addition or changes to: • Machines • Equipment • Processes • Procedures • Program

Responsibilities: Department Directors/ Deans/Managers/Supervisors • Provide standardized energy isolating equipment, standardized locks, tags, and resources to control hazards • Provide authorization for emergency/abandoned lock removal • Assure development of procedure utilizing the Lockout Tagout Procedure Form (Appendix B)

Responsibilities: Department Directors/ Deans/Managers/Supervisors • Maintain procedures within designated department • Ensure employees have access to the most recent version of the Lockout Procedure developed • Make Lockout/Tagout Procedures available for periodic inspections, safety and health audits, or regulator agency inspections

Responsibilities: Project Manager/WVU Personnel Hiring Third Party • Communicate the WVU LOTO Program requirements to all vendors/contractors • Communicate known hazards to vendor/contractor

Responsibilities: Responsibilities: Project Manager/WVU Personnel Hiring Third Party • Where contractors’ LOTO work may expose WVU employees: • WVU Affected Employees are clearly notified of hazards and operations and methods to minimize exposure • Conduct and/or participate in preplanning meetings prior to LOTO work • WVU employees must follow the WVU Control of Hazardous Energy Program at all times • LOTO activities must be coordinated with the WVU Project Manager and Affected Employees

Responsibilities: Environmental Health and Safety (EHS) • Develop & provide overall administrative support. • Review programs on an annual basis or as needed. • Assist WVU in selecting equipment as requested • Manage & schedule WVU Control of Hazardous Energy (LOTO) Safety Training. • Conduct Periodic Audits • Maintain documentation & records: • Training records • Periodic inspection form audits

Responsibilities: Safety and Health Extension (SHE) • Provide scheduled training • Assist in the Control of Hazardous Energy Program development and review • Assist departments in evaluating and determining LOTO procedures in coordination with EHS

Responsibilities: Authorized Employees • Attend training • Follow the Program • Know and understand the associated energy, related hazards, and methods to control the equipment that will be serviced and/or maintenance. • Complete LOTO using appropriate equipment and procedures • Inform affected and other employees of lockout and when re-energizing equipment • Use appropriate PPE • Report incidents or near misses to supervision AND EHS

Responsibilities: Affected Employees • Attend Training on the purpose and use of LOTO procedures • DO NOT attempt to energize equipment locked/tagged out • Inform supervisor of accidents, unsafe conditions, or unsafe work practices

Training Section 5

Training • Authorized Employees • Consists of 2 Parts: • Classroom/Regulatory • Departmental OJT • Affected Employees • Classroom or informative training focusing on awareness • Retraining • Reestablishes employee proficiency • Updates employees on new or changed conditions Documentation of ALL training is required to be sent to WVU Environmental Health and Safety

Training (Classroom) Authorized Employees Affected Employees Requirements of the LOTO Program in relation to Affected and Other Employees Prohibited actions Restarting equipment Cutting locks Etc. • Requirements of the LOTO Program • Examples of hazardous energy sources, types, magnitudes, and means for isolation • LOTO Devices • Purpose and use of procedures • Tagout Systems

OJT Specific LOTO Training • Provided by WVU Management/Directors/Deans/Supervisors • Provided to ALL Authorized Employees • Content includes: • Purpose and use of the program elements • Recognition of hazards and controls • Equipment and device usage • Equipment Specific LOTO Procedures

Control of Hazardous Energy- Procedures/Process Section 6 Refer to Hand Out- LOTO Procedure

Control of Hazardous Energy Procedures/Process • WVU Personnel are ONLY permitted to work on de-energized equipment. * Exemptions may apply • In order to perform service or maintenance, the WVU LOTO Program must be followed. • Documented LOTO Procedures must be developed initially by an authorized employee/equipment specialist, and approved by the departmental supervision prior to work.

Control of Hazardous Energy Procedures/Process • A new documented procedure must be updated and approved by the department when there are process changes that impact the current LOTO procedure. • Procedures must be maintained and accessible for authorized employees and audits.

*Exemption: Circumstances requiring service or maintenance during trouble shooting and or energized operations require a written standard operating procedure and approval by the department Dean, Director, Manager, and Supervisor of that department.

Appendix B-1: Specific Engery Control LOTO Procedure Form (Frame 1 of 3)

Appendix B-2: Procedure Assistance Form

6.2 Lockout/Tagout Required Process • Whenever WVU personnel are exposed to potential hazardous energy, the following steps must be followed: 1. Notifications 2. Preparing for shutdown 3. Performing shutdown 4. Isolating equipment 5. Discharge of residual energy 6. Locking/tagging devices 7. Energy verification 8. Maintenance/Servicing 9. Restoring power

Temporary Removal of Lockout/Tagout Device • In situations in which lockout or tagout devices must be temporarily removed: • Clear the machine or equipment of tools and materials • Remove employees from the machine or equipment area. • Remove the lockout or tagout devices. • Energize and proceed with testing or positioning • De-energize all systems and reapply energy control measures per the documented LOTO procedure to continue the servicing and/or maintenance.

Removal of Lock/Tag by Supervisory Personnel • If a lock is abandoned or emergency situation arises, the supervisor of the authorized employee must make every attempt to contact that employee. To remove the lock, the supervisor of the authorized employee must follow the steps on the Abandoned Lock Removal Form (Appendix D)

6.3 Energy Control Procedures • Appendix B.1- Specific Energy Control Lockout/Tagout Procedure Form • Appendix B.2- LOTO Procedure Assistance Form

6.4 Lockout • Locks: • Be capable of withstanding their environment • Be standardized within the department in at least color, shape, or size. • Be substantial enough to prevent unintentional removal • Indicate the identity of the employee applying.

Use of Locks • Departmental Management and Authorized Employees will maintain a supply of appropriate lockout/tagout devices • Equipment used for lockout/tagout procedures must be kept in designated areas and used only for lockout/tagout operations • Locks will remain on equipment during the service and maintenance operations with the exception of shift changes and troubleshooting • Locks are required to be applied and removed by authorized employees who applied the lock

6.5 Group LOTO • An authorized employee must take primary responsibility for the employees working under the protection of a group LOTO device. • The primary authorized employee determines the exposure status of individual group members • WVU employees and Contractors must use individual LOTO boxes for their respective designated authorized employees

Shift or Personnel Change • The Department Dean, Director, or Manager is to assure specific procedures are utilized during shift change to ensure continuity.

6.6 Tagout • Tagout Devices: • Standardized print and format for each department • Constructed and printed to withstand environmental conditions • Not deteriorate due to environment • Will warn against hazardous conditions • Will be substantial enough to prevent inadvertent removal • Attachments will be non-reusable, attachable by hand, self locking, and non releasable with a minimum unlocking strength of no less than 50 pounds

Tagout Operations Requirements • An approved tag will be placed on the hasp of each padlock used for the lockout • Tags are placed or applied by authorized employees conducting the LOTO operation to notify affected and other personnel. • At a minimum, the tags will contain the following information: • Authorized employee name • Date and time of lock operations • Phone number to reach employee in case of emergency

Tagout Operation (Used in Lieu of a LOTO Operation) * NOTE: Where equipment is capable of accepting a lock, a lock and tag must be used.

Tagout Operation (Used in Lieu of a LOTO Operation) • A tagout alone must be approved by the dean, director, or their designee of the department and the following requirements are to be met: • Procedures are written, available, communicated, and used that provide equal protection as a lockout operation • The tagout device is attached to the same location that the lockout device would have been attached and can be demonstrated that the tagout procedure will provide an equal level of safety

Tagout Operation (Used in Lieu of a LOTO Operation) • The authorized employee and supervisor must demonstrate full compliance with all tagout related provisions of the control of hazardous energy standard AND provide one of the following or equivalent safety measures: • Removal of an isolating circuit element, • Blocking of a controlling switch, • Opening of an extra disconnecting device, or • Removal of a valve handle to reduce likelihood of inadvertent energization

Comprehensive Lockout/Tagout Program for Safety Control - Mandatory Training