PSU Lockout/Tagout Training for Authorized Employees

1. PSU Lockout/Tagout Training for Authorized Employees www.ehs.psu.edu

2. Objectives • Clarify requirements of PSU Lockout/Tagout (LOTO) Program • Ensure everyone is aware of their role within LOTO Program • Provide an opportunity to discuss concerns related to LOTO Program

3. Training Outline • How Do Injuries Occur During Servicing? • What is LOTO? • Types of hazardous energy • When should LOTO be applied? • Energy isolation devices • LOTO Basics • General LOTO procedure at PSU • Special Situations • “Safe or Unsafe?” Exercise

4. I. How Injuries Occur During the Servicing of Equipment? • BLS study on injuries while servicing equipment revealed: • 80% failed to turn off equipment • 10% equipment activated by someone else • 5% failed to control potential energy • Most of remaining 5% disconnected power but failed to verify effectiveness

5. II. What is LOTO? • “LOTO” is a technique used to prevent energy from being released during the servicing of equipment. This is accomplished by placing locks on energy isolation devices prior to starting work.

6. Types of Hazardous Energy • What types of hazardous energy are subject to LOTO?

7. Electrical Pneumatic Hydraulic Mechanical Thermal Chemical Radiation Steam Spring-Driven Suspended Parts Types of Hazardous Energy  Some energy sources can be turned on/off.  Others can only be dissipated or controlled.

8. Potential Energy vs. Kinetic Energy Potential energy can be converted to kinetic! Goal of LOTO is to achieve “Zero Energy State”

9. Adjusting Inspecting Modifying Replacing parts Tool changes Clearing jams Lubricating Cleaning When is LOTO applied? “…during the servicing of equipment”. There are some situations where LOTO is not required…

10. Exceptions to LOTO • Normal production operations • Routine, repetitive, & integral to production • Guards/safety devices not bypassed • Body part not placed in the point of operation or other dangerous area during machine cycle • Need to use alternative measures for protection • Cord & plug connected equipment • Plug is only source of energy • Plug is under continuous control of one person

11. Examples: Electrical disconnect switch Electrical breaker switch Hydraulic valve Pneumatic valve Line valve Pushbuttons, selector switches, and other control circuit devices are NOT energy isolation devices. Energy Isolation Devices “…accomplished by placing locks on energy isolation devices…” Device that physically prevents the transmission or release of energy

12. Review of LOTO Definition • “LOTO” is a technique used to prevent energy from being released during the servicing of equipment. This is accomplished by placing locks on energy isolation devices prior to starting work.

13. III. LOTO Basics All employees fit into one of the following LOTO roles: • “Authorized employee” • Services equipment & authorized to apply LOTO. • “Affected employee” • Operates or uses equipment being serviced under LOTO. • “Other employee” • Works in an area where LOTO being used.

14. LOTO Basics • Preferred means of controlling hazardous energy at PSU is LOCKOUT IN CONJUNCTION WITH TAGOUT. • Each isolation point must have both a lock and a tag attached to it. • Locks must be standardized & used only for LOTO. • Tags must indicate lock holder & date of application.

15. IV. General PSU LOTO Procedure STEP 1 ID Energy Sources STEP 2 Notify Others STEP 3 Shutdown Equipment STEP 4 Isolate Equipment STEP 5 LOTO Equipment STEP 6 Release Stored Energy STEP 7 Verify Isolation STEP 8 Perform Servicing STEP 9 Release from LOTO

16. Step 1: ID All Energy Sources • Know types & magnitude of energy associated with equipment. • ID all energy sources feeding the equipment (including potential energy). • Gather appropriate control devices. • Clarify any questionable identification of energy sources before proceeding.

17. Step 2: Notify Others • Verbally notify all “affected” and “other” employees of impending shutdown. • Not all equipment will have someone “assigned” to it.

18. Step 3: Shut Down Equipment • Use normal stopping procedures to shut down equipment. • Push “Stop” button, open toggle switch, etc.

19. Step 4: Isolate Equipment • After shutdown, operate all energy isolation devices so equipment is disconnected from energy sources. • Turn electrical disconnect to “OFF” position; open circuit breaker; close valve, etc.

20. Step 5: LOTO the Equipment • Attach locks & devices to each isolation point. • Tag must accompany each lock. • Good idea to also tag point of operation if located remotely from isolation points. • What if equipment won’t accept a lock?

21. Step 6: Release Stored Energy • Ensure all potential or residual energy is controlled.  Block elevated parts.  Block/release springs.  Relieve system pressure.  Drain fluids.  Vent gases.  Allow system to cool.  Discharge capacitors.  Stop rotating flywheels.

22. Step 7: Verify Isolation • Before any servicing begins, verify effectiveness of LOTO. • Use normal starting procedure or otherwise verify “Zero Energy State”. • Return controls to “OFF” position after testing. • Verification is the step which is most frequently skipped during evaluations.

23. Step 8: Perform Servicing • Complete required service work. • Avoid doing anything that could potentially reactivate the equipment. • OK to interrupt LOTO, but must be reapplied if servicing is to continue.

24. Step 9: LOTO Release • All locks, tags, & devices removed by same person who applied. • Remove all tools from equipment area. • Replace all machine guards. • Verbally inform all “affected” & “other” employees that LOTO is complete. • Ensure area is clear prior to restart.

25. V. Special Situations • Group LOTO • Each employee applies own locks/tags to each isolation point. • EHS must OK alternative procedures. • Shift changes • Oncoming employee attaches locks/tags prior to outgoing employee removing theirs. • EHS must OK alternative procedures. • Lock removal procedure • Supervisor must be notified if lock owner not present. • Use Appendix C of program to document removal.

26. Summary • All hazardous energy sources must be controlled (kinetic & potential). • Control via energy isolation device (do not rely on control circuit). • Only use designated lock for LOTO. • Tags must accompany all locks. • Nine-step general procedure – remember to verify isolation. • Protection must be ensured during special situations.

27. Any Questions?