The modern art of controlling hazardous energy.

Transcription

1 The modern art of controlling hazardous energy. TM

2 Lockout-Tagout is what we do. TM ESC is the world s largest company dedicated to lockout-tagout services. Your Path to Efficient Safety Basics for Compliance 3 OSHA s Eight Criteria 4 What Machines Need Procedures 5 Top Ten Fatal Mistakes 6 Why Choose ESC 7 Modern Methodology 8 Comprehensive Plan 9 Efficiency Statistics 10 Internal Audit Form 11 Compliancy Calculator 12 Other Resources 13

3 Basics for Compliance The purpose and intent behind the Control of Hazardous Energy has been around for decades. The minimum components needed for federal OSHA and all state OSHA standards are as follows: Corporate Policy The brains of the program that will keep everyone in check and establish rules that the company wants followed. Machine Specific Procedures Hazardous Energy Control procedures, often called Lockout-Tagout Procedures, must be developed for every piece of equipment unless it meets 8 specific criteria. Auditing Schedule All procedures and authorized employees must be audited at least on a 12 month cycle to ensure program integrity. Locks, Tags and Devices Locks, tags, and devices exclusively dedicated to controlling hazardous energy must be available as needed. Training Training must be provided to every person applying locks in the facility as well as others who are in the general vicinity. 3

4 OSHA s Eight Criteria *source: search (c)(4)(i) Procedures shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section. Note exception the employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist: (1) The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees; (2) The machine or equipment has a single energy source which can be readily identified and isolated; (3) The isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment; (4) The machine or equipment is isolated from that energy source and locked out during servicing or maintenance; (5) A single lockout device will achieve a locker-out condition; (6) the lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; (7) The servicing or maintenance does not create hazards for other employees; and (8) The employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance. IMPORTANT NOTE: ALL eight criteria must be met in order to be exempt from requiring a machine specific procedure. 4

5 What machines need procedures? In addition to the typical production and packaging equipment, some examples of other equipment types that require procedures: Exhaust Fans, Air Handler Units, Unit Heaters This style of equipment requires a procedure because it has electrical and kinetic energy. This particular equipment setup also does not have a local electrical disconnect (criteria 2) that can be readily identified and isolated. Welders, Plasma Cutters, Gas Cutter This style of equipment requires a procedure because it has electrical, Gas, and thermal. Welders are often overlooked when companies are assessing their LOTO compliancy; this can lead to a separate OSHA citation for each unit that does not have a specific procedure. Chiller Systems, Cooling Towers This style of equipment requires a procedure because they contain electrical energy, chilled water lines, glycol lines and kinetic energy from fan blades. Depending on the chiller system it may also contain a refrigeration loop. The complexity of the chiller systems and cooling towers water system results in having to lock out multiple valves. A detailed lockout procedure assists in the safe maintenance and repair of these systems. Clothing Washer, Dishwasher This style of equipment requires a procedure because it has electrical and water. In this example pictured, the washer has electricity, hot water, and two cold water inlets in addition to thermal energy. It has five sources total, but OSHA requires anything over two sources have a machine specific procedure. Boiler Systems, Condensate Return Tanks, Condensate Pumps This style of equipment requires a procedure because it has electrical, water, steam, natural gas and/or fuel oil, thermal energy and kinetic energy. Boilers can use electrical, gas, or fuel oil to change water into high pressure steam. Boiler systems need procedures due to the inherent hazards of such high temperatures and pressures. A proper lockout-tagout procedure for a boiler will completely isolate all incoming sources, identify and address any internal heat and pressure, and address the steam output valves so no feedback from the other boilers could possibly occur. Due to the high heat and high pressure, any steam-condensate tank or pump will also need a written lockout-tagout procedure. Grinders, Mills, Lathes, Drill Press This style of equipment requires a procedure because it has electrical and kinetic energy. Even though the picture shows one of the simplest pieces of shop equipment, OSHA requires a lockout-tagout procedure due to the residual energy from the grinding disks. Supply Pumps, Return Pumps, Booster Pumps This style of equipment requires a procedure because it has electrical and water/ product/chemical liquids. All types of pumps required lockout-tagout procedures so safe preventative maintenance or repairs can be conducted. In addition to the electrical isolation, the suction and discharge of each pump needs to be locked out. The fluids that are being transported by the pump (hot water or chemicals) may be hazardous to the mechanic. Proper lockout of the suction and discharge lines can prevent property damage from occurring if the lines remained open while another machine introduces pressurized fluid into the system. 5

6 6 Top Ten Fatal Lockout-Tagout Mistakes Lockout-Tagout (LOTO) has been in the top ten most cited regulations for over 15 years and the trend is even more focus by OSHA. Last year, LOTO citations went up over 65%. Avoid the fatal ten mistakes by paying special attention to the following: 1 2 Lack of Machine Specific Procedures (c)(4) Not identifying all energy source or adjacent equipment (b) and (c)(4) 9 10 Lack of Training of all your employees (authorized, affected, other) (c)(7) Not performing annual audits of procedures and 10 employees (c)(6) 3 4 Wrong use of tags & locks (c)(5)(ii) 5 6 Not understanding when to administer lockout (major vs. minor maintenance) No corporate policy No oversight or plan for continuous improvement/review Working under someone else s lock (d) Duplicate keys existing just use bolt cutters to send the right message

7 Why choose ESC Services? Lockout-Tagout (LOTO) has been in the top ten most cited regulations for over 15 years and the trend is even more focus by OSHA. Last year, LOTO citations went up over 65%. Avoid the fatal ten mistakes by paying special attention to the following: Lockout-tagout is Our turn-key solution enables you to own the program. All projects are completely customizable. Our dedicated team allows for amazing turn-around times. our core focus; it is what we do. ESC specializes in lockout-tagout compliance. Full-time mechanical engineers are used to assess your equipment, take pictures of the isolation points, and create your unique machine-specific lockout-tagout procedure. ESC generates over 30,000 lockout tagout procedures annually and oversees annual audits on a pool of over 250,000 procedures annually. At project completion, you will be provided with machine specific procedures mounted at the equipment point of use along with graphical tags labeling every isolation point. You ll receive the actual template used to create all of your procedures as well as digital source files for each procedure created. If your equipment changes, simply open the file on any computer, make the change and print a new copy. ESC offers templates, ideas, and concepts that revolve around the industry s best practices; however, we listen too. We understand that each company, and each location has its own unique challenges and we customize your program to meet or exceed your needs. This ensures you get not only a compliant program, but a program that you will use for years to come. Because lockout-tagout is ESC s core focus, we have refined the process and deliver a highly polished world-class program. Our lockout-tagout programs are typically completed in a quarter of the time it would take to create the program with in-house resources. What might take months or years in-house, usually only takes ESC a few weeks with our dedicated expert engineering staff. ESC was selected to receive the CSXT Industrial Hygiene Project Excellence Award because they were able to respond to a special need in a unique and cost effective way that significantly improved workplace health & safety at our facilities. Director of Industrial Hygiene CSX Transportation 7

8 Modern Methodology 8 Graphical Procedures and Tags A visual program is an efficient program. Graphical procedures have been shown to reduce the time it takes to lock out a piece of equipment by 50% or more. Cloud Platform and Open Source Files With a cloud based web portal supporting open source MS Excel files the entire solution is intuitive and future proof. Tablet Access and Interactivity With off the shelf tablet hardware and an award winning application, ScanESC, the entire lockout-tagout program can be accessed and maintained up to 85% more efficiently.

9 Comprehensive Plan Every company deserves a plan customized to their exact needs. A comprehensive hazardous energy control plan must include all the basics needed for compliancy, plus ways to ensure the system is properly maintained and embraced by everyone. A long term successful lockout-tagout solution can only be achieved through a combination of utilizing degreed engineers to implement the system, providing expert advice on industry best practice, and working with the in-house tradespeople to extract critical equipment data. With ESC, our philosophy is to not only implement a world class program quickly and accurately, but to also teach each company we work with how to properly maintain it so they can truly take ownership and protect their investment. 9

10 Efficiency Statistics Safety Case Studies A case study was conducted with a fortune 500 company at 4 of the company s locations to determine accuracy of in-house completion of a lockout-tagout program (conducted by safety professionals). Every site had over 80% inaccuracies resulting in non-compliance, the majority of which would lead to severe injuries to a worker if the procedures were followed. OSHA requires every procedure to be audited on an annual basis to ensure the procedures accurately represent the equipment. A different company implemented a 100% accurate and compliant lockout-tagout program with an outside resource, then failed to maintain and audit the program for 3 years. A third-party audit of the program revealed over 70% of the procedures were inaccurate due to equipment modifications and turnover. OSHA reports compliance with the lockout-tagout regulation prevents an estimated 120 FATALITIES and 50,000 INJURIES a year. Workers injured due to exposure to hazardous energy lose an average of 24 WORK DAYS per incident. *Lockout-Tagout OSHA Fine Data Source: OSHA.gov 10 Machine and Site Specific Statistics: Cooling tower was locked out 65% faster using a new graphical procedure compared to existing (and familiar) text based procedure A packaging line (case erector, case packer, conveyor system, sealer, and palletizer system) was locked out 80% faster and also now allowed for component lockouts so down-stream components can to continue to function (safely) Decrease in return to service times ranged from 28% to 125% (R.O.I. associated with more up-time) Pre-known devices and lock quantities allowed for 70% faster gathering of supplies Annual audits are 50% faster to conduct (achieve compliance and integrity of the program) GRAPHICAL lockout-tagout procedures are at least 50% faster to use than TEXT based lockout-tagout procedures.

11 Resources Lockout-Tagout Internal Audit Form A successful lockout-tagout program will contain these key components. OSHA CFR To cover compliancy basics, your program must have the following: o Machine-specific lockout-tagout procedures Developed in non-proprietary software like MS Word or MS Excel. o Authorized employee lockout-tagout training o Affected employee lockout-tagout training Annual audits to ensure employees comprehend responsibility o Corporate policy that outlines means of enforcement o Audit of each machine-specific procedure annually o Locks, tags and devices necessary to perform service To gain efficiency your program also must have all of the following: o Picture-based graphical machine-specific lockout-tagout procedures o Graphical tags mounted at each lockable energy source isolation point o Lockout-tagout stations that are customized to include specific devices for each area o Employee pictures on tags to help aid in identification and safety o Develop complimentary programs that work with your lockout-tagout program Arc Flash Confined Space To become world-class with lockouttagout, the following tools exist: o Tablet based procedure auditing with QR codes o Tablet based employee auditing and testing to ensure comprehension and improve program o Tablet based access to real time corporate policy o Website dedicated to sharing lockout-tagout information real-time to safety managers o Scheduled internal audits on a 6 month frequency o Scheduled 3rd party audits to help ensure program integrity o Move all disconnects to nearby each piece of equipment to ensure quick lockouts o Develop SOP procedures to safely avoid lockouts for common tasks 11

12 Resources Compliancy Risk Calculator Lockout-tagout compliancy is a federal requirement under OSHA (Occupational Safety and Health Administration) to keep employees safe while servicing equipment. The black and white truth is the regulation exists to ensure employers are providing clear instructions, support, and guidance to their employees to keep them safe. The real cost of non-compliancy is an unsafe workplace resulting in accidents, injuries, and fatalities. OSHA enforces compliancy with citations and fines. There some companies unaware of the full requirements and receive a citation out of ignorance or inaction (see below for first time offender s section). Unfortunately, there are also some employers who willfully neglect to update or complete their program. These companies receive fines that are ten times an original offense. ESC Services views noncompliance as an endangerment to people s lives; however, some companies are driven by the bottom-line. Omitting lost time injuries, workman s comp, insurance adjustments, and equipment failure OSHA s citations and fines can have a huge monetary impact. First Time Offender: Fill out the information below to estimate you total exposure due to OSHA non-compliance. A fully compliant lockout-tagout program would mitigate or eliminate all OSHA related fines. Number of pieces of equipment example with no procedure 1,000 Number of procedures not audited in the last 12 months N/A Number of employees not trained on lockout-tagout 100 Number of employees not audited in last 12 months N/A TOTAL 1,100 Multiply the total by $7,000* and that is your exposure to OSHA related fines for non-compliancy. TOTAL EXPOSURE $7,700,000 Repeat Offender: Note: If your company (includes all companies joined under a parent company) have been cited by OSHA for in the last 5 years, multiply the procedure total by $70,000. TOTAL EXPOSURE $77,000,000 12

13 Other Resources With Hazardous Energy Control there s always a learning opportunity. Expert Tips Confined Space FAQ A wealth of knowledge awaits - only one click away. LOTO University Arc Flash escservices.com 13

14 Your safety. Our passion. TM Toll Free: Fax: ESC Services