UC LOTO app 24-Months in Use and Lessons Learned

Transcription

1 ASSE GOLDEN GATE CHAPTER Annual PDC March 8, 2017 UC LOTO app 24-Months in Use and Lessons Learned Jim Gilson, PE, CPCC, OWSI Senior Safety Engineer, University of California Berkeley / UCOP Environment Health & Safety

2 Who s here today? Raise your hand if you, or people you support: Maintain / repair / modify facility s utility and/or HVAC delivery systems Maintain / repair / modify vehicles of any kind Maintain / repair / modify any kind of conveyance equipment Design / build / modify research or automation equipment Manage safety program(s) that support the above kinds of work Slide 2

3 Why s LOTO a big deal? Lock out Tag out (LOTO) is always in top-10 most cited OSHA code violations nationally 300+ people die and are injured at work annually due to equipment starting or energy released unexpectedly All of the above injuries are completely avoidable if LOTO is practiced judiciously Definition of LOTO LOTO = Energy Isolation before hazardous work LOTO = SOP in Engineering, Research and/or Facility Operations Slide 3

4 What does LOTO apply to? ALL forms of hazardous energy: Utility energy Electricity, compressed air, steam, condensate, gas distribution, vacuum, domestic water, hydraulics, etc. Potential energy Mechanical springs in tension or compression, compressed gas cylinders, elevated counter weights, heat or cryogenics (cold), parked vehicles on a slope, fuels, or any stored energy (capacitors, batteries, etc.). Kinetic energy Rotating flywheel, moving / sliding parts, rolling components, convection in fan / duct systems, etc.

5 Research Equipment requires LOTO SOPs

6 Large Capacitors / Lasers Require LOTO SOPs Capacitors store electric charge and can cause electric flow to happen in dead wires if a pathway to ground is created.

7 Electrophoresis Equipment and Power Supplies Operate from volts on the bench-top Operate up to 1 amp Newer units can have onboard safety features that detect no-load, overload, sudden load change, short circuit, arc or ground leak, etc. Older units have no electrical protection Building GFCIs may not protect older equipment

8 Facility and Utility Infrastructure requires LOTO SOPs

9 UC Berkeley s Paper LOTO Program Must: Adapt to research and facilities work alike Be quickly understood by disparate user groups with differing needs for information Be implemented across multiple kinds of equipment and locations Qualify and Authorize different kinds of personnel to conduct LOTO Slide 9

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11 Standard Energy Isolation LOTO Procedure 1. All maintenance personnel are issued a suitable lock (or locks for multiple energy sources). Each lock has the individual worker s name or other identification on it. Each worker has the only key to the lock / lock set. 2. The Authorized Person checks to be sure that no one is operating the machinery BEFORE turning off energy sources. All persons in the area, and especially the machine operator and project supervisor, are informed before the energy sources are being turned off because unexpected sudden loss of power could cause an accident. 3. Steam, air, and hydraulic piping or tanks must be bled, drained, and/or brought to atmospheric pressure and locked open to assure no pressure or vacuum in piping or in reservoir tanks. 4. Gas cylinders must be locked closed and if possible disconnected from distribution piping. 5. Any mechanical component that could roll, shift or otherwise move, such as springs, counterweights, wheels, fan blades, etc. must be barred or blocked. 6. Each person who will be working on the machinery must put a lock on each of the machine s lockout device(s). Each lock must remain on the machine until the work is completed. Only the worker who placed the lock may remove their lock. 7. The Supervisor or Authorized Person places a tag on each lock-out location. 8. All energy sources which could activate the machine must be locked or blocked out following an equipment-specific Energy Isolation Procedure developed for that equipment. (Other side) 9. All disconnects must be tested to be sure that all energy sources to the machine are off. 10. Electrical circuits must be checked by qualified persons with proper and calibrated electrical testing equipment. Stored energy in electrical capacitors must be safely discharged. 11. CAUTION: Return disconnects and operating controls to the off position after each test. 12. Attach accident prevention tags which give the reason for placing the lock/tag, the name of the person placing the lock/tag, how they may be contacted, and the date and time the lock/tag was placed. Testing / Adjusting Equipment during Lockout In many maintenance and repair operations, machinery must be tested and therefore energized before additional maintenance work can be performed. For such situations, this procedure must be followed: 1. Clear all personnel to safety. 2. Clear away tools and materials from equipment. 3. Remove blocks and lockout devices and re-energize systems, following the established safe procedure. 4. Proceed with tryout or test. 5. Shut off all energy sources reinstalling lockouts on energy sources, reinstall blocks, bleed all pressure systems and verify all energy sources de-energized prior to continuing work. Equipment design and performance limitations may dictate that effective alternative worker protection be provided when the established lockout procedure is not feasible. If machinery must be capable of movement in order to perform a maintenance task, workers must use extension tools, personal protective equipment and other means to protect themselves from moving parts and potential injury. Restoring Equipment to Service After the work is completed and the equipment is ready to be returned to normal operation, this procedure must be followed: 1. Remove all non-essential items. 2. See that all equipment components are operationally intact, including reinstalling guards and safety devices. 3. Repair or replace defective guards before removing locks. 4. Remove each lockout device using the correct removal sequence. 5. Make a visual check before restoring energy to ensure that everyone is physically clear of the equipment. Each lock is removed by the authorized person that applied it, or under his/her direct supervision. If the authorized person is absent from the work place then the lock or tag can be removed by a qualified person designated to perform this task provided that the immediate supervisor: 1. Verifies that the qualified person is not present and therefore unable to remove the lock; 2. Makes all reasonable efforts to inform the qualified person that the lockout/tagout device has been removed; and 3. Ensures that the qualified person knows their lockout/tagout device has been removed before their work resumes. Finally, notify any Affected Person(s) that the equipment has been restored to its operational state. Joint Projects If University personnel and contractor personnel are working on the same piece of equipment, each work team installs their own hasp and locks on each energy source. The University provides the hasps that University personnel install their locks on, and the Contractor provides their hasps and locks that their personnel install / use. 11

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13 A Wood Planer LOTO Accident started the march to mobile technology. 13

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15 University of California System 10 Campuses 5 Research / Teaching Hospitals Research on 7 continents $25.46B (2015 Budget) 39 Agricultural Field Stations in-state Supports 4 National Laboratories (2 in CA, NM & SD) 19,700 Faculty 135,900 Staff 238,700 Students 129 Nobel Laureates 34M Items in UC Libraries Oversees 756,000 acres of Natural Reserves 1 Airport (Davis) 1 Research Seaport (San Diego) Berkeley Davis Irvine Los Angeles Merced Riverside San Diego San Francisco Santa Barbara Santa Cruz ANR LBNL 15

16 UC LOTO app Demonstration Copying a LOTO Procedure (ipad / Android mobile device) Retrieving a LOTO Procedure (ipad / Android mobile device OR web-browser) LOTO Metrics (next slide)

17 UC LOTO App Current Adoption Status

18 User Levels / Access Level 1 User (Students, Visiting Scholars, One-off Contractors, etc ) Can retrieve / view LOTO / Research SOPs as PDF files using LOTO app search functions and download them to their computer / mobile device. Will be able to sign-on and download the app to their mobile device using their UC address and Shibboleth Authentication. Level 2 Creator (Trades, Trades-Contractors, Consultants, Architects, Engineers, etc ) Besides the above, may create / modify / verify procedures using LOTO app. Also, have limited access to the online dashboard, and may only: a) View heat maps and click on and open a PDF-file procedure based upon location on the heat map. b) Conduct a Procedure Search via location, equipment name, asset number and GPS coordinates. c) May view a PDF file procedure, download, copy and the PDF file of a procedure. d) May see the procedure history. Level 3 - Researcher / Supervisor May do all the above plus: a) May protect access to a LOTO procedure with a passcode and change passcodes on their procedures. b) May change the title of a procedure from Lockout-Tagout Procedure to Equipment Standard Operating Procedure c) May view and create PDFs of Archived procedures using the web portal. d) May delete their procedures from their lab archives. Level 4 - Administrator - This person has all access / functions of User, Creator and Researcher, plus. a) Can access fully their campus LOTO procedure database b) Can edit LOTO users assigned to a campus with full addition / deletion / setting of the individual userlevel, etc. for all LOTO app users. c) Can use any data-mining capabilities of SBN web portal. d) Can modify the campus real estate database with local terminology and name references. e) Can remove procedures from the active campus database by moving procedures into a permanent archive. The archive can only be seen by persons with Researcher/Supervisor and Administrator user levels. f) Can permanently delete procedures from the permanent archive. g) Can modify some menu options of the LOTO app for campus-specific needs.

19 Training Video-on-demand streamed to the mobile device 6 Videos available UC LOTO app - TRAINING VIDEO LINK? Located throughout the LOTO app refer to onboard references Library of pre-configured LOTO procedure templates for common kinds of equipment are in development Training is tracked in the UC-LMS

20 Campus Adoption / Strategy Each campus has their own LOTO database Various campus have different models of adoption User access is managed by local campus EH&S Administrator(s) Local EH&S Websites detail access by campus User applies via to activate LOTO app once downloaded to their mobile device Future = Anyone with UC address will be able to download LOTO app at the user level using UC s Shibboleth Security clearance Campus LOTO Admins will set higher-level access for users upon request / supervisor approval

21 LOTO Dashboard Current Dashboard (SBN web portal) UCLA LOTO DASHBOARD - LINK Demonstrate Heat Mapping Demonstrate procedure search Demonstrate User Add / Delete

22 Operations Logistics LOTO procedures must be verified annually by someone not working on the equipment LOTO program must be audited annually for compliance and integration LOTO database notifies UC asset database when procedures are needing verification Work-order system modifies WOs to include verification of LOTO procedure as part of assigned repair work Assigns two personnel for 5-minute verification only (1-worker / 1 verifier) Slide 22

23 Research Logistics LOTO procedure process doubles as the safe Standard Operating Procedure for most dry-lab research equipment. Supervisor / PI has access to all procedure archives PI can change name of LOTO Procedure to Research SOP when LOTO isn t needed Researchers use the Verify / Modify functions to update their Research SOPs GPS locations, or certain equipment names, included in LOTO procedures may NOT be desirable for researchers with proprietary / valuable / controversial equipment. Password access may be needed. Slide 23

24 Lessons Learned Complex LOTO Complex pieces of equipment must be broken down into components each with their own LOTO procedure Organize complex equipment needing LOTO into a LOTO file with multiple LOTO procedures. Sequence the multiple LOTO procedures to ensure safe shut-down / restart Slide 24

25 Lessons Learned - Training Trades workers have little-to-no experience with ipads or tablets. Training must start basic to device use, but Trades will adopt quickly when they find value to do so. Have a teaching site so that learning / practice procedures don t pollute your campus LOTO database and skew implementation data statistics Users like video-training in the palm of their hand for quick reference Tracking LOTO training of videos as completed by individuals is a difficult problem for trainers / recordkeeping Slide 25

26 Lessons Learned Management Support Selling an end user vision of LOTO app must be done at various levels throughout the organization to gain buy in by management and various user groups Use LOTO app to return injured skilled trades to work more-quickly and use their facilities-knowledge to institutional advantage for documenting / training future trades Crafting a well written software specification with deliverables and target date commitments is crucial when using 3 rd party software-development vendors. Need to include target achievement carrots and penalty clause sticks in software development contracts. Need to license content technology to 3 rd parties for resale and funding of in-house program work Slide 26

27 Lessons Learned - Adoption Find allies who understand the safety-importance of LOTO and see the job-planning and new-employee orientation benefits for well documented LOTO procedures Users want LOTO templates to follow and will often copy a procedure they like as a starting place for similar equipment Use heat maps to demonstrate integration into operations and determine departments needing help toward adoption. Maps are also good for remote locations without buildings. Find early adopters to gain functional databases, create value and demonstrate viability, then use work-task-value or competition to shame others into adoption! Slide 27

28 UC LOTO app Program Manager CoE Safety and Risk Engineering Jim Gilson, PE, CPCC, OWSI Senior Safety Engineer, UC Berkeley Center of Excellence Safety Engineering, UCOP office / cell j_gilson@berkeley.edu (Search on home page for LOTO.)