L OCKOUT T AGOUT. For Authorized Employees

Transcription

1 L OCKOUT T AGOUT For Authorized Employees FA C I L I TAT O R S G U I D E

2 What s Inside Facilitator s Guidelines a Overview b Getting Started d Presentation Guidelines f Lesson Plan h Frequently Asked Questions 1 Introduction 2 What Is An Authorized Employee 4 Preparing For Lockout 6 Lockout: Best Safety Practices 9 Additional Procedures 13 Summary 14 Quiz 16 Quiz Answers 2005 Summit Training Source Inc. All rights reserved. No part of this book may be reproduced in any form or by any means without written permission from Summit Training Source Inc. If you wish to purchase additional copies, please call our office at

3 Overview The work you perform each day can be dangerous and demanding. Your role in keeping equipment running is important to maintain your company s level of productivity. In addition, your knowledge and training in proper lockout/tagout procedures is vital to keep you and your co-workers safe. As an authorized employee you have made a commitment to follow these procedures and try to correct any hazards that may arise. Everyday you encounter machines that contain potentially hazardous energy. It is your job to follow your facility s energy control program to keep you as well as affected and other employees safe from these dangers. Your life and that of your co-workers depends on your level of awareness and training when working around or repairing industrial machinery. a

4 Getting Started Training Materials Collect all of the necessary materials and supplies before training begins. Here are some suggested materials and supplies: A training location that is free of distractions, has good lighting, and a comfortable temperature. Desks and chairs arranged so that everyone will be able to see the viewing screen, the facilitator, and each other. The video, a VCR, and a TV with a remote. Make sure the video is rewound. An employee handbook and pen/pencil for each trainee. Each handbook includes a quiz at the back, which can be used to test comprehension and document training. Other supplies and equipment you may need - blackboard chalk, paper, handouts, transparencies, overhead projector, markers, notepads, etc. Additional information, such as a copy of the regulation or other reference tools. b

5 Preparation A successful presentation requires preparation and planning. Give yourself several days before the training session to get organized. Locate and schedule the training site as soon as possible. Notify trainees of the training date and time, the training schedule, and proper dress. Obtain all necessary equipment and supplies. Make sure you know how to operate the TV, VCR, and other equipment. Check to ensure that it is working properly. Replace or repair any damaged equipment. Review all training materials, including the Facilitator s Guide, handouts, and any other reference materials. Prepare your presentation, including a lesson plan or outline of the training. Include the training goals and objectives. Some presentation guidelines are included on the next page. A sample lesson plan has been included on page f of this Facilitator s Guide. A day or so before conducting the training session, you may want to have participants take the quiz as a pre-test. The results of this test can help you determine weak areas to focus on during the training session. Preview the videotape. Note any key points you want to expand upon in your training. c

6 Presentation Guidelines How you present the training course can have a great impact on learning. By following these simple presentation guidelines and keeping your objectives in mind, you can effectively and efficiently get the most out of your training session. Organize Training Time Efficiently In today s busy work climate it can be difficult to find the time needed for training, so it is important to be organized and wellprepared when you do schedule training sessions. Whether you use Summit s suggested lesson plan or not, it is important to have a lesson plan prepared that you can implement comfortably. This ensures that time spent in training is productive and beneficial for everyone. Stress the Purpose and Goals of Training Training needs to be goal-oriented. State the purpose of training in a clear, specific manner - whether it s to reduce injuries, increase production, improve quality, improve working conditions, etc. Review the goals and objectives of the training so trainees know what is expected of them. Capture Their Attention Training needs to be interesting and compelling to hold trainees attention. To help motivate learners, give them specific evidence that their effort makes a difference and provide feedback on their progress. Also, remember that the first experience with a new subject usually forms a lasting impression on the learner. By making that experience a positive one, you can help ensure your audience retains the information learned. d

7 Make New Learning Experiences Pleasant For some adults, past experiences with education were unpleasant and not helpful. Adults learn best when they feel comfortable. By making the learning environment open and friendly, you can help adults to feel secure in their new learning experience. Offer support and feedback as often as possible, and be ready to provide extra attention to those who may require it. Ask If There are any Questions When most adults learn new information that conflicts with what they already know, they are less likely to integrate those new ideas. It is very important to make sure participants fully understand the training and do not have any unresolved questions. Provide for a question and answer period so participants can resolve those questions and/or answer questions throughout the training session. e

8 Lesson Plan As a qualified trainer, your job is to effectively communicate a great deal of information in a well-organized manner. By preparing a lesson plan, you can ensure that each minute of the training session is productive. Summit has provided a suggested lesson plan for your use. 1. Program Objective This guide reviews Lockout/Tagout For Authorized Employees. In it, we will cover: Who is considered an authorized employee How to prepare for lockout Lockout-best safety practices Additional procedures 2. Show the Video: Lockout/Tagout For Authorized Employees 3. Discussion and Demonstration To help relate the training to your site, you may wish to incorporate your own discussion topics and exercises. Key issues you might consider include: What type of hazards may we encounter at our site when lockout/tagout procedures need to be performed? What are the guidelines that must be followed in the lockout/tagout program at our site? What are possible consequences we may face if proper lockout/tagout procedures are not followed correctly? What procedures must be followed in the event of an emergency? f

9 4. Use Handbooks to Reinforce Training The handbooks increase comprehension and reinforce the information learned in the video program by explaining the main points and expanding on the original material. For increased employee information retention, go over one section at a time and stop to answer questions. The quiz at the back of the Facilitator s Guide is provided to document employee training. Answers to the quiz are provided on a separate page. 5. Questions and Answers Provide for a Q&A session to answer any questions. It may be necessary to review some of the material when providing answers. The employee handbook, equipment manuals, and other reference tools may be helpful. g

10 Frequently Asked Questions What happens when an authorized employee locks out equipment and then is called away for an emergency before removing his lock? Under regular circumstances the person who placed the lock is the only one who should remove it. However, if the person is called away for an emergency and the lock needs to be removed before he returns there are some other options. Each facility may have their own procedures you must follow, but here are some guidelines to follow. Removing the lock will require your employer s approval. It must first be verified that the authorized employee who applied the lock is definitely not in the facility; a reasonable effort must be made to try to contact the employee to let him know the lockout device has been removed; and when the authorized employee returns to work, he must be informed that the lockout device has been removed before he begins work. Are tags only to be used with locks when locking out a piece of equipment? Since tags only provide a visual warning they are mainly used with locks. However, there are a couple of instances when tags can be used without a lock. For example, when a machine cannot be locked out, a tag must be securely attached directly to the energy isolating device, or as close to the device as possible, and be clearly visible. The other exception is when the employer can show that the machine is just as safe tagged-out as it would be if it were locked-out. This usually occurs when some alteration to the machine has taken place to make it inoperable, like blocking a controlling switch or removing a valve handle. When a tag is in place, it s important to use extra caution as they can be easily bypassed or damaged. Also, along with locks, a tag should only be removed by the same person who placed it on the energy isolating device in the first place. h

11 Introduction At most banks security is tight. Armed guards, armored trucks, alarms and cameras and, of course, a steel vault with a highly sophisticated locking mechanism. We expect this at the place that handles our money. Yet every year, workers who would never leave their savings in an unlocked vault, lose more than money because they didn t take the time to lockout their energy sources before attempting to repair equipment. Fortunately, by using lockout/tagout procedures to control hazardous energy, serious and fatal injuries can be eliminated. In this handbook, Lockout/Tagout For Authorized Employees, we will discuss: What Is An Authorized Employee Preparing For Lockout Lockout--Best Safety Practices Additional Procedures A lockout/tagout program has one goal: to keep workers safe from the accidental release of energy while maintenance or repairs are being performed on machinery. Under the program s guidelines, all sources of energy on a machine are isolated and locked out, using locks and tags specially designed for that purpose. Why is it important to keep these energy sources under control? In the United States alone, it is estimated that lockout/tagout safety programs prevent over 60,000 injuries and about 120 fatalities each year. Still, accidents continue to occur. 1

12 What Is An Authorized Employee As companies strive to stay competitive in the global marketplace, industrial machinery has grown more complex and powerful. For the skilled workers who keep this equipment running, the challenge is to maintain a high level of safety awareness while doing demanding work. Even workers who understand the dangers inherent in a piece of equipment can become desensitized when they work around that equipment eight or more hours a day. When rushing to get a piece of machinery back on line, it s especially important that workers remember to make safety their priority. By following the guidelines in this facility s lockout/tagout program every time a machine requires repairs or maintenance, workers can avoid accidents to themselves and others. During a lockout/tagout procedure, employees fall into one of three categories depending on their level of responsibility. Employees with the highest level of responsibility are called authorized employees. These are the only employees who can participate in a lockout/tagout procedure. They receive training on how to perform the procedure correctly, and will usually be involved in repairing, maintenance, or cleaning a machine while it is locked out. 2

13 The last two categories, affected and other employees, do not participate in lockout/tagout. Affected employees work in the area where lockout/tagout is taking place, while employees classified as Other are typically office workers who may occasionally enter the production area. For their safety as well as that of their co-workers, affected and other employees receive training on how to recognize when lockout/tagout is taking place, so that they can avoid the area until the procedure is completed. 3

14 Preparing For Lockout Lockout/tagout procedures prevent an unintended energy release from occurring when a machine needs to be repaired or maintenance performed. The same general steps are followed in any lockout procedure, but each machine is different. If you are an authorized employee, before beginning a lockout/tagout procedure consult your supervisor and your facility s written energy control program. To keep your work environment safe, you must start with a complete understanding of the power sources that energize the machine you ll be working on. First, all sources of energy for that machine must be identified. This isn t as obvious as it sounds. Mention energy to most people and they ll probably think of electricity. But industrial machinery can be powered by many energy sources besides electricity, there is hydraulic, pneumatic, mechanical, chemical, thermal and gravity. Each one of these energy sources is capable of producing two forms of energy: kinetic and potential. Kinetic energy is the force created by an object in motion in machinery, kinetic energy is usually easy to observe. 4

15 Potential energy, however, is stored in an object and may not be obvious at all. A spring under tension, for example, has potential energy. So does a pipe with steam trapped inside, or equipment that is suspended above the ground. When taking an inventory of the energy that powers a machine, be careful not to overlook these hidden sources if potential or stored energy is released in an uncontrolled fashion it can pose serious danger to you and to workers nearby. Before an authorized employee can lockout a machine, the machine operator and all other affected employees must be notified, and advised of the reason for the lockout. The operator may shut the machine down following normal procedures but after this step, the operator and all other employees who are not authorized must avoid the area until the lockout is completed. 5

16 Lockout: Best Safety Practices The authorized employee identifies every source of energy that powers that machine, and all switches, valves, or other disconnects are put into the safe or off position. At each one of these energy control points, called an energy isolating device, a lock is attached that prevents the accidental start-up of the machine. All locks used in the lockout process are assigned to individual employees and are always to remain under their control. In other words, the employee who placed a lock pockets the key and is the only one allowed to remove the lock. In addition, the locks are designed to have a distinctive look, so that any employee at this facility immediately recognizes and respects their purpose. For this to be effective, however, the locks must only be used to lockout equipment using them for any other purpose will weaken their effectiveness as a warning device. Key Point Only when the last individual has finished working on the machine and removed their assigned lock, is it safe to return the machine to production. 6

17 To further alert employees that lockout procedures are taking place, many facilities use tags along with locks; besides providing a clear warning, tags can be labeled with other useful information such as the name of the worker, the type of procedure being performed and the time when work began. After all locks and tags are placed, the next step is to see that any potential or stored energy is rendered safe. All energy stored in capacitors, springs, flywheels, hydraulics, or piping systems must be either de-energized or restrained by such means as blocking, bleeding off, grounding, or repositioning. Even after this is done, in some machinery it is possible for stored energy to re-accumulate to a hazardous level in these cases, for as long as the repair work continues, there needs to be on-going verification that the hazardous energy is safely isolated. Depending on the machinery, verification methods can include installing grounding devices, opening a valve for venting or breaking a flanged connection. Until work is completed, any method of verification should be tagged as a way of ensuring that it continues to provide protection. 7

18 Lockout: Best Safety Practices continued Once all energy sources have been neutralized, you must confirm that the machine cannot start through normal procedures. To do this, first check that all personnel are at a safe distance, then operate the start button or other operating controls. If the machine does not function, the test is completed successfully. After returning the controls to the neutral or off position, you can begin work on the machine. There may be times when your shift ends before your work is completed. When this occurs, you must inform the person in charge of the incoming shift where the work stands, and make them aware of any problems you ve encountered. Good communication is key -- accident rates tend to be higher shortly after a shift change and the reason can often be traced to poor communication. Meet the person who ll be taking over for you at the energyisolating device and do not remove your lock until they place their lock on the machine. When preparing to return a machine back to production, clear all tools and non-essential items, and replace all guards and safety devices. Inform the machine operator and other affected employees that the machine is ready to run again. Do a second check around the machine to see that no one is in harm s way in the event of an unexpected energy release, then remove the locks that you placed on the machine and restore power. 8

19 Additional Procedures Remember, under normal circumstances, the only person to remove a lock is the person who placed it there in the first place. On rare occasions, a person may be called away for an emergency or other reasons and their lock will be left in place. If their lock needs to be removed before they return this can only be done with your employer s approval. The exact procedure for your facility will be written into the energy control program and must incorporate these three conditions: First, it must be verified that the authorized employee who applied the lock is not at the facility. Next, a reasonable effort must be made to contact the authorized employee and let them know that their lockout device has been removed. And, finally, before the authorized employee returns to work, they must be informed that the lockout device was removed. 9

20 Additional Procedures continued Whenever a contractor enters this facility to perform work that requires a lockout/tagout procedure, that contractor s energy control program is compared to the facility s program. Where the programs differ, the stricter policy must be followed by both internal employees and outside contractors. There may be times when two or more employees will be working on a machine. This requires a group lockout procedure. During a group lockout, each worker must place their own lock or locks on the machine -- only after the last employee has finished his work and removed his lock can the machine be started. In this way, each employee is accounted for and protected from an accidental start-up. When performing a group lockout there are two basic approaches. The first is to have each worker place a personal lock at every energy-isolating device. If an energyisolating device is not designed to accept multiple locks, a multi-lock hasp can be used, with each worker placing his lock on the hasp. 10

21 This approach works well for some situations, but when there are many locations to lockout or many workers on a single job, a less cumbersome approach is to use a lockbox. In this approach, the individual designated as the principal authorized employee places a personal lock at each energy-isolating device, then places his keys inside a lockbox. The lockbox is then secured with a personal lock from each individual who will be working on that machine. Only when the last person to complete his work removes his lock from the box, can the principal authorized employee retrieve his keys and unlock the rest of the machine. In many cases, tags are used along with locks to provide a visual warning. To be effective, a tag must be clearly visible and its warning must be understood and respected by all employees. Because tags do not create an effective physical barrier to the accidental release of energy, in most circumstances they cannot be used without a lock. There are, however, two exceptions to this regulation: The first is when a machine s energy isolating device cannot be locked out. When this occurs the tag must be attached directly to the energy isolating device or, if this cannot be done, attached as near to the device as possible. The other exception is when an employer can show that the machine is just as safe tagged-out as it would be if it were locked-out. Usually, this requires some alteration to the machine to make it inoperable, such as blocking a controlling switch or removing a valve handle. 11

22 Additional Procedures continued When a tag is in place it s easy to develop a false sense of security, but remember that tags can be easily damaged or bypassed, and extra caution must be taken. Whether used alone or with a lock, tags must meet some minimum requirements: Tags and their means of attachment must be made of materials that will withstand the environmental conditions encountered in the workplace. They must be securely attached so that they cannot become detached during use. They must be legible and provide an appropriate warning, such as Do Not Start, Do Not Open, Do Not Close, Do Not Energize, or Do Not Operate. And, when a tag is attached to an energy-isolating device, it must not be removed except by the person who attached it. 12

23 Summary As part of an on-going commitment to the safety of employees at this facility, each lockout/tagout procedure is inspected at least once a year. An authorized employee who is not directly involved with the procedure being reviewed, analyzes how it is carried out and looks for weaknesses in the overall process. While these inspections are important to the success of our energy control program, keeping this facility a safe place to work requires an ongoing commitment from every employee. Whenever you participate in a lockout/tagout procedure, keep these guidelines in mind Lockout/tagout procedures must only be performed by authorized personnel. When beginning a lockout procedure, be sure to identify all potentially hazardous energy. Before attempting maintenance or repairs, test that all energy sources have been isolated. Only use a lock that has been assigned to you, and never loan your lock or key to anyone else. Tags are warning devices only; because they are not as secure as locks and extra caution must be used. After a lock or tag is placed by an authorized individual, only they can remove it. During group lockout procedures, use a one lock / one person approach so that the machinery cannot be restarted until the last worker has removed his lock. If you encounter any problems during a lockout procedure or have questions about the energy control program, contact your supervisor. We use locks to protect our property that only makes sense. To protect your most valuable asset your health keep your work environment safe by following lockout/tagout procedures. 13

24 Quiz To review your knowledge of Lockout/Tagout For Authorized Employees, answer the questions below. Your Name Date 1. The only employee who can participate in a lockout/tagout procedures is called an employee. a. affected b. authorized c. other d. any employee can perform lockout/tagout procedures 2. Affected employees cannot participate in lockout/tagout and are typically office workers who occasionally enter the production area. a. True b. False 3. Before beginning a lockout/tagout procedure, what must an Authorized employee do? a. Pray they will not receive an electric shock b. Consult your supervisor c. Consult your facility s written energy control program d. Have a complete understanding of the power sources that energize the machine they will be working on 4. The machine operator and all other affected employees must be notified and advised of the reason for the lockout by the authorized employee before the machine can be locked out. a. True b. False 5. The employee who places the lock is the only one allowed to remove that particular lock. a. True b. False 14

25 Quiz continued 6. Which of the following are possible energy sources for industrial machinery? Select all that apply. a. Electricity b. Hydraulic c. Pneumatic d. Mechanical e. Chemical f. Thermal g. Gravity 7. Whenever a contractor enters the facility to perform work that requires a lockout/tagout procedure, which energy control program is required to be followed by both contractors and internal employees? a. Always the contractor s energy control program b. Always the facility s energy control program c. Whatever policy is more strict d. Neither program; a new policy needs to be written 8. If two or more employees will be working on a machine, only one of the authorized employees needs to lockout the machine? a. True b. False 9. If a machine s energy isolating device cannot be locked out, a tag must be attached directly to the energy isolating device to warn others. a. True b. False 10. How often must a facility s lockout/tagout procedure be inspected? a. Only when there is a lockout/tagout accident b. At least once a year c. At least twice a year d. At least once every two years 15

26 Quiz Answers 1. b authorized 2. b False 3. b Consult your supervisor c Consult your facility s written energy control program d Have a complete understanding of the power sources that energize the machine they will be working on 4. a True 5. a True 6. a Electricity b Hydraulic c Pneumatic d Mechanical e Chemical f Thermal g Gravity 7. c Whatever policy is more strict 8. b False 9. a True 10. b At least once a year 16

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