Mine Safety & Health Conference HAZARDOUS ENERGY CONTROL LOCK and TAG Todd Nicholes

Mine Safety & Health Mine Safety & Health ConferenceConference

HAZARDOUS ENERGY HAZARDOUS ENERGY CONTROL LOCK and CONTROL LOCK and TAGTAG

Todd NicholesTodd Nicholes

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AGENDAAGENDA

What is Hazardous Energy?What is Hazardous Energy? Why hazardous energy control?Why hazardous energy control? Lock and Tag Procedures/Training.Lock and Tag Procedures/Training. Questions and Answers.Questions and Answers.

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Identify all hazardous Identify all hazardous energyenergy

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Sources of hazardous Sources of hazardous energyenergy

ElectricalElectrical

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Sources of hazardous Sources of hazardous energyenergy

ElectricalElectrical Mechanical Mechanical

MovementMovement

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Sources of hazardous Sources of hazardous energyenergy

ElectricalElectrical Mechanical Mechanical

MovementMovement• ElectricityElectricity• Water siphoningWater siphoning• Head/PressureHead/Pressure

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Sources of hazardous Sources of hazardous energyenergy

ElectricalElectrical Mechanical Mechanical

MovementMovement• ElectricityElectricity• Water siphoningWater siphoning• Head/PressureHead/Pressure

HeatHeat

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Sources of hazardous Sources of hazardous energyenergy

ElectricalElectrical Mechanical Mechanical

MovementMovement• ElectricityElectricity• Water siphoningWater siphoning• Head/PressureHead/Pressure

HeatHeat• CavitationCavitation• Current FlowCurrent Flow

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Sources of hazardous Sources of hazardous energyenergy

ElectricalElectrical Mechanical Mechanical

MovementMovement• ElectricityElectricity• Water siphoningWater siphoning• Head/PressureHead/Pressure

HeatHeat• CavitationCavitation• Current FlowCurrent Flow

ChemicalChemical Gravity Gravity Stored- pneumatic or Stored- pneumatic or

hydraulichydraulic

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Consider This Source of Consider This Source of EnergyEnergy

Between 1995 Between 1995 and 1998 -- 62 and 1998 -- 62 serious injuries serious injuries took place in took place in the US with the the US with the sudden release sudden release of energy of energy stored in stored in garage door garage door springs.springs.

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Consider This Source of Consider This Source of EnergyEnergy

GravityGravity Counter Counter

BalanceBalance

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Lock and Tag TrainingLock and Tag Training

Employee must have knowledge and an Employee must have knowledge and an understanding of hazardous energy in understanding of hazardous energy in the facility.the facility.• ElectricalElectrical• MechanicalMechanical• HydraulicHydraulic• GravityGravity• StoredStored• ChemicalChemical• PneumaticPneumatic• ThermalThermal

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Why Hazardous Energy Why Hazardous Energy Control? Analysis has Control? Analysis has found--found--

Prior to LOTO regulation each year Prior to LOTO regulation each year general industry experiencedgeneral industry experienced• 37,500 minor injuries37,500 minor injuries• 33,400 lost workday injuries33,400 lost workday injuries• 144 fatalities144 fatalities

Employees face significant risk of Employees face significant risk of serious injury and death due to serious injury and death due to Hazardous Energy that is not controlledHazardous Energy that is not controlled

Estimated 85% reduction in injuries with Estimated 85% reduction in injuries with regulationregulation

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Why Hazardous Energy Why Hazardous Energy Control?Control?

You do not want to be injured.You do not want to be injured. Your company does not want you Your company does not want you

injured.injured. No one should be injured on the No one should be injured on the

job, we do not come to work to be job, we do not come to work to be injured.injured.

WARNINGWARNING

Graphic Graphic photo’s of photo’s of

actual injuriesactual injuries

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Why Lock and TagWhy Lock and Tag

Employee working Employee working on a pump. Pump on a pump. Pump had been had been cavitating, heating cavitating, heating up the liquid up the liquid inside. Employee inside. Employee failed to relieve failed to relieve pressure prior to pressure prior to removing bolts.removing bolts.

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Why Lock and TagWhy Lock and Tag

Employee was Employee was taking a sample taking a sample of slurry from this of slurry from this mixing vat.mixing vat.

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Why Lock and TagWhy Lock and Tag

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Why Lock and Tag

Back when I was younger, I stuck my hand in what's called a rotary valve in the bottom of a silo at work. This valve clogged up all the time and the lock out point was on the other end of the plant. All of us were guilty of doing what I was doing, but I was the one that got caught. Not only did I loose my left thumb, and I am left handed, I also lost my job over this stupid act

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Why Lock and TagWhy Lock and Tag

They had to use They had to use my big toe to my big toe to replace my replace my thumb.thumb.

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Why Lock and TagWhy Lock and Tag

Use lock and tag Use lock and tag at home, this guy at home, this guy removed a plug in removed a plug in his snow blower his snow blower without shutting it without shutting it off. off.

At least he was At least he was able to retrieve able to retrieve his fingerhis finger

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Why Lock and TagWhy Lock and Tag

This employee This employee removed a guard removed a guard and then and then attempted to make attempted to make an adjustment to a an adjustment to a 5000 rpm roller on 5000 rpm roller on a conveyor system.a conveyor system.

The hand could not The hand could not be reattached. be reattached.

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Why Lock and Tag it’s the Why Lock and Tag it’s the law 30 CFR 75.820law 30 CFR 75.820

(b) Prior to performing electrical (b) Prior to performing electrical work…a qualified person mustwork…a qualified person must• (3) lock out the disconnecting device (3) lock out the disconnecting device

with a padlock – (each person must with a padlock – (each person must install own padlock)install own padlock)

• (4) Tag the disconnecting device to (4) Tag the disconnecting device to identify each person working and the identify each person working and the circuit or equipment on which work is circuit or equipment on which work is being performed.being performed.

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Why Lock and Tag it’s the Why Lock and Tag it’s the law 30 CFR 77.404 law 30 CFR 77.404 and 30 CFR 75.1725and 30 CFR 75.1725

(c) Repairs or maintenance shall (c) Repairs or maintenance shall not be performed on machinery not be performed on machinery until the power is off and the until the power is off and the machinery is blocked against machinery is blocked against motion, except where machinery motion, except where machinery motion is necessary to make motion is necessary to make adjustments.adjustments.

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Why Lock and TagWhy Lock and Tag

Fatality 33 year old Fatality 33 year old electrician- 6 yrs electrician- 6 yrs exp.exp.

Performing repairs Performing repairs during mine wide during mine wide power outage on a power outage on a continuous miner continuous miner trailing cable.trailing cable.

Power was restored Power was restored while repairing 3while repairing 3rdrd phasephase

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Why Lock and TagWhy Lock and Tag

Fatality 45 yr old Fatality 45 yr old belt foreman. 22 belt foreman. 22 yrs exp.yrs exp.

Left arm was Left arm was amputated by the amputated by the rotating rollers of rotating rollers of belt take up unit.belt take up unit.

No witnesses to No witnesses to incident.incident.

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Lock & Tag Lock & Tag Procedures/TrainingProcedures/Training

Detailed Detailed procedures that procedures that includeinclude• StartupStartup• ShutdownShutdown• Normal operationNormal operation• Emergency Emergency

operationoperation• Lock and tag Lock and tag

pointspoints

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Lock & Tag Lock & Tag Procedures/Training Special Procedures/Training Special Precautions for ElectricalPrecautions for Electrical

Locate the Locate the disconnect (s)disconnect (s)

De-energize the De-energize the circuitcircuit

Every worker to Every worker to place own lock and place own lock and tagtag

Test circuitTest circuit Ground conductorsGround conductors

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Lock & Tag Lock & Tag Procedures/TrainingProcedures/Training

Employee must know how to Employee must know how to control energy.control energy.• ElectricalElectrical• MechanicalMechanical• HydraulicHydraulic• GravityGravity• StoredStored• ChemicalChemical• PneumaticPneumatic

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Lock & Tag Lock & Tag Procedures/TrainingProcedures/Training

Employee must know how to use Employee must know how to use the Lock and tag procedure to the Lock and tag procedure to protect himself/herself and co protect himself/herself and co workers.workers.

Affected employees also need to Affected employees also need to be protectedbe protected

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Steps To Energy- Free Steps To Energy- Free MaintenanceMaintenance

Preparation – Think through the taskPreparation – Think through the task Notification of other workers who will be Notification of other workers who will be

affected by the shut-down of machineryaffected by the shut-down of machinery Shut down the operating controlsShut down the operating controls Isolating the area where work will be Isolating the area where work will be

performedperformed Lock-Out/Tag-Out of the affected controls or Lock-Out/Tag-Out of the affected controls or

switches switches Performing a safety check to see if re-Performing a safety check to see if re-

activation is possibleactivation is possible Purging or dissipation of any residual energyPurging or dissipation of any residual energy

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Energy- Free Maintenance Energy- Free Maintenance Step 1Step 1

Preparation – Think through the taskPreparation – Think through the task• What equipment am I working onWhat equipment am I working on• What are the sources of energyWhat are the sources of energy• Are there prints/electrical drawings to Are there prints/electrical drawings to

reviewreview• Is there a procedure to read throughIs there a procedure to read through• Is there vendor information that will helpIs there vendor information that will help• Has other employees worked on this Has other employees worked on this

equipment previouslyequipment previously

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Energy- Free Maintenance Energy- Free Maintenance Step 2Step 2

Notification of other workersNotification of other workers• Check with the supervisorCheck with the supervisor• Walk the area downWalk the area down• Does announcement need to made Does announcement need to made

over PAover PA

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Energy- Free Maintenance Energy- Free Maintenance Step 3Step 3

Shut down of the operating Shut down of the operating controlscontrols• Are there remote operating control Are there remote operating control

stationsstations• Is there a procedure that must be Is there a procedure that must be

followed to shut down the equipmentfollowed to shut down the equipment• Will shut down of equipment put Will shut down of equipment put

others in harms wayothers in harms way

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Energy- Free Maintenance Energy- Free Maintenance Step 4Step 4

Isolating the area where work will Isolating the area where work will be performedbe performed• Are barricades needed with warning Are barricades needed with warning

signs explaining hazardssigns explaining hazards• Overhead hazardsOverhead hazards• Hazards belowHazards below

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Energy- Free Maintenance Energy- Free Maintenance Step 5Step 5

Lock-Out/Tag-Out of the affected Lock-Out/Tag-Out of the affected controls and switches.controls and switches.• Lock out electrical breakersLock out electrical breakers• Close supply and discharge valvesClose supply and discharge valves• Open vents and drainsOpen vents and drains• Pull control fusesPull control fuses

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Energy- Free Maintenance Energy- Free Maintenance Step 6Step 6

Performing a safety check to see if Performing a safety check to see if re-activation is possible.re-activation is possible.• Push the start buttonPush the start button

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Energy- Free Maintenance Energy- Free Maintenance Step 7Step 7

Purging or dissipation of any Purging or dissipation of any residual energyresidual energy• Open vents and drains to relieve liquid Open vents and drains to relieve liquid

pressures i.e. water, chemical, or oilpressures i.e. water, chemical, or oil• Open vents and drains to relieve gas Open vents and drains to relieve gas

pressures i.e. air, nitrogen, O2 etcpressures i.e. air, nitrogen, O2 etc• Spring tension or compressionSpring tension or compression• Weld or block counter weights in placeWeld or block counter weights in place• Block rotating equipmentBlock rotating equipment

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Lock and TagLock and Tag

Questions and AnswersQuestions and Answers Personal ExperiencesPersonal Experiences

Lock and TagLock and Tag

Have a safe and Have a safe and productive productive workday. workday.