Section 8: Energy Safety & Isolation – EI- LOTO

Shop Safety Managers Tool Kit

Section 8 – Energy Safety & Isolation Draft 2 1

Section 8: Energy Safety & Isolation – EI-LOTO

OVERVIEW This section contains the documents referenced in the Shop Safety Reference Manual – Section 8 – Energy Safety and Isolation – EI-LOTO. When using information in this section for training remember:

• Effective dissemination of safety information is an integral part of the Illness and Injury Prevention Program.

• Training must be completed before the use of any tool or piece of equipment, exposure to any hazardous conditions, and/or when new hazards are identified.

• The training must be documented using the training documentation form (see Section 2).

• Be prepared to demonstrate the techniques and equipment discussed in the handout materials.

• Have copies of the training handouts to give to the trainees.

• Contact the EH&S Department if you need assistance finding supplemental training materials.

This Section includes:

1. Tail Gate Meeting and Training Handout Materials:

a. Lockout/Tagout/Blockout Terms Defined

b. UC Energy Isolation-Lockout/Tagout Procedures

c. Lockout/Tagout – Code of Safe Practice

d. Energy Sources – Code of Safe Practice

e. Basic Electrical Safety – Code of Safe Practice

2. Lockout/Tagout/Blockout Program Forms

a. Equipment Specific Procedures Example and Use Instructions

b. Equipment Specific Procedures Template (pages 1 and 2 – print two-sided for hardcopy use)

c. LOTO Inspection Documentation Form



3. Safety Sign Samples

4. Quiz

5. Quiz Answers



1. TAIL GATE MEETING AND TRAINING

HANDOUT MATERIALS



Lockout/Tagout/Blockout Terms Defined In order to best understand lockout/tagout/blockout procedures and how to best protect yourself and others, it is important to understand the terms used during discussions of lockout/tagout/blockout procedures. Affected Personnel – According to Cal-OSHA, an affected person is an employee whose job requires them to operate or use a machine or equipment on which cleaning, repairing, servicing, setting-up or adjusting operations are being performed under lockout or tagout procedures, or whose job requires the employee to work in an area in which such activities are being performed under lockout or tagout procedures. Authorized Person – An authorized employee or person is a qualified (trained) person who locks out, tags out and/or block outs specific machines or equipment in order to perform: cleaning, repairing, servicing, setting-up, and adjusting operations. An affected employee becomes an authorized employee when that employee's duties include performing cleaning, repairing, servicing, setting-up and adjusting operations covered under this section. Block Out – Install an obstacle that prevents machine components from moving. Blockout Devices – Are devices that prevent the unexpected movement of machinery or working components or other sources of energy within a machine. Closed – Switch, breaker, or valve position that prevents the energy flow and/or prevents it from completing its circuit. Energized – Connected to an energy source or containing residual or stored energy. Energy Isolating Device – An energy isolating device is a mechanical device that physically prevents the transmission or release of energy. This includes: valves; breakers; switches; blank flanges for piping systems; and restraining devices to prevent movement of parts; etc. Locked Out – A machine is lockout when the use of devices, positive methods and procedures, result in the effective isolation or securing of prime movers, machinery and equipment from mechanical, hydraulic, pneumatic, chemical, electrical, thermal or other hazardous energy sources. Lockout Devices – Lockout devices are devices that use a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds.



Normal (Production) Operations – Normal operations occur when a machine or equipment is utilized to perform its intended function. Open – Switch, breaker, or valve position that allows the energy to flow and/or to complete its circuit. Prime Mover – The prime mover is the source of mechanical power for a machine. Qualified Person – A qualified person is a person designated by the employer; and by reason of training, experience, or instruction has demonstrated the ability to perform safely all assigned duties; and, when required is properly licensed in accordance with federal, state, or local laws and regulations. Tags – Tags must:

• have means by which they can be readily secured to the controls

• be of a non-reusable type,

• be attachable by hand, self-locking, and non-releasable with a minimum unlocking strength of no less than 50 pounds.

Tagout Devices – Tagout devices are warning devices, such as a tag which can be securely fastened to an energy-isolating device in accordance with the established procedure to indicate that the energy-isolating device and the equipment being controlled may not be operate until the tagout device is removed.



UC Energy Isolation – Lockout/Tagout/Blockout

Procedures

Standard Energy Isolation LOTO Procedure

1. Issue all maintenance personnel authorized to implement lockout/tagout/blockout procedures a suitable lock (or locks for multiple energy sources).

2. Ensure each lock has the individual worker’s name or other identification on it.

3. Ensure the worker assigned the lock has the only key to the lock and/or lock set.

4. Ensure that no one is operating the machinery BEFORE turning off energy sources. This is the responsibility of the supervisor or ‘Authorized Person’.

5. Inform all persons in the area, and especially the machine operator and project supervisor, BEFORE the energy sources are turned off to avoid unexpected sudden loss of power that could cause an accident.

6. Place a tag on each lock-out location. This is the responsibility of the supervisor or ‘Authorized Person’ to ensure personnel working on the project know where to apply lockout devices.

7. Ensure that all energy sources which could activate the machine are locked or blocked out following an equipment-specific Energy Isolation Procedure developed for that equipment.

8. Turn to the ‘off’ position all starting devices.

9. Bleed, drain, and bring to atmospheric pressure all steam, air, and hydraulic piping or tanks and then lock them in the “open” position to assure there is no pressure or vacuum in the piping or in the reservoir tanks.

10. Lock gas cylinders in the ‘closed’ position and if possible disconnect the cylinders from the distribution piping.

11. Bar or block any mechanical component that could roll, shift or otherwise move, such as springs, counterweights, wheels, fan blades, etc.

12. Turn off all electrical switches and/or disconnects.

13. Check electrical circuits with appropriate and calibrated electrical testing equipment. This is the responsibility of qualified persons.

14. Discharge any stored energy.

15. Ensure that each person working on the machinery puts a lock on each of the machine’s energy control 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.

16. Attach lockout tags to all lockout/blockout locations. Ensure the tags provide the reason for placing the lock and tag, the name of the person placing the lock and tag, how they may be contacted, and the date and time the lock and tag were placed.

17. Test all disconnects and operating controls to ensure that all energy sources to the machine are off and there is zero energy.

18. CAUTION: Always return disconnects and operating controls to the “off” position after each test.



Testing / Adjusting Equipment during Lockout

In many maintenance and repair operations, machinery/equipment must be tested and therefore energized before additional maintenance work can be performed. For such situations, the following procedure must be followed:

1. Move all personnel to safety.

2. Remove all tools and materials from equipment.

3. Remove blocks and lockout devices and re-energize systems following the established safe procedures.

4. Proceed with tryout or test.

5. Shut off all energy sources.

6. Reinstall lockout devices on energy sources, reinstall blocks, bleed all pressure systems, discharge any capacitors, and verify all energy sources are de-energized and the machine/equipment is in a zero energy state prior to continuing the maintenance/repair work.

Machinery/equipment design and performance limitations may dictate that effective alternative worker protection be provided when the established lockout procedure is not feasible. If machinery/equipment 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 maintenance/repair work is completed and the machine/equipment is ready to be returned to normal operation, the following procedural steps must be followed:

1. Remove all non-essential items.

2. Ensure 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 for the specific machine/equipment.

5. Only the person who applied the lock (authorized person) may remove it, or provide direct supervision of its removal. If the authorized person is absent from the work place and unavailable to remove their lock(s), then the lock and/or tag can be removed by that person’s supervisor, or a qualified person designated, to perform this task, provided that:

• Actions are taken to verify that the authorized person is not present and therefore unavailable to remove the lock;

• All reasonable efforts are made to inform the authorized person whose lock is being removed that the lockout/tagout device has been removed; and

• The authorized person knows their lockout/tagout device has been removed before they resume their work.

• The supervisor/qualified person removing the authorized person’s lock(s) understands that they are responsible for the consequences of removing the authorized person’s lock(s).

6. Make a visual check before restoring energy to ensure that everyone is physically clear of the machine/equipment and its operational zone.

7. Notify any “Affected Person(s)” that the equipment has been restored to its operational state.



Joint Projects

When University personnel and contractor personnel are working on the same piece of machinery/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 the hasps and locks that their personnel install/use. University personnel must follow the lockout/tagout/blockout procedures outlined above.



Lockout/Tagout/Blockout – Code of Safe Practices Lockout/tagout/blockout (LOTO) is a method of preventing equipment from being set in motion and endangering workers. Failure to properly isolate and de-energize energy sources can be fatal. Compliance with the University’s LOTO policy is mandatory for your protection and the protection of others. The application of lockout/tagout/blockout is often limited to electrical energy. It is critical for your safety to remember that power sources include mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources. An additional energy source is stored energy, such as in electrical batteries, capacitors, and springs. Even gravity presents a form of energy.

General Guidelines: 1. Consult with the EH&S Department and

refer to the campus-specific LOTO Program, procedures, and training requirements.

2. Apply LOTO procedures whenever adjusting, servicing, or maintaining any power tool or machine. Examples include changing the blades or attachments on power tools or machinery, whenever a guard or safety device must be removed or by-passed, whenever you will place any part of your body where it might be caught in moving machinery, or whenever the unexpected movement of the machinery or tool could cause injury.

3. Identify all sources of energy supplying the tool or machine prior to starting the procedures.

4. Ensure you have the appropriate lockout/blockout devices, locks, and tags.

5. Never assume when the power switch is in the “off” position there will be no movement. Dissipate all residual energy prior to beginning the service or repair work. Ask your supervisor if you do not know how to do this procedure.

6. Ask your supervisor if you are unsure of how to proceed at any point in the operation.

Applying Energy Controls:

1. Notify others in the area that you are shutting down and locking out the tool or equipment.

2. Shut down the tool or machine using its on/off switch and normal shut-down procedures.

3. Bleed, drain, and clear all steam, air, gas, and hydraulic lines to ensure there is no residual energy.

4. Release and block any mechanism under load or pressure.

i. Apply the lockout devices and/or blockout devices, as well as the locks and tags. Unplug tools and equipment equipped with a power cord; apply a clamp-shell cover to the plug. Remember some machinery and power tools have more than one source of energy; ensure all energy sources are de-energized and lockout.

5. Fill out the lockout tags: name of person performing the lockout, reason, and date.



6. Test the on/off switch to verify there is no movement or energy release.

7. Keep the keys to the lockout devices on your person at all times.

Removing Energy Controls:

1. Only the personnel who applied the LOTO may remove the LOTO. See your supervisor for exceptions.

2. Remove all tools, parts, and scrap.

3. Ensure the system is fully assembled, and all guards and safety devices have been restored.

4. Notify personnel in the area that you are re-energizing the tool or machine.

5. Remove the locks, tags, and lockout/blockout devices following manufacturer’s checklist to re-energize.

6. Make another visual check to ensure everyone is clear prior to starting the tool or machine.

7. Never remove a lock until you are absolutely sure that it is completely safe to do so.



Energy Sources – Codes of Safe Practice Assuming that the only energy source that needs to be controlled is electricity can place your safety and the safety of others at risk. It is important to know the various types of energy sources, and that some machinery and equipment has more than one source of energy. As an example, heating, ventilation and air conditioning (HVAC) units may involve electricity, natural gas, chemical (Freon), and mechanical (the fan). The following list provides some guidelines for isolating various energy sources, controlling re-activation, and dissipating any residual energy. These are simple guidelines – ALWAYS follow the manufacturer or shop-specific procedures for locking, tagging, and/or blocking out machines and equipment to ensure a zero energy state while the machine or equipment is adjusted, serviced and/or repaired. Energy Sources – Isolation and Controls

• Electrical – Electrical energy sources are the most commonly recognized source of energy. Electrical energy is found in electrical wiring to machines and equipment and in power cords. It is also stored in batteries and capacitors. Capacitors are found in a number of electrical appliances that allows them to continue running during power outages; these sources are often overlooked. o Isolate the Energy:

• Turn the power switch to the ‘off’ position.

• Unplug the power cord.

• Move the breaker switch to the ‘off’ position.

• Move the handle of the disconnect box to the ‘off’ position.

• Remove the batteries.

• Disconnect the battery cables.

• Remove the capacitor. o Control Re-activation:

• Remove the key from a key-operated on/off switch. • Place:

� Clam-shell lockout devices over the end of power plugs and secure locks to the devices.

� Lockout devices designed for the purpose on the breaker switches and secure locks to the devices to prevent movement.

� Locks on the disconnect control switches. o Dissipate Stored Energy:

• Follow the manufacturers’ and/or shop-specific procedures for dissipating stored electrical energy for the machinery/equipment/system on which you are working.

• Mechanical – Mechanical energy is basically the combination of the energy of motion (kinetic energy) and the energy in a system based on the position of its parts. Gravity can create mechanical energy. Examples include: rotating wheels, fans, drive components, suspended counter weights, elevated components, springs, gas struts, and other mechanical hazards.



o Isolate the Energy: • Turn the power switch to the ‘off’ position.

• Set the brakes on the machinery/equipment with its braking mechanisms. o Controls:

• Place blocks under suspended or elevated components, i.e. blocking the forks of a forklift in an elevated position; blocking the ram of a power press to prevent it from descending.

• Chain the suspended or elevated component in its current position so that it cannot move unexpectedly. Ensure the structure to which it is chained is capable of sustaining the suspended load.

o Dissipate Stored Energy: o Release the tension on belts and chains.

• Hydraulic – Hydraulic energy is created by compressing liquids, such as the hydraulic power of a vehicle hoist. o Isolate the Energy:

• Turn the power switch for the machine, the pump, and/or the compression to the ‘off’ position.

• Close the supply valve; the valve may be a gate, ball or butterfly valve. o Control Re-activation:

• Supply valve – Install lockout devices designed for the purpose to lock the supply valve in the ‘closed’ position and secure locks to the devices to prevent the device from being opened or moved.

• Drain valve – Install lockout devices designed for the purpose to lock the drain valve in the ‘open’ position and secure locks to the devices to prevent the device from being opened or moved.

• Engage locking pins or install blockout devices to prevent the machine/equipment from moving due to the weight or position of the component.

o Dissipate Stored Energy:

• Open the ‘bleeder’ valve where one is present.

• Follow the manufacturer’s or shop procedures to release any residual fluid or pressure on the line that is downstream from the lockout device.

• Pneumatic – Pneumatic energy is created by compressing

air, such as compressed air hose, or pneumatic power tool. o Isolate the Energy:

• Turn the power switch for the machine, the pump, and/or the compression to the ‘off’ position.

• Close the supply valve; the valve may be a piston, ball or regulator valve.

• Release the quick-disconnect connections. o Control Re-activation:

• Install lockout devices designed for the purpose and secure locks to the device to prevent the device from being opened or moved.

• Install blocks to prevent movement whenever pressure on the line cannot be relieved.




• Typically the piston or ball valve on a pneumatic system will also have a venting feature that releases the energy.

• Vent the system to release residual energy in the line or in the system if the valve does not automatically vent it.

• Follow the manufacturer’s or shop procedures to release any residual fluid or pressure on the line that is downstream from the lockout device.

• Chemical – Chemical energy involves pressurized chemicals, such as compressed gas cylinders, or chemicals in pipelines, such as natural gas that feed into HVAC systems. o Isolate the Energy:

• Turn the power switch to the ‘off’ position. • Close the supply valve; the valve may be a gate, ball or

butterfly valve.

• Remove the supply control valve from compressed gas cylinders.

o Control Re-activation:

• Install lockout devices designed for the purpose and secure locks to the lockout device to prevent the lockout device from being opened or moved.

• Insert a blank in the downstream flange after the valve is closed and locked.



• Follow the manufacturer’s or shop procedures to release any residual chemical or pressure on the line that is downstream from the lockout device.

• Thermal – Thermal energy involves heat, such as steam. o Isolate the Energy:


• Shut down the process in accordance with the manufacturer’s instructions.

• Close the supply valve; the valve may be a gate, ball or butterfly valve.

o Control Re-activation:

• Install lockout devices designed for the purpose and secure locks to the lockout devices to prevent the lockout device from being opened or moved.

• Insert a blank in the downstream flange after the valve is closed and locked. o Dissipate Stored Energy:





• Radiation – Radiation energy includes non-ionizing radiation and ionizing radiation (such as X rays). Examples include X-rays – ionizing radiation, and lasers – non-ionizing radiation. o Isolate the Energy:


• Shut down the process in accordance with the manufacturer’s instructions. o Control Re-activation:

• Install lockout devices designed for the purpose and secure locks to the devices to prevent movement of the control mechanism.





Basic Electric Safety – Code of Safe Practices Electrical hazards can be found throughout shop operations and include, but are not limited to, exposed wiring; improperly spliced wires; improperly installed temporary power distribution; improperly grounded wiring; use of damaged electrical cords; i.e., frayed, repaired, missing ground prongs, and the use of inappropriate extension cords.

Common Examples of Misused Equipment* (Source: Fed OSHA)

1. Homemade ungrounded multi-receptacle boxes.

2. Fabricating extension cords with ROMEX® wire.

3. Using equipment outdoors that is labeled for use only in dry, indoor locations.

4. Attaching ungrounded, two-prong adapter plugs to three-prong cords and tools.

5. Using circuit breakers or fuses with the wrong rating for over-current protection, e.g., using a 30-amp breaker in a system with 15- or 20-amp receptacles. Protection is lost because it will not trip when the system's load has been exceeded.

6. Using modified cords or tools; e.g., removing ground prongs, face plates, insulation, etc.

7. Using cords or tools with worn insulation or exposed wires.

Electrical Safety Measures:

1. Conduct routine documented inspections and correct electrical hazards immediately.

2. Permit only qualified, trained personnel to correct electrical equipment.

3. Stop the work and correct the conditions when:

a. Circuit breakers are tripped and/or fuses are blown

b. An electrical tool, machine, wire, or connection feels warm

c. A burning odor is noticed

d. A tingling sensation or minor shock is felt when contacting the tool, cord, machine, or piece of equipment

4. Maintain at least a 36-inches clearance in front of and to the sides of all electrical cabinets.

5. Ensure all wiring is appropriately encased in conduit (including ROMEX®).

6. Never drape or staple electrical wiring over doorways or openings.

7. Provide strain relief equipment for all electrical cables.

8. Use and test the Ground Fault Circuit Interrupters (GFCI).

9. Use grounded (three-prong plug) or double insulated power cords.

10. Use extension cords only when necessary.

11. Never use an extension cord in place of permanent wiring.

12. Ensure extension cords are in good condition and the right type for the job and/or work environment.

13. Never connect multiple extension cords and surge protection devices together.



14. Protect all temporary cables/extension cords subject to vehicular or pedestrian traffic.

15. Never wrap an electrical cable or power cord around a pipe or race way.

Motorized Equipment:

1. Provide precautionary signage in those areas where electrical equipment is being used and where there are high-energy sources.

2. Check all motorized equipment on a regular basis to ensure its proper operation.

3. Apply lockout/tagout/blockout controls for equipment that may involve unexpected energization or start up (or release of stored energy) during cleaning, repairing, servicing, setting-up, adjusting, or un-jamming.



2. LOCKOUT/TAGOUT/BLOCKOUT PROGRAM

FORMS



University of California - EI-LOTO “Equipment Specific” Procedure – EXAMPLE

Equipment: Building: Location/Room #:

Describe scope of work: Instructions: Follow the steps to create a written sequence for de-energizing, lockout, testing, and start-up of equipment requiring energy isolation. Use completed procedure for safety meetings / training for the equipment-specific lockout process. Discuss with workers how equipment energy isolation – LOTO is applied to this specific equipment during these planned job/tasks. Also, discuss communication methods on the job site.

Survey Check

off 1. ENERGY SOURCE 2. MAGNITUDE/TYPE 3. ISOLATION DEVICE/LOCATION/METHOD

ELECTRICITY – Main Power Amps: Volts: # Phase:

ELECTRICITY – Control Circuit(s) Amps: Volts: # Phase:

BATTERY/SOLAR/ALT POWER

AC/DC/PH

Amps: Volts:

COMPRESSED AIR/GASES PSI: Gas Type:

STEAM/CONDENSATE PSI: Source:

FLUID UNDER PRESSURE PSI: Source:

HEAT/COLD +/- C° OR +/- F° TEMP: Source:

VACUUM CHAMBER/PIPING Hg”: Source:

FUEL(S) – SOLID/LIQUID/GAS Volume: Fuel:

ROTATING WHEEL/FAN/DRIVE Details:

SUSPENDED WEIGHT Details:

MECHANICAL OTHER: Details:

PPE to be Worn During Work Safety Equipment To Be Used During Work Procedure Prepared by:

Goggles / Face Shield / Weld Gear Fire Extinguisher / Fire Watcher

(PRINT NAME)

Boots – Steel Toe / Rubber / Other Lines Blinds & Tags _____________________________ __________________

Gloves – Leather / Rubber / Insulated Valve/Switch – Locks & Tags Signature / Date

Safety Harness / Lanyard & Line Remove Flammables / Combustibles

Respirator – Dust / Chemical Bleeders - Locks & Tags Annual Review Completed by:

Thermal – Heat / Cold Protection Shields – Arc Curtain / Heat Blanket

(PRINT NAME)

Apron / Wet Gear / Other Blocks / Bars / Barricades / Chains ________________________________ __________________

Instructions continued: Isolate energy sources in sequence. Assure each worker installs their own locking device on each disconnect location. Supervisor /Authorized Person installs the warning tags. Verify Energy Isolation prior to starting work. When testing/jogging the equipment, follow program procedures on the back of this form. When restoring the equipment to operation, reverse isolation sequence unless otherwise discussed/approved by the Project Supervisor. Use personal protective equipment and safety equipment as noted below during work activities. Contact EH&S for technical support and special concerns.

Step 1 – Survey and Check

off [X] all Energy Sources

Step 4 – List sequence of Energy Isolation Number 1 up to 12

Step 2 – Note Magnitude and type of each energy

Step 3 – Note Device and Location of each energy disconnecting / isolation source/method.

Step 5 – Check off [X] and circle all PPE and safety equipment to be used for Energy

Isolation.



Other: _______________________________ Tools – Long Handle / Insulated Signature / Date

University of California - EI-LOTO “Equipment Specific” Procedure – Form – Page 1

Equipment: Building: Location/Room #:

Describe scope of work: Instructions: Follow the steps to create a written sequence for de-energizing, lockout, testing, and start-up of equipment requiring energy isolation. Use completed procedure for safety meetings / training for the equipment-specific lockout process. Discuss with workers how equipment energy isolation – LOTO is applied to this specific equipment during these planned job/tasks. Also, discuss communication methods on the job site.

Survey Check

off 1. ENERGY SOURCE 2. MAGNITUDE/TYPE 3. ISOLATION DEVICE/LOCATION/METHOD

Instructions continued: Isolate energy sources in sequence. Assure each worker installs their own locking device on each disconnect location. Supervisor/Authorized Person installs the warning tags. Verify Energy Isolation prior to starting work. When testing/jogging the equipment, follow program procedures on the back of this form. When restoring the equipment to operation, reverse isolation sequence unless otherwise discussed/approved by the Project Supervisor. Use personal protective equipment and safety equipment as noted below during work activities. Contact EH&S for technical support and special concerns.

PPE to be Worn During Work Safety Equipment To Be Used During Work Procedure Prepared by:

Goggles / Face Shield / Weld Gear Fire Extinguisher / Fire Watcher

(PRINT NAME)

Boots – Steel Toe / Rubber / Other Lines Blinds & Tags _____________________________ __________________

Gloves – Leather / Rubber / Insulated Valve/Switch – Locks & Tags Signature / Date

Safety Harness / Lanyard & Line Remove Flammables / Combustibles

Respirator – Dust / Chemical Bleeders - Locks & Tags Annual Review Completed by:

Thermal – Heat / Cold Protection Shields – Arc Curtain / Heat Blanket

(PRINT NAME)



Apron / Wet Gear / Other Blocks / Bars / Barricades / Chains ________________________________ __________________

Other: _______________________________ Tools – Long Handle / Insulated Signature / Date

University of California - EI-LOTO “Equipment Specific” Procedure – Form – Page 2 Standard Energy Isolation LOTO Procedure

1. Issue all maintenance personnel a suitable lock (or locks for multiple energy sources). 2. Ensure each lock has the individual worker’s name or other identification on it. 3. Ensure the worker assigned the lock has the only key to the lock/lock set. 4. Ensure that no one is operating the machinery BEFORE turning off energy sources. This is the responsibility of the supervisor or ‘Authorized Person’. 5. Inform all persons in the area, and especially the machine operator and project supervisor, BEFORE the energy sources are turned off because unexpected sudden loss of power could cause an accident. 6. Place a tag on each lock-out location. This is the responsibility of the supervisor or ‘Authorized Person’ to ensure personnel working on the project know where to apply lockout devices. 7. Ensure that all energy sources which could activate the machine are locked or blocked out following an equipment-specific Energy Isolation Procedure developed for that equipment. 8. Turn to the ‘off’ position all starting devices. 9. Bleed, drain, and bring to atmospheric pressure all steam, air, and hydraulic piping or tanks and the lock them in the “open” position to assure there is no pressure or vacuum in the piping or in the reservoir tanks. 10. Lock gas cylinders in the ‘closed’ position and if possible disconnect the cylinders from the distribution piping. 11. Bar or block any mechanical component that could roll, shift or otherwise move, such as springs, counterweights, wheels, fan blades, etc. 12. Turn off all electrical switches and/or disconnects. 13. Check electrical circuits with appropriate and calibrated electrical testing equipment. This is the responsibility of qualified persons. 14. Discharge any stored energy in electrical capacitors. 15. Ensure that each person working on the machinery puts a lock on each of the machine’s energy control 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. 16. Attach lockout tags to all lockout/blockout locations. Ensure the tags provide 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. 17. Test all disconnects and operating controls to ensure that all energy sources to the machine are off and there is zero energy. 18. CAUTION: Always return disconnects and operating controls to the “off” position after each test.

Testing / Adjusting Equipment during Lockout In many maintenance and repair operations, machinery/equipment must be tested and therefore energized before additional maintenance work can be performed. For such situations, this procedure must be followed:

1. Move all personnel to safety. 2. Remove all 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. 6. Reinstall lockout devices on energy sources, reinstall blocks, bleed all pressure systems, discharge any capacitors, and verify all energy sources are de-energized and the machine/equipment is in a zero energy state for prior to

continuing the maintenance/repair work. Machinery/equipment design and performance limitations may dictate that effective alternative worker protection be provided when the established lockout procedure is not feasible. If machinery/equipment 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 maintenance/repair work is completed and the machine/equipment is ready to be returned to normal operation, the following procedural steps must be followed:

1. Remove all non-essential items. 2. Ensure 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. Only the person who applied the lock (qualified person) may remove it, or provide direct supervision of its removal. If the authorized person is absent from the work place and unable to remove their lock(s), then the lock or tag can

be removed by that person’s supervisor, or qualified person designated to perform this task, provided that the immediate supervisor:

• Verifies that the qualified person is not present and therefore unable to remove the lock;

• Makes all reasonable efforts to inform the qualified person that the lockout/tagout device has been removed; and

• Ensures that the qualified person knows their lockout/tagout device has been removed before their work resumes. 6. Make a visual check before restoring energy to ensure that everyone is physically clear of the machine/equipment and its operational zone. 7. Notify any “Affected Person(s)” that the equipment has been restored to its operational state. Joint Projects When University personnel and contractor personnel are working on the same piece of machinery/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. University personnel must follow the lockout/tagout/blockout procedures outlined above.



Lockout/Tagout/Blockout Inspection Form Sample

For What Piece of Equipment

(name & location)

Date/ Time

Locked or Tagged

Reason for Locking or Tagging

By Whom (name, job title)

Supervisor/Managers Signature

Date/Time Unlocked or

Untagged

By Whom (name, job title)

Supervisor/Managers Signature



3. SAFETY SIGNS Print and post the safety signs located on the following pages to provide information, guidance and warnings to personnel in shop areas. These signs can also be used during training meetings.



DANGER

DO NOT ENTER

UNTIL LOCK-OUT PROCEDURES HAVE BEEN COMPLETED



DANGER

Do Not Tamper with Lockout

Devices



DANGER

LOCKOUT EQUIPMENT BEFORE SERVICING



DANGER

LOCK OUT

EQUIPMENT

BEFORE SERVICING



DANGER

DO NOT

OPERATE



DANGER

EQUIPMENT

BEING

SERVICED

DO NOT

OPERATE



DANGER

Lockout

Equipment

Before Entering



CAUTION

LOCKOUT FOR SAFETY



CAUTION

LOCKOUT FOR SAFETY



CAUTION

LOCKOUT HERE



4. QUIZ



QUIZ – ENERGY SAFETY AND EI-LOTO

Print Trainee Name___________________________ Date _____________________ Trainee Signature _______________________ Supervisor Signature ______________

1. Which of the following are hazards of electricity? a. Shock and Electrocution b. Fire and burns c. Explosion and arc blast d. All of the above

2. Energy sources, particularly electrical panels and pressurized plumbing control valves,

should be properly secured easily accessible for 36” clearance.

True or False

3. A compressed air powered nail-gun is likely made safe simply by unplugging it from the compressed air system.

True or False

4. If I’m working on a large and heavy piece of equipment that I have jacked-up in the air with a rugged scissors or hydraulic jack, as long as the jack’s in good shape I don’t have to block the equipment before I crawl under it.

True or False

5. Once EI-LOTO is in place, who is allowed to remove the locks and tags to enable machinery to restart?

a. The qualified person who locked it out only b. Anybody who has the key to the lock c. The shop supervisor (under emergency situations following strict procedures for

notifying the qualified person) d. A and B e. A and C

6. Written procedures for Lock out/ tag out are needed for each and every piece of equipment

that is connected to, or produces more than, one kind of utility-energy used for its operation.

True or False 7. The EH&S Department on your campus has safety engineers available at no cost to help

you develop EI-LOTO procedures specific to your equipment. And, these procedures can be used as SOPs for research lab equipment, and as job-planning tools for facility maintenance.

True or False

8. Lock out/ tag out is not required when replacing saw blades on a hand-held circular saw. True or False



5. QUIZ ANSWERS

1. D 2. True 3. False – Compressed air equipment often has an accumulator tank inside the equipment that must

be bled to atmosphere before the equipment is safe to work on. Look at equipment manuals to understand how your compressed air equipment operates, and locate safety bleed valves and open them before working on the equipment.

4. False – Never put any part of your body underneath a heavy object that’s being held-up by jack or hoist piece of equipment without blocking. Always raise the equipment and set it down securely onto blocks that can support its weight before you put any part of your body underneath it.

5. E 6. True 7. True 8. True – As long as the circular saw is unplugged, and you have exclusive control over the plug.



Documents

Section 8: Energy Safety & Isolation – EI- LOTO