psu loto training
TRANSCRIPT
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PSU Lockout/Tagout Training forAuthorized Employees
(Note: This training is intended to be presented by
EHS)
www.ehs.psu.edu
http://www.ehs.psu.edu/http://www.ehs.psu.edu/ -
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Objectives
Clarify requirements of PSU Lockout/Tagout
(LOTO) Program
Ensure everyone is aware of their role within
LOTO Program
Provide an opportunity to discuss concerns
related to LOTO Program
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Training Outline
I. How Do Injuries Occur During Servicing?
II. What is LOTO?
Types of hazardous energy
When should LOTO be applied? Energy isolation devices
III. LOTO Basics
IV. General LOTO procedure at PSU
V. Special Situations
VI. Energy Isolation DeviceVideo Review
VII. Safe or Unsafe? Exercise
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I. How Injuries Occur During the Servicing
of Equipment?
BLS study on injurieswhile servicing
equipment revealed:
80% failed to turn off
equipment
10% equipment
activated by someone
else
5% failed to control
potential energy
Most of remaining 5%
disconnected power but
failed to verify
effectiveness
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II. What is LOTO?
LOTO is a technique used to prevent energy
from being released during the servicingof
equipment. This is accomplished by placing
locks on energy isolation devices prior to
starting work.
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Types of Hazardous Energy
What types of hazardous energyare subject to
LOTO?
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Types of Hazardous Energy
Electrical
Pneumatic
Hydraulic
Mechanical
Thermal
Chemical
Radiation
Steam
Spring-Driven
Suspended Parts
Some energy sources can be turned on/off.Others can only be dissipated or controlled.
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Potential Energy vs. Kinetic Energy
Potential energy can be converted to kinetic!
Goal of LOTO is to achieve Zero Energy State
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When is LOTO applied?
Adjusting
Inspecting
Modifying
Replacing parts
Tool changes
Clearing jams
Lubricating
Cleaning
during the servicingof equipment.
There are some situations where LOTO is not required
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Exceptions to LOTO
Cord & plug connected equipment Plug is only source of energy
Plug is under continuous control of one person
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Exceptions to LOTO
Minor tool changes and adjustments, and other minor
servicing activities, which take place during normal
production operations, if they are routine, repetitive and
integral to the use of the equipment for production,
provided that the work is performed without the removal
or bypassing of machine guards.
Alternative measures for protection are used. Body part not placed in the point of operation or other
dangerous area during machine cycle.
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Energy Isolation Devices
Examples:
Electrical disconnect switch
Electrical breaker switch
Hydraulic valve
Pneumatic valve
Line valve
Pushbuttons, selectorswitches, and other control
circuit devices are NOT energyisolation devices.
accomplished by placing locks on energy isolation devices
Device that physically prevents the
transmission or release of energy
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Review of LOTO Definition
LOTO is a technique used to prevent energy
from being released during the servicingof
equipment. This is accomplished by placing
locks on energy isolation devices prior tostarting work.
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III. LOTO Basics
All employees fit into one of the following
LOTO roles:
Authorized employee Services equipment & authorized to apply LOTO.
Affected employee Operates or uses equipment being serviced under
LOTO.
Other employee Works in an area where LOTO being used.
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LOTO Basics
Preferred means of controllinghazardous energy at PSU isLOCKOUT IN CONJUNCTIONWITH TAGOUT.
Each isolation point must haveboth a lock and a tag attachedto it.
Locks must be standardized &used only for LOTO.
Tags must indicate lock holder& date of application.
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IV. General PSU LOTO Procedure
STEP 1
ID Energy
Sources
STEP 2
Notify
Others
STEP 4
Isolate
Equipment
STEP 5
LOTO
Equipment
STEP 3
Shutdown
Equipment
STEP 6
Release Stored
Energy
STEP 7
Verify
Isolation
STEP 8
Perform
Servicing
STEP 9
Release
from LOTO
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Step 1: ID All Energy Sources
Know types & magnitude of energy associated
with equipment.
ID all energy sources feeding the equipment
(including potential energy).
Gather appropriate control devices.
Clarify any questionable identification of
energy sources before proceeding.
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Step 2: Notify Others
Verbally notify all affected and other
employees of impending shutdown.
Not all equipment will have someone
assigned to it.
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Step 3: Shut Down Equipment
Use normal stopping
procedures to shut
down equipment.
Push Stop button Off/On toggle switch
etc.
http://images.google.com/imgres?imgurl=http://www.esrf.eu/UsersAndScience/Experiments/MX/How_to_use_our_beamlines/Run_Your_Experiment/Sample_Changer_Manual/crate-on-off&imgrefurl=http://www.esrf.eu/UsersAndScience/Experiments/MX/How_to_use_our_beamlines/Run_Your_Experiment/Sample_Changer_Manual/&usg=__lRS2EL1saW0piMiwI5f_p1Iv43s=&h=497&w=605&sz=40&hl=en&start=44&um=1&itbs=1&tbnid=9EiqXiPdmpnmUM:&tbnh=111&tbnw=135&prev=/images?q=on/off&ndsp=20&hl=en&sa=N&start=40&um=1 -
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Step 4: Isolate Equipment
After shutdown,operate all energyisolation devices soequipment is
disconnected fromenergy sources. Turn electrical
disconnect to OFFposition
Open circuit breaker Close valve
Etc.
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Step 5: LOTO the Equipment
Attach locks & devices to
each isolation point.
Tag must accompany each
lock.
Good idea to also tag point
of operation if located
remotely from isolation
points.
What if equipment wont
accept a lock?
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Step 6: Release Stored Energy
Ensure all potential orresidual energy iscontrolled.
Block elevated parts.
Block/release springs.
Relieve system pressure.
Drain fluids.
Vent gases.
Allow system to cool.Discharge capacitors.
Stop rotating flywheels.
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Step 7: Verify Isolation
Before any servicing begins, verify
effectiveness of LOTO.
Use normal starting procedure or otherwise
verify Zero Energy State.
Return controls to OFF position after testing.
Verification is the step which is most
frequently skipped during evaluations.
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Step 8: Perform Servicing
Complete required service work.
Avoid doing anything that could potentially
reactivate the equipment.
OK to interrupt LOTO, but must be reapplied if
servicing is to continue.
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Step 9: LOTO Release
All locks, tags, & devices removed by same
person who applied.
Remove all tools from equipment area.
Replace all machine guards.
Verbally inform all affected & other
employees that LOTO is complete.
Ensure area is clear prior to restart.
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IV. General PSU LOTO Procedure
STEP 1
ID Energy
Sources
STEP 2
Notify
Others
STEP 4
Isolate
Equipment
STEP 5
LOTO
Equipment
STEP 3
Shutdown
Equipment
STEP 6
Release Stored
Energy
STEP 7
Verify
Isolation
STEP 8
Perform
Servicing
STEP 9
Release
from LOTO
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V. Special Situations Shift changes
Oncoming employee attaches locks/tags prior to outgoing employeeremoving theirs.
EHS must OK alternative procedures.
Vehicle hazardous energy control Alternative vehicle control methods are permitted in circumstances
where removal of the key fully ensures employee protection.
The authorized employee performing the maintenance would need to
retain sole control of the key. If removal of the key does not fully ensure employee protection
additional measures are needed. (removal of battery cable, chockwheels, etc)
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Lock removalprocedure
Supervisor mustbe notified if lockowner is notpresent.
Use Appendix C ofprogram todocumentremoval.
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V. Special Situations
Group LOTO Each employee applies own
locks/tags to each isolation point.
OR
A designated person locks out eachof the energy sources and puts thekeys into a group lockbox. Theauthorized employees place theirlock on the group lockbox before
they begin work. After each workerfinishes, the worker removes hislock from the box.
EHS must OK alternative procedures.
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Summary
All hazardous energy sources must be controlled(kinetic & potential).
Control via energy isolation device (do not rely oncontrol circuit).
Only use designated lock for LOTO.
Tags must accompany all locks.
Nine-step general procedureremember to verify
isolation. Protection must be ensured during special situations.
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Any Questions?