The Safe Isolation of Machinery and Equipment using Lockout Tagout

1. The Safe Isolation of Machinery and Equipment using Lockout Tagout Tim Hughes Total Lockout (Safety) Ltd Daryl Wake Smart Staff International

2. I want to talk to you about worker safety!! Every year, numerous Alcoa workers are injured so badly that they miss a day of work.  Our safety record is better than the general workforce, especially considering that our employees work with metals that are 1500 degrees and we have machines that can rip a man’s arm off.  But it’s not good enough.  I intend to make Alcoa the safest company in America.  I intend to go for zero injuries October 1987 Source: “Is this the best CEO speech ever..? Digicast.com.au , M. Claire-Ross, Sept. 2012 Paul O’Neill – CEO, Alcoa

3. Summary & Learning Objectives • Anecdotal incidents of LOTO failure [prepare to be shocked…] • Legal requirements • When & how to implement? • Understanding the hardware

4. Why should we be concerned about LOTO? • HSE Statistics 2011/12 • 173 workers killed at work • 111,000 injuries to employees under RIDDOR • Mostly manual handling, slips and trips, falls from height. However………

5. Why is LOTOTO important • Man dragged in to a wood chipper during landscaping job! • While attempting to clear a blockage with his feet, he became entangled and was drawn into the machine. • Prosecution: Lack of adequate training and risk awareness. • Father of 3 pinned by a moving milk machine” • While carrying out routine maintenance on a container loading machine, it was somehow activated, pinning him inside. • Prosecution: Failure to isolate.

6. Three sub-contractors from a specialist engineering company undertaking maintenance work were drenched in a liquid jet of caustic soda when repairing a valve on a line running from a detergent tank.  Up to 6,000 litres of the chemical spilled out from the container.  One worker was temporarily blinded and one of his colleagues suffered 25 per cent burns left him with scars and continuing sensitivity, making it difficult for him to tolerate heat. The third man suffered minor skin burns and irritation to his eyes.  The men had not been given adequate instructions or appropriate personal protective equipment.  The company employing the men had not managed their contractors properly or carried out suitable risk assessments for the work that they had been asked to do.

7. Two electricians suffered life-threatening injuries when they were engulfed by a fireball at a factory as they were about to clean debris from a damaged fuse box. One of the electricians is still undergoing treatment for his burns, nearly five years on, and will never be able to return to work. There had been a fire in the fuse box during the previous afternoon but live cables had been routed through it so that the cooling equipment at the factory could continue to operate. This meant the company avoided having to shut down the plant for 36 hours. A suitable risk assessment had not been carried out for the work and management at the company had allowed the work to go ahead without the electricity supply being isolated, even though this went against their own work procedures.

8. An employee lost an arm at a giant industrial auger as he was carrying out repairs. He initially attempted a repair with the electrical power to the auger incorrectly isolated and without completing the permits for work required by company policy. The repair failed, so he attempted another repair the following day. However, both he and his supervisor failed to check that the power had been isolated, in breach of company procedures. • When the supervisor accidentally activated the machine, his colleague's arm was removed above the elbow. Although the facilities to correctly isolate the machines were available, and the worker’s employer had trained its workforce in safety, it failed to provide the injured man with initial training or any additional information about the equipment he was working on or about company procedures. In addition, the plant manager did not supervise work correctly, which meant company permits to work were frequently not completed

9. Judge Slates engineering firm for shambolic safety.... • Engineering Firm fined £300k after investigation uncovers repeated failings that put employees at risk of death for several years. • Isolation valve jammed while closing. • Maintenance worker crushed when stored energy caused the valve to suddenly closed. • HSE Investigation reveals ineffective isolation procedure.

10. What is LO/TO/TO? Control Measure Risk Assessment http://www.hse.gov.uk/pubns/indg163.pdf Permit to Work

11. In summary... • A safe method to work on machinery, equipment and other energy sources. • The placement of a lockout device on an energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed.

12. What energy sources present a risk? Electrical Mechanical Hydraulic/Pneumatic Flow i.e. liquid/gas

13. Also consider… • Kinetic energy - moving/spinning shafts, inertia • Springs • Chemicals and Acids • Asphyxiants • Radiation – X-Ray, ionizing, lasers, microwave, RF • Thermal – steam, cryogens

14. Legal references • Provision & User of Work Equipment Regulations 1998 (PUWER) • Electricity at Work Regulations 1989 (EAWR) • BS7671:2008 17th Ed. Wiring Regulations • Health & Safety at Work etc Act 1974

15. The employers role...Provision & Use of Work Equipment Regulations (1998) • Regulation 19 (1): Every employer shall ensure that where appropriate work equipment is provided with suitable means to isolate it from all its sources of energy. • Regulation 19 (3) : Every employer shall take appropriate measures to ensure that re-connection of any energy source to work equipment does not expose any person using the work equipment to any risk to his health or safety.

16. Legal references…cont’dProvision & Use of Work Equipment Regulations (1998) • 277: An isolating switch or valve may have to be locked in the off or closed position to avoid an unsafe reconnection. Source: http://machinerysafety101.com Source: Brady Corporation

17. Legal references…cont’dProvision & Use of Work Equipment Regulations (1998) • 278: If work on isolated equipment is being done by more than one person, it may be necessary to provide a locking device with multiple locks and keys. Each will have their own lock or key, and all locks have to be taken off before the isolating device can be removed. Keys should not be passed to anyone other than the nominated personnel and should not be interchanged between nominated people. aka: Group Lockout

18. Legal references…cont’dThe Electricity at Work Regulations (1989) • Regulation 12 Para 188– Suitable means of isolation • (b) include, where necessary, means directed at preventing unauthorised interference with or improper operation of the equipment, for example means of locking off; • Regulation 13 – Precautions for work on equipment made dead: Adequate precautions shall be taken to prevent electrical equipment, which has been made dead on order to prevent danger while work is carried out on or near that equipment, from becoming electrically charged during that work if danger may thereby arise. • Para 195: Ideally a means of locking off an isolator can be used. Where such facilities are not available, the removal of fuses or links and their being held in safe keeping can provide a secure arrangement if proper control procedures are used.

19. Fuse removal…

20. Legal references…cont’dBS7671:2008 17th Ed. Wiring Regulations • Where an isolating device is located remotely from the equipment it serves, it is necessary, for compliance with Regulation 537.2.1.5, for the device to be provided with a means of securing it in the open (OFF) position. This can be achieved by, for example, a locking arrangement on an MCB, a locked distribution board with only one key or with a removable key or handle which is one of a kind. Source: Master Lock Corporation

21. Section 8: Health & Safety at Work etc. Act 1974 No person shall intentionally or recklessly interfere with or misuse anything provided in the interests of health, safety or welfare in pursuance of any of the relevant statutory provisions. OSHA GUIDELINES – The Control of Hazardous Energy 1940.147 (a) (1) (i)

22. When to Lockout/Tagout? • There are two occasions for gaining access to potentially hazardous machinery or processes. • Unplanned access e.g. clearing a blockage • Planned access e.g. scheduled maintenance or repair.

23. When to Lockout/Tagout? Any interaction with a potential hazard, energy source. • Planned Access • Unplanned Access

24. Equipment • Safety Padlock • Multi Hasp • Tag • Speciality Device

25. One padlock – one key • Unique key number recorded against end-user register. • Key is trapped in the lock when shackle is open. • Key cannot be duplicated at high-street key cutters.

27. Considerations for Effective Isolation Systems • Sites should appoint a standout accountable representative, supported by a steering committee. • Define the responsibilities and accountabilities of the persons performing isolations. • Establish the training and competency requirements for permit issuers, permit holders and persons performing isolations. • Ensure hazards associated with the planned activity are identified, appropriate mitigations documented and the work is authorised by a responsible person. • Define isolation design criteria and process. "Creating Practical Workplace Systems"

28. Considerations for Effective Isolation Systems • Define the controls which apply to personnel accessing machinery that may start and stop automatically or by instruction from a remote location. • Control and approve any software overrides, hard-wire bridging or interlock bypassing. • Control isolations which span one or more shift handovers. • Identify any points of isolation and provide personnel performing the work with unique, secure, control of the point of isolation. "Creating Practical Workplace Systems"

29. Define how a competent person in ensuring safe isolation is achieved before commencing work. • Determine the actions required if there is any doubt safe isolation was achieved. • Manage isolations for interacting and/or simultaneous activities and where there is potential for multiple sources of energy (e.g. work on electrical ring feed systems). • Develop systems to manage the isolation of HSE critical systems. "Creating Practical Workplace Systems"

30. Manage changes which may affect the scope of the permit-to-work and/or the isolation standard(s) required, including changes to planned tasks and the action to be taken by the permit-holder in response to an emergency. • Verify isolated equipment/plant is returned to a safe operating condition before it is brought back into service. • Scheduled auditing/reviewing of the system, regularly analysing audit findings. "Creating Practical Workplace Systems"

31. Systematic Steps for Successful LOTO • Prepare and notify • Shutdown • Isolate • Apply lockout devices • Release stored energy • Verification "Creating Practical Workplace Systems"

32. LOTO Equipment – Padlocks Padlocks should: • Be keyed to suit business needs, consider: • Personal – Uniquely keyed / Keyed to differ • Keyed alike – Used for multiple isolations • Not be combination locks. • Not have an unauthorised second-party master override key. • Be kept under the exclusive control of the owning individual, and key (s) shall not be transferred to another person for lock removal Other considerations: • Corrosion • Non-conductive • UV • Length of shank • Colour "Creating Practical Workplace Systems"

33. LOTO Equipment – Padlocks "Creating Practical Workplace Systems"

34. Hardware Considerations - Tags "Creating Practical Workplace Systems"

35. Hardware Options - Permit Control Boards "Creating Practical Workplace Systems"

36. Electronic PTW / LOTO Systems - Options SAGE - ‘Suprpass’ PetroTechnics – ‘ISSoW’ CGE – ‘Permit Board’ ApplyIt – ‘IntelliPermit’ "Creating Practical Workplace Systems"

37. Video clips…

38. Spoiler Alert No animals were harmed in the making of this film!!!

39. How to avoid the accident

40. But the dangers are real…….

42. Thank you for watching…. www.totallockout.com www.smartstaffinternational.com @totallockout @wakedj http://www.linkedin.com/company/total-lockout-safety-ltd