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Remote Lockout/Tagout

Join us for an engaging workshop on the integration of remote Lockout/Tagout (LO/TO) systems like the Allen Bradley Electroguard. This session will cover the vital importance of proper LO/TO execution, exploring significant challenges such as the need for PPE, training, and the availability of skilled workforce. We will examine the design of the Electroguard system, its compliance with safety standards, and its potential as a tool for energy isolation. Additionally, the discussion will include the future of regulations and the process of obtaining variances for innovative safety solutions in DOE facilities.

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Remote Lockout/Tagout

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  1. Remote Lockout/Tagout DOE Accelerator Safety Workshop August 7-9, 2007

  2. Introduction • Proper execution of lockout/ tagout (LO/TO) of hazardous energy sources is of vital importance to safe operation at DOE facilities • Proper execution of LO/TO can result in many issues: • PPE • Proper test equipment • Procedure • Training/ Qualification • Significant time to lock and unlock equipment • Required to use craft workers, not always available

  3. Remote LO/TO • One device on the market holds the promise of greatly simplifying electrical LO/TO • The Allen Bradley Electroguard product allows a worker to shut off power by the operation of one switch without verification • “But does this meet OSHA requirements?” Stay Tuned!

  4. Electroguard Design • A complex system composed of: • Safety Contactors • Safety Relays • PLC base I/O for communications • Designed to EN 954-1, category 4, certified by TUV • To perform power isolation, worker turns switch and if green light illuminates, then applies lock. Equipment is now de-energized and locked out • Can be interfaced with other control equipment (i.e. remote actuation, holdoff)

  5. Electroguard Design • “Double block and bleed” design • Two contactors in series between line and load and one contactor to ground the load

  6. Normal LO/TO PPE required Proper test equipment required Procedure may be required Training/ Qualification required Significant time to lock and unlock equipment Required to use craft workers, not always available Remote LO/TO No PPE No test equipment No procedure Less training Minimum time to lock/ unlock Can be performed by trained workers System must be periodically tested however Comparison

  7. Machinery safety Less complex Well defined/ limited functions Behavior of components well understood Prescriptive (cat 4- no single faults, diagnostic coverage Process safety More complex Particular safety functions not defined Involves use of more complex (PES) components Performance based (SIL 2) EN 954-1 Machinery Safety/ Control vs. IEC 61508

  8. Replacement for EN 954-1: standard EN ISO 13849-1 is ratified! • A significant revision in the standard that’s now appeared as EN ISO 13849-1 is the probabilistic approach to the assessment of safety-related control systems • Will allow use of standard components with known performance levels; formula used to calculate performance level (PLr)

  9. I’m from the Government…. • Last February OSHA responded to a letter from AB: • Does the Electroguard… meet the energy isolating device definition contained in 1910.147(b)? • No… circuit control devices cannot be used to control hazardous energy • If used (properly) would the Electroguard (be suitable for) the LOTO standard’s minor servicing exception? • Yes… on a case by case basis

  10. Now What? • AB intends to apply for a permanent variance from OSHA to allow the EG product to be used for LO/TO • With this variance as a model, a company can apply for their own permanent variance (one per company, not one per site) • In time (years), the regulations may change to recognize approved control devices for LO/TO • Meanwhile companies can: • Use the device for “minor servicing” • Use the device for LO/TO anyway

  11. Questions for Attendees • Would this product or equivalent be useful at BES facilities? • What requirements could be agreed on (i.e. category, SIL, PLr ,formal analysis/ certification requirements etc.) for this product or for an in-house system? • Would we pursue a variance from DOE to allow the use of this (or similar) design?

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