Electrical Safety Subpart S
Charles O Reynolds, CECM
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High Voltage or Low Voltage
Charles O Reynolds, CECM
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Some Work is More Dangerous
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Electricity - The Dangers • About 5 workers are electrocuted every week • Causes 12% of young worker workplace deaths • Takes very little electricity to cause harm • Significant risk of causing fires
Charles O Reynolds, CECM
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Electricity – How it Works • Electricity is the flow of energy from one place to another • Requires a source of power: usually a generating station • A flow of electrons (current) travels through a conductor • Travels in a closed circuit Charles O Reynolds, CECM
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Electrical Terms • Current -- electrical movement (measured in amps) • Circuit -- complete path of the current. Includes electricity source, a conductor, and the output device or load (such as a lamp, tool, or heater) • Resistance -- restriction to electrical flow • Conductors – substances, like metals, with little resistance to electricity that allow electricity to flow • Grounding – a conductive connection to the earth which acts as a protective measure • Insulators -- substances with high resistance to electricity like glass, porcelain, plastic, and dry wood that prevent electricity from getting to unwanted areas Charles O Reynolds, CECM
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Electrical Injuries There are four main types of electrical injuries: • Direct: Electrocution or death due to electrical shock Electrical shock Burns • Indirect - Falls
Charles O Reynolds, CECM
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Electrical Shock An electrical shock is received when electrical current passes through the body. You will get an electrical shock if a part of your body completes an electrical circuit by… • Touching a live wire and an electrical ground, or • Touching a live wire and another wire at a different voltage.
Charles O Reynolds, CECM
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Shock Severity • Severity of the shock depends on: Path of current through the body Amount of current flowing through the body (amps) Duration of the shocking current through the body, • LOW VOLTAGE DOES NOT MEAN LOW HAZARD
Charles O Reynolds, CECM
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No Laughing Matter
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Dangers of Electrical Shock • Currents above 10 mA* can paralyze or “freeze” muscles. • Currents more than 75 mA can cause a rapid, ineffective heartbeat -- death will occur in a few minutes unless a defibrillator is used • 75 mA is not much current – a small power drill uses 30 times as much
Defibrillator in use
* mA = milliampere = 1/1,000 of an ampere Charles O Reynolds, CECM
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Electricity Can Kill
Charles O Reynolds, CECM
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Burns • Most common shock-related injury • Occurs when you touch electrical wiring or equipment that is improperly used or maintained • Typically occurs on hands • Very serious injury that needs immediate attention
Charles O Reynolds, CECM
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Falls • Electric shock can also cause indirect injuries • Workers in elevated locations who experience a shock may fall, resulting in serious injury or death
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Electrical Hazards and How to Control Them Electrical accidents are caused by a combination of three factors: Unsafe equipment and/or installation, Workplaces made unsafe by the environment, and Unsafe work practices. Charles O Reynolds, CECM
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Hazard – Exposed Electrical Parts
Cover removed from wiring or breaker box Charles O Reynolds, CECM
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Control – Isolate Electrical Parts • Use guards or barriers • Replace covers
Guard live parts of electric equipment operating at 50 volts or more against accidental contact Charles O Reynolds, CECM
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Control – Isolate Electrical Parts Cabinets, Boxes & Fittings
Conductors going into them must be protected, and unused openings must be closed Charles O Reynolds, CECM
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Control – Close Openings • Junction boxes, pull boxes and fittings must have approved covers • Unused openings in cabinets, boxes and fittings must be closed (no missing knockouts) Photo shows violations of these two requirements Charles O Reynolds, CECM
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Hazard - Overhead Power Lines • Usually not insulated • Examples of equipment that can contact power lines: Crane Ladder Scaffold Backhoe Scissors lift Raised dump truck bed Aluminum paint roller Charles O Reynolds, CECM
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Control - Overhead Power Lines • Stay at least 10 feet away • Post warning signs • Assume that lines are energized • Use wood or fiberglass ladders, not metal • Power line workers need special training & PPE
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Dangers of Overhead Power Lines
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Hazard - Inadequate Wiring • Hazard - wire too small for the current • Example - portable tool with an extension cord that has a wire too small for the tool The tool will draw more current than Wire Gauge the cord can handle, causing overheating and a possible fire without tripping the circuit breaker WIRE The circuit breaker could be the right Wire gauge measures size for the circuit but not for the wires ranging in size from number 36 to 0 American smaller-wire extension cord wire gauge (AWG)
Charles O Reynolds, CECM
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Control – Use the Correct Wire • Wire used depends on operation, building materials, electrical load, and environmental factors • Use fixed cords rather than flexible cords • Use the correct extension cord
Must be 3-wire type and designed for hard or extra-hard use Charles O Reynolds, CECM
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Extension Cords • The OSHA standard requires flexible cords to be rated for hard or extra-hard usage. These ratings are to be indelibly marked approximately every foot of the cord. Since deterioration occurs more rapidly in cords which are not rugged enough for construction conditions, the National Electric Code and OSHA have specified the types of cords to use in a construction environment. This rule designates the types of cords that must be used for various applications including portable tools, appliances, temporary and portable lights. The cords are designated HARD and EXTRA HARD SERVICE. Charles O Reynolds, CECM
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Reading the jacket code All extension-cord jackets are marked with a code that indicates (among other information) the American wire gauge (AWG) and the jacket material and its properties, according to standards established by the National Electrical Code.
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Reading the jacket code •
S: Standard service (synthetic-rubber insulated, rated for 600v) SJ: Service junior (synthetic-rubber insulated, rated for 300v) ST: Extra-hard usage, thermoplastic (PVC) SE: Extra-hard usage, elastomer O: Oil-resistant, usually synthetic-rubber jacket, more flexible in cold temperatures OO: Oil-resistant synthetic-rubber jacket and inner-conductor insulation W: Extra-hard usage, weather-resistant
•
SJTW: Thermoplastic-jacketed, weather-resistant, rated for 300v
•
SEOW: Oil-resistant and weather-resistant elastomer jacket, rated for 600v (photo below)
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SJOW: Oil-resistant and weather-resistant synthetic rubber, rated for 300v
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SJOOW: Oil-resistant and weather-resistant synthetic rubber (jacket and conductor insulation), rated for 300v
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SJTOW: Oil-resistant and weather-resistant thermoplastic, rated for 300v Charles O Reynolds, CECM
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Hard Service Extension Cords • Examples of HARD SERVICE designation types include S, ST, SO, STO, SJ, SJO, SJT, & SJTO. Extension cords must be durably marked as per 1926.405(g)(2)(ii) with one of the HARD or EXTRA HARD SERVICE designation letters, size and number of conductors
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Hazard – Defective Cords & Wires • Plastic or rubber covering is missing • Damaged extension cords & tools
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Hazard – Damaged Cords • Cords can be damaged by: Aging Door or window edges Staples or fastenings Abrasion from adjacent materials Activity in the area • Improper use can cause shocks, burns or fire Charles O Reynolds, CECM
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Control – Cords & Wires • • • •
Insulate live wires Check before use Use only cords that are 3-wire type Use only cords marked for hard or extra-hard usage • Use only cords, connection devices, and fittings equipped with strain relief • Remove cords by pulling on the plugs, not the cords • Cords not marked for hard or extrahard use, or which have been modified, must be taken out of service immediately Charles O Reynolds, CECM
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Permissible Use of Flexible Cords DO NOT use flexible wiring where frequent inspection would be difficult or where damage would be likely. Flexible cords must not be . . . • run through holes in walls, ceilings, or floors; • run through doorways, windows, or similar openings (unless physically protected); • hidden in walls, ceilings, floors, conduit or other raceways. Charles O Reynolds, CECM
Stationary equipment-to facilitate interchange
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Grounding Grounding creates a lowresistance path from a tool to the earth to disperse unwanted current. When a short or lightning occurs, energy flows to the ground, protecting you from electrical shock, injury and death.
Charles O Reynolds, CECM
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Hazard – Improper Grounding • Tools plugged into improperly grounded circuits may become energized • Broken wire or plug on extension cord • Some of the most frequently violated OSHA standards
Charles O Reynolds, CECM
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Control – Ground Tools & Equipment • Ground power supply systems, electrical circuits, and electrical equipment • Frequently inspect electrical systems to insure path to ground is continuous • Inspect electrical equipment before use • Don’t remove ground prongs from tools or extension cords • Ground exposed metal parts of equipment Charles O Reynolds, CECM
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Control – Use GFCI (ground-fault circuit interrupter) • Protects you from shock • Detects difference in current between the black and white wires • If ground fault detected, GFCI shuts off electricity in 1/40th of a second • Use GFCI’s on all 120-volt, singlephase, 15- and 20-ampere receptacles, or have an assured equipment grounding conductor program. Charles O Reynolds, CECM
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Hazard – Overloaded Circuits Hazards may result from: • Too many devices plugged into a circuit, causing heated wires and possibly a fire • Damaged tools overheating • Lack of overcurrent protection • Wire insulation melting, which may cause arcing and a fire in the area where the overload exists, even inside a wall
Charles O Reynolds, CECM
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Hazard – Overloaded Circuits • If the circuit breakers or fuses are too big (high current rating) for the wires they are supposed to protect, an overload in the circuit will not be detected and the current will not be shut off. A circuit with improper overcurrent protection devices – or one with no overcurrent protection devices at all – is a hazard. Charles O Reynolds, CECM
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Control - Electrical Protective Devices • Automatically opens circuit if excess current from overload or ground-fault is detected – shutting off electricity • Includes GFCI’s, fuses, and circuit breakers • Fuses and circuit breakers are overcurrent devices. When too much current: Fuses melt Circuit breakers trip open Charles O Reynolds, CECM
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Control - Electrical Protective Devices • To prevent too much current in a circuit, a circuit breaker or fuse is placed in the circuit. If there is too much current in the circuit, the breaker “trips” and opens like a switch. If an overloaded circuit is equipped with a fuse, an internal part of the fuse melts, opening the circuit. Both breakers and fuses do the same thing: open the circuit to shut off the electrical current Charles O Reynolds, CECM
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Control - Electrical Protective Devices • The basic idea of an overcurrent device is to make a weak link in the circuit. In the case of a fuse, the fuse is destroyed before another part of the system is destroyed. In the case of a circuit breaker, a set of contacts opens the circuit. Unlike a fuse, a circuit breaker can be re-used by re-closing the contacts. Fuses and circuit breakers are designed to protect equipment and facilities, and in so doing, they also provide considerable protection against shock in most situations. However, the only electrical protective device whose sole purpose is to protect people is the ground-fault circuit-interrupter. Charles O Reynolds, CECM
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Power Tool Requirements • Have a three-wire cord with ground plugged into a grounded receptacle, or • Be double insulated, or • Be powered by a low-voltage isolation transformer
Charles O Reynolds, CECM
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Tool Safety Tips • • • • • • • • •
Use gloves and appropriate footwear Store in dry place when not using Don’t use in wet/damp conditions Keep working areas well lit Ensure not a tripping hazard Don’t carry a tool by the cord Don’t yank the cord to disconnect it Keep cords away from heat, oil, & sharp edges Disconnect when not in use and when changing accessories such as blades & bits • Remove damaged tools from use Charles O Reynolds, CECM
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Preventing Electrical Hazards - Tools • Inspect tools before use • Use the right tool correctly • Protect your tools • Use double insulated tools Double Insulated marking Charles O Reynolds, CECM
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Temporary Lights
Protect from contact and damage, and don’t suspend by cords unless designed to do so. Charles O Reynolds, CECM
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Clues that Electrical Hazards Exist • Tripped circuit breakers or blown fuses • Warm tools, wires, cords, connections, or junction boxes • GFCI that shuts off a circuit • Worn or frayed insulation around wire or connection
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Lockout and Tagging of Circuits • Apply locks to power source after deenergizing • Tag deactivated controls • Tag de-energized equipment and circuits at all points where they can be energized • Tags must identify equipment or circuits being worked on
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Safety-Related Work Practices To protect workers from electrical shock: Use barriers and guards to prevent passage through areas of exposed energized equipment Pre-plan work, post hazard warnings and use protective measures Keep working spaces and walkways clear of cords
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Safety-Related Work Practices • Use special insulated tools when working on fuses with energized terminals • Don’t use worn or frayed cords and cables • Don’t fasten extension cords with staples, hang from nails, or suspend by wire.
Charles O Reynolds, CECM
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Preventing Electrical Hazards Planning • Plan your work with others • Plan to avoid falls • Plan to lock-out and tagout equipment • Remove jewelry • Avoid wet conditions and overhead power lines
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Avoid Wet Conditions • If you touch a live wire or other electrical component while standing in even a small puddle of water you’ll get a shock. • Damaged insulation, equipment, or tools can expose you to live electrical parts. • Improperly grounded metal switch plates & ceiling lights are especially hazardous in wet conditions. • Wet clothing, high humidity, and perspiration increase your chances of being electrocuted. Charles O Reynolds, CECM
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Preventing Electrical Hazards - PPE • Proper foot protection (not tennis shoes) • Rubber insulating gloves, hoods, sleeves, matting, and blankets • Hard hat (insulated nonconductive)
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Preventing Electrical Hazards – Proper Wiring and Connectors • Use and test GFCI’s • Check switches and insulation • Use three prong plugs • Use extension cords only when necessary & assure in proper condition and right type for job • Use correct connectors Charles O Reynolds, CECM
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Training Train employees working with electric equipment in safe work practices, including: • Deenergize electric equipment before inspecting or repairing • Using cords, cables, and electric tools that are in good repair • Lockout / Tagout recognition and procedures • Use appropriate protective equipment
Charles O Reynolds, CECM
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Summary – Hazards & Protections Hazards • Inadequate wiring • Exposed electrical parts • Wires with bad insulation • Ungrounded electrical systems and tools • Overloaded circuits • Damaged power tools and equipment • Using the wrong PPE and tools • Overhead powerlines • All hazards are made worse in wet conditions
Protective Measures • Proper grounding • Use GFCI’s • Use fuses and circuit breakers • Guard live parts • Lockout/Tagout • Proper use of flexible cords • Close electric panels • Training
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Summary Electrical equipment must be: Listed and labeled Free from hazards Used in the proper manner If you use electrical tools you must be: Protected from electrical shock Provided necessary safety equipment
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When You Don’t Lockout
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Arc Flash Kills
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Another Arc Flash Accident
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Lockout - Tagout
• Control of Hazardous Energy • OSHA Standard 1910.147
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• January 12, 2004 • Company faces $92,000 in fines after worker dies making electrical repairs • OSHA has cited ConAgra Foods Refrigerated Foods Co. for failing to protect workers from electrical hazards following an investigation of a worker's death July 8 at the company's Montgomery, Ala., processing plant. The agency is proposing penalties totaling $92,000.
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• On the day the employee died, company officials reportedly instructed workers to repair a malfunctioning overhead light fixture. The workers couldn't locate the correct circuit breaker because none of them were labeled, so they tried to trip the appropriate breaker by "short circuiting" the line, an unsafe work practice. The breaker didn't trip, and one worker received an electrical shock. A worker then cut a neutral wire in the electrical junction box, left it unprotected and told a supervisor repairs would be made the next morning.
Charles O Reynolds, CECM
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• Night-staff employees weren't advised that a repair had been attempted, and they also weren't told about the condition of the wiring or the plan to complete the job the next day. Two night-shift workers tried to repair the fixture; they, too, attempted to short circuit the line and received electric shocks
Charles O Reynolds, CECM
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• One of the workers, an electrician, told management about the problems they were having making the repair and suggested waiting until the next day. According to OSHA's investigation, he was instructed to fix the light right away. Co-workers later found the electrician dead, with a pair of wire strippers in his hand, still in contact with the 277-volt electrical circuit. Charles O Reynolds, CECM
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ACCIDENT SUMMARY No. 60
Accident Type:
Electrocution
Weather Conditions:
Indoor Work
Type of Operation:
Installing and Trouble-shooting overhead lamps
Size of Work Crew:
15
Competent Safety Monitor on Site: Safety and Health Program in Effect: Was the Worksite Inspected Regularly:
Yes Inadeqaute Yes
Training and Education Provided: Employee Job Title:
No Electrician
Age & Sex:
53-Male
Experience at this Type of Work: Time on Project:
Journeyman 1 Month
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• BRIEF DESCRIPTION OF ACCIDENT The employee was attempting to correct an electrical problem involving two non-operational lamps. He proceeded to the area where he thought the problem was. He had not shut off the power at the circuit breaker panel nor had he tested the wires to see if they were live. He was electrocuted when he grabbed the two live wires with his left hand and then fell from the ladder
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•
ACCIDENT PREVENTION RECOMMENDATIONS
•
The employer should not allow work to be done on electrical circuits unless an effective lock-out/tagout program is implemented. The employer should not allow work to be done on energized electrical circuits or circuits which are not positively de-energized or tagged out.
•
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You will learn… Purpose of Lockout-Tagout Requirements for LOTO Types of Hazardous Energy Procedures for LOTO
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Electric shock can kill
• as low as 30 volts can carry enough current to kill
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Use Safe Electrical Practices • Use non-conducting tools • • Check circuits dead before working • Lock & Tag source breakers not switches • Ensure all control power is de-energized • Discharge all capacitors after Lockout Charles O Reynolds, CECM
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LOCKOUT/TAGOUT PROCEDURES
KNOW YOUR PROGRAM REQUIREMENTS! Charles O Reynolds, CECM
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Types of Energy •
• • • • •
Electrical Mechanical Chemical Thermal Hydraulic Pneumatic Charles O Reynolds, CECM
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Mechanical Energy Hazards • 2 Types • Kinetic – in motion • Potential - stored
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Kinetic Energy Hazards • Energy of moving machinery can cause
Lacerations Fractures Loss of life - Bowater Amputations Graphic Picture Coming Up Charles O Reynolds, CECM
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Lockout Failure • Accidental Start Up of Machines can be costly when someone is working on equipment!
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Potential Energy Hazards Energy stored in machinery • Weights & Springs • Pistons under pressure • Hydraulic controls •
• Stored potential energy
can be released during work causing injury or death Charles O Reynolds, CECM
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Chemical Energy Hazards • Chemicals have energy that can
start fires cause skin burns generate harmful gases or fumes • Before working – release, drain or vent chemicals safely Charles O Reynolds, CECM
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Thermal Energy Hazards • Energy of Heat (and cold) • Hot equipment & fluids will burn you • Cold fluids can cause injury also • Quick release of compresses gases can freeze your skin • Allow equipment to reach a safe temperature before starting work. Charles O Reynolds, CECM
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Hydraulic Energy • Energy of Liquids Under Pressure pressure can cause equipment to move rapid release can cause injury or ejection of system parts Relieve pressure slowly into a proper container Charles O Reynolds, CECM
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Pneumatic Energy Hazards • Energy of Compressed Gases uncontrolled release can cause injury rapid de-pressurization creates extreme low temperature • Properly vent all systems before starting work Charles O Reynolds, CECM
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ONLY TRAINED AND AUTHORIZED EMPLOYEES VERIFY – VERIFY –VERIFY
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First Step In LOTO • Know your equipment & systems
hazards isolation points procedure for Lockout • Working on unfamiliar machinery is a hazard Charles O Reynolds, CECM
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Who Can Lockout Equipment? • Only Employees who have been trained and authorized by management
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Items needed for LOTO • • • • • • •
Written LOTO schedule Locks & Tags - identified to the worker Hasps - for placing locks & tags Breaker Clips - for electrical LOTO Blank Flanges (pancakes)- for fluid lines Valve Covers - for LOTO of Valves Plug Buckets - for electrical plugs Charles O Reynolds, CECM
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Upcoming Slides • The next few slides are not in your book. They were added last night to this presentation. • These slides are a part of the M&M Mars Lockout/Tagout presentation.
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Types of LOCKOUT EQUIPMENT
Lock -must have name, company name & number
Hasp
Tag
Watchman
Lockable Circuit Breaker Charles O. Reynolds, CECM Valve Cover Lockout Device
Plug Cover
Types of Lockout Locks Contractors can not use the following Colors NO
Operations Personal Lock
NO
Maint Personal Locks Yes
NO
Transfer Lock NO
NO
Charles O. Reynolds, CECM Temporary Associates Example for Contractor
Lock Box Locks
Lock Box Use In the situation where there are multiple work groups (e.g., plumbers, carpenters, electricians, & metal workers, etc.,) involved in a single project, group lockout procedures will be implemented; these will include the use of a lock box
Typical Lock Box
Charles O. Reynolds, CECM
Page______of______
LOCKOUT / TAGOUT EQUIPMENT LIST - LOCK BOX SYSTEM Date:
Lock Box ID Number:
Transfer Lock Number: ________________
Area: ___________________________
Shift: _______________________
(1) Transferred Shift: __________________
System Locked Out: ________________________________________________ Line Number
DATE LOCKED OUT
DATE UNLOCKED
Equipment Isolation Lock Number
(2) Transferred Shift: __________________
EQUIPMENT IDENTIFICATION
LOCKED OUT POSITION (or tagged)
1 2 3 4 5 6 7 8 9 Signature – Group Lockout Leader: (1) Signature – Transferred Group Lockout Leader: (2) Signature – Transferred Group Lockout Leader: ___ ______ Lockout Group Member: _____________________________________________ Lockout Group Member: _____________________________________________ Lockout Group Member: _____________________________________________
Lockout Group Member: ___________________________________ Lockout Group Member: ___________________________________ Lockout Group Member: ___________________________________ Lockout Group Member: ___________________________________ Lockout Group Member: ___________________________________ Lockout Group Member: ___________________________________
Charles O. Reynolds, CECM
Maintaining Effective Protection • Continuous effective protection must be maintained using one of the following two methods: Direct Lockout/Tagout Transfer Use of Transfer Locks/Tags
Charles O. Reynolds, CECM
The Transfer Lock Process
Charles O. Reynolds, CECM
• These slides are in your book.
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Use of Locks & Tags • Use only those issued to you • Never use another workers lock or tag • Ask your supervisor if you need more LOTO equipment
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6 Step LOTO Procedure • • • • • •
Prepare for Shutdown Shutdown Equipment Isolate all energy sources Place Locks & Tags Release Stored Energy Verify Equipment Isolation Charles O Reynolds, CECM
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More Graphic Pictures Coming Up‌ • Here are 3 very graphics pictures where verification was not done!!!!!
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This lineman had done this kind of work for years‌.
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But today something went wrong!
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This man does not go home to his family tonight‌.
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1. Prepare for Shutdown • Understand equipment hazards • Notify other workers of shutdown
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2. Shutdown Equipment • Use normal shutdown procedure • Turn all switches to OFF • Shut all control valves • Disable all sources of energy Charles O Reynolds, CECM
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3. Isolate All Energy Sources • Shut valves • Open breakers & disconnects
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4. Place Locks & Tags on • Valves • Breakers / electrical disconnects • Block or disconnect all lines • Lock and tag blank flanges Charles O Reynolds, CECM
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5. Release or Block all Stored Energy • • • • • • • •
Discharge capacitors Block or release springs Block elevated parts Stop rotating flywheels Relieve system pressure Drain fluids Vent gases Allow system to cool Charles O Reynolds, CECM
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6. Verify Equipment Isolation •
• • • •
Check all other workers are clear Check locking devices securely placed Check isolation Attempt normal startup Return Controls to OFF/Neutral
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Release from LOTO •
• • • • • • •
Inspect Area and Equipment Ensure all Machine Guards in place Move tools away from equipment Inform others of startup Restore system connections Remove Locks & Tags Restore equipment to normal Conduct normal startup
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Who can remove Locks & Tags? • Only the employee who placed the tag
• or • a supervisor, after obtaining permission from the worker who placed the tag. Charles O Reynolds, CECM
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If we can’t find the worker we must make every attempt to locate the employee: 1. 2. 3. 4. 5.
Call their home Call their cell phone Call their pager Attempt to locate through relatives Call any other location where it is known that the employee might be Charles O Reynolds, CECM
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When the Employee Returns to Work 1. You must immediately inform the employee that his/her lock was cut off and removed from the lockout/tagout procedure. 2. Issue an Employee Safety Violation Report. 3. Consider if retraining is necessary.
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A piece of equipment already has a locked and tagged. Do I have to place my own locks & tags?
• YES . Each person
working on the equipment must place their own locks and tags to ensure their safety. • ANOTHER GRAPIC PICTURE Charles O Reynolds, CECM
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Lockout-Tagout Protects YOU! • USE Proper Lockout - Tagout Procedures • Please be careful when working on equipment
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Questions? • Thanks YOU!
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