Equipment Lockout Procedure PDF

Safety Management Systems • Chapter 14 fs OBJECTIVE 5 Explain the purpose of equipment lookout, describe lookout devices, and describe a typical equipment lookout procedure. EQUIPMENT LOOKOUT CAUTION Information on equipment lookout is based on information available from the British Columbia OH&...

Safety Management Systems • Chapter 14 fs OBJECTIVE 5 Explain the purpose of equipment lookout, describe lookout devices, and describe a typical equipment lookout procedure. EQUIPMENT LOOKOUT CAUTION Information on equipment lookout is based on information available from the British Columbia OH&S Regulation. This information is presented as an example only and should not be construed as exact or applicable to all jurisdictions. Nor should the wording be accepted as the exact wording in the BC OH&S Regulation. Equipment lookout is a system of locks and tags that secure devices that prevent hazardous energy from release. The control devices that are secured by locks include the main disconnect switches, circuit breakers, valves, and clutches. Hazardous energy is any energy source (electric, compressed gas, steam, hydraulic energy, a moving part, or an elevated object) that could release or move and injure a worker. If there is the potential for an unexpected energization or startup of machinery or equipment, or the unexpected release of an energy source that could cause injury, the energy source must be isolated and effectively controlled. Equipment lookout is required when machinery or equipment is shut down for maintenance. No maintenance work may be done until the following conditions are met: a) All parts and attachments are secured against inadvertent movement. b) The hazards are effectively controlled where the work will expose the workers to energy sources. c) The energy isolating devices are locked out. Figure 2 shows an example of a typical lockout station that is used in the industry. The lockout station includes a series of locks, multiple tags that read "do not operate," and multiple hasps that are used in an equipment or process lookout. The keys from the locks that are used to complete the lockout (as well as any unused locks) are placed into a lookout box. A designated operations or safety lock with a do not operate tag and hasp is then attached to the box to ensure the equipment lockout keys cannot be accessed. The key from the designated lock that is attached to the box is then held for safekeeping by operations or safety personnel. 3rd Class Edition 3 • Part A2 727 ^ Chapter 14 • Safety Management Systems Figure 2 - Typical Lookout Station (SocoXbreed/Shutterstock) A typical portable lockout box is pictured in Figure 3. The lockout box in Figure 3 would be positioned near the work being done so workers can attach their personal locks before starting the work. Equipment lockout systems have various levels of control to ensure the safety of all workers performing work on the de-energized and locked out piece of equipment, machinery, or process. 728 3rd Class Edition 3 • Part A2 Safety Management Systems • Chapter 14 f£ Figure 3 - Typical Portable Lookout Box ^5^1 ^§L •<—'»«1 p~'-^«i»r Lookout Procedures When a lockout of energy isolating devices is required, the devices must be secured in the safe position using locks. The devices are secured in accordance with procedures that are made available to all workers who are required to work on the machinery or equipment. The employer must ensure that each worker required to lock out has ready access to sufficient personal locks to implement the required lockout procedure. Personal locks are assigned to a specific person, meaning only that person has the keys for that lock. Combination locks must not be used for lockout. Each personal lock must be marked or tagged to identify the person applying it. Provisions must be implemented for shift or personnel changes and must include the orderly transfer-of-control of locked out energy isolating devices between outgoing and incoming workers. If the use of a personal lock is not practical for lookout, other effective means may be used to secure an energy isolating device in the safe position. An example of an alternate lockout device may be a metal cable seal with a unique identifier on it. 3rd Class Edition 3 • Part A2 729 Chapter 14 • Safety Management Systems A lookout procedure is generally viewed as the most reliable way to protect a worker from hazardous energy because the system is reduced to a zero energy state. A zero energy state describes a condition in which the machine, piece of equipment, vessel, tool, or electrical installation is incapable of spontaneous or unexpected action. In this state, the equipment in question is also incapable of releasing spontaneous kinetic or potential energy. A zero energy state is not accomplished by simply turning off a machine and removing the keys. A zero energy state ensures there is no residual energy left for the machine to utilize even when it is turned off. The confirmation of a zero energy state is another level of protection for the workers from any unintentional movement, unexpected energization, or release of stored energy. Proving the zero energy state involves a procedure with a more rigorous and thorough approach to ensure full de-energization of the machine, piece of equipment, vessel, tool, or electrical installation, even before starting a lockout. The following is an example of the procedure used to prepare a pump for maintenance and ensure a zero energy state condition before beginning the lockout. Steps to safely shut down a 1A pump to a zero energy state: 1. Shut down 1 A pump 2. Place J-O-R (jog-ofF-remote) switch to the "off" position 3. Electrician de-energize pump motor in the MCC 4. Bump test from D CS 5. Bump test local start/stop switch 6. Close 12" discharge block valve 7. Close upstream 2 warm up line block valve 8. Close downstream 2 warm up line block valve 9. Open 3/4 drain valve in between the warm up line isolation valves 10. Close 16" suction block valve 11. Open first 3/4 pump casing drain valve 12. Open second 3/4" pump casing drain valve 13. Open third 3/4 pump casing drain valve 14. Open inboard 3/4" pump casing vent valve 15. Open centre 3/4 pump casing vent valve 16. Open outboard 3/4 pump casing vent valve 17. Open 3/4" drain on pump suction piping 18. Open 3/4 drain on pump discharge piping 19. Close 1" upstream glycol supply valve to seal water coolers 20. Close 1" downstream glycol supply valve to seal water coolers 21. Close 3/4 inboard seal water cooler glycol outlet isolation valve 22. Close 3/4" outboard seal water cooler glycol outlet isolation valve 23. Close 1" common pump seal water cooler glycol outlet isolation valve End of procedure: The pump is now at zero energy state and ready for lockout/tagout. 732 3rd Class Edition 3 • Part A2