First Safety Systems Training Services

‘ Your total safety solutions’

OCCUPATIONAL SAFETY & HEALTH SEMINAR

1
 First Safety Systems Training Services
‘ Your total safety solutions’

INTRODUCTION
1. Electricity is a source of power at home, or at work.
2. Although recently, there have been much advancement
in the control of electrical hazards, there are still many
injuries and fatalities in industry.
3. It is important that workers and other users of
electricity be familiar with its nature, learn how to
properly control it and should know the basic rules that
should govern its safe maintenance and utilization.

2
 First Safety Systems Training Services
‘ Your total safety solutions’

MYTHS AND MISCONCEPTIONS ABOUT ELECTRICITY

1. Electricity takes the path of

least resistance. This myth
implies that current only
takes low resistance paths.
Actually, current will take any path,
high or low resistance in order to return
to the source that provides power.
3
 First Safety Systems Training Services
‘ Your total safety solutions’

MYTHS AND MISCONCEPTIONS ABOUT ELECTRICITY

2. Electricity wants to go to ground. A person is

led to believe that electricity wants to go to
ground and simply disappear. In reality, ground
serves as just one of the electrical loops that
misdirected current can use to get back to its
grounded power source.
3. Double-insulated power tools are doubly safe
and can be used in wet and damp locations.

4
 First Safety Systems Training Services
‘ Your total safety solutions’

MYTHS AND MISCONCEPTIONS ABOUT ELECTRICITY

4. When electrical tool or appliance fall into

water, it does not short out. If the switch is
ON, the item will continue to operate. If the
switch is OFF, it will simply get wet. In both
cases, a person should not reach into the water
with another part of his body in contact with a
grounded object as he could get a severe, if not
fatal shock.

5
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL FUNDAMENTALS

OHM’S LAW
Ohm’s Law simply states that one volt will
cause a current of one ampere to flow
through a resistance of one ohm. An easy
way to remember this formula, and the
different ways it can be expressed is to put
the symbols in a circle as shown in the next
slide: 6
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL FUNDAMENTALS

E
(Volts) Put your finger on I : I = E/R
Put your finger on R : R = E/I
I R
Put your finger on E : E = I x R
(Amps) (Ohms)

7
 First Safety Systems Training Services
‘ Your total safety solutions’

DEFINITION OF TERMS
ELECTRICITY
It is composed of the simplest form of matter, the electron.
Electrons spin around the nucleus of an atom and are easily
broken away and when sent to a circuit, we have an
electrical system.

CURRENT
Current is a flow of electron in a conductor.It is similar to
water flowing in a pipe. Electric current is measured in
amperes (amps).
8
 First Safety Systems Training Services
‘ Your total safety solutions’

DEFINITION OF TERMS
VOLTAGE
Think of voltage as the pressure in a pipeline. Voltage is
measured in volts.
RESISTANCE
Resistance is the difficulty of an electron to flow in a
circuit.
Resistance is any condition that retards current flow and
is measured in ohms.
9
 First Safety Systems Training Services
‘ Your total safety solutions’

DEFINITION OF TERMS

INSULATOR
A material having few free electrons that cannot
move easily. Example: Rubber, Porcelain, Dry
Wood

CONDUCTOR
A material having many free electrons that can
move easily. Example: Metal, Copper,
10
 First Safety Systems Training Services
‘ Your total safety solutions’

DEFINITION OF TERMS

ALTERNATING CURRENT
Oscillating electrical waves that appear to
reverse direction at a regular rate.
DIRECT CURRENT
Current that flows in one direction.

11
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SHOCK/INJURIES

1. Death or injuries from electric shock may

result from the following effects of current
on the body.
a. Contraction of the chest muscles, which
may interfere with breathing to such an
extent that death will result from
asphyxiation when the contact is
prolonged.
12
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SHOCK/INJURIES
b. Temporary paralysis of the nerve center, which
may result in failure to breathe, a condition that
often continues long after the victim is freed
from the circuit.
c. On contact with heavy current, the muscular
contractions of the heart stop. In this case, the
heart may resume its normal rhythm when the
victim is freed from the circuit or a CPR is
administered.

13
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SHOCK/INJURIES
d. Interference with the normal rhythm of
the heart, causing ventricular
fibrillation. The heart cannot
recover from this
condition. It has
been estimated that
more than 23mA is
sufficient to cause
ventricular fibrillation
14
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SHOCK/INJURIES
HOW DOES AC AFFECT THE BODY?
a. At .4 mA : No sensation
b. At 1.1 mA : A slight tingling sensation
c. At 1.8 mA : Shock
d. At 16 mA : Painful shock. Loss of muscle
control can cause victim to lock
on to the source
e. Above 23 mA : Severe injuries and possible
death.
15
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SHOCK/INJURIES
e. Hemorrhages and destructionof tissues, nerves
and muscles from heat due to heavy current along
the electrical circuit’s path through the body.

f. Severe burns may result from contact with low

voltage systems in cars, trucks and lift trucks
when metal, wrenches or jewelry comes in contact
with current carrying conductors. 16
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SHOCK/INJURIES

2. Injury from falls

Other injuries from electrical shock include
falls from one level to another. The shock
causes muscles to contract, causing the
worker to lose his or her balance and fall.

17
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SHOCK/INJURIES
3. Electrical shock is the most serious electrical hazard.
It may cause:
a. Pain;
b. Nerve, muscle or tissue damage;
c. Loss of muscle control and coordination;
d. Cardiac arrest;
e. Internal bleeding; and
f. Death
18
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SHOCK/INJURIES

4. Severity of shock is determined by:

a. The quantity of current flowing through the body;
b. The path of the current flowing to the body;
c. The length of time the body in contact; and
d. Physical condition of the victim.

19
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL HAZARDS
1. Wiring – Are the connections and ground wires tight
and free from breaks?
2. Insulation – Can you see worn spots or breaks that
could cause shocks? Are the cords and extension cords
in good shape?
3. Belts and gears – Can you detect excess tension or
binding that can cause a power overload?
4. Personal Protective Equipment – Are hand and foot
protection in good repair and readily available?
20
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL HAZARDS

5. Machinery – Can you detect overloading, too much

vibration or motor obstruction?
6. Equipment – Do equipment and power hand tools
work properly? Are they free of defects or damage?

21
 First Safety Systems Training Services
‘ Your total safety solutions’

WHAT IS ENERGIZED ELECTRICAL WORK?

1. EEW is defined as any work
requiring performance of DANGER
duties on exposed circuits or
components where energy
magnitude is from 50 to 600
volts or 240 volt amps and
above.

2. Actual work performed could include IR scanning,

testing and metering, manipulating wires,
troubleshooting, labeling and circuit verifications.
22
First Safety Systems Training Services
‘ Your total safety solutions’

23
 First Safety Systems Training Services
‘ Your total safety solutions’

WHAT IS ENERGIZED ELECTRICAL WORK?

3. When working on EEW, workers should take note of the
following:
a. Current travels easily to the human body because it is
composed mostly of water.
b. The degree of injury will depend on the:
- The amount of current or amperage passing through the
body.
- The current path through the body.
- The frequency of the current (ac or dc).
- The duration of the current flow.
- The intensity of the arc/flash. Electrical arc flash can
cause instantaneous third degree burns.

24
 First Safety Systems Training Services
‘ Your total safety solutions’

WHAT IS ENERGIZED ELECTRICAL WORK?

3. Typical PPE for electrical works include:

a. Non-conductive barriers, properly rated and tested rubber
insulated gloves and tools;
b. Rubber insulated boots, blankets or floor mats;
c. Test meters and scanning equipment;
d. Flash protective clothing, hard hats (when required); and
e. Hearing protection.

25
 First Safety Systems Training Services
‘ Your total safety solutions’

WHAT IS ENERGIZED ELECTRICAL WORK?

4. Application of One-Arm Method may be used:

a. This requires one to work on live circuits using only
one hand.
b. The method used to minimize the
likelihood of creating a path for current
to flow from one hand, up the arm, across the heart,
and out through the second hand.
c. The second arm should be tucked behind the back
as a means of keeping it clear of all circuits,
reducing the chance of current flowing through the
heart area.
d. This method should only be used if doing so does
not increase the risk since many tasks require two
hands.

26
 First Safety Systems Training Services
‘ Your total safety solutions’

WHAT IS ENERGIZED ELECTRICAL WORK?

5. Never work on energized electrical work if you are
not trained and without a buddy and a permit.

Buddy

27
 First Safety Systems Training Services
‘ Your total safety solutions’

WHAT IS ENERGIZED ELECTRICAL WORK?

5. What is an electrical arc flash?
a. It affects personnel working on Electrical
Distribution Equipment such as (but not limited to)
Panel Boards, Switchboards, Distributions Boards,
Motor Control Centers and Industrial Control
Centers that are likely to require examination,
adjustment, servicing, or maintenance while
energized.
b. It occurs when a substantial amount of current flows
through what previously had been air due to power
surges, faults, etc.

28
 First Safety Systems Training Services
‘ Your total safety solutions’

WHAT IS ENERGIZED ELECTRICAL WORK?

c. The air is converted to plasma allowing the current

to flow from point to point generating heat and
light.
d. The temperatures at terminal points can reach
50,000 Kelvin (89,540 F) and the temperatures in
the Arc/Flash Zone can reach 20,000 Kelvin
(35,540 F).
e. These temperatures can ignite clothing and cause
fatal burns up to 8 feet away from the source.

29
 First Safety Systems Training Services
‘ Your total safety solutions’

WHAT IS ENERGIZED ELECTRICAL WORK?

4 feet

Minimum Flash Protection

30
Boundary as required in
NFPA 70E.
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL INSPECTION GUIDELINES

1. Service Entrance Panel – circuit ID, secure

mounting, connectors, live parts, etc.
2. System Grounding – secure connections,
corrosion, access, protection, proper size.
3. Wiring (General) – temporary, splices,
protected, J-Box covers, insulation,
knockouts, fittings, workmanship.

31
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL INSPECTION GUIDELINES

4. Electrical Equipment/Machinery –
grounding, wiring size, overcurrent/
disconnect devices, installation, protection.
5. Small Power Tools – attachment plugs,
cords, cord clamps, leakage, grounding.
6. Receptacles – adequate number, mounting,
covers, connections, protection, adapters.

32
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL INSPECTION GUIDELINES

7. Lighting – grounding, connections, attachment plugs
and cords, cord clamp, live parts
8. GFCI Protection – wet locations, fountains, outdoor
circuits, testing.
9. Switches – labeled or marked, covered as needed,
lockable
10. Extension Cords – condition, plugs, receptacles,
GFCI
11. Protectors – fuses, circuit breakers, link fuses
33
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SAFETY POLICIES

1. Plug power equipment into wall receptacles
with power switches in the OFF position.

2. Unplug electrical equipment by grasping the

plug and pulling. Do not pull or jerk the cord
to unplug the equipment.

3. Check for frayed, cracked, or exposed Wiring

on equipment cords.
34
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SAFETY POLICIES

4. Personnel should know the location of
electrical circuit – breaker panels that control
equipment and lighting in their respective
areas. Circuits and equipment disconnects
must be identified.

5. Temporary or permanent storage of any

materials must not be allowed with in 3 feet
of any electrical panel or electrical equipment.
35
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SAFETY POLICIES

6. When defective electrical equipment is identified by

personnel, it should be tagged immediately and
removed from service for repair or replacement.
7. Any electrical equipment causing shocks or with
high leakage potential must be tagged with a
DANGER – DO NOT USE label.
8. Conduct regular inspection and servicing of electrical
controls and transformers.

36
 First Safety Systems Training Services
‘ Your total safety solutions’

ELECTRICAL SAFETY POLICIES

9. Comply to your EEW Program
10.Strictly implement a Lock-Out and Tag-Out
Program.

37
 First Safety Systems Training Services
‘ Your total safety solutions’

What is the policy for electrical work?

The policy is to work on equipment in a de-

energized state in order to:
 Minimize hazardous electrical exposures
to personnel.
 Ensure compliance with regulatory
requirements applicable to electrical
systems.
First Safety Systems Training Services
‘ Your total safety solutions’

39
 First Safety Systems Training Services
‘ Your total safety solutions’

What is a hazardous energy?

Any form of energy, in an

uncontrolled state, which presents a
POTENTIAL for injury or damage.

As a part of company’s commitment to safety,

the Control of Hazardous Energies program is
to be strictly followed to ensure the safety of its
employees.
 First Safety Systems Training Services
‘ Your total safety solutions’

What is the Importance of CoHE / LOTO?

• Lockout/tag out procedures are for your safety. -
These are designed to prevent accidents and injuries
caused by the unexpected release of energy. These
procedures prevent workers from accidentally being
exposed to injurious and even life threatening situations
with energized machinery.

Where are the Regulations?

The Occupational Safety and Health Administration (OSHA)
regulates lockout/ tag out through the Control of Hazardous
Energy standard, found at 29 CFR 1910.147. This standard
mandates training, audits, and record keeping to ensure that
workers will not be injured by unintentionally energized equipment
41
 First Safety Systems Training Services
‘ Your total safety solutions’

Types of Hazardous Energies

Electrical: voltage, current, static electrical potentials, RF

Chemical: reaction, fire, explosion

Mechanical: shearing, rolling, crushing, pinching

Thermal: hotter than 140°F/60°C, colder than 32°F/0°C

Potential or stored energy: batteries, springs,

capacitors

Other: laser, ionizing & non-ionizing radiation, pneumatic,

hydraulic, gravitational, pressure
 First Safety Systems Training Services
‘ Your total safety solutions’

KNOW THE MACHINES

AND THEIR POWER
SOURCES

Some may have more than one source of power.

 First Safety Systems Training Services
‘ Your total safety solutions’

Terms and Definitions

(Lifted from Intel CoHE Guidelines)

• Lockout: The placement of a physical restraint energy isolating

device, which ensures that the equipment cannot be operated or
cannot release a hazardous energy.

• Tagout: The placement of a warning/ identification tag on an

energy isolating device to indicate that the equipment must not
be operated. It also identifies the person who applied the
lock/tag.

• Energy Control Point: The single point at which hazardous

energy flow can be effectively and positively blocked so that it
can no longer cause injury or loss of resources. There may be
more than one Energy Control Point on a tool.
 First Safety Systems Training Services
‘ Your total safety solutions’

LOCKOUT is blocking the flow of

energy from the power source to the
equipment – and keeping it blocked out.
 First Safety Systems Training Services
‘ Your total safety solutions’

TAGOUT means placing a tag on the

power source to WARN co-workers
and others not to turn the power on.
 First Safety Systems Training Services
‘ Your total safety solutions’

Terms and Definitions, continued

• Affected person: A person who operates
or maintains equipment that may be
locked/tagged out. Also, a person who
works in an area where equipment is being
serviced.
• Authorized person: A person who
locks/tags out machines or equipment in
order to perform servicing or maintenance.
• Danger Zone: The area or work space
where, if the hazardous energy was
inadvertently released, the energy could
potentially cause injury.
 First Safety Systems Training Services
‘ Your total safety solutions’

Must b isolated b4 employees can

perform maintenance n servicing of
equipment.
1. By closing valves
2. Relieving trapped pressures
3. Disconnecting circuits
4. Blanking fluid or gas lines
5. Blocking/restraining elevated machine parts
 First Safety Systems Training Services
‘ Your total safety solutions’

Uses lockout/tagout?
 Authorized employees who perform repair, servicing and
maintenance operations
 Affected employees who work with the equipment to be
locked out or tagged out
 Other workers
 First Safety Systems Training Services
‘ Your total safety solutions’

1. Turn off the equipment and disconnect the energy

source.
2. Lockout energy sources.
3. Tag at disconnect point.
4. Release residual energy.
5. Restore energy safely.
 First Safety Systems Training Services
‘ Your total safety solutions’

Lockout/Tagout safeguards are designed

to protect workers.
 First Safety Systems Training Services
‘ Your total safety solutions’

LO/TO programs includes:

 Written procedures on all aspects of the LO/TO
program
 Effective initial training of authorized, affected
and other employees to help them recognize
hazardous energy sources
 Identification of hazardous energy sources
 Training authorized, affected and other
employees on the company’s LO/TO procedures
 First Safety Systems Training Services
‘ Your total safety solutions’

LO/TO programs includes:

 Issuingpadlocks and tagouts for authorized
workers for use in LO/TO operations
 Effective retraining as needed for all three
groups of employees.
 Certification of training which identifies each
employee by name and date of training
 Conducting periodic and annual inspection
of LO/TO procedures, equipment and machines.
 First Safety Systems Training Services
‘ Your total safety solutions’

CoHE Alternative Method

• Exception when lockout/tagout is not required or is

impractical during maintenance activities

• Alternative means must enable employees to service the

machine without being exposed to hazardous energy

• Must be approved by governing body (NPO board)

before lockout/tagout requirement is discontinued

54
 First Safety Systems Training Services
‘ Your total safety solutions’

Situations Requiring Lockout/Tagout

• Servicing, maintaining, or repairing any

equipment where hazardous energies
are present.

 Working on electrical circuits and

systems to prevent the risk of
electrical shock, flash, or blast.

 Working near other hazardous

energies that could result in the
unintentional release of stored
energy, causing injury.
 First Safety Systems Training Services
‘ Your total safety solutions’

Situations Requiring Lockout/Tagout cont.

• Working on lines that carry hazardous European
United States

Union
production materials (HPMs) in gas, Signage

vapor, or liquid forms, which are high-

pressure, toxic, corrosive, etc.
• HPMs are:
 Production materials that carry a 3
or higher rating in the health,
flammability, or reactivity category
on the Hazard Management
Information System (HMIS) or
 That are labeled according to the
European Union Hazards Labeling
System.
56
 First Safety Systems Training Services
‘ Your total safety solutions’

Guideline Requirements
• Lockout/tagout is required when the work
requires an employee to place any part of
his/her body into an area where a danger
zone exists.
SAFETY NOTE: Moving parts may increase
the size of a danger zone.
• Only authorized persons are allowed to
perform lockout/tagout on equipment.

• All equipment using hazardous energies

must be capable of accepting
lockout/tagout.
 First Safety Systems Training Services
‘ Your total safety solutions’

Guideline Requirements cont.

• A lockout/tagout device may NOT be removed on

behalf of another person, unless the Abandoned
Lock Removal Procedures are followed.

• Assessments shall be performed on each

tool/equipment set to identify potential hazardous
energies and to document energy control
procedures. These procedures must be written in
preventive maintenance, modification, or other
relevant procedures.
 First Safety Systems Training Services
‘ Your total safety solutions’

Lockout/Tagout Rules

• Follow the lockout/tagout procedures to

control hazardous energies during servicing,
maintenance, or repairing.
• Lockout/tagout devices shall not be used for
any purpose other than controlling hazardous
energies.
• Do not remove someone else’s lock or tag.
• Use only approved locks and tags and include
the following information:
 Employee name
 Any other information required by your site
EHS.
 First Safety Systems Training Services
‘ Your total safety solutions’

Lockout/Tagout Rules:

• Energy Control Point: The single point at which hazardous

energy flow can be effectively and positively blocked so that it
can no longer cause injury or loss of resources.
• Locks and/or tagout devices must be attached to the energy
control point in the off position.
• Use locks for which only ONE key exists.
• Each point to be controlled should be identified in the Energy
Control Procedure of the PM Documentation and at the tool or
equipment.
SAFETY NOTICE: There may be multiple energy control points
controlling multiple types of energy in a specific danger zone.
 First Safety Systems Training Services
‘ Your total safety solutions’

Lockout/Tagout Rules cont.

• Unacceptable means of lockout/tagout include
interlocks, EMOs, selector switches, software controls,
and control circuit devices.

Exceptions to Lockout/Tagout
• You are not required to lockout/tagout plug-connected
equipment if we can demonstrate that we can keep
physical control of the plug 100% of the time.

• Alternative measures of protection may be used during

normal production operations IF approved by the
accepted governing body (the NPO Review Board).
 First Safety Systems Training Services
‘ Your total safety solutions’

Energy Control Procedures

Energy Control Procedures for lockout/tagout

will be written for each equipment type.

These procedures cover:

• Specific steps for shutting down and isolating
hazardous energies.
• Specific procedures for applying, removing, and
transferring lockout/tagout devices.
• Specific requirements for testing a machine/piece
of equipment to determine and verify the
effectiveness of lockout/tagout procedure.
 First Safety Systems Training Services
‘ Your total safety solutions’

What steps should you follow to do

lockout/tagout safely?

Lockout/tagout is done in 4 easy steps:

1. Prepare for application.

2. Apply CoHE devices.

3. Prepare for re-energization.

4. Remove the CoHE devices.

63
 First Safety Systems Training Services
‘ Your total safety solutions’

Step 1: Prepare for Application

• Reference the CoHE Procedure Checklist for the
affected tool.
• Read and understand the equipment-specific
procedures.
• Obtain the lockout/tagout devices.
• Notify “Affected Employees.”

• Locate the energy control point for each

hazardous energy.

• Stop and/or shut off the equipment.

• Isolate the equipment from all hazardous

energies sources.
 First Safety Systems Training Services
‘ Your total safety solutions’

Step 2: Apply Lockout/Tagout Devices

• Apply the lockout/tagout device to the

energy control point in the off position.
• Apply the lock to the lockout/tagout device.
• Apply the tag to the lock.
• Dissipate, drain, or safely
release any stored energy.
• Verify that ALL energy
sources have been isolated.
• Attempt to restart.
• Test with meters, gauges, etc.
 First Safety Systems Training Services
‘ Your total safety solutions’

How do you meter and test for zero voltage?

• Remember to do a 3-point check to ensure your volt
meter is working properly:
 Ensure the meter is calibrated.
 Set the voltage scale to appropriate voltage and
test on a known voltage source.
 Check danger zone voltage
with meter and confirm it to
1000 2000
500

E
3000
S
be zero. 5000 4000

 Check meter with a known

voltage again to confirm 10
20
30
40

proper operation of the 150

140
100
80
50
60

meter.
66
 First Safety Systems Training Services
‘ Your total safety solutions’

Step 3: Prepare for Re-Energization

• Inspect work area for removal of
nonessential items.

• Ensure all safety controls have been

replaced (interlocks, valves, guards,
covers, etc.).

• Notify “Affected Employees” before re-

energization.

• Ensure personnel are in a safe location

before re-energizing system.
 First Safety Systems Training Services
‘ Your total safety solutions’

Step 4: Removal of Lockout/Tagout Devices

• Remove locks and tags

 Remove blocks, blinds, etc. if
applicable.
• Re-energize the equipment/system.
• Communicate to all affected personnel
that the equipment has been re-energized.

68
 First Safety Systems Training Services
‘ Your total safety solutions’

The Custodial Lockout Procedure

• May also be known as “equipment lockout” or “operational

lockout”.
• Provides protection to systems, equipment, and/or
machinery ONLY--no employees.
• Requires different locks and tags than the locks and tags
used for Controlling Hazardous Energies.
• Absolutely does not allow an employee to place any part of
his/her body into an area where a danger zone exists,
relying on the protection of a custodial lockout. Standard
site CoHE locks and tags will be used for such purposes.

69
 First Safety Systems Training Services
‘ Your total safety solutions’

When to Use the Custodial Lockout Procedure

• System, equipment, or machine is secured to

prevent its operation when a component is missing
• System, equipment, or machine is secured to
prevent its operation when demolition is scheduled
• Installation is complete or in progress, but the
system, equipment, or machine has not been
qualified and, therefore, not released for use To
secure valves/controls that are set in a prescribed
position to maintain system integrity

70
First Safety Systems Training Services
‘ Your total safety solutions’

Advantages of Using the

Custodial Lockout Procedure

• Improves compliance of CoHE

Program (i.e. reduces passing
of keys/tags)
• Reduces abandoned lock
removal
• Obvious color distinction
between custodial and CoHE
locks/tags

71
First Safety Systems Training Services
‘ Your total safety solutions’

Conduct a Demonstration
of Lockout/Tagout Procedures
 First Safety Systems Training Services
‘ Your total safety solutions’

Temporary Removal of Lockout/Tagout Devices

for Testing or Positioning of Equipment

• Clear equipment of tools and materials.

• Remove “Affected Employees” from area.
• Remove locks, tags, and devices.
• Energize and proceed with testing or
positioning.
• De-energize and re-apply energy control
measures.
 First Safety Systems Training Services
‘ Your total safety solutions’

Equipment Used for Lockout/Tagout

• All lockout/tagout equipment must be available; if
equipment is not available, contact the shift
manager or supervisor.
• If proper equipment cannot be located:
 STOP! Do not proceed any further with
lockout/tagout activities.
 Contact the shift manager or supervisor.
 Contact EHS.
 Ensure proper lockout/tagout equipment is
provided and on hand before continuing.
 If equipment cannot be obtained, discontinue
work and ensure EHS is contacted.
 First Safety Systems Training Services
‘ Your total safety solutions’

Equipment Used for Lockout/Tagout cont.

• Lockout/tagout devices must be
standardized.
• Locks must be unique with a single key,
and not used for any other purpose.
• Tags must:
• Be durable and withstand the
environmental conditions encountered
in the workplace.
• Be used whenever a lock is placed.
• Contain specific employee information.
• Be secured to the energy control point.
75
 First Safety Systems Training Services
‘ Your total safety solutions’

Hazardous Production Materials (HPM) Requirements

• Dual valve isolation is required for HPMs when systems are

pressurized (>15 psi).
• One valve must be under lockout/tagout and a second valve
closed between the source of hazard and the authorized
employee. At least one of these valves is to be locked and
tagged out.
• When two-valve isolation cannot be achieved, EHS-approved
alternate measures will be used; there cannot be a single point
of failure that results in HPM exposure.
• SAFETY NOTICE: For a valve to be considered locked/tagged
out, you must use a lockable valve, a locking valve cover, or a
valve cover that prevents the pneumatic line from being
reconnected during lockout.
 First Safety Systems Training Services
‘ Your total safety solutions’

Special Situations

• Abandoned locks
• Contract workers

• Multiple workers

• Lock boxes

• Change of shift
 First Safety Systems Training Services
‘ Your total safety solutions’

Special Situations: Abandoned Locks

The lock may not be cut until:
• All forms of hazardous energy are identified to be at zero
hazardous energy level. Refer to the applicable Energy Control
Procedures.
• The Abandoned Lock Removal Form has been completed and
procedures followed. (Review the form on the next page of the
Student Handbook.)
• After the lock is cut, you must notify the owner of the lock and
his/her first link supervisor within 24 hours.
 First Safety Systems Training Services
‘ Your total safety solutions’

Special Situations: Contract Workers

• Contractors will inform their Intel Sponsors of

their control of hazardous energies program.

• All contractor procedures must meet OSHA

requirements, as well as Intel expectations.

• The Intel Sponsor will ensure that the

contractor has an understanding of Intel’s
Control of Hazardous Energies program, as
well as specific procedures that may affect
him/her.
 First Safety Systems Training Services
‘ Your total safety solutions’

Special Situations: Multiple Workers

• Always use a multi-lock hasp and/or lock box.
• Never remove anyone else’s lock and tag.
• Never rely on anyone else’s lock and tag.
• Each lock will have a single key and the key must
be held by the person who applied the lock.
 First Safety Systems Training Services
‘ Your total safety solutions’

Special Situations: Lock Boxes

The Tool Owner, Project Manager, or person

supervising the lockout must:

• Apply a lock and tag to each hazardous energy

control point.

• Place the key(s) to the lock(s) in a lock box.

• Affix his/her own lock and tag to the lock box.

 First Safety Systems Training Services
‘ Your total safety solutions’

Special Situations: Lock Boxes cont.

Authorized Persons working on the locked system must:

• Affix their lock and tag to the lock box prior to beginning work. Use a
multiple lockout hasp or lock box if more than one employee needs to
lock out. All personnel exposed to potential danger zones shall apply
their own lockout/tagout device.
• Verify that the systems they are working on are de-energized and that
the lock is on the correct isolation device.
• Remove their lock and tag when they have completed their work.
• Stop work and inform the person supervising the task of start and stop
times as well as any issues found.
First Safety Systems Training Services
‘ Your total safety solutions’

Conduct a Demonstration of
the Lockbox Procedures
 Keep all employees a safe distance from the machine or equipment
 Remove tools and equipment from the work area
 Reinstall the machine safeguards
 First Safety Systems Training Services
‘ Your total safety solutions’

Special Situations: End or Change of Shift

• If work is extended beyond one shift, or a relief

person is needed to complete the work, a
handoff must be coordinated between both
parties.

• Both parties must be in attendance.

• The new shift worker must secure the source or
lockout point with his/her own lock and tag and verify
zero energy (always refer back to the applicable
Energy Control Procedure).
• The current shift worker must remove his/her own
lock and tag.
• Keys shall never be exchanged or passed between
employees.
 First Safety Systems Training Services
‘ Your total safety solutions’

 Remove LO/TO devices

 Restore energy
 Test for operation
 Notify affected and other employees that the equipment or
machinery is in service and safe to operate
 First Safety Systems Training Services
‘ Your total safety solutions’

Authorized Employee: Re-Training Requirements

Re-training is required when there is:

• A change in job assignment.
• A change in machines, equipment, or
processes that present a new hazard.
• A change in or identified deficiencies in the
Energy Control Procedures.
• A periodic inspection that reveals the
Authorized Employee is not proficient in
lockout/tagout.
 First Safety Systems Training Services
‘ Your total safety solutions’

Lockout/Tagout Periodic Inspections

• Periodic inspections will be conducted annually to ensure

compliance with lockout/tagout operation requirements.
• The Authorized Person will be asked to demonstrate
lockout/tagout procedures by referencing the applicable ECP
of his tool or system.
• Inspections are performed by Certified Periodic Inspectors.
• Inspections will use a form to document:
 Equipment and personnel identity.
 Date of inspection.
 Inspector’s name.
• Inspections must be reviewed with the employees inspected
and documented with Intel University.
First Safety Systems Training Services
‘ Your total safety solutions’
Don’t Let This Happen To You!!

89
 First Safety Systems Training Services
‘ Your total safety solutions’

….or THIS!!!

90
First Safety Systems Training Services
‘ Your total safety solutions’
First Safety Systems Training Services
‘ Your total safety solutions’

92
First Safety Systems Training Services
‘ Your total safety solutions’

93
First Safety Systems Training Services
‘ Your total safety solutions’

94
First Safety Systems Training Services
‘ Your total safety solutions’

95