The Energy Control and Power Lockout Mini-Manual

A Publication of the UAW-Ford National Joint Committee on Health and Safety

A JOINT COMMITMENT

ENERGY CONTROL AND POWER LOCKOUT (ECPL), is considered by many to be a benchmark health and safety training program. Launched in 1987, the program was targeted at the skilled trades, set-up, clean-up, and other personnel whose duties could expose them to unexpected motion of machines and equipment. Since this time, a number of facilities have chosen to train the entire plant population in ECPL.

In every Ford location, as well as some locations outside of the Ford organization, the ECPL program has been well received. A comprehensive evaluation of the program by one of the country's leading Universities revealed that the program proved to be very effective in communicating its primary message to its targeted audience: the need to control and lock out energy, despite production pressures.

The success of the ECPL program has brought with it new insights and greater responsibilities. Even with the good that has been accomplished by the ECPL program, we are not there yet. Continuous improvement must be ongoing. We continue to experience serious injuries and even fatalities that are related to controlling energy.

In this regard, we would like to reaffirm our joint commitment to the principles laid out by the ENERGY CONTROL and POWER LOCKOUT program. As you read through this text and participate in the training program, strive to do more then understand the lockout procedures. Make the lockout procedures a part of your work habit, and remember: lock out, it's your life, it is your right.



Ron Gettelfinger Vice President, Director National Ford Department UAW	Peter J. Pestillo Vice Chairman and Chief of Staff Ford Motor Company

Introduction

Welcome to the Energy Control and Power Lockout Mini-Manual. The Mini-Manual is intended as a quick reference for on-the-job use. It contains, in abbreviated form, the essential information on ECPL which is provided in detail in the ECPL Participant Manual.

This manual is organized according to the ECPL Guide, which you have seen throughout the Lockout Training Program, and which appears in full on page 22 of the Participant Manual. Approximately one page is devoted to each step. The segment names appear along the outside edge of each page to help you find the appropriate section of the manual as you are thumbing through it.

The Mini-Manual is not intended to serve as a substitute for the training. It does not tell you how to lock out specific equipment, not does it tell you how to do your job. It is designed only as an outline of important reminders and cautions. Use it to jog your memory and to reinforce the lockout training.

Failure To Lock Out Kills - The right attitude toward safety and ECPL is just as important as skill and knowledge. Know that accidents can happen to you and that correctly following ECPL procedures will reduce your chances of injury on the job.

Personal Barriers - Pride, fear, desire for a "macho" image, lack of knowledge, trade-offs, disincentives and overconfidence are barriers to watch for and overcome.

Environmental Barriers - Poor machine safety design and poor housekeeping can present hazards. Report them!

Organizational Barriers - Inadequate supplies of safety locks and other lockout equipment, non-use of departmental locks, lack of enforcement, and production pressure (direct and indirect) may make ECPL difficult. Report such problems to appropriate Union or management personnel.

Your Responsibility, Authority And Accountability -The rule: Whenever a worker has a need to place any part of his/her body in a position on or near machines or equipment where unexpected movement, release of stored energy, energizing of electrical systems, or the flow of gases, fluids or other materials could have potential to injure the worker, then the worker has the RESPONSIBILITY and the AUTHORITY to correctly apply ECPL procedures and shall be held ACCOUNTABLE for that correct application.

Plant Management's Responsibility, Authority and Accountability:

Check Yourself

Check yourself for fatigue caused by:

	Lack of sleep
	Poor eyesight or tired eyes
	Stress
	Alcohol and drugs
	Anger
	Poor physical condition

Check yourself for correct clothing:

	Avoid loose-fitting or greasy clothing
	Wear safety shoes
	Wear protective clothing the job calls for
	Wear eye protection
	Wear the right gloves for the job
	Don't wear gloves around rotating equipment
	Don't wear rings, bracelets or long necklaces
	Tie back long hair or put under a cap

Check Your Equipment

Check your tools:

	Keep your tools clean, orderly and in good repair
	Use the right tool for the job

Check the safety locks:

	Use only an approved safety lock for ECPL
	Keep your safety lock with you
	Never lend or borrow a safety lock
	One worker - one safety lock on each entry point of power

Check your multiple lockout device:

	Use only an approved multiple lockout device
	Use when more then one person is locking out
	Never use "daisy-chaining"

Check danger tags:

	Use a danger tag only to supplement a lock
	Check out information on a tag for yourself
	Use your personalized danger tag with your lock

Check heavy lockout equipment:

	When called for, use approved chains, blocks and wedges, or pins as energy control devices
	Use only approved lockout devices provided for specific equipment
	Use devices correctly

Check the Hazards

Check personal hazards:

	Pride
	Fear
	Desire for a "macho" image
	Lack of knowledge
	Trade-offs
	Disincentives
	Overconfidence

Check environmental hazards:

	Poor machine safety lockout design or defects'
	Poor housekeeping**
	Insufficient Insufficient lighting"*
	Excessive noise affecting communications
	Confined spaces

Check organizational hazards:

	Not enough locks or lockout devices**
	ECPL not enforced
	Production pressures (direct and indirect)

Check hidden hazards:

	People hazards
	Communications hazard
	Familiarity hazards (too much or too little)
	Concentration hazards (too much or too little)

* Report these hazards to your ECPL Coordinator

** Report these hazards to your supervisor

Check the Problem

STOP AND THINK!

Troubleshooting requires special caution. LOCK OUT AND CONTROL ENERGY if you must place any part of your body where it could be injured by moving machinery, electric shock or contact with process materials.

Troubleshooting hazards:

	Frustration and impatience
	Long machine cycles
	Overconcentration; underconcentration
	Poor communications among workers

The troubleshooting process:

	Check the rule
	Check surrounding machines
	Check with the operator
	Check the machine (observation)
	Check the safety guards
	Check communications
	Check the energies
	Check your concentration
	Check the DON'Ts:

	DON'T reach into energized machinery
	DON'T take anything for granted
	DON'T cut down your margin of safety

	Production supervisor in charge of the machine
	Maintenance or other immediate supervisor
	Machine operator
	Other area production personnel
	Other skilled tradesmen whose help you may need

	Using special personal protective equipment
	Arranging for clean-up or removal of obstructions
	Following procedures for confined space entry
	Posting danger signs or barricades when required
	Alerting others to hazards

	Conveyors
	Overhead cranes
	Unloaders and loaders
	Vehicular traffic in the area

	How it cycles when working properly
	The timing of the cycle
	What it is doing wrong
	What types of energy are used
	The pinch or crush points

	Your knowledge and experience
	Posted procedures on ECPL, if available
	Machine prints
	Other printed materials such as manufacturers' manuals
	Knowledgeable individuals

	Check above, below and on all sides of your machine
	Perform ECPL on nearby machinery, if necessary
	Pay particular attention to:

	Never assume. Always double-check
	Prints can get out of date. Confirm with others
	Use more then one source whenever possible

	Mechanical motion (rotation)
	Gravity
	Stored mechanical energy (springs)
	Thermal (temperature extremes)
	Residual electricity (in capacitors or batteries)
	Residual pressure (fluids, air, gas, steam, chemicals)

	Make sure you shut off equipment at the operating controls and that no one is operating it
	Know position in which machine is to be stopped
	Know whether an energy must be left on for safety Know the sequence for multiple energy shutoff

	Electrical: Face away from panel or cabinet. Use left hand (or right if you are left-handed) to operate disconnect
	Pressure systems: Shut off with pressure-supported parts in lowest position
	Watch machine movement if pressure is lost Gas/water/steam/chemical piping systems: Shut off pump(s). Close valves near machine first then move up-line
	Multiple energies: Caution: machine may be operated from more then one location

	Let all motors and machine movement stop
	Make sure all controls are in off position

	Jumpered circuits, making ECPL ineffective
	Inaccurate prints or labels
	Missing or defective disconnects or energy control devices
	Inconvenience of lockout points
	Assumptions that disconnects are operative

	Piston type - Push handle inward and attach lock or multiple lockout device around groove in valve stem and matching indent in the housing
	T -handle piston type - Turn T -handle one quarter turn, pull outward and attach lock through stem
	Handle/lever type - Place in closed position and attach lock or multiple lockout device through marching holes in lever and fitting
	Gate valve - Pass approved chain through handle and around pipe for secure closure. Attach lock or multiple lockout device to hold chain in place

	Turn off motor. Wait for movement to cease
	Throw disconnect at entry point of power
	Attach lock or multiple lockout device
	Verify that lock and disconnect are secure
	Press motor start push button to verify that power is off

	When closing valves, start near the equipment and move up-line toward the source
	Close valves or blank pipes on both sides of a portion you want to isolate
	Don't assume that the procedure for handling one gas or chemical is the right one for handling another

	Atmospheric hazards
	Physical hazards
	Communications hazards
	Possibility of engulfment
	Chance that hazardous materials will enter

	Fly wheels
	Drill presses
	Grinder wheels
	Circular saws

	Waiting until components have stopped moving
	Applying brakes where available

	Observe the correct shutoff sequence
	Identify and lock out all sources of energy
	Disconnects may be in more then one location
	One person - one lock on all entry points of power being locked out

	Know both the work envelope and the operating envelope
	Never defeat interlocked guarding
	Never use interlocked guarding as a substitute for full lockout procedures
	Watch for sudden and unexpected movement when re-energizing
	When in doubt, consult a knowledgeable individual

	Obtain a special permit form
	Perform thorough atmospheric testing and monitoring
	Use special tools and personal protective equipment
	Use approved tools and materials
	Make certain authorized attendants are stationed
	Observe ECPL procedures rigorously

	Don't be impatient. Let rotation cease completely
	Don't wear loose clothing or jewelry
	Do wear your safety glasses
	Do tie back long hair
	Don't wear gloves around rotating equipment

	Blocks and wedges: These are manufactured for a specific machine and kept in a special place nearby. Some are interlocked with the machine
	Pins: Used on some machines
	Chains: Use approved chains only

	Use energy control devices only in the proper manner.
	Do not substitute odd pieces of pipe or lumber
	Do not use devices from one machine for another
	Shut off and lock out power before using devices
	Let machine movement stop before using devices

	Waiting for temperature to moderate
	Using warming or cooling means

	Use thermal barriers where possible
	Wear temperature resistant gloves and clothing
	Use tools, not hands, to handle surfaces or components

	Do not trust gauges for release of pressure
	Listen for air release from exhaust ports
	Be careful around jammed pneumatic equipment
	Watch for machine movement as pressure is released
	If air is left on in a press, also use positive control devices (blocks, pins, chains)

	Do not trust gauges when checking release of pressure
	Be careful around jammed hydraulic equipment
	Watch for machine movement as pressure is released

The Energy Control and Power Lockout Mini-Manual

A JOINT COMMITMENT

Introduction

Introduction

Introduction

Additional Lock It! Issues

INTRODUCTION

Release Pneumatic Pressure

Release Hydraulic Pressure

Release Gas/Water/ Steam/Chemicals

INTRODUCTION

	Venting gases
	Draining chemicals
	Releasing pressure
	Blanking or separating pipes

	Wear the right personal protective equipment
	Know the right procedure for handling pipe contents
	Consult HazCom information, if necessary
	Consult a knowledgeable individual, if in doubt
	Exercise special caution in confined space situations

	Manually operate all applicable start/stop switches, buttons and controls
	Look for movement, lights, motor start-ups
	Listen for unusual noises
	Return all controls to the off position
	Use voltage testing equipment, if appropriate

	Check gauges for zero pressure
	Do not trust gauges alone
	Let a qualified person open fittings, if necessary
	Be careful around jammed equipment

	Check gauges for zero pressure
	Don't trust gauges alone
	Consult a knowledgeable person, if necessary

	Try all energy controls. Return to off position
	One person - one lock on each appropriate disconnect

	Locks securely in place
	Controls in off position
	Energy control devices correctly placed
	Nothing is moving and nothing can move

	Watch for changing conditions
	Watch out for coworkers
	If you leave temporarily, recheck when you return:

	Remove your lock(s) and only your lock(s)
	Inform supervisor and coworkers, if necessary
	Have departmental lock attached, if necessary

	Recheck the machine. Remove materials, tools, equipment, trash, etc.
	Make sure all personnel are cleared from the machine and at a safe distance
	Remove all energy control devices. Replace in proper storage positions
	Make sure all guards, fencing and safety devices are in place