The Energy Control and Power Lockout Mini-Manual A Publication of the UAW-Ford National Joint Committee on Health and Safety
© Copyright 1987. Revised 1993 and in 1999. The UAW-Ford National Joint Committee on Health and Safety. Reproduction in any manner, in whole or in part, in English or other languages, is prohibited. All Rights Reserved.
A JOINT COMMITMENTENERGY 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 than 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.
IntroductionWelcome 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, nor 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.
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Ensuring machines can be safely and correctly locked out |
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Lock issuance |
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Control of locks and keys |
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ECPL training |
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Enforcement of strict compliance with approved lockout procedures |
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Maintenance of good housekeeping conditions, allowing the correct use of ECPL procedures |
Check
YourselfCheck
EquipmentCheck
Hazards
Check
Problem Check Yourself Check yourself for
fatigue caused by:
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Lack of sleep |
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Poor eyesight or tired eyes |
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Stress |
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Alcohol and drugs |
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Anger |
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Poor physical condition |
Check yourself for correct
clothing:
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Avoid loose-fitting or greasy clothing |
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Wear safety shoes |
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Wear protective clothing the job calls for |
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Wear eye protection |
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Wear the right gloves for the job |
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Don't wear gloves around rotating equipment |
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Don't wear rings, bracelets or long necklaces |
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Tie back long hair or put under a cap |
Check Your Equipment Check your
tools:
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Keep your tools clean, orderly and in good repair |
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Use the right tool for the job |
Check the safety
locks:
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Use only an approved safety lock for ECPL |
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Keep your safety lock with you |
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Never lend or borrow a safety lock |
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One worker - one safety lock on each entry point of power |
Check your multiple
lockout device:
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Use only an approved multiple lockout device |
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Use when more than one person is locking out |
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Never use "daisy-chaining" |
Check danger
tags:
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Use a danger tag only to supplement a lock |
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Check out information on a tag for yourself |
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Use your personalized danger tag with your lock |
Check heavy lockout
equipment:
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When called for, use approved chains, blocks and wedges, or pins as energy control devices |
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Use only approved lockout devices provided for specific equipment |
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Use devices correctly |
Check the Hazards Check personal
hazards:
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Pride |
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Fear |
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Desire for a "macho" image |
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Lack of knowledge |
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Trade-offs |
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Disincentives |
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Overconfidence |
Check
environmental hazards:
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Poor machine safety lockout design or defects' |
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Poor housekeeping** |
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Insufficient Insufficient lighting"* |
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Excessive noise affecting communications |
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Confined spaces |
Check organizational
hazards:
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Not enough locks or lockout devices** |
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ECPL not enforced |
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Production pressures (direct and indirect) |
Check hidden
hazards:
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People hazards |
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Communications hazards |
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Familiarity hazards (too much or too little) |
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Concentration hazards (too much or too little) |
* Report these hazards to your ECPL Coordinator
** Report these hazards to your supervisor
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:
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Frustration and impatience |
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Long machine cycles |
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Overconcentration; underconcentration |
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Poor communications among workers |
The troubleshooting process:
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Check the rule |
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Check surrounding machines |
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Check with the operator |
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Check the machine (observation) |
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Check the safety guards |
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Check communications |
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Check the energies |
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Check your concentration |
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Check the DON'Ts: |
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DON'T reach into energized machinery |
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DON'T take anything for granted |
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DON'T cut down your margin of safety |
Use special caution when unjamming machinery.
Prep It! has to do with communications and information. You will use the four steps to communicate with fellow workers, supervisors and other personnel in order to give and receive information abut the job you are going to do and the equipment you are about to work on.
Prepare
PersonnelPrepare The
AreaPrepare
YourselfPrepare The
MachineInform personnel, when necessary, that you intend to perform ECPL:
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Production supervisor in charge of the machine |
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Maintenance or other immediate supervisor |
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Machine operator |
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Other area production personnel |
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Other skilled tradesmen whose help you may need |
When in doubt, consult a knowledgeable individual.
Remember the rule:
It's your right to lock out and control energy whenever you have a need to place any part of your 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 you.
Environmental prep involves removing, reducing or protecting
against hazards identified in Check It!, such as:
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Using special personal protective equipment |
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Arranging for clean-up or removal of obstructions |
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Following procedures for confined space entry |
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Posting danger signs or barricades when required |
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Alerting others to hazards |
Prepare
associated/adjacent machinery:
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Check above, below and on all sides of your machine |
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Perform ECPL on nearby machinery, if necessary |
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Pay particular attention to: |
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Conveyors |
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Overhead cranes |
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Unloaders and loaders |
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Vehicular traffic in the area |
ONE PERSON - ONE LOCK on every entry point of power being locked out.
Prepare YourselfGet necessary
information about the machine in order to perform ECPL effectively. Be
sure you know:
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How it cycles when working properly |
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The timing of the cycle |
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What it is doing wrong |
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What types of energy are used |
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The pinch or crush points |
Sources
of information:
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Your knowledge and experience |
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Posted procedures on ECPL, if available |
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Machine prints |
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Other printed materials such as manufacturers' manuals |
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Knowledgeable individuals |
Cautions
when using these sources:
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Never assume. Always double-check |
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Prints can get out of date. Confirm with others |
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Use more than one source whenever possible |
It's better to ask a question when you are in doubt than to take a risk and get hurt.
Prepare the MachineTrace energies to acceptable disconnect points. An acceptable disconnect effectively cuts off the energy supply to the equipment and can be secured so that no one except the person working on the equipment can reconnect the power.
Trace energies to learn:
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How it moves through the system |
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How many locks and other devices you need for ECPL |
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Which stored energies need to be neutralized |
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Which residual pressures need to be released |
Primary (main) energies:
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Electrical |
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Hydraulic (fluid under pressure) |
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Pneumatic (air under pressure) |
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Gas/water/steam/chemicals (usually in piping systems) |
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Multiple energies (any combination of the above) |
Secondary (stored)
energies:
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Mechanical motion (rotation) |
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Gravity |
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Stored mechanical energy (springs) |
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Thermal (temperature extremes) |
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Residual electricity (in capacitors or batteries) |
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Residual pressure (fluids, air, gas, steam, chemicals) |
Lock It! and Release It! cover the actual steps you take to lock out and control energy on machinery.
The stop signs remind you to STOP and THINK BEFORE YOU ACT!
NEVER assume. Always double-check
Remember the rule
Whenever a worker has a reed 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.
Shut Off
PowerLock Out
Electrical EnergyLock Out
HydraulicsLock Out
PneumaticsLock Out G.W.S.C
(Gas/Water/Steam/Chemicals)
Shut Off and Disconnect Power Before you disconnect
power:
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Make sure you shut off equipment at the operating controls and that no one is operating it |
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Know position in which machine is to be stopped |
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Know whether an energy must be left on for safety Know the sequence for multiple energy shutoff |
You must make sure that machine controls are in the OFF position before proceeding to disconnect and lock out power.
Cautions while
shutting off power:
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Electrical: Face away from panel or cabinet. Use left hand (or right if you are left-handed) to operate disconnect |
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Pressure systems: Shut off with pressure-supported parts in lowest position |
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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 |
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Multiple energies: Caution: machine may be operated from more than one location |
Before you perform
ECPL:
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Let all motors and machine movement stop |
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Make sure all controls are in off position |
Lock Out Electrical EnergyYou must make sure that machine controls are in the OFF position before proceeding to disconnect and lock out power.
Electrical disconnects are usually located in the machine's control panel, not necessarily visible from the operating controls.
The disconnect must be lockable in the open or off position. Never use operating controls for ECPL. Always lock out at the entry point of power.
Hazards to watch
for:
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Jumpered circuits, making ECPL ineffective |
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Inaccurate prints or labels |
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Missing or defective disconnects or energy control devices |
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Inconvenience of lockout points |
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Assumptions that disconnects are operative |
If you can't lock out, report problems to your supervisor.
Always verify security of disconnect and lock.
Always try the controls after locking out to make sure that machine is de-energized.
Don't take short cuts with electricity. When in doubt, consult a knowledgeable individual.
Lock Out Hydraulic Energy Shut off the hydraulic pump.
For electrical motors:
1. Shut off power at operating controls
2. Wait for movement to cease
3. Throw disconnect at entry point of power
4. Attach lock at entry point of power
5. Verify that lock and disconnect are secure
6. Press motor start button to verify that power is off
For battery operated hydraulic pump, turn off the pump and disconnect the battery.
For a pump serving more than one machine, discuss shutoff with your supervisor, if necessary.
If hydraulic valves are lockable, close valves and attach safety lock(s) or multiple lockout device(s).
If hydraulic valves do not release pressure, let a qualified person open the line at a fitting
Do not begin work until residual pressure has been released.
As valves are closed and pumps shut off, watch for possible machine movement if pressure is lost.
Caution: Hydraulically powered equipment tends to drift.
Lock Out PneumaticsYou must make sure that machine controls are in the OFF position before proceeding to disconnect and lock out power.
Caution: Air pressure may have to be left on if it supports machine components. This must not jeopardize safety. Blocking and pinning must also be used to prevent components from moving.
Locking out pneumatic
valves:
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Piston type - Push handle inward and attach lock or multiple lockout device around groove in valve stem and matching indent in the housing |
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T -handle piston type - Turn T -handle one quarter turn, pull outward and attach lock through stem |
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Handle/lever type - Place in closed position and attach lock or multiple lockout device through marching holes in lever and fitting |
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Gate valve - Pass approved chain through handle and around pipe for secure closure. Attach lock or multiple lockout device to hold chain in place |
Listen for escaping air as you operate valves.
Verify security of lock and position of valve.
Release residual pressure before starting work.
Use extra caution when unjamming pneumatically powered equipment.
Lock Out Gas/Water/ Steam/ChemicalsGas/Water/Steam/Chemicals tend to be carried in pipes. ECPL usually involves shutting off pumps, draining, venting or releasing contents, and blanking or separating pipes.
You must make sure that machine controls are in the OFF position before proceeding to disconnect and lock out power.
Caution: Piping systems are not always clearly
marked. Never attempt to control
these systems unless you know:
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Contents |
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Hazards |
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Approved handling procedures |
When in doubt, consult a knowledgeable individual.
To lock out a gate valve, pass approved chain through handle and around pipe for secure closure. Attach lock to hold chain in place.
To lock out a
pump:
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Turn off motor. Wait for movement to cease |
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Throw disconnect at entry point of power |
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Attach lock or multiple lockout device |
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Verify that lock and disconnect are secure |
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Press motor start button to verify that power is off |
Cautions:
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When closing valves, start near the equipment and move up-line toward the source |
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Close valves or blank pipes on both sides of a portion you want to isolate |
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Don't assume that the procedure for handling one gas or chemical is the right one for handling another |
Additional Lock It! IssuesMultiple energies:
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Observe the correct shutoff sequence |
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Identify and lock out all sources of energy |
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Disconnects may be in more than one location |
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One person - one lock on all entry points of power being locked out |
Robots:
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Know both the work envelope and the operating envelope |
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Never defeat interlocked guarding |
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Never use interlocked guarding as a substitute for full lockout procedures |
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Watch for sudden and unexpected movement when re-energizing |
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When in doubt, consult a knowledgeable individual |
Confined Space Entry: Know the special hazards:
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Atmospheric hazards |
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Physical hazards |
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Communications hazards |
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Possibility of engulfment |
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Chance that hazardous materials will enter |
Follow strict guidelines for
working in confined spaces:
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Obtain a special permit form |
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Perform thorough atmospheric testing and monitoring |
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Use special tools and personal protective equipment |
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Use approved tools and materials |
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Make certain authorized attendants are stationed |
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Observe ECPL procedures rigorously |
Release It! covers the steps you take to neutralize all types of stored and residual energy which can potentially cause injury to workers on equipment, even after primary energies have been shut off and locked out.
Dissipate
Rotation (Mechanical Motion)Control
GravityControl
or Release Springs (Stored Mechanical Energy)Dissipate
Thermal EnergyRelease
Primary Energies (Electricity and Pressure)Dissipate Rotation Rotation is present in such
components as:
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Fly wheels |
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Drill presses |
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Grinder wheels |
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Circular saws |
Dissipate
rotation by:
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Waiting until components have stopped moving |
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Applying brakes where available |
Special cautions around
rotating components:
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Don't be impatient. Let rotation cease completely |
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Don't wear loose clothing or jewelry |
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Do wear your safety glasses |
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Do tie back long hair |
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Don't wear gloves around rotating equipment |
Neutralizing stored energy is just as critical as locking out primary energy sources.
Control GravityGravity is a form of energy that cannot be shut off, it must be controlled by physically blocking or restraining affected machine parts after power shutoff.
Gravity poses a special hazard where machine components are kept in position by pressure or electricity. When these energies are shut off, gravity takes over.
Control gravity chiefly by
means of:
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Blocks and wedges: These are manufactured for a specific machine and kept in a special place nearby. Some are interlocked with the machine |
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Pins: Used on some machines |
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Chains: Use approved chains only |
Cautions:
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Use energy control devices only in the proper manner. |
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Do not substitute odd pieces of pipe or lumber |
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Do not use devices from one machine for another |
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Shut off and lock out power before using devices |
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Let machine movement stop before using devices |
Be sure to remove blocks, wedges and pins before restoring power.
Control or Release
Springs
A compressed or extended spring is the chief source of
stored mechanical energy you will have to handle.
Since springs are often not readily visible:
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Consult machine prints |
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Consult a knowledgeable individual |
Control a spring's energy by blocking it in the compressed position or restraining it in the extended position.
Release a spring's energy by allowing it to return to its rest position.
Maintain a safe position while neutralizing the energy in a spring.
Dissipate Thermal EnergySupercooled or superheated machine parts or working materials can cause serious injury if they contact your skin.
Neutralize thermal energy
by:
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Waiting for temperature to moderate |
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Using warming or cooling means |
If you must work on or near
supercooled or superheated surfaces or materials:
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Use thermal barriers where possible |
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Wear temperature resistant gloves and clothing |
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Use tools, not hands, to handle surfaces or components |
Release Stored ElectricityElectricity can be stored in capacitors and batteries.
Before working on machinery
so equipped, make sure a qualified person:
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Discharges capacitors |
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Disconnects batteries |
Release Pneumatic
PressureRelease residual air pressure
from:
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Air lines |
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Storage tanks |
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Surge tanks |
Cautions:
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Do not trust gauges for release of pressure |
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Listen for air release from exhaust ports |
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Be careful around jammed pneumatic equipment |
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Watch for machine movement as pressure is released |
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If air is left on in a press, also use positive control devices (blocks, pins, chains) |
Release Hydraulic
PressureBefore releasing residual hydraulic pressure, you may have to block or chain parts held in position by that pressure.
In systems where valves are equipped with special release mechanisms, use the special switch or button to release pressure.
In systems without control valves, let a qualified person open a line at a fitting or fittings. This should be done gradually.
Isolate accumulators and lock out if possible.
Cautions:
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Do not trust gauges when checking release of pressure |
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Be careful around jammed hydraulic equipment |
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Watch for machine movement as pressure is released |
Release Gas/Water/
Steam/ChemicalsA qualified person controls
piping systems by:
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Venting gases |
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Draining chemicals |
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Releasing pressure |
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Blanking or separating pipes |
Cautions:
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Wear the right personal protective equipment |
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Know the right procedure for handling pipe contents |
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Consult HazCom information, if necessary |
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Consult a knowledgeable individual, if in doubt |
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Exercise special caution in confined space situations |
To verify means to double-check and to make sure that your action in locking out and controlling energy have in fact made the machinery safe for repair, maintenance, cleaning or setup.
The Union and the Company want YOU to lock out and work safely!
Lock out! It's your life! It's your right!
Verify
ECPLBe Alert To
DangerRecheckRemove
LocksRe-EnergizeTest Equipment
OperationFinish
TaskVerify ECPLAfter performing ECPL and before starting work, you must make sure that the machine is completely safe. Verify absence or control of energy.
Electrical:
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Manually operate all applicable start/stop switches, buttons and controls |
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Look for movement, lights, motor start-ups |
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Listen for unusual noises |
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Return all controls to the off position |
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Use voltage testing equipment, if appropriate |
Pneumatic and
Hydraulic:
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Check gauges for zero pressure |
|
Do not trust gauges alone |
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Let a qualified person open fittings, if necessary |
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Be careful around jammed equipment |
Gas/Water/Steam/Chemical:
|
Check gauges for zero pressure |
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Don't trust gauges alone |
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Consult a knowledgeable person, if necessary |
Stored
Energy:
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Double-check effectiveness of neutralization |
Multiple
Energies:
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Try all energy controls. Return to off position |
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One person - one lock on each appropriate disconnect |
Be Alert to DangerDouble-check before you start work.
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Double-check yourself: |
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Clothing |
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Protective equipment |
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Physical condition |
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Locks securely in place |
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Controls in off position |
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Energy control devices correctly placed |
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Nothing is moving and nothing can move |
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Hazards controlled or removed |
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Necessary communications made |
Be cautious as you work:
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Watch for changing conditions |
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Watch out for coworkers |
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If you leave temporarily, recheck when you return: |
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Locks securely placed |
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Conditions still safe and secure |
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Remove your lock(s) and only your lock(s) |
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Inform supervisor and coworkers, if necessary |
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Have departmental lock attached, if necessary |
Recheck Before Lock RemovalIf work has been
completed and the equipment is ready for re-energizing:
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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 |
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Make sure all guards, fencing and safety devices are in place |
Remove LocksAfter a thorough recheck, remove your lock(s) and only your lock(s) from all disconnects.
If equipment is not ready for power restoration, replace personal safety locks with departmental locks.
A departmental lock is used to protect equipment from activation when this could cause damage to the equipment or injury to personnel in the area.
A departmental lock is not a substitute for a personal safety lock.
Re-EnergizeBefore
you re-energize, double-check:
|
Make sure personnel are clear |
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Make sure energy control devices are removed |
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Inform area personnel, if necessary |
Electrical:
|
Stand to one side of the panel or cabinet |
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Use your "off" hand on the switch |
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Reconnect batteries, if necessary |
Pneumatic:
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Reconnect fittings |
|
Open valves gradually |
|
Watch for machine movement |
Hydraulic:
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Close fittings and drains |
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Turn on pump |
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Open valves gradually |
Gas/Water/Steam/Chemical:
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Remove blanks |
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Reconnect piping |
|
Open valves gradually |
|
Use special reactivation procedures, if required |
Multiple
energies:
|
Use correct sequence for re-energizing |
Robots and automated
machinery:
|
Stand outside perimeter guarding |
|
Watch for sudden movement |
Test Equipment OperationAfter re-energizing, equipment may be tested for correct operation.
Teamwork, communications and caution are called for.
If the machine runs properly, it may be returned to service.
If not, you must repeat ECPL procedures if you are performing further work on the equipment.
Finish TaskYour work is not complete until you have made sure that the machine is left in safe operating condition or that appropriate departmental locks and tags and other protective measures are in place.
Your work is not complete until you have made sure that you have informed all personnel who need to know that you have finished the job.
Your work is not complete until you have made sure that you have arranged for any necessary housekeeping tasks to be performed.
Take the time to work safely.
Follow The
ProceduresLive With The
PolicyUse The ECPL
GuideMake It
WorkFollow the ProceduresIn order to use the ECPL procedures, you must apply them to the particular machine you are working on. You must implement your training by taking GENERAL procedures and making them SPECIFIC for situations you deal with on the job.
Your concern with safety starts the moment you approach a job and ends only after your work is done, including any necessary replacement of safeguards, clean-up and communications.
Live With The Policy: |
Observe ECPL correctly every time you need it |
|
Remember 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 |
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One worker - one lock on every point of power being locked out |
|
Check and double-check. Never assume |
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Two heads are better than one. Work together to execute procedures correctly and completely |
|
The importance of good communications cannot be overstressed |
|
When in doubt, consult a knowledgeable individual |
Use The ECPL GuideRemember that what you actually do in each step will depend on the specific situation and the specific machine. Keep in mind that certain factors may affect how you execute ECPL, such as:
|
The kind of equipment |
|
The work to be done |
|
The use of special energy sources or combinations of energies |
|
The condition of disconnects and lockout mechanisms |
In all cases, the principles of ECPL still apply.
Make It WorkThere are many things you can do to keep the ECPL program alive in your facility. These include:
|
Individual action and awareness. It will take the total commitment of each and every one of us to prevent lockout-related accidents. Never compromise your right and responsibility to lock out! |
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Interaction with fellow workers. Peer support can reinforce safe practices on the job. Be ready to help. Intervene to prevent injuries. Look out for one another |
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Interaction with management and Union representatives. It may be appropriate for you to report and/or take action on the following issues: |
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Environmental hazards |
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Defective/missing lockout equipment |
|
Special problems with ECPL procedures |
|
Inconvenient lockout means |
Exercising your right to lock out includes taking an active part in making conditions safer for everyone in your facility.
For more information, see the Energy Control and Power
Lockout Placarding Standard and Materials Catalog.
|
© Copyright 1995-2003 Ford
Occupational Health & Safety |
