Machine-Specific Energy Control Process

Form 000.653.F0295 Machine-Specific Energy Control Process

ECP No.: Machine No.: Date:

Project No./Contract No.: Employer: Machine/Equipment Description: Location:

Authorized Workers:

Affected Workers:

WARNING: THIS MACHINERY HAS MULTIPLE ENERGY SOURCES

Failure to follow an Energy Control Process (ECP) may result in serious injury. If in doubt, contact your supervisor for assistance.

Hazardous Energy Source Description Additional ID Isolating Action Verification Lockout Safety Energy Type Magnitude Location No. Device Required Method Device Measures For Tagout

M1 Mechanical

E1 Electrical

E2 Electrical

P1 Pneumatic

H1 Hydraulic

T1 Thermal

C1 Chemical

G1 Gas

W1 Water

A. Controlled Shutdown and Lockout Procedure: 1 Notify all affected operators and department personnel.

2 If machine is in operation, stop the machine using the normal operating controls (on/off or start/stop button).

3 Make certain no one is operating or using equipment when shutting down system. 4 Turn all machine controls to the OFF position. 5 Ensure that all machine motion has stopped. Operate (shut off, deactivate, deenergize) all energy-isolating devices so equipment is isolated from its energy sources 6 (main electrical disconnect switch, main shutoff valve). 7 Be certain to isolate all energy sources, secondary supplies as well as main one. 8 Lockout/tagout energy-isolating devices as necessary and as listed above. 9 Make certain that main disconnect switch or circuit breaker cannot be moved to the ON position. 10 With all personnel clear, verify lockout by trying to restart the equipment.

11 If machine starts, or if unexpected motion is observed, stop and notify supervisor – ECP modifications may be needed.

12 If machine does not start and no unexpected motion is observed, return all machine-operating controls to OFF position.

13 Perform service or maintenance. 14 B. Special Verification Procedures: Before electrical work, a person trained in electrical work/electricity must perform a voltage check with an approved test 1 instrument. 2 3 4 C. Special Instructions or Specific Startup Procedures: 1 Check machine and area of operation; remove exposed personnel and other potential hazards. 2 Make certain equipment is safe to operate. 3 Be sure machine is fully assembled. 4 Make certain guards and other safety devices are reactivated or back in place. 5 Notify all personnel in the area of imminent machine startup. 6 Remove lockout devices and tags. 7 Follow required steps to safely reenergize the equipment. 8

Note: Where appropriate, attach a machine or equipment diagram or schematic to the ECP identifying the location of all energy- isolating devices identified above. Where feasible, laminate this ECP and post on or nearby machine for reference by both the equipment operators and authorized workers. This ECP needs to be verified annually.

Written by: Date: Approved by: Date:

Note: This form is referenced in Practice 000.653.3315.

MACHINE-SPECIFIC ECP WORKSHEET

Project No./Contract No.: Employer: Machine/Equipment Description: Location:

Authorized Workers:

Affected Workers:

Affected Workers1 Authorized Workers2

Operators Operators Maintenance Personnel

Others Outside Contractors Other

Note: When conducting an ECP assessment, consider the job tasks of the operator as well as the maintenance department. Some equipment may need more than one machine-specific ECP process based on work or job tasks performed by these groups.

In order to determine all energy sources for each piece of equipment, all questions must be answered. If a question does not apply, write N/A in the blank. Otherwise, check “Yes” or “No,” or fill in the blank. ELECTRICAL ENERGY SOURCES Yes Yes No 1. Does this machine have electrical energy sources? a. If Yes, identify:

Energy Type Magnitude Type of Isolating Device Location of Isolating Device A.C. A.C. D.C. Battery

b. If Yes, identify the specific equipment, devices, or operations these energy-isolating devices control:

2. Yes No Is each electrical energy source properly labeled as to function and voltage present? If No, what action will be taken:

1 Affected Worker – an employee whose job requires him/her to operate, use, or be in the area of a machine or equipment on which servicing or maintenance is being performed under lockout or tagout. An affected worker does not perform maintenance or service work. Note: Specific job duties may require elevation to “authorized worker” status (such as machine operator removes a guard to grease a fitting or change cutter blade).

2 Authorized Worker – an employee who is trained to implement a lockout or tagout procedure on machines and equipment to perform servicing or maintenance. An authorized worker knows and understands the types, magnitudes, and hazards of energy sources he or she works around or with.

3. Yes No Can energy-isolating device(s) be locked only in the OFF position? a. If Yes, will they accept a (lockout) lock and hasp? b. If No, what action will be taken:

4. Yes No Are energy-isolating devices readily accessible and do they have proper clearances? If No, what action will be taken:

5. Yes No Do any of the energy-isolating devices affect other equipment or machinery? If Yes, identify the other affected equipment:

6. Yes No Is this machine controlled by a programmable logic controller (PLC) or other computer-based system or software? a. If Yes, has a separate disconnect been provided for the control circuit? b. If No, is one required to prevent memory loss or other programming problems?

7. Yes No Were energy-isolating devices tested to ensure that they function as intended? If Yes, outline the steps required to verify operation of each device:

8. Yes No Are there any electrical capacitors present? a. If Yes, are they the self-dissipating type? b. If No, outline the procedure to safely discharge stored energy:

Yes No 9. Are there any external feed power sources present? If Yes, identify their location and voltages:

10. Yes No Have any safeguard devices been jumpered or bypassed (such as wiring, limit switches, light curtains, safety mats, and electric eyes) If Yes, identify bypass and corrective action to be taken:

11. Yes No Will activation of any energy-isolating device cause automatic startup of this machinery? If Yes, identify action that will be taken to correct this hazard:

12. Yes No Does the machine have operator control stations (such as on/off or start/stop control station buttons? a. If Yes, identify number and location(s):

b. If Yes, are they all working properly? c. If Yes, are they clearly labeled as to intended function? 13. Yes No Does the machine have emergency stop buttons? a. If Yes, identify number and location(s):

b. If Yes, are they placed in the correct location? c. If Yes, are they in working order? d. If Yes, are they clearly labeled as to intended function? 14. Yes No Does the machine have any electric eyes or proximity devices? a. If Yes, identify number and location(s):

b. If Yes, are they in working order? c. If Yes, has their energy-isolation source been verified?

15. Yes No Does the machine have any operator-controlled pendant(s)? a. If Yes, identify number and location(s):

b. If Yes, are they in working order? c. If Yes, has their energy-isolation source been verified? d. When pendant is in use, is machine under exclusive control of operator? e. Does pendant override all other controls when in use? f. Is pendent equipped with E-stop and dead-man control? g. Can pendant run in “jog” mode only, not continuous mode? h. When pendant is in jog mode, can it only run in “slow” speed, not full-line speed? i. When pendant is in use, does it override any safeguard devices such as interlocks: j. If Yes, is an approved safety procedure in place to permit such operation? * (Refer to Note below section 18) k. Identify specific action to be taken, if any, with pendants:

16. Yes No Is this machine equipped with any interlocked access gates or guards? a. If Yes, identify number and location(s):

b. If Yes, will all hazardous machine motion stop before workers can access hazard zone? c. Do workers have to open interlocked gates or guards to access machine or equipment to perform “repetitive” or “routine” production-related tasks with equipment control power off (but not under lockout/tagout)? d. If Yes, have approved safeguard measures and procedures been established? *(Refer to Note below section 18) e. If Yes, are approved positive-break, control-reliable, safety interlock devices used? f. Identify specific actions to be taken, if any, with interlocks:

17. Yes No Do procedures exist for this machine that addresses jam-ups or other process upset conditions or emergency conditions? Identify specific actions, if any, with regard to special conditions or situations:

18. Outline any other steps, action items, or measures to be taken:

Note: Minor tool changes, adjustments, and other minor-servicing activities that take place during normal production operations are not covered by this process if they are routine, repetitive, and integral to the use of the equipment for production, provided that the work is performed using measures that provide effective protection. MECHANICAL ENERGY SOURCES 19. Yes No Does machine have any mechanical power sources? 20. If Yes, record the type of energy source that applies: Yes No a. Counterweights, suspended loads, or other materials affected by gravity . Describe the methods that will be taken to lower, block, support, secure, or prevent movement:

. Does this method(s) include lockout capability? . If No, what method will be used to ensure energy control?

b. Engine driven . Identify switch or key location:

. Does method include lockout capability? c. Flywheels/fan blade movement/rotating components (such as continued rotation after equipment is turned off) . Describe the method to be used to stop/prevent further movement:

. Does method include lockout capability? . If No, what method will be used to ensure energy control?

d. Spring tension or compression . Describe the method used to prevent spring activation, or to safely release or secure spring energy:

. Does method include lockout capability? . If No, what method will be used to ensure energy control?

e. Other

21. Yes No Were the energy isolation/control steps outlined in this section verified for effectiveness?

HYDRAULIC ENERGY SOURCES 22. Yes No Does the machine have hydraulic energy sources? a. If Yes, what are their operating and stored pressures:

b. If Yes, identify the location of main control panel/shutoff (isolating) valve:

23. Yes No Can electrical disconnect switch controlling the hydraulic pump be locked out? a. If Yes, is switch labeled? b. If Yes, is switch readily accessible? c. If No, what action will be taken?

24. When pump is turned off, what is the pressure in both the hydraulic reservoir tank and lines?

25. Yes No Does a line isolation valve(s) exist for the hydraulic system? a. If Yes, can it/they be locked in closed position b. If No, what action will be taken:

c. If Yes, is the line isolation valve labeled and readily accessible? d. If No, what action will be taken:

26. Yes No Is there a bleed or drain valve to reduce pressure to zero? If No, what is the required action to safely bleed off the pressure:

27. Yes No Are there any check valves in the system that would allow pressure to remain in the line or system? If Yes, describe the actions required to address this situation:

28. Yes No Will turning off power or closing isolation valve cause components to move or fall? If Yes, describe preventive measures that will be applied:

29. Yes No Were energy isolation/control steps outlined in this section verified for effectiveness?

PNEUMATIC (AIR) ENERGY SOURCES 30. Yes No Does the machine have pneumatic energy sources If Yes, what are their operating pressures:

If Yes, identify the location of main control panel/shutoff (isolating valve):

31. Yes No Can the electrical disconnect switch controlling the air compressor be locked out? a. If Yes, can it accept a lockout lock and hasp? b. If No, describe the action that will be taken:

c. If Yes, is switch labeled? d. If Yes, is switch readily accessible? 32. Yes No Does a line isolation valve(s) exist for the pneumatic system? a. If Yes, how many and what are their locations:

b. If Yes, can it be locked out in the closed position? c. If No, describe the action that will be taken:

d. If Yes, are line isolation valves labeled and readily accessible? e. If No, describe the action that will be taken:

33. Yes No Is there a bleed or drain valve to reduce pressure to zero? If No, describe the action that will be taken to safely bleed off the pressure:

34. Yes No Will turning off power or closing isolation valve cause components to move or fall? If Yes, describe preventive measures that will be taken:

35. Yes No Were the energy-isolating measures/steps outlined in this section verified?

CHEMICAL SYSTEMS Yes No 36. Does this machine have chemical energy sources? a. If Yes, identify:

Chemical Type Magnitude Type of Isolating Device Location of Isolating Device

37. Yes No Can the chemical system control panel electrical disconnect switch be locked out? a. If Yes, can it accept a lockout lock and hasp? b. If No, describe the action that will be taken:

c. If Yes, is switch labeled and accessible? 38. Yes No Does a line isolation valve(s) exist for the chemical piping system? a. If Yes, can it be locked out in the closed position? b. If No, describe the action that will be taken:

c. If Yes, is the line isolation valve labeled and readily accessible? d. If No, describe the action that will be taken:

e. Are any special line breaking and blanking procedures required? f. If Yes, describe the action to be taken:

39. Yes No Is there a bleed or drain valve to reduce system pressure, drain, or neutralize the system of chemicals? If No, describe the action that will be taken to safely bleed off the pressure:

40. List the personal protective equipment and clothing that will be used while working on this equipment:

THERMAL ENERGY SOURCES (temperature extremes) Yes No 41. Does the equipment have any hazardous thermal energy sources? a. If Yes, identify:

Type Location Temperature Pressures Cryogenic Materials Molten Metals/Materials Pressurized Steam Hot Work Surfaces Other

b. If Yes, identify location of the main control panel/shutoff (isolation) valve(s):

42. Yes No Can the control panel (disconnect switch) or shutoff (isolation) valve(s) be locked out (lockout lock and hasp) only in the OFF position? a. If No, describe the action that will be taken:

b. If Yes, are they readily accessible and labeled? 43. Yes No Is there any specific action or measure to be taken to control extreme temperature? If Yes, describe action to be taken:

44. List the personal protective equipment and clothing that will be used while working on this equipment:

OTHER ENERGY SOURCES Yes No 45. Does this machine have any other hazardous energy sources present? a. If Yes, identify:

Type Magnitude Location Gas Ionizing Radiation Non-Ionizing Radiation Pressurized Liquids Water Other

b. Describe the energy control measures to be taken for each source: Yes No

c. Do energy control measures include lockout capability?

. If No, describe the measures that will be employed to control the individual energy sources:

. If Yes, are they readily accessible and labeled?

. If No, describe the action that will be taken:

46. Yes No Does the equipment, machinery, or process incorporate any confined spaces? If Yes, describe entry permit requirements for inclusion on the ECP placard:

Important Reminders: 1. It is imperative that a “zero energy state” condition has been verified to ensure that all hazardous energy sources have been identified and capable of being locked and tagged out. 2. Use this completed ECP worksheet to complete a machine-specific ECP, which should be posted on equipment where feasible and readily accessible to all authorized employees. 3. If changes to equipment or machinery are planned or take place, reevaluate ECP for accuracy and zero energy state verification.

Note: This form is referenced in Practice 000.653.3315.