160706-LOTO Best practices-Todd Grover-第二季第56期安全无止境微课堂（总59期）.pdf

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Since the beginning of the Industrial Revolution, people young and old have exponentially increased their exposure to powerful machinery and motive s of the energy that drives it. 自工业革命开始以来，无论 是年轻人还是老人，人类与强力机械及驱动机械的原动能量形 式的接触越来越多。 We have come a long way in terms of machine guarding and other safe work requirements.在机器防护及其他安全生产要求方面，我们已 经走过了一条漫长的道路。 But, accidents still persist during maintenance, repair and operational support of the machinery in our workplaces. 但在车间机械的维护、修理和运行保障过程中，事故仍然存在。 Why this ination should matter to you 为什么这一信息对你很重要为什么这一信息对你很重要 Despite the precautions taken, workers still need to remove safeguards or go into danger zones around equipment to per their assigned duties.尽管已采取预防措施， 但作业人员仍然需要拆除防护装置或是进入到设 备周围的危险区域中实施其所分配的职责。 And when that occurs without controlling the possibility for unexpected startup, instantaneous exposure to moving parts, live electricity, and other sources of hazardous energy inflict serious injuries and often death on unprotected workers. 在未针对意外启动可能性进行控制的情况下实施 上述作业时，与运动部件、带电电流及其他危险 能量来源的瞬时接触会造成严重的受伤和经常性 的死亡。 The National Safety Council was founded in 1913 by industrial contributors and government representatives to “organize and create a permanent body for the promotion of the safety to human life in the industries of the United States.” 国家安全委员会成立于1913年，由工业参与者及政府代表共同发起，目的是“在美国组织建 立一个促进人类在工业生产方面的生命安全的永久性机构”。 Chartered by the U.S. Congress in 1953 1953年得到美国国会的特许 Industrial Machine Safety ally began in the U.S. in 1913 工业机器安全在工业机器安全在1913年正式始于美国年正式始于美国 American National Standards Institute 美国国家标准协会 ANSI began researching a history of accidents related to sudden startup of machinery in the mid 1970’s that provided the foundation for the OSHA Lockout Standard. Their lockout standard was first published in 1990 美国国家标准协会于20世纪70年代中期开始研究与机械突然启动相关的事故的历史记录， 而奠定了OSHA上锁标准的基础。其上锁标准于1990年首次出版。 Updated lockout standard ANSI Z244.1 released in 2014 2014年发布了修订后的上锁标准ANSI Z244.1 Title The Control of Hazardous Energy Lockout Tagout, 标题危险能源控制（上锁挂牌）危险能源控制（上锁挂牌） Regulation 规章 29 CFR 1910.147 This OSHA Regulation originated in December 1989 该该 职业安全与卫生法案的规定于职业安全与卫生法案的规定于1989年首次发行。年首次发行。 This regulatory standard is intended to prevent the unexpected energization or start-up of machinery and equipment, or the unintentional release of stored energy, that could severely injure or even kill employees during maintenance and service. 这一监管标准目的在于防止机械及设备的意外加电或启动，或所储蓄能量的意外释放，避免 其在维修和保养过程使人员受到严重伤害甚或死亡。 Primarily focuses on general industry applications 重点关注一般的工业应用 Decree No. 70 of the Chairman of the People’s Republic of China Effective Date November 1, 2002 Revised December 1, 2014 The orientation of these laws are very much about responsibility to protect workers from exposure to hazardous materials and conditions in general without specific reference to the many common sources of these dangers. Chinese’s Safety law does establish significant personal accountability for failure to understand and control hazards, both on the management side as well as from the role of employees. There is no direct guidance language requiring the practice of energy control measures such as lockout. When the employer adopts new techniques, technology, materials or equipment, they shall understand the hazards created, adopt effective control measures to prevent accidents, and provide the employees with work instructions safety equipment and safety training. This is, perhaps, the strongest tie in to a lockout protection requirement. Accidents must be prevented or significant liability will be the result if the State becomes engaged in the enforcement action. Safe Production Law of the People’s Republic of China Accidental Restarting of Equipment During Servicing or Repairs 维修或修理过程中设备的意外重启 Failure to Stop Equipment 未停止设备 Failure to Secure Equipment during Servicing 维修过程中未锁定设备 Failure to Disconnect From Power Sources 未从电源中断开 Failure to Dissipate Residual Energy 未消除残余能量 Failure to Clear Work Areas Before Reactivation 重新启动之前未清理作业区域 People, tools and work materials 人员、工具及作业材料 Insufficient Guarding of Dangerous Machinery 危险机器的防护不充分 Nonexistent or Removed Machine Guarding 不存在（或已拆除）机械防护 Poorly Designed/Installed Machine Guarding 设计/安装不良的机械防护 Defeat of Presence Sensing Safety Devices 存在感知安全装置失效 What are the Main Causes of Serious Machinery Accidents 严重机械事故的主要原因是什么严重机械事故的主要原因是什么 Electrical 电气电气 Mechanical 机械机械 Hydraulic 液压液压 Pneumatic 气压气压 Chemical 化学化学 Thermal 热能热能 Gravity 重力重力 Electrical work 电气工程电气工程 Rotating machinery 旋转机械旋转机械 Lines, pumps and cylinders 管路、水泵、 汽缸 管路、水泵、 汽缸 Compressed air system 压缩空气系统压缩空气系统 Chemical dispensing 化学分散化学分散 Heating and Cooling units 加热与冷却装 置 加热与冷却装 置 Shifting or falling objects搬运或 下落物体 搬运或 下落物体 Capacitors and secondary or backup circuits 电容器及二次 或备用电路 Spin down time, torque release, load shift Movement 消旋时间、扭 矩释放、负载 转移运动 Captured pressure in lines or equipment 管路或设备中 捕获的压力 Captured pressure in lines or equipment 管路或设备中 捕获的压力 Toxic or flammable liquid or gas residue 有毒或易燃液 体或气体残留 Warm up or cool down period 加热或冷却周 期 Release of power or linkage causes movement 力量或连杆释 放产生运动 Electrocution, burns, shock, equipment damage 触电、烧伤、 休克、设备 损坏 Amputations, lacerations, fractures, crushing injuries 截肢、撕裂 伤、骨折、 挤压伤 Trauma from movement, hydraulic oil injection injuries 运动损伤、 液压油喷射 伤害 Trauma from movement, embolic air injection injuries 运动损伤、 栓塞气体喷 射伤害 Skin and eye injuries, inhalation injuries, organ damage 皮肤和眼睛 损伤、吸入 性损伤、器 官损伤 Heat burns, heat exhaustion frostbite, hyp Othermia 热灼伤、热 衰竭、冻伤、 低体温症 Amputations, lacerations, fractures, crushing injuries 截肢、撕裂 伤、骨折、 挤压伤 Lockout applies to all Hazardous Energy Sources 上锁适用于所有的危险能量来源上锁适用于所有的危险能量来源 What s of energy are common at your workplace 你的车间中有哪些常见的能量形式 Sources 来源来源 Residual 残余残余 Injuries 伤害伤害 The process of personally controlling hazardous energy during the service and maintenance of machinery and equipment 机械及设备维修和保养过程中个人控制危险能量的过程机械及设备维修和保养过程中个人控制危险能量的过程 ■ Specific work safety procedures and practices that safeguard employees from ■ 保护员工不受以下伤害的具体工作安全规程和实践 The unexpected powering or start up of machinery or equipment 机械或设备的意外加电或启动 The release of hazardous energy during service or maintenance activities 维修或保养作业过程中危险能量的释放。 ■ Hazardous energy sources are isolated and inoperative before any service procedure is started 应在任何维修程序启动之 前对危险能量来源进行隔离，使其无法运行。 ■ Facilities are responsible for developing a Lockout program which clearly outlines the process for isolating hazardous energy 工厂负责建立一项清晰概述危险能量隔离过程的上锁程 序。 How to lockout each piece of equipment 如何锁定各设备 Who is authorized to complete Lockout 何人有权完成上锁 Use of padlocks and devices 挂锁和设备的使用 What is Lockout 什么是上锁什么是上锁 What is Tag out 什么是挂牌什么是挂牌 “Tag out” is the placement of Tag out device on an energy isolating device, to indicate that the energy isolating device and the equipment being controlled may not be operated until the Tag out device is removed. “挂牌挂牌”是指在某一能量隔离设备上放置标志，表示该能 源隔离装置及这一处于受控状态的设备在移除挂牌设备 之前是不可以使用的。 In addition – at least one other of protecting personnel must also be used during tag out such as; 此外，在挂牌期间还必须使用至少一种其他的保护人员 的方法，诸如 Removing and isolating a circuit element 拆 除和隔离电路元件； Blocking a controlling switch 阻断某一控制开关； Opening an extra disconnecting device; 打开一个额外的断路装置； Removing a valve handle. 拆除一个阀杆。 “Blockout” is a term used with “Lockout” because some equipment can’t be “locked”, but rather must be blocked to prevent movement.“闭锁闭锁”是某些国家与“上锁”一起使用 的一个术语，因为某些设备无法“上锁”，而必须堵塞 以防止其移动。 Best Practice When must Lockout be applied 最佳实践何时必须应用锁具最佳实践何时必须应用锁具 When one or more people will be servicing or repairing machinery or equipment 当一人或多人将要对机械或设备进行维修 或修理， 当一人或多人将要对机械或设备进行维修 或修理， AND 且且 It is possible that an unexpected machinery start-up or release of stored energy could cause injury to personnel. 意外机械启动或储存能量的释放可能会对 人员造成伤害时。 意外机械启动或储存能量的释放可能会对 人员造成伤害时。 Best Practice When must Lockout be applied最佳试验何时 必须应用锁具 最佳试验何时 必须应用锁具 Installing new equipment or replacement parts 安 装新设备或更换部件 Constructing or assembly of machinery or systems 机械或系统的构造或组装 Modifying equipment 改装设备 During machine setup and adjustments 在机器设 置与调整过程中 While unjamming machinery 在回松机械时 During the cleaning of equipment 在设备的清洗 过程中 Lubrication tasks 润滑作业 Inspecting machinery 检查机械 During activities involving在涉及以下各项的作业过程中在涉及以下各项的作业过程中 Investigations have found that the two most common tasks involved with Lockout accidents are 调查发现涉 及上锁事故 的两项最常 见的任务是 调查发现涉 及上锁事故 的两项最常 见的任务是 Unjamming Objects 30 回松物件 （30） Cleaning Equipment 29 清洗设备 （ 清洗设备 （29）） When the unexpected startup or sudden release of energy could cause injury在意外启动或能量的 突然释放可能造成伤害时 在意外启动或能量的 突然释放可能造成伤害时 Best Practice When must Lockout be applied 最佳实践何时必须进行上锁最佳实践何时必须进行上锁 Anytime a worker is required to remove or bypass machine guards or other safety devices resulting in exposure to hazards at the point of operation. 作业人员需要拆除或绕过机械防护或其他 安全装置，导致自身暴露在操作危险点处 时， Or 或或 An employee is required to place any part of his/her body任何人员需要用自己身体的任 何部位 In contact with the point of operation of the operational machine or piece of equipment. 与运行机器或设备项的操作点接触时 Or, 或或 Into a danger zone associated with a machine operating cycle. 放入与机器操作循环相 关的某一危险区域时 If an energy isolating device is capable of being locked out, it must be locked out 若某能量隔离设备能够上锁， 则必须对其上锁 unless the employer can demonstrate that the utilization of a Tag out system will provide full employee protection. 除非业主可证明，某一挂牌系统 的使用能够提供完整的员工防护。 If an energy isolating device is not capable of being locked out, the employer shall utilize a Tag out system. 某一能量隔离设备无法锁定，则 业主应使用挂牌系统。 Per ANSI Z244.1 All new machinery or equipment must have energy isolating devices designed into it and existing equipment must have it added whenever major modifications or repairs are made 依据依据ANSI Z244.1， 所有新机械或 设备必须具备 集成设计的能 量隔离设备， 且现有设备在 进行重大改装 或维修时必须 加装能量隔离 设备。 ， 所有新机械或 设备必须具备 集成设计的能 量隔离设备， 且现有设备在 进行重大改装 或维修时必须 加装能量隔离 设备。 Best Practice When must Lockout be applied 最佳实践何时必须进行上锁最佳实践何时必须进行上锁 The purpose, scope and application of the workplace lockout program 车间上锁程序的目的、范围和应用 Responsibilities of all participating personnel Administration, Authorized, and Affected 所有参与人员、行政管理人员、授 权人员及受影响人员的职责 Documented energy control procedures 文件化的能量控制程序 of accessing all necessary energy control equipment and hardware 访问所有必要能量控制设备和硬件的方法 Employee training / retraining program 员工培训/再培训程序 Annual inspections of the use of the procedures to verify, maintain or improve their effectiveness 程序使用的年度检查，以验证、保 持或提高其有效性 Provision for a disciplinary procedure when purposeful violations of the Lockout policy are noted. 在发现有蓄意违反上锁政策的行为时 规定惩戒性程序 Written Hazardous Energy Control Program书面的危险能量控制程序书面的危险能量控制程序 A facility-specific program or policy is needed to establish how the following compliance requirements will be implemented 需要一项工厂特定的计划或政策以规定如何落实以下各项合规性要求需要一项工厂特定的计划或政策以规定如何落实以下各项合规性要求 Machine Specific Lockout Procedures 机器专用上锁程序机器专用上锁程序 These include the rules, regulations, and various techniques that can be employed in the control of hazardous energy, such as 这其中包括可在危险能量控制中使用的规 则、法规和各种技术等，例如 这其中包括可在危险能量控制中使用的规 则、法规和各种技术等，例如 Procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy 关闭、隔离、 堵塞和固定机器或设备以控制危险能量 的程序步骤 Procedural steps for the placement, removal and transfer of lockout devices 上锁设备安 置、拆除和转移的程序步骤 Instructions for testing a machine or equipment to verify the effectiveness of lockout devices, tagout devices, and to verify the energy control measures worked 测试机器或设备以验证锁 定设备、挂牌设备的有效性并验证所用能量 控制措施的指导说明 Lockout procedures outline the appropriate steps that must be completed to adequately lockout each piece of equipment 上锁程序概述了为充分锁定各设备而必须落实的适当措施上锁程序概述了为充分锁定各设备而必须落实的适当措施 Provide quick access to the procedures that are used often by posting them near the point of use. 通过将常用程序 张贴在使用地点 的附近区域对其 进行快速存取。 通过将常用程序 张贴在使用地点 的附近区域对其 进行快速存取。 Be sure to manually write up a procedure following a checklist prior to working on an undocumented machine. 确保在对某一无 正式文件的机器 进行作业之前遵 循检查表的方法 手动编写一份程 序。 确保在对某一无 正式文件的机器 进行作业之前遵 循检查表的方法 手动编写一份程 序。 Verification of Lockout上锁的验证上锁的验证 As an important precautionary measure, workers must check to confirm that 作为一项重要的预防措施， 作业人员必须验证确认 作为一项重要的预防措施， 作业人员必须验证确认 The equipment has been properly shut down 设备已正 确关闭 All energy sources have been isolated 所有能量来源均 已隔离 Lockout devices are in place 上锁设备已就位 The equipment is then verified for a Zero Energy Condition by trying to make the machine function using the normal operating controls to make certain the equipment will not operate 之后应通过 使用正常的操作控制使机器运作来针对零能量状态进行验证，确定设备不会运行。 Once a zero energy condition is verified, return all controls to their “off” position 在验证零能量状 态后，将所有控件拨回执“关闭”状态 Electrical Safe Work Practices requires testing of electrical circuits to verify zero energy if a contact shock or arc flash hazard could exist. 电气安全工作规范要 求对电路进行测试以验证零能量，及是否存在接触冲击或弧闪危害。 电气安全工作规范要 求对电路进行测试以验证零能量，及是否存在接触冲击或弧闪危害。 Only Qualified Personnel are allowed to do per this testing when working around open conductors. 仅允许具有相关资质的人员在开路导线周围作业时实施这一测试。 Lockout should be applied when working inside electrical cabinets and panels or whenever machine disassembly exposes conductors that would otherwise be covered. 当在电气柜或 面板内部作业时或当机器组件外露出本应有覆层的导线时应进行锁定。 ■ Each isolated energy source is secured first with a group hasp, and then by a personal lock placed by each Authorized worker participating in the task. 各 已隔离的能量来源均应先使用群组搭扣进行 锁定，然后使用由参与该任务的各授权人员 安置的个人锁锁定。 ■ One Lock – Per Person – Per Energy Source 每种能量来源每种能量来源每人每人一把锁一把锁 ■ Common Practice - works best with limited number of participating Authorized workers 2-3 and a limited number lockout points to be controlled. 习惯做法习惯做法作业时应确保有限数量的参与授权作 业人员（2-3名）和有限数量的待控制上锁点 Group Lockout Techniques – Hasps and Personal Locks 群组上锁技术群组上锁技术搭扣和个人锁搭扣和个人锁 When servicing and/or maintenance is pered by group of authorized workers, they can use a procedure that provides a level of protection equal to each placing a personal lockout device at each energy control point. 当维修和当维修和/或维护由成组的授权作业人员实施时，可使用在 各能量控制点处每次安置个人上锁设备时能够提供相同防护等级的程序。 或维护由成组的授权作业人员实施时，可使用在 各能量控制点处每次安置个人上锁设备时能够提供相同防护等级的程序。 ■ Identify an Authorized lockout Leader to be responsible for the effective lockout of equipment according to the wr