Control of Hazardous Energy (Lockout/ Tagout) Procedure Development

Challenges

A National Passenger Rail Company requested that all maintenance facilities update their control of hazardous energy (lockout/tagout) machine specific procedures, including creating new ones. The facilities requested 100 individual procedures be created for equipment and machines that included, but not limited to, the following:

• Train-car washing station
• High pressured air compressors
• High volume fuel pumps
• Wastewater treatment
• Overhead cranes
• Boiler units
• Train wheel truing machines

Results

TRC was to review equipment and current lockout/tagout machine specific procedures on site with facility workers and staff. TRC facilitated an initial kick-off meeting to explain the overall process of developing the procedures and review the following:

• Machines and equipment that require new/updated procedures
• Identify staff that will be involved in the development process
• Establish a schedule and prioritization by department or production area
• Development of a standardized client specific lockout/tagout procedure template using our TRC Mobile Data Solutions app
• Discuss potential obstacles, limitations and/or safety concerns with developing the procedures

TRC interviewed on site facility workers about current operating procedures and reviewed equipment manuals and the purpose and function of each machine or piece of equipment. During the walkthrough and interviews while utilizing TRC’s Mobile Data Solutions app, each draft version of the procedure was created live. The procedure laid out the following:

• Shutdown procedures
• Identification of the individual energy hazards
• Location of isolation points for each energy hazard using photographs
• Process for releasing stored energy as applicable
• Startup verification by hazard

Results

TRC developed approximately 100 lockout/tagout procedures at two facilities. The procedures were subsequently reviewed by company personnel for completeness and accuracy.