Lock-Out Tag-Out Try-Out, Does Your Team Have the Tools to Succeed?

NUCOR STEEL • LARGEST STEEL PRODUCER IN THE US • LARGEST RECYCLING COMPANY IN THE US • 16.9 MILLION TONS OF SCRAP MELTED IN 2015 • UTAH- 951,227 MILLION TONS (equivalent of almost half a million full size pickup trucks)

We melt an average of 3400 ton of steel every 24 hours. Or 80,000 ton each month.

NUCOR NUCOR STEEL, STEEL,UTAH UT • 460 TEAMMATES • APPROX. 23.6 ACRES UNDER OUR ROOF • 1,200,000 FINISHED TON CAPACITY • ANGLES, CHANNELS, FLATS, ROUNDS, REBAR, GRINDING BALL, GRAPESTAKES/FENCE POST & OTHERS

• 460 TEAMMATES • APPROX. 23.6 ACRES UNDER OUR ROOF • 1,200,000 FINISHED TON CAPACITY • ANGLES, CHANNELS, FLATS, ROUNDS, REBAR, GRINDING BALL, GRAPESTAKES/FENCE POST & OTHERS

What is LOTO, really?

• Elimination? • Engineering? • Administrative?

How effective is LOTO?

It’s only as effective as we make it…

• Types of Energy – – – – – – –

Electrical Mechanical Hydraulic Pneumatic Chemical Thermal Other • Gravity • Stored

LOTO Procedure – general information

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The LOTO procedure is applicable: – To all employees – To all contractors

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LOTO Procedure STEPS – 3 General Steps • 1. Preparation for Energy Control • 2. Conducting Energy Control • 3. Restoration of Energy

Step #1- Preparation For

1.

Identify the need for energy control – Is any part of your body going to be in a point of operation, where it could be injured if the equipment were energized, and/or – Are you removing a guard in order to do the work.

2.

Communicate to all affected personnel.

3.

Remove the energy from the equipment. – All of the energy sources need to be identified in order to do this •

You may need physical blocks or other equipment.

Step #2- Conducting

1.

Isolate the energy identified – Apply locks to the equipment in a manner that it could not be unintentionally reenergized. – Apply personal locks to either the equipment or to the lockbox.

2.

Try out – Testing the equipment/machine to determine or verify the energy control –

3.

This is a critical step. Each employee involved in the work must know that this has been done.

Now you can go to work.

What can affect a try-out?

• Limits being met? • Permissives? • Sequence Locks? • What else?

Industrial Ball Valve

Locomotive Ball Valve

Step #3- Restoration

1. Communicate to all affected personnel that the work is done. 2. Inspect the area for people, missing guards, rags, tools, etc. – Everything must be cleaned up and all guards replaced before the locks are removed. – Remove energy control devices. – Each person will remove his/her own personal locks from the system, then the locks may be removed from the equipment. – Close out Form- Return to Safety office for auditing

3. Return the equipment to normal production mode.

There are 2 basic types of locks: • Personal Locks: These shall only be used as LOTO devices (i.e. locks will not be used for locker or bike locks) • New employees will have a different colored lock and hard hat for the first 3 months.

• Equipment Locks: These are locks that can be used when you need to lock out several pieces of equipment. • (Personal locks must be placed on lock box) Only the person who owns the locks can place and remove personal locks. Do not ever remove another person’s lock. Unless using lock removal policy.

STICKY LOCKS? There is a lock cleaner located in the entrance of the Safety Office.

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Clean your locks periodically to keep them in good working order. CLEAN, DRY, AND GRAPHITE

Responsibilities

• Master – – – –

To ensure the LOTO is performed correctly Paperwork is filled out correctly All tasks have been performed Pass on or close out LOTO

• Verifier – Verify the correct point is locked – Verify the valve/switch is in the correct position – Verify the lock is preventing the valve/switch from being engaged

• Perform Try-Out Together

Paperwork Must Be Filled Out Completely

• We keep all completed paperwork for 3 years. • We use this to audit our LockOut points. • We audit for TM performance and give frequent feedback.

Let’s Look At Our System

Some of the Benefits

• Universal labeling throughout the plant

• Individual #’s on each point that are specific to different areas of the plant

Some of the Benefits

Some of the Benefits

• Editable in Word • Close picture & far away picture • Try-out on forms • Comprehensive approval process

Teammate Run Program

1. Changes require three(3) signatures from Qualified Teammates who know and understand the equipment. 2. Teammates are trained to edit the checklists then submit for final approval. 3. The approver will review the changes and notes and either approve the checklist or get in contact with one of the teammates to address any questions. 4. All kept track of through SharePoint workflows.

Some of the Benefits •

4 LOTO toolbox meetings per year

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In-depth hands-on training (5-5-5) – New hire – Existing team – Job transfer

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Changes are highlighted for 90 days

Cross Turn Tags

• Cross turn tags are to hold the place of a Master to keep the equipment at zero state when NO WORK is being performed on the affected equipment. • Cross turn tags are uniquely identified/numbered and are single use, tamper proof seals. • When a cross turn tag is placed, the number shall be documented on the lockout form by the master. When work resumes, the new master will verify the cross turn tag identification number and document that they have assumed control of the lockout. • The master will apply his/her lock to the group lockout box and remove the cross turn tag.

Responsibilities of a New Master  Verify the paperwork is correct (cross turn #)  Verify the valves and switches are in the correct position  Verify locks are locked and preventing the valves and switches from being reenergized

Interlock Procedures • Equipment work consists SOLELY of, minor tool changes, and other adjustments that take place during normal operations – NOT ALLOWED if the situation involves servicing &/or maintenance, and the following exists: • An employee REMOVES or BYPASSES A GUARD or safety device • An employee places a body part into a point of operation

Interlock Procedures

• Risk Assessment must be performed. – Combined effort with Production, Maintenance, and Safety.

• Detailed procedures are developed. – Only teammates trained on the procedure may use it

CONTRACTORS • Their Leadership/Safety attend our training to ensure proper expectations are set.

• Our team performs pre-job hazard analysis with them before every job. • Nucor Management and the Safety Department must approve any contractor lock-out that is performed without Nucor TM’s. – These tasks shall be performed under the Nucor LOTO policy

Questions & discussion