Lockout / Tagout Control of Hazardous Energy OSHA Standard 29CFR1910.147 MIOSHA PART 85 - The Control of Hazardous Energy Sources 1

Case Study #1 An employee was cleaning the unguarded side of an operating granite saw. The employee was caught in the moving parts of the saw and pulled into a nip point between the saw blade and the idler wheel resulting in fatal injuries.

Case Study #2 A trainee employee was cleaning a flour batch mixer. The employee was reaching into the machine when another worker activated the wrong switch turning the machine on. The employee cleaning the mixer suffered fatal crushing injuries to his neck. There was an unwritten company procedure for locking out during all maintenance. The procedure was not followed.

Case Study #3 An employee was cleaning scrap from beneath a large shear when a fellow employee hit the control button activating the blade. The blade came down and decapitated the employee cleaning the scrap.

OF THESE LOSSES HAVE IN COMMON? WHAT DO ALL OF THESE LOSSES HAVE IN COMMON?

FAILURE TO LOCKOUT / TAGOUT

You will learn… Four E’s of LOTO Purpose of LOTO Requirements for LOTO Types of Hazardous Energy Procedures for LOTO 2

Four E’s of LOTO E Energy Engineering Education Enforcement E E E

Energy More than just switching a machine on/off Energy is dangerous when it is strong enough to injure your body Types of energy include: Kinetic Potential

Types of Energy Electrical Mechanical Thermal Hydraulic Pneumatic 3

Mechanical Energy Hazards 2 Types Kinetic - In Motion Potential - Stored 6

Kinetic Energy Hazards Energy of moving machinery can cause: Amputations Lacerations Fractures Loss of life 7

Potential Energy Hazards Energy stored in machinery Weights & Springs Pistons under pressure Hydraulic controls Stored potential energy can be released during work causing injury or death 8

Before working – release, drain, or vent chemicals safely Chemical Hazards Some chemicals can: Start fires Cause skin burns Generate harmful gases, vapors, or fumes Before working – release, drain, or vent chemicals safely 9

Thermal Energy Hazards Hazards of Heat and Cold Hot equipment and fluids can burn you Very cold fluids can cause injury Quick release of compressed gases can freeze your skin Allow equipment to reach a safe temperature before starting work 10

Relieve pressure slowly into a proper container Hydraulic Energy Energy of Liquids Under Pressure Pressure can cause equipment to move Rapid release can cause injury Rapid release can also cause the ejection of system parts Relieve pressure slowly into a proper container 11

Pneumatic Energy Hazards Energy of Compressed Gases Uncontrolled release can cause injury Rapid depressurization can create extremely low temperatures Properly vent all systems before starting work 12

Engineering Do not bypass safety devices - they are designed for your protection! Engineered mechanisms built into machines for your safety include: Mechanical guards Mechanical stops (pins, valves) Point-of-Operation guards Interlocks Light curtains

Education Know all places hazardous energy releases might occur on each machine you are working on. Make sure people in the area know were all energy sources are located. Review and follow the written OCC Lockout/Tagout Program.

Working on unfamiliar machinery is a hazard First Step In LOTO Know your equipment and systems Hazards Isolation points Machine-specific procedures for lockout / tagout Working on unfamiliar machinery is a hazard 13

When is LOTO necessary? To prevent unexpected start-up during service/maintenance There is the potential for the hazardous release of stored energy Safety devices are bypassed for service Body is exposed to hazardous energy Clearing jams Electrical repairs

Energy Isolation Machine specific LOTO instructions Required if more than one power source involved Identifies isolation points Many different scenarios possible LOTO devices are assigned to specific affected employees

Use Safe Electrical Practices Use non-conducting tools Check that circuits are dead before working Lock & Tag source breakers, not switches Ensure all control power is de-energized Discharge all capacitors after Lockout 5

Energy Isolation Identify potential sources of hazardous energy release Identify method(s) for isolating the energy Document procedures for each piece of equipment

Enforcement Know the results of tampering with or not following complete LOTO procedures: LOTO procedures have been established to protect OCC employees from serious injury or death. Failure to comply with OCC LOTO policies and procedures can result in disciplinary actions up to, and including, dismissal.

Who Can Lockout Equipment? Employees who have been trained and authorized by management ONLY! 14

All contract employees must follow OCC LOTO procedures! Contractors All contract employees must follow OCC LOTO procedures! 25

Items Needed for LOTO Written LOTO schedule Locks & Tags - specific to the worker Hasps - for placing locks & tags Breaker Clips - for electrical LOTO Blank Flanges (Pancakes) - for fluid lines Valve Covers - for LOTO of valves Plug Buckets - for electrical plugs 15

Use only those issued to you Never use another worker’s lock or tag Use of Locks and Tags Use only those issued to you Never use another worker’s lock or tag Ask your supervisor if you need more LOTO equipment 16

Who Can Remove Locks and Tags? The employee who placed the tag or A supervisor, after obtaining permission from the worker who placed the tag NO EXCEPTIONS! 26

Frequently Asked Questions Q: A piece of equipment already has a lock and tag.  Do I have to place my own locks and tags? A: YES.  Each person working on the equipment must place their own locks and tags to ensure their safety. 27

Procedures for Lockout / Tagout Remember Know your equipment and systems before proceeding Hazards Isolation points Procedures for Lockout Working on unfamiliar machinery is a hazard! 13

6 Step LOTO Procedure Prepare for shutdown Shut down equipment Isolate all energy sources Place Locks and Tags Release stored energy Verify equipment isolation 17

Understand equipment hazards Notify other workers of shutdown 1  Prepare for Shutdown Understand equipment hazards Notify other workers of shutdown 18

Use normal shutdown procedures 2  Shutdown Equipment Use normal shutdown procedures Turn all switches to OFF Shut all control valves Disable all sources of energy 19

3 Isolate All Energy Sources Shut valves Open breakers and disconnects 20

Shut off and lock valves 4 Place Locks & Tags On Shut off and lock valves Deactivate and lock breakers / electrical disconnects Block or disconnect all lines Lock and tag blank flanges 21

5 Release or Block All Stored Energy Discharge capacitors Block or release springs Block elevated parts Stop rotating flywheels Relieve system pressure Drain fluids Vent gases Allow system to cool 22

6 Verify Equipment Isolation Ensure that all other workers are clear Check that locking devices are securely placed Check isolation Attempt normal startup (should fail!) Return controls to OFF/Neutral 23

Release from Locked Out / Tagged Out Status Inspect area and equipment Ensure all machine guards are in place Move tools away from equipment Inform others of startup Restore system connections Remove Locks & Tags Restore equipment to normal operating parameters Conduct normal startup 24

Lockout / Tagout Protects YOU!  Use Proper Lockout / Tagout Procedures 28