Lockout/Tagout By: Brice Moeller

Overview What lockout is What lockout is –Lockout is a technique used to prevent the release of hazardous energy, or to prevent the hazardous energy from escaping. Go over a list of hazardous energy sources Go over a list of hazardous energy sources –Electrical –Mechanical –Thermal –Potential Types of lockout devices Types of lockout devices –Plug Locks –Ball Valve Lockout –Gate Valve Lockout –Group Lockout Hasp –Electrical

Overview (continued) When to lock out a machine When to lock out a machine –Repairs –Servicing –Maintenance –Tool Changes An example of what a placard will look like An example of what a placard will look like Special situations concerning lockout Special situations concerning lockout –Servicing more than one shift –Worker who applied the lock is not available

Lockout/TagoutLockout/Tagout Covers the servicing and maintenance of equipment where the unexpected energization or start up of equipment, or release of stored energy could cause injury Covers the servicing and maintenance of equipment where the unexpected energization or start up of equipment, or release of stored energy could cause injury Establishes the OSHA minimum requirements for controlling hazardous energy Establishes the OSHA minimum requirements for controlling hazardous energy

Lockout  Lockout is a technique used to prevent the release of hazardous energy, or to prevent the hazardous energy from escaping.  A padlock is placed on the appropriate energy isolating device that is in the off or closed position.

The “Fatal Five” Main Causes of Lockout/Tagout Injuries  Failure to stop equipment  Failure to disconnect from power source  Failure to dissipate (bleed, neutralize) residual energy  Accidental restarting of equipment  Failure to clear work areas before restarting

Statistics on LOTO Injuries 82% - Failure to completely isolate, block, and or dissipate the energy source(s) 82% - Failure to completely isolate, block, and or dissipate the energy source(s) 11% - Failure to lockout or tagout energy control devices and isolation points after de- energization 11% - Failure to lockout or tagout energy control devices and isolation points after de- energization 7% - Failure to verify that the energy source was de-energized before beginning work 7% - Failure to verify that the energy source was de-energized before beginning work

Definitions  Authorized Employee:  One who locks out machines or equipment in order to perform the servicing or maintenance on that machine or equipment.  Affected Employee:  One whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed.

Definitions (continued) Lockout device: Lockout device: –A device that utilizes a positive means such as a lock either key or combination type, to hold an energy isolating device in the safe position and prevents the energizing of a equipment Tagout device: Tagout device: –A warning device, such as a tag and a means of attachment –Can be securely fastened to an energy isolating device in accordance with an established procedure to indicate that the energy isolating device and the equipment being controlled can not be operated until the tag is removed

Definitions (continued)  Lockout/Tagout Procedure - Safety program adopted by the employer that includes energy control procedures plus provisions for inspecting the procedures and training employees for lockout/tagout.

Hazardous Energy Sources Found in the Workplace  Electrical  Generated  Static  Mechanical  Transitional  Rotational  Thermal  Machines or Equipment  Chemical Reactions  Potential  Pressure  Hydraulic  Pneumatic  Vacuum  Springs  Gravity

Types of Lockout Devices  Plug Locks  Ball Valve Lockout  Gate Valve Lockout  Group Lockout Hasp  Electrical  Hydraulic, pneumatic, and other pressurized systems

Lockout/Tagout Devices Durable Durable –All devices must be capable of withstanding the workplace environment. –All tags and their means of attachment must be sturdy enough to prevent inadvertent removal Substantial Substantial –Removal of lockout devices should be extremely difficult to remove, requiring the use of excessive force and the help of tools such as bolt cutters –Tagout devices and their attachments must be tough enough so that they can’t be accidentally removed

LockoutLockout Lockout is a more appropriate means of ensuring deenergization of equipment than tagout Lockout is a more appropriate means of ensuring deenergization of equipment than tagout If an energy-isolating device can’t be locked out, tagout may be used If an energy-isolating device can’t be locked out, tagout may be used –Tagout may be used in place of lockout if it can be demonstrated that it will offer equivalent protection to that offered by lockout

TagoutTagout When only a tag is used because equipment cannot be locked out, the following steps must be taken: When only a tag is used because equipment cannot be locked out, the following steps must be taken: –Removing an isolating circuit element (fuses) –Block machine (control switch, die) –Opening an extra disconnecting device –Other means of isolation

Tagout (continued) Tags must be placed where the lockout device would have been placed Tags must be placed where the lockout device would have been placed A legend must be used such as: A legend must be used such as: –Do not start –Do not open –Do not close –Do not energize –Do not operate

Tagout Limitations Tags are attached to energy isolation devices, but they are only warnings. Tags are attached to energy isolation devices, but they are only warnings. They do not provide the protection offered by a lockout procedure They do not provide the protection offered by a lockout procedure A tag is never to be bypassed or ignored, and it may not be removed without the specific authorization of person responsible for it A tag is never to be bypassed or ignored, and it may not be removed without the specific authorization of person responsible for it

Tagout Limitations (continued) Tags must be clearly visible and easily understandable by any employee who may be in the area Tags must be clearly visible and easily understandable by any employee who may be in the area Tags and their attaching materials must be able to withstand any adverse environmental conditions in the workplace Tags and their attaching materials must be able to withstand any adverse environmental conditions in the workplace

When to Lockout a Machine A machine must be locked out when doing any of the following: A machine must be locked out when doing any of the following: –Repairs –Servicing –Maintenance –Tool Changes

Basic Lockout Procedure 1. Inform 2. Preparation for Shutdown 3. Equipment Shutdown 4. Equipment Isolation 5. Application of Lockout Devices 6. Control of Stored Energy 7. Equipment Isolation-Verification

1. Inform The authorized personnel notifies all affected employees that a lockout/tagout system is going to be utilized and the reason because of it The authorized personnel notifies all affected employees that a lockout/tagout system is going to be utilized and the reason because of it

2. Prepare for Shutdown Before an authorized or affected employee turns off a machine or equipment, the authorized employee shall have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy. Before an authorized or affected employee turns off a machine or equipment, the authorized employee shall have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy.

3. Machine or Equipment Shutdown The machine or equipment shall be turned off or shut down using the procedures established for the machine or equipment. An orderly shutdown must be utilized to avoid any additional or increased hazard(s) to employees as a result of the equipment stoppage. The machine or equipment shall be turned off or shut down using the procedures established for the machine or equipment. An orderly shutdown must be utilized to avoid any additional or increased hazard(s) to employees as a result of the equipment stoppage.

4. Machine or Equipment Isolation All energy isolating devices that are needed to control the energy to the machine or equipment shall be physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s) All energy isolating devices that are needed to control the energy to the machine or equipment shall be physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s)

5. Lockout/Tagout Device Application –Lockout or tagout devices shall be affixed to each energy isolating device by authorized employees. –Lockout devices, where used, shall be affixed in a manner to that will hold the energy isolating devices in a “safe” or “off” position

5. Tagout Device Application (continued)  Tagout devices, where used, shall be affixed in such a manner as will clearly indicate that the operation or movement of energy isolating devices from the “safe” or “off” position is prohibited  Where tagout devices are used with energy isolating devices designed with the capability of being locked, the tag attachment shall be fastened at the same point at which the lock would have been attached.  Where a tag cannot be affixed directly to the energy isolating device, the tag shall be located as close as safely possible to the device, in a position that will be immediately obvious to anyone attempting to operate the device.

6. Control of Stored Energy  Following the application of lockout or tagout devices to energy isolating devices, all potentially hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise rendered safe.  If there is a possibility of re-accumulation of stored energy to a hazardous level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists.

7. Verification of Isolation Prior to starting work on machines or equipment that have been locked out or tagged out; the authorized employee shall verify that isolation and de-energization of the machine or equipment have been accomplished. Prior to starting work on machines or equipment that have been locked out or tagged out; the authorized employee shall verify that isolation and de-energization of the machine or equipment have been accomplished.

Basic Removal of Lockout 1. Ensure equipment is safe to operate 2. Safeguard all employees 3. Remove lockout/tagout devices. Except in emergencies, each device must be removed by the person who put it on. 4. Test the equipment to ensure that it is working properly 5. Inform all affected employees that the machine is working

Temporarily Reactivating Equipment  Remove unnecessary tools from the work area and make sure everyone is clear of the equipment  Remove lockout/tagout devices and re- energize the system  As soon as the energy is no longer needed, isolate the equipment and re-apply lockout/tagout, using the six step procedure.

Special Situations  Servicing lasts longer than one shift.  Contractors are performing service or maintenance at your workplace  Worker who applied lock is not available

Annual Inspections Certain circumstances lend themselves to the opportunity for an inspection Certain circumstances lend themselves to the opportunity for an inspection –Construction of new equipment –Installation of new equipment –Modification or adjustment of equipment –Routinely scheduled cleaning and maintenance –Major repairs

Designating an Inspector Periodic inspections must be performed by an authorized employee other than the one(s) using the energy control procedure Periodic inspections must be performed by an authorized employee other than the one(s) using the energy control procedure Who can inspect Who can inspect –Department manager –Plant management –Safety manager –Others

Tidbits of Info.  Never attempt lockout/tagout procedures unless you have been trained and certified by your employer under an approved Energy Control Program.  Never loan or share your lock, combination, or key with anybody else.  Always be sure all lockout/tagout devices are compatible with the environment in which they will be used i.e. corrosive, humid, etc.

Georgia – OSHA has cited Roger Woods Foods Inc. for a fatal accident resulting from a lockout violation. OSHA fined the company $237,000 as a result of investigating the accident. A maintenance worker was crushed by a mechanical meat vat dumper, which had not been locked out.

An employee was attempting to correct an electrical problem involving two non-operational lamps. He had not shut off the power at the circuit breaker panel nor had he tested the wires to see if they were live. He was electrocuted when he grabbed the two live wires with his left hand and then fell from the ladder.

SummarySummary Accidents will happen Accidents will happen Equipment will occasionally malfunction Equipment will occasionally malfunction People will still make mistakes People will still make mistakes There is no excuse for serious injury that results from ignorance, carelessness, complacency, or lack of an Lockout/Tagout Program

Any Questions?