1. Lockout/Tagout (LOTO):
Creating a Safer Workplace through the Control of Hazardous Energy
Welcome to today’s training where we will discuss Lockout/ Tagout. My name is Trey Brown and I am a Senior Loss Control Consultant for Summit and I will be the one presenting today. The purpose of today’s training is to discover ways in which we can create a safer workplace by controlling hazardous energy. It is to protect employees involved in the servicing or maintenance of equipment from injury due to the unexpected start up or release of stored energy
Lockout/Tagout procedures can be found present in virtually every workplace to some extent. That said, some industries do not see the need for these procedures to the extent that other industries do, however, understanding the principles of Lockout/ Tagout is extremely important. It is important to understand the when, where and why aspects so that the workplace can remain as safe as possible regardless of how often the hazard is encountered.
With all of this said, let’s get started.

2. What does it mean to “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.
So what does it mean to “Lockout” a device?
Locking out a device describes a technique that is used to prevent the release of hazardous energy or to prevent the hazardous energy from escaping.
The most common example of locking out a device is a padlock placed on an appropriate energy isolating device that is in the off or closed position. This simply means to turn off some type of equipment and then locking it in the off position so that it can only be turned back on by the person who locked it out..

3. What is Tagout?
A method of securing a power source through use of a distinguishable danger tag.
Now What is Tagout?
Tagout is A method of securing a power source through use of a distinguishable danger tag.
Essentially, Lock out refers to the physical lock or device used so that the machine or equipment can not be turned on and Tagout refers to the tag to inform as to who has locked it out as well as some additional information such as when it will be turned back on or energized.

4. 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
So let’s start by looking at the top five causes of injury relating to Lockout/ Tagout issues:
1) Failure to stop equipment: It is simply not possible to safely work on any type of equipment while it is in operation. If a piece of equipment is still in operation, there are moving parts to possible account for and the exposure for electrical shock or electrocution is also present.
2) Failure to disconnect from power source: Just like not stopping the equipment, failure to disconnect the equipment for the power source, typically but not limited to electricity, can result in contact with the power source which in the case of electricity can lead to everything from severe burns and even death from electrocution.
3) Failure to dissipate (bleed, neutralize) residual energy: If a device has stored energy, such as a pneumatic or hydraulic device, the energy that is stored must be bled out so that the device can not discharge while being serviced. This discharge can cause a wide range of injuries including death.
4) Accidental restarting of equipment: When other employees other than the employee working on the device or equipment have the ability to turn on or re-energize the device or equipment, there is a chance that the it could be turned back on without the employee working on the equipment knowing. Imagine working on a large mechanical press in a manufacturing environment and being under the press when someone turned it back on. These types of breakdowns in lockout tagout programs lead to countless preventable deaths each year.
5) Failure to clear work areas before restarting: The final crucial component in a Lockout / Tagout program is how to properly restart an equipment or device. All work areas should be cleared so that no one finds themselves in an area where they could be hurt by the operation of that machine.

5. Key Terms What is an Authorized Employee ?
What is an Affected Employee?
What is an energy Isolating Device?
What are energy control procedures?
Let’s look now at some terms key in discussing Lockout/ Tagout programs.
What is an Authorized Employee ?
Authorized Employee – An authorized employee is the one who locks out machines or equipment in order to perform the servicing or maintenance on that machine or equipment.
What is an Affected Employee?
Affected Employee is 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.
What is an energy Isolating Device?
An Energy Isolating Device is A mechanical device that physically prevents the transmission or release of energy.
What are energy control procedures?
An Energy Control Procedure is A Safety program adopted by the employer that includes energy control procedures plus provisions for inspecting the procedures and training employees for lockout/tagout.

6. Sources of Hazardous Energy in the Workplace
Electrical
Generated
Static
Mechanical
Transitional
Rotational
Thermal
Machines or Equipment
Chemical Reactions
Potential
Pressure
Hydraulic
Pneumatic
Vacuum
Springs
Gravity
Sources of Hazardous Energy can be found in many places throughout the Workplace
Hazardous energy can come from:
Electrical Sources such as Generated and Static
Mechanical sources that are Transitional and Rotational
Thermal Sources from Machines or Equipment and from Chemical Reactions
Potential other sources include Pressure sources that are Hydraulic, Pneumatic, or even Vacuum or sources that use Springs or even using Gravity

7. Types of Lockout Devices
Plug Locks
Ball Valve Lockout
Gate Valve Lockout
Group Lockout Hasp
Electrical
Hydraulic, pneumatic, and other pressurized systems
If there is an energy source that has to be controlled, there is a lockout device that has been developed to control that energy source
Plug Locks
Ball Valve Lockout
Gate Valve Lockout
Group Lockout Hasp
Electrical
Hydraulic, pneumatic, and other pressurized systems
You can see by the pictures on the right some of the many different types of devices that are out there.

8. Steps to a Proper Lockout Procedure
Alert the operator (s) that power is being disconnected.
Preparation for Shutdown
Equipment Shutdown and Isolation
Here are the steps to properly locking out a piece of equipment.
First, you must Alert the operator or operators that power is being disconnected. – Good communications will save lives and reduce injury.
Once the operators have been informed, then you take the steps to Prepare for the Shutdown: You must Follow established procedures for shutting down the machine or piece of equipment.
Next, it is time for the Equipment Shutdown and isolation: This is Officially turning “off” the equipment

9. Steps to a Proper Lockout Procedure
Application of Lockout Devices
Control of Stored Energy
Equipment Isolation-Verification
Next we are going to place the Lockout Device or devices on the equipment so that the hazard is contained
Next we have to make sure we have Control of the Stored Energy. What does this mean?
This could be Bleeding the lines and leave vent valves open
It could be Draining piping systems and closing valves to prevent the flow of hazardous materials
It could be Dissipating extreme cold or heat, or wear protective clothing
If stored energy can re-accumulate, it must be monitored and kept below hazardous levels
Finally we have the Equipment Isolation and Verification
The Main disconnect switch or breaker must be fixed in off position
You have to then Check any switches with a voltmeter. This takes out all uncertainty as to whether or not there is an electrical charge present
Then Press all equipment activating controls. Try to make the machine work to see if tries to operate. If any part tries to operate, then the lockout is not complete. You must Assure by testing that all machine controls are “off”

10. Removal of Lockout Ensure equipment is safe to operate
Safeguard all employees
Remove lockout/tagout devices.
Last person to take off lock
Follow checklist
Prior to removing the lockout device, you must Ensure equipment is safe to operate
The Next step it to Safeguard all employees. Just like operators are informed prior to the lockout, the must be informed when the equipment is coming back online so that they are prepared.
Now you can Remove lockout/tagout devices. Except in emergencies, each device must be removed by the person who put it on.
Last person to take off lock
Follow a checklist regarding the steps to re-energizing the machine

11. Our critical safety rule
Authorized and affected employee’s share one critical safety rule:
The Person Who Applied the Lock is the Only Person allowed to Remove the Lock
Authorized and affected employee’s share one critical safety rule:
The Person Who Applied the Lock is the Only Person allowed to Remove the Lock

12. Machine Specific Procedures
Required on equipment with more than one source of energy
Identify the equipment’s specific types of energy sources
Specify steps
Let’s now discuss machine specific procedures:
Machine specific procedures are required on equipment with more than one source of energy (electrical, gas, hydraulic, pneumatic, chemical, steam, springs, raised equipment parts, etc.)
Note: Procedures are not required for single energy equipment with a cord and plug, provided the equipment is unplugged and remains under the control of the employee performing the work.
Identify the equipment’s specific types of energy sources (electric, gas, hydraulic, pneumatic, chemical, raised equipment parts, etc.)
Specify steps for the release of stored energy and placement of lockout devices to prevent accidental start up

13. Procedures Must Be Written, Unless All Exist:
Equipment has:
No potential for stored or residual energy
A single energy source, capable of isolation and lockout for deactivating equipment
Been isolated from energy source and locked
Lockout device under exclusive control of authorized employee performing maintenance
No other hazards created
Employer has had no related accidents
LOTO Procedures Must Be Written, Unless All of the following conditions Exist:
The Equipment has:
No potential for stored or residual energy
A single energy source, capable of isolation and lockout for deactivating equipment
Been isolated from energy source and locked
Lockout device under exclusive control of authorized employee performing maintenance
No other hazards created
Employer has had no related accidents

14. Training Schedule For LO/TO
Primary training plan
Initial, retraining, certification of training
Retraining of authorized/affected staff
Change in assignments
Introduction of new equipment or process
Change in LO/TO protocol
Audit results at least annually
Let’s now talk a little about training in regards to loto.
Primary training plan
Initial, retraining, certification of training
Retraining of authorized/affected staff
Change in assignments
Introduction of new equipment or process
Change in LO/TO protocol
Audit results at least annually

15. 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 seven step procedure.
On occasion you may have to Temporarily Reactivate the Equipment. Here are some steps to follow.
First, Remove any unnecessary tools from the work area and make sure everyone is clear of the equipment
Then Remove the lockout/tagout devices and re-energize the system
Lastly, As soon as the energy is no longer needed, isolate the equipment and re-apply lockout/tagout, using the six step procedure that we discussed earlier.

16. Special Situations Servicing lasts longer than one shift.
Contractors are performing service or maintenance at your workplace
Worker who applied lock is not available
Sometimes Servicing lasts longer than one shift. When shift change or reassignment occurs during a lockout/tagout, the following rules apply:
The off-going employee will review the job with the on-coming employee
The off-going employee will remove his/her locks/tags
The on-coming employee will place his locks/tags
The on-coming employee will verify that all energy controls are in the off or safe position
Always check your lockout/tagout after being away from the job, even after breaks and lunch
If Contractors are performing service or maintenance at your workplace
Contractors are required to have a program equivalent to yours
Contractor personnel will be made aware of your procedure, locks and tags
All personnel who work with contractors will be made aware of the contractor procedure, locks and tags
Any problems that are observed should be immediately brought to the attention of the LOTO program administrator
What if the Worker who applied lock is not available
The decision to remove the lock must be made by a member of management
Every effort must be made to contact the employee including calling her/him at home
A member of management will meet the employee at the entrance before the next scheduled work shift or The cut-off lock will be left with a note on the employee’s bench or tool box. The fact that the employee left without making arrangements requiring the lockout device, this uncertainty in itself created a hazard. The employee must be instructed of his error so that it can not happen again.

17. Words to Live By…
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.
In closing, here are some words to live by…
Never attempt lockout/ tagout procedures unless you have been trained and certified by your employer under an approved Energy Control Program.
I conducted a site survey for one of Summit’s insureds and saw for myself how a little information can be a very bad thing. The owner wanted to have a lockout/tagout program. So he went out, bought the locks and issued them to his employees. Where his big mistake came into play was that he had all of the locks keyed the same. The employees could open each others locks. This leaves the chance for the lock to be removed and the equipment re-energized without the employee who is working on the equipment knowledge which could result in serious injury. This leads us to our next words to live by.
Never loan or share your lock, combination, or key with anybody else.
Last but not least, Always be sure all lockout/tagout devices are compatible with the environment in which they will be used i.e. corrosive, humid, etc.

18. When in doubt…….. LOCKOUT! Words to Live By… When in doubt……..
Some final words to live by:
When in doubt……..
LOCKOUT!

19. Thank You from Summit!