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

2. 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.

3. 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.

4. 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.

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

6. FAILURE TO
LOCKOUT / TAGOUT

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

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

9. 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

10. Types of Energy
Electrical
Mechanical
Thermal
Hydraulic
Pneumatic 3

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

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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

19. 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.

20. 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

21. 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

22. 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

23. 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

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

25. 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.

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

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

28. 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

29. 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

30. 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

31. 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

32. 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

33. 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

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

35. 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

36. 3 Isolate All Energy Sources
Shut valves
Open breakers and disconnects 20

37. 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

38. 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

39. 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

40. 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

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