Transcript Lockout/Tagout Awareness Training

Risk Management and Safety
Camp Auburn Safety Annex
971 Camp Auburn Road
Auburn University, Alabama
334-844-4805
FAX 334-844-4197
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“LOTO” is a technique used to prevent energy
from being released during the servicing of
equipment. This is accomplished by placing
locking or tagging out energy isolation devices
prior to starting work.
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Occupational Safety and Health recognizing the hazards
associated with energized machinery and equipment has
developed this program. The purpose of the Auburn
University lockout/tagout program is to prevent injury or
risk of fatality to all employees and students caused by the
unexpected energizing, start-up or release of stored
energy when working on equipment, machinery or
systems. The program has been designed to provide
suitable and practical guidance in the proper application of
the university’s lagout/tagout program.
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Authorized Employees or Students must isolate the energy
source and make the machine, equipment or system
inoperative (establish a Zero Mechanical State) prior to
performing any service or maintenance. Only properly trained
authorized employees or students may isolate the energy
source. This policy requires the authorized employees or
students to turn off and disconnect the machinery or equipment
from all energy sources before carrying out service or
maintenance. It also requires these individuals to lockout
and/or tagout the energy-isolating device to prevent the release
of hazardous energy, and take all necessary measures to
confirm that the energy has been isolated successfully. When
physically locking the device is not possible, a secondary
control system of “tagging out” will be put into place.
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Authorized employee or student: An employee or
student who performs servicing or maintenance on
machines and equipment. Lockout or tagout is used by
these employees for their own protection.
Affected employee or student: An employee or student
who performs the duties of his or her job in an area in
which the energy control procedure is implemented and
servicing or maintenance operations are performed.
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Capable of being locked out: An energy isolating device
that has a locking mechanism built into it, or one that has
a hasp or other means of attachment to which a lock can
be affixed.
Energized: When the machine or equipment is connected
to an energy source, or it contains residual or stored
energy.
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Energy Isolating Device : A mechanical device that
physically prevents the transmission or release of energy,
including (but not limited to) the following:
• A manually operated electrical circuit breaker;
• Disconnect switch;
• Manually operated switch where the conductors of
a circuit can be disconnected from all ungrounded
supply conductors, and no pole can be operated
alone;
• Line valve; or
• A block or any similar device that is used to block or
isolate energy.
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Energy Source: Any source of electrical, chemical,
mechanical, thermal, pneumatic, hydraulic, or other
energy.
Hot Tap: A system that is used in repair, maintenance,
and service activities that involves welding on a piece of
equipment (pipelines, vessels, or tanks) under pressure to
install connections or accessories. It is generally used to
replace or add sections of pipeline without the interruption
of service for air, gas, water, steam and petrochemical
distribution systems.
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Lockout device:
Use
to hold an energy isolating
device
in the safe position and
prevents
the energizing of
equipment
or machinery.
Lockout: The placement of a lockout device including a
padlock on the energy isolating device of a piece of
equipment, machinery or system.
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Tagout
device:
Use along with lockout devices as additional warning or
information that the equipment or machinery is not to be
operated.
Zero Mechanical State: The mechanical potential energy
of all portions of the equipment or machine is set so that
the opening of pipes, tubes, hoses or actuation of any
valve, lever or button, will not produce a movement which
could cause injury.
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Occupational Safety and Health is responsible for:
• Development and administration of the
lockout/tagout program.
• Providing online initial training
• Evaluating each department’s lockout/tagout
compliance with the program.
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Departments/Divisions
• Identify machinery and equipment that requires
lockout/tagout before servicing.
• Develop machine specific procedures for each type of
machine or equipment.
• Approve lockout devices to be used for each type of
equipment that may need to be serviced.
• Provide individual tags and key locks to each employee
or student who will need to de-energize equipment.
• Appointing Shop Supervisor
• Coordinate with outside contractors when servicing of
equipment is done by them, or will affect them.
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Shop Supervisor
• Coordinate and provide required hands-on training.
• Be familiar with the pertinent regulations and the
lockout/tagout program.
• Identify authorized and affected employees and students.
• Ensure that employees and students know and follow the
lockout/tagout program rules.
• Provide lockout/tagout devices to authorized employees
and students.
• Provide individually identified locks, which are red
(personal) & green (machine), to all authorized employees
and students.
• Complete a Hazardous Energy Control Procedure for each
covered piece of equipment or machine in his or her areas
of responsibility with more than one energy source.
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Shop Supervisor
• Forward completed and signed copies of each
departmental Hazardous Energy Control Procedure to
Occupational Safety and Health.
• Remove lockout/tagout devices when the authorized
employee or student is not available.
• Perform periodic on-site inspections, at least annually, for
each authorized departmental employee and student to
ensure that he/she is properly complying with
lockout/tagout program.
• Document that a training session has occurred with all
employees and students on each annual inspection
completed.
• Request assistance from Occupational Safety and Health
as needed.
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Authorized Employees/Students
• Understand the intended use of each type of lockout/tagout
hardware.
• Understand specific procedures for machinery, equipment and
processes, including: the hazards involved with working on
electrical circuit and/or machinery or equipment.
• Use the proper procedure for locking/tagging out an electrical
source or piece of equipment.
• Ensure the devices are kept in such a manner as to prevent use by
other employees or students.
• Notify any affected employees or students prior to the application of
lockout/tagout devices and after they are removed.
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Affected Employee or Student
• Comply with restrictions and limitation imposed upon
them during lockout/tagout of equipment or machinery.
• Do not attempt to move lockout/tagout devices or start,
energize or use equipment that have been locked or
tagged out.
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•
•
•
•
•
Electrical
Pneumatic
Hydraulic
Mechanical
Thermal
•
•
•
•
•
Chemical
Radiation
Steam
Spring-Driven
Suspended Parts
• Some energy sources can be turned on/off.
• Others can only be dissipated or controlled.
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
•
•
•
•
“…during the servicing of equipment”.
Adjusting
Inspecting
Modifying
Replacing parts
•
•
•
•
Tool changes
Clearing jams
Lubricating
Cleaning
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Lockout/Tagout rules apply (the equipment must be deenergized and locks or tags must be applied to the energyisolation devices) to servicing and maintenance activities
when:
• The employee or student must either remove or bypass
machine guards or other safety devices, resulting in
exposure to hazards at the point of operation.
• The employee or student is required to place any part of
his or her body into a danger zone associated with a
machine operating cycle.
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Normal production operations
• Routine, repetitive, and integral to
production.
• Guards/safety devices not bypassed.
• Body part not placed in the point of
operation or other dangerous area during
machine cycle.
• Need to use alternative measures for
protection.
Cord & plug connected equipment
• Plug is only source of energy.
• Plug is under continuous control of one
person.
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Hot tap operations that involve transmission and
distribution systems for gas, steam, water, or petroleum
products on pressurized pipelines IF continuity of service is
essential, shutdown of the system is
impractical, documented procedures
are followed, and employees or
students are effectively protected by
special equipment.
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Electrical Procedures
• Shut off power on machine and disconnect.
• Lockout/tagout on disconnect sources.
• Press start button to ensure that energy source has
been locked.
• Remember the keys points:
If a machine or piece of equipment contains
capacitors, they must be drained of stored energy.
Possible disconnecting sources include the power
cord, power panels (look for primary & secondary
voltage), breakers, the operator’s station, motor
circuit, relays, limit switches, electrical interlocks.
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Hydraulic/Pneumatic Procedures
• Shut off all energy sources (pumps &
compressors).
• Lockout/tagout the valve on the pumps and
compressors that supply energy to more than one
piece of equipment.
• Drain or bleed stored pressure from
hydraulic/pneumatic lines during lockout/tagout
procedures.
• Make sure controls are returned to their safest
position (off, stop, neutral, etc.).
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Fluids and Gases
• Identify the type of fluid or gas properly.
• Close valves to prevent flow during lockout/tagout.
• Determine the isolating device, close and
lockout/tagout.
• Drain and bleed lines to zero energy state.
• Check for zero energy state on the equipment.
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Mechanical Energy Procedures
• Block out or use die ram safety chain.
• Lockout or tagout safety device.
• Shut off, lockout or tagout electrical system.
• Check for zero energy state
on equipment.
• Return controls to safest
position.
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Extra precaution
• Know equipment and systems
Understand equipment hazards
Isolation points
Procedures for lockout
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Locks/tags must clearly identify the employees or
students who applied them.
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A written procedure is required for a piece of equipment or
machinery that utilizes multiple power sources. Each case
must outline:
• ALL energy sources & lockout points
for the equipment or process.
• Specific steps to shut down, isolate,
block and secure the machine or
equipment to control the hazardous energy.
• Steps for the placement, removal and
transfer of the lockout devices and the
responsibility for the devices.
• Specific requirements for testing the equipment
or machine to ensure the effectiveness of the lockout devices
and other energy control devices.
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Prepare for Shutdown
• Identify lockout points
Locate and identify all energy isolating devices that apply
to the machine/equipment to be locked out.
Refer to the manufacturer’s control diagram detailing the
location of all isolating points for complex equipment.
Determine the magnitude of the energy, the hazards of the
energy to be controlled, and the methods to control the
energy.
If authorized employees or students are unable to
determine each form of energy, they must consult their
supervisors before starting work.
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Notification
• Notify all affected employees and students that a
lockout/tagout is about to take place.
 The reason for the lockout/tagout.
 The specific machinery or
equipment affected.
Shutdown
• Shut Off Equipment
 If the equipment is operating,
employees or students shall shut it down by the
normal stopping procedures (depress the stop
button, open the switch, close valve, etc.)
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Deactivate Energy
• Disconnect the device from ALL
energy sources
• Inspect the equipment to ensure
ALL energy sources are
disconnected.
Release of Stored or Residual Energy
• Release the stored or residual energy such as
that in capacitors, springs, elevated machine
members, rotating flywheels, hydraulic systems
and pressurized systems such as air, gas, steam,
or water.
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Attach Locking and Tagging Devices
• Locks and tags should be standardized.
• Locks shall be attached to energy isolating devices
so that they cannot be accidentally detached
during maintenance.
• Tags shall be attached to
all points where equipment
or circuits can be energized.
• A multiple lock plate shall
be used when more than one
employee or student attaches
their own lock on the same equipment.
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Ensure all potential or residual energy is controlled.
•
•
•
•
•
•
•
•
Block elevated parts
Block/release springs
Relieve system pressure
Drain fluids
Vent gases
Allow system to cool
Discharge capacitors
Stop rotating flywheels
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Tryout
• Test the deactivation of the equipment to ensure that equipment
cannot be energized.
 Checking that no employees or students are exposed.
 Verifying the isolation of equipment by operating the push
button or other normal operating controls.
 Checking pressure gauges to ensure de-pressurization of lines.
 Inspecting electrical circuits to confirm zero voltage.
 Testing equipment by pushing start buttons or other controls to
make certain the equipment will not run.
 Returning the operating control(s) to “NEUTRAL” or “OFF”
position after the test.
 Ensuring equipment is now locked out/tagged out.
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• Complete required service work.
• Avoid doing anything that could potentially reactivate the
equipment.
• OK to interrupt LOTO, but must be reapplied if servicing
is to continue.
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Inspect the machine and work area to ensure that:
• Non-essential materials have been removed.
• Tools and equipment are removed.
• Blocks, pins and chain (used during the lockout) are
removed.
• Secured safe guards are in place.
• All equipment components are fully assembled and
operational.
Ensure that all employees and students have left the
area or are safely positioned.
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• Verify that controls are in neutral or the “OFF”
position.
• Remove all locking/tagging devices
 Each lock shall be removed by authorized
employee or student that applied it or under
his/her direct supervision.
• Notify affected employees and students that the
servicing or maintenance is completed and the
machine/equipment is ready for use.
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If the authorized employee or student who placed a lockout/tagout
is absent from the workplace, when necessary, the immediate
supervisor of that employee or student may remove the lock/tag
device after completing ALL of the following specific procedures:
• Verify that the employee or student is not present and therefore
unable to remove the lock.
• Obtain approval to remove the lock from one of the following:
Dean, Department Head, Director, Associate Director, and/or
Assistant Director.
• With the assistance of one of the above, get the “Second Key”.
• Remove lock/tag device (if supervisor is an authorized person) or
supervise the removal by a person authorized to do so.
• Ensure that the authorized employee or student who placed the
lockout/tagout device is aware that the lock and or tag has been
removed.
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•
•
•
•
The primary authorized employee or student applies a multi-lock
accepting device to the energy – isolating device and attaches
his/her lock.
One authorized employee or student in the group is allowed to
function as the lockout/tagout coordinator
to ensure that all control methods are applied and there
is continuity of protection for the group.
Each authorized employee or student shall affix a
personal lockout/tagout device to the multi-lock
accepting device when they begin work and
shall remove those devices when they stop
work.
The primary authorized employee or student removes
his/her lock and the multi-lock accepting device when
all work has been completed.
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Either on the same shift or on the next shift, the following
procedures should be followed:
• The on-coming employee or student shall notify the off-going
employee or student that they are ready to begin work on the
machine or equipment.
• All lockout/tagout devices attached to the machine or equipment by
the off-going employee or student shall be removed and
immediately replaced with like devices by the on-coming authorized
employee or student.
• The primary authorized employee or student shall ensure that all
pertinent coordination between off-going and on-coming employee
or student has been completed before the on-coming authorized
employee or student begins work on the machine or equipment.
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Inspections must be performed at least annually to assure
that the energy control procedures continue to be
implemented properly and that the employees and students
are familiar with their responsibilities.
The machine or equipment, the date of the inspection, the
employees and students included, and the name of the
person performing the inspection must be identified. Must
identify any deficiencies or deviations and correct them.
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• Only authorized employees or students may
perform lockout/tagout using only the
prescribed procedures.
• Identify ALL energy sources and establish a
zero energy prior to servicing equipment.
• Take your time and do it RIGHT!!!
(Lockout, Tagout, Tryout)
• IF YOU DO NOT KNOW, ASK!!!
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1.
Place numbers from 1 to 7 in the
blanks indicating the correct order of steps
to be taken in lockout/tagout.
___
___
___
___
___
___
___
Isolate equipment
Verify isolation
Control stored energy
Shut down equipment
Prepare for shutdown
Apply lockout/tagout devices
Removal of locks
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2.
Lockout/Tagout is a system used
to ensure that equipment you have isolated
and de-energized to work on remains shut
down.
True___, False___
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3.
In a tagout, a tag is placed on all
primary and secondary energy sources.
True___, False___
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4.
You know the equipment is safe
when the power has been shut down.
True___, False___
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5.
It’s a good idea to have a pre-job
briefing with your co-workers before a
lockout operation.
True___, False___
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6.
Locks should be removed only by
the person who installed them.
True___, False___
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7.
Which of the following must an
employee know before starting to work on
a piece of equipment.
a)
b)
c)
d)
Types of energy to be controlled
Magnitude of energy to be controlled
Hazards of energy to be controlled
Method and means to control the
energy
e) All of the above
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8.
Which of the following must be
notified prior to equipment shutdown for
repair?
a)
b)
c)
d)
Plant manager
Supervisor
Safety person
Affected employees.
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9.
Which of the following would be
part of equipment isolation?
a)
b)
c)
d)
Closing valves
Locking out feeders
Turning off power
All of the above
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10.
Which of the following would be
part of control of stored energy?
a) Releasing hydraulic pressure
b) Releasing steam pressure
c) Blocking movement of parts
d) Releasing spring tension
e) All of the above
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Bonus. Verifying isolation involves:
a) Putting locks on the equipment
b) Putting a tag on the equipment
c) Attempting to turn the machine on
d) All of the above
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Answers
#1 Order: 3,6,5,2,1,4,7
True/False: 2)T, 3)T, 4)F, 5)T, 6)T,
Multi-choice: 7)e 8)d, 9)d, 10)e, Bonus)c
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If you have questions please call:
Risk Management and Safety,
Occupational Safety and Health Program
334-844-4805
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