Transcript Lockout/Tagout/Verify Awareness

Lockout/Tagout
MEETING THE STANDARD
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Purpose
 The purpose of lockout/tagout is to prevent
energy from accidentally being released
while a machine or equipment is being
serviced.
 The ultimate goal of lockout/tagout is to
protect the safety and health of employees.
 Secondary is the protection of equipment
from damage.
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Scope & Application
 The OSHA Standard for the Control of
Hazardous Energy (Lockout/Tagout) 29 CFR
1910.147 covers the servicing and
maintenance of machines and equipment
in which the unexpected start-up of
machinery or release of stored energy
could possibly cause injury to employees
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Types of Energy
 Mechanical
 Hydraulic
 Pneumatic
 Chemical
 Thermal
 Other
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Lockout/Tagout Applies

Whenever the employee:
- removes or bypasses machine guards or other safety
devices, resulting in exposure to hazards at the point
of operation;
- places any part of their body in contact with the point
of operation of the machine or piece of equipment;
- places any part of their body into a danger zone
associated with a machine operating cycle.
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Does Not Apply

While servicing or maintaining cord and plug connected
electrical equipment. The plug must be removed from the
energy source and remain under the exclusive control of
the employee performing the service or maintenance.

During hot tap operations that involve transmission and
distribution systems for gas, steam, water, or petroleum
products when they are performed on pressurized
pipelines; when continuity of service is essential and
shutdown impractical and an equivalent form of
employee protection is provided.
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Definitions

Affected Associate

Authorized Associate

Capable Of Being Locked Out
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Definitions (cont’d)

Communications Network

Department Lock

Double Block and Bleed

Energized

Energy Isolating Device
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Definitions (cont’d)

Energy Source

Energy Control Procedure

Energy Control Program

Line Blanking or Blinding

Lockout
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Definitions (cont’d)
 Lockout Boundary
 Lockout Device
 Lockout/Tagout Lock Box
 Multiple Lockout Device
 Normal Operations
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Definitions (cont’d)

“Other” Associate

Tagout

Tagout Device

Unexpected Release Of Energy
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Associate Training
Initial training and retraining (as necessary)
must be provided and must certify that such
training has been given to all associates
who work in or around lockout/tagout.
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Written Energy Control Procedures
 A written procedure must identify the
information the “Authorized” associates
must know in order to control hazardous
energy during servicing or maintenance.
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Periodic Inspections
 At least annually, the employer (supervisor
or manager) shall conduct an inspection of
the energy control procedure to ensure the
requirements of the standard are being
followed.
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Serving or Maintenance Operations
 If servicing activity such as lubricating,
cleaning or un-jamming production
equipment takes place during production,
the associates performing the servicing
may be subjected to hazards that are not
encountered as part of the production
operation itself.
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Minor Servicing Tasks

Associates performing minor tool changes and
adjustments or other minor activities during
normal production operations that are routine,
repetitive and integral to the use of the
production equipment, are not covered by the
lockout/tagout standard providing using
alternative measures that give effective
protection against unexpected machine cycling,
for example.
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Equipment Modifications
 After October 31, 1989 whenever major
replacement, repair, renovation or
modification of machines is performed,
and whenever new machines or equipment
are installed, energy isolating devices for
machines and equipment shall be
designed or retrofitted to ensure that
lockout devices may be placed on the
equipment
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Appendix B
Appendix B – Machine Specific Shutdown
Procedures will be used for ALL lockout
tagout. No matter how small the job, this
form should be used. After completion of the
job, the completed form should be filed by
the supervisor.
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Application Of Controls And Lockout/Tagout
Devices – Seven Basic Steps
 The established procedure of applying
energy controls includes the specific
elements and actions that must be
implemented in sequence. They are
identified specifically in Appendix – B
Machine Specific Shutdown Procedures.
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Preparation for Shutdown - 1
 Understand the types and amounts of
energy that power the equipment, discuss
with your Supervisor – Establish boundary
 Understand the hazards associated with
the energy
 Notify all affected persons
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Equipment Shutdown - 2
 Shut the system down using available
operating controls
 Follow whatever procedure is appropriate
for the equipment to avoid endangering
anyone during the shutdown
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 Be sure to isolate all energy sources,
secondary power supplies as well as
primary supplies
 Never just remove a fuse when you can
disconnect the equipment completely
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Application of Devices - 3
 All energy isolating devices are to be
locked, and tagged. Only tags are
permissible – Why?
 When lockout is used, every employee in
the work crew must attach their personal
lock to the lockout/tagout lockbox
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Release of Stored Energy - 4
 Ensure all parts have stopped moving
 Relieve trapped pressure
 Block or brace parts that could fall
 Bleed lines and vent valves open
 If stored energy can re-accumulate, then
monitor conditions to make sure it stays
below hazardous levels
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Verify Equipment Isolation -5
 Ensure all danger areas are clear of
personnel
 Verify disconnect switch or circuit breaker
cannot be moved to the “on” position
 Attempt to start equipment by engaging all
activating controls and return controls to
the “off” position when testing is complete25
Secure The Keys - 6
 Once the lockout devices have been locked
with department locks, place the
department lock keys in the lockout/tagout
lockbox and place your personal lock on
the box.
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Supervision Verification - 7
 Have your Supervisor verify that all
procedures have been followed, all energy
sources have been locked or tagged and
that the boundary is correct. The
Supervisor should sign Appendix B
Machine Specific Shutdown Procedures
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Typical Lockout/Tagout
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Removal Of Locks and Tags
Before lockout or tagout devices are removed
and energy is restored to the machine or
equipment, the authorized associate(s) must
follow the Restoring To Service Procedures in
Appendix B.
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Additional Safety Requirements

Special circumstances may arise due to:
1.
Machines need to be tested or repositioned
during serving or repair
Outside (contractor) personnel perform work
Servicing or maintenance is performed by a
group rather than one associate
Shifts or personnel change
2.
3.
4.
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Testing or Repositioning Machines
 The temporary removal of locks or tags and
the re-energization of the machine is
allowed ONLY under special conditions for
example, when power is needed for the
testing or repositioning of machines,
equipment or components.
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Outside Contractors

When using an outside contractor to service a piece of
equipment of perform any maintenance activity that
requires lockout/tagout, the authorized associates or
Supervisor must meet with the contractor and discuss the
lcokout/tagout procedure. You must decide which
procedure will be used and the requirements. If the
outside contractor does not have a lockout/tagout
procedure, locks, or isolating devices, you must
administer your lockout/tagout program.

You could possibly be held liable if an accident occurs
within your facility with a contractor.
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Group Lockout/Tagout
 During all group (two or more)
lockout/tagout operations where the
release of hazardous energy is possible,
each authorized associate performing
servicing or maintenance shall be
protected by his/her personal lock placed
on the lockout/tagout lock box and by a
department lock on isolating devices.
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Energy Isolating Devices
 The primary tool for providing protection
under the 1910 standard is the energy
isolating device, which is the mechanism
that prevents the transmission or release
of energy to which all locks or tags are
attached.
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Tagout Devices
 When an energy isolating device cannot be
physically locked out, it must have at a
minimum a tagout device (TAG) applied to
it.
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Lockout vs. Tagout
 If an energy isolating device is capable of
being locked out, it must be locked out
unless it can be shown that a tagout system
provides full employee protection
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Lockout/Tagout Devices
 When attached to an energy isolating
device, both lockout and tagout devices are
tools that can be used to protect
associates from hazardous energy.
The lockout device provides protection by
holding the energy isolating device in a
safe position, thus preventing the machine
or equipment from becoming energized.
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Types Of Lockout Devices
 Gate Valve Handle
 Ball Valve Handle
 Butterfly Valve
 Single Pole
 Multiple Pole
 Cord and Plug
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Types, cont.
 Wall Switch
 Chains
 Scissor Lock Hasp
 Blinds
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Keys & Locks

You will see two different colored locks in
your program.
(1)
Red Lock – Department Lock
Yellow Lock – Personal Lock
(2)
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Lockout/Tagout Lock Box
 The Lockout/Tagout lock box is a box used
to secure the keys of department locks
once a lockout device has been placed on
an energy isolating device or a lockout
device.
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Typical Lockout/Tagout Using a Hasp and
Department Lock
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Appendix A – Model Lockout Procedure

Purpose
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Responsibilities
 Management
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Responsibilities, cont.

Authorized Associate
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Responsibilities, cont.
 General
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Paperwork Procedure
Supervisor issues Appendix B to Associate
 Associate completes each step of lockout
sequence and signs and dates and times.
 Associate returns Appendix B to Supervisor for
verification. Supervisor verifies, signs and retains
 Supervisor retains Appendix B until Associate
finishes job or needs Appendix B to clear lockout
for testing purposes.
 Associate gets Appendix B from Supervisor to
clear lockout, signs and returns to Supervisor. 67

Locking Out & Isolating The Power Source
 Appendix B – Sequence Of Lockout
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Removal Of Locks & Restoring Power Source

Appendix B – Restoring Equipment To
Service
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Emergency or Authorized Lock Removal
 Supervision will be authorized to remove
an associates personal lock or department
lock under specific conditions.
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Shift Changes
 If service or maintenance activities last
longer then one shift - lockout/tagout
protection must not be interrupted
 If the employee who applied the device is
not there to remove it – then it can only be
removed in an emergency and under the
direction of the supervisor
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Contractors

The outside contractor and the on-site employer
must exchange lockout/tagout information

Employees on-site must understand the rules
used by the contractor and attach a department
lock on the energy source

Be alert for new types of lockout/tagout devices
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Contractor & Department Lock
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Acceptable Isolating Techniques
 Cord and Plug Powered Equipment
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Minor Adjustments
 Printers, Printing Presses, Molding
Machines, Stamping Machines, etc.
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Acceptable Isolating Devices
 Mechanical Repair Work
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
Panel Breaker Boxes
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 Minor Tool Change or Minor Adjustment
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Appendix B

Appendix B - Machine Specific Shutdown
Procedures
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Appendix C
Machine Specific Shutdown/Lockout Procedures
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Questions ?
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