Transcript Lockout/Tagout Standard

Lock Out/Tag Out
Training
OSHA 29 CFR 1910.147
Why Lockout/Tagout?

Approximately 3 million workers service
equipment and face the greatest risk of
injury if lockout/tag out is not properly
implemented. Compliance with the
lockout/tag out standard (29 CFR
1910.147) prevents an estimated 120
fatalities and 50,000 injuries each
year. Workers injured on the job from
exposure to hazardous energy lose an
average of 24 workdays for recuperation.
U.S. Department of Labor
Occupational Safety & Health
Administration (OSHA)
WHO MUST BE TRAINED?
Anyone
who may
have reason to be
in an area where
energy control
procedures are
used.
Training must be
completed on an
annual basis.
LOCKOUT

Lockout is a technique used to block the flow
of hazardous energy from the power source
to the equipment.

The placement of a lock and tag on an
isolating device which ensures that the
equipment being controlled cannot be reenergized until the locking device is removed.
GOAL


The ultimate goal of lockout/tag out is to
protect the safety and health of employees.
Secondary is the protection of equipment
from damage.
Lock-Out/Tag-Out is
a safety procedure
mandated by OSHA.
The “Fatal Five” Main Causes of
Lockout/Tag out Injuries

FAILURE TO DISSIPATE (BLEED, NEUTRALIZE)
RESIDUAL ENERGY

FAILURE TO STOP EQUIPMENT
FAILURE TO DISCONNECT FROM POWER
SOURCE

FAILURE TO CLEAR WORK AREAS BEFORE
RESTARTING

ACCIDENTAL RESTARTING
OF EQUIPMENT

REQUIREMENTS
Equipment Specific Lockout
Procedures
 Authorized & Affected Training
 Audits of Proficiency & Supervisor
Audits for Authorized Employees
 Type of Energy Isolating Devices
 Group Lockouts
 Start-Up Alarms

Definitions
 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.
 Authorized
Employee - one who locks out
machines or equipment in order to perform
the servicing or maintenance on that machine
or equipment. Must have an Audit of
Proficiency annually.
TAG INFORMATION
Information that may be found on a tag may include:
Name of the worker who put it there
The date and/or time the work began
Type of work being done
If you see a Lock-Out Tag that is not legible it
should be reported immediately to your
Supervisor.
Only the employee who attached the
Lock/Tag can remove it! No else is
Authorized to remove someone else’s
Lockout device. (IN only certain instances can a
lockout device be removed by someone other than
who locked out the equipment originally and it must be
Approved by a Manager).
TAGs
Tags are essentially warning devices affixed to energyisolating devices, they are not to be removed except by the
person who applied them.
Tags must be legible and understandable by all
employees.
Tags and their means of attachment must be
made of materials that will withstand the envir-onmental conditions encountered in the work
place.
Tags must be securely attached to the energyisolating devices so that they cannot be detached
accidentally during use.
Authorized
Locks
One lock, one key rule.
 Cannot work under another
employee’s lock.
 Any lock that gets damaged or lost
should be reported immediately.

Authorized
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 Procedure
Alert the operator (s) that power is being
disconnected.
 Preparation for Shutdown
 Equipment Shutdown
 Equipment Isolation
 Application of Lockout Devices
 Control of Stored Energy
 Equipment Isolation-Verification

Authorized
REMEMBER
Always personally lock the energyisolating device (disconnect, switch,
valve, etc.)
 NEVER WORK UNDER ANOTHER
PERSON’S LOCK (except as described
in systems lockout).

Authorized
Energy Control Situations
All employees including outside
contractors must utilize energy control
procedures prior to engaging in any
work such as repair, setup,
maintenance, inspection, installation, or
adjustment on processes, systems or
equipment.
LOTO Procedure-Area
Specific



The plant will have a designated lock-out/tagout box that contains all the supplies needed
to safely perform LOTO.
The plant will also have a LOTO Procedure
book with all the procedures.
This book must be signed in and out each
time a LOTO is performed.
Authorized
LOCK-OUT STATIONS

KNOW WHERE THE LOCKOUT
STATION IS LOCATED.

LOCKOUT STATIONS ARE NOT TO BE
USED FOR STORAGE OF ANYTHING
BUT LOCKOUT SAFETY DEVICES AND
PROCEDURES.
Authorized
Servicing and/or Maintenance
Operations
If a servicing activity - such as lubricating, cleaning, or unjamming the production equipment - takes place during
production, the employee performing the servicing may be
subjected to hazards that are not encountered as part of the
production operation itself. Workers engaged in these
operations are covered by lockout/tagout when any of the
following conditions occurs:
The employee must either remove or bypass machine
guards or other safety devices, resulting in exposure to
hazards at the point of operation;
The employee is required to place any part of his or her
body in contact with the point of operation of the operational
machine or piece of equipment; or
The employee is required to place any part of his or her
body into a danger zone associated with a machine
operating cycle.
Authorized
LOTO Procedure
Equipment Specific
MACHINE SPECIFIC
Authorized
Using Lock-Out/Tag-Out
When normal servicing tasks - such as
setting equipment up, and/or making
significant adjustments to machines - do
not occur during normal production
operations, employees performing such
tasks are required to lock-out/ tag-out if
they can be injured by unexpected
energization of the equipment.
Ask yourself the question:
Can I be hurt if this machine starts up?
Authorized
No Lock-Out/Tag-Out Required…
Always
check the Standard Operating
Procedure (SOP) for the equipment you are
operating.
Employees performing minor tool changes and
adjustments and/or other minor service activities
during normal production operations that are
routine, repetitive, and integral to the use of the
production equipment are not covered by the lockout/tag-out standard, provided the work is
performed using alternative measures that give
effective protection.
Authorized
Removal of Lockout
Employees in the area shall be
alerted by a clearly audible
signal to start-up
 Visual inspection by the
operator and a verbal warning is
permissible on smaller
equipment.
 Remove all tools and nonessential items from equipment.

Authorized
Important Rules
to REMEMBER…




Never attempt lockout/tag out 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/tag out devices
are compatible with the environment in
which they will be used i.e. corrosive,
humid, etc.
Never use a lockout lock for any other
reason than lockout.
Group Lock-Out/Tag-Out
During all group lockout/tagout operations
where the release of hazardous energy is
possible, each authorized employee
performing service or maintenance shall be
protected by his/her personal lockout or
tagout device or comparable mechanism that
affords equivalent protection.
Examples of Group LOTO
Conveyor Line, Other
Authorized
LOCK-OUT/TAG-OUT
STEPS
To
Effective
Lockout
Authorized
STEP 1- Before the Shutdown
THE STANDARD: (d)(1)
"Preparation for Shutdown." Before
an authorized or affected associate
turns off a machine or equipment, the
authorized associate 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

Authorized
Step 2- Powering Down
THE STANDARD: (d)(2) "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
associates as a result of the equipment
stoppage.
Use the specific procedures for the
individual unit of equipment.
Authorized
Step 3-Isolating the Power
Source
THE
STANDARD: (d)(3) "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).
This step involves flipping a power switch,
breaking a circuit, closing a valve, etc. If the
equipment has more than one shutdown point,
be sure that all are isolated from power. Authorized
Step 4-Applying the Lock/Tag
THE STANDARD: (d)(4) "Lockout /Tagout
Device Application.“
(i) Lockout/tagout devices shall be affixed
to each energy isolating device by
authorized associates.
(ii) Lockout devices, where used, shall be
affixed in a manner to that will hold the
energy isolating devices in a "safe" or
"off" position.
(iii) 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
Authorized
"off" position is prohibited.
Step 5-Releasing Residual
Energy
THE STANDARD: (d)(5) "Stored energy.“
(i) 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.
(ii) 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.
Authorized
Step 5cont’d
-Releasing Residual Energy
After all LO/TO devices have been applied,
associates must ensure that no hazardous energy is
still stored in the equipment or machinery. This kinetic
energy may be found in flywheels, steam lines,
hydraulic systems, springs, capacitors, etc. Energy
may need bleeding from capacitors or grounded from
electrical circuits. Steam lines and hydraulic and
pneumatic systems need activated to determine all
energy has been released. Additionally, any water,
chemical, sewer, or other liquid lines need
emptied, e.g. block and bleed.
Authorized
Step 6-Try to Power Up
THE
STANDARD: (d)(6)
"Verification of isolation."
Prior to starting work on
machines or equipment that
have been locked out or
tagged out, the authorized
associate shall verify that
isolation and de-energization
of the machine or equipment
have been accomplished.
Authorized
Step 6cont’d
-Try to Power Up
This step requires the associate to turn all
controls of the equipment or machinery in
the "ON" position to ensure that all energy
sources have been isolated and that it will
not start up while work is being performed
on it. Before trying to power up, be sure
that no one is near the equipment or
machinery in case the equipment should
operate. Lastly, the associate should verify
that the isolation point cannot be moved to
the "ON" position. The associate can then
perform his servicing or maintenance.
.
Authorized
Removal of Lockout/Tagout
Step 1- Machine and/or Equipment
Inspection
THE
STANDARD: (e)(1) "The machine or
equipment." The work area shall be
inspected to ensure that nonessential
items have been removed and to ensure
that machine or equipment components
are operationally intact.
Authorized
Removal of Lockout/Tagout
Step 2- Give Notification to All Associates
THE STANDARD: (e)(2) "associates."
(i) The work area shall be checked to ensure that
all associates have been safely positioned or
removed.
(ii) Before lockout /tagout devices are removed
and before machines or equipment are energized,
affected associates shall be notified that the
lockout or tagout devices have been removed.
(iii) After lockout /tagout devices have been
removed and before a machine or equipment is
started, affected associates shall be notified that
the lockout or tagout device(s) have been removed.
Authorized
Removal of Lockout/Tagout
Step 3- Remove the Lockout/Tagout Device
THE STANDARD: (e)(3) "Lockout/Tagout Devices
Removal." Each lockout or tagout device shall be
removed from each energy isolating device by
the associate who applied the device. Exception
to paragraph (e)(3). When the authorized
associate who applied the lockout or tagout
device is not available to remove it, that device
may be removed under the direction of the
employer, provided that specific procedures and
training for such removal have been developed,
documented
and
incorporated
into
the
employer's energy control program.
Authorized
Removal of Lockout/Tagout Step 3cont’d
Remove the Lockout/Tagout Device
The employer shall demonstrate that the specific
procedure shall include at least the following
elements:
(i) Verification by the employer that the authorized
associate who applied the device is not at the facility:
(ii) Making all reasonable efforts to contact the
authorized associate to inform him/her that his/her
lockout or tagout device has been removed; and
(iii) Ensuring that the authorized associate has this
knowledge before he/she resumes work at that
facility.
Authorized
What If You Forget to Remove
Your Lock-Out/Tag-Out Device?
Employees who leave the
facility without removing their
locks will be called back at their
own expense to remove them,
and may result in a disciplinary
action.
Never use a lockout lock for any
other reason than lockout.
Authorized
Cutting Off a Lock
Appendix C
REMOVAL OF LOCK
I________________________have attempted to contact___________________________
(Employee Name)
(Name on Lock/Tag)
for the purpose of determining why the lockout control device is still on
____________________________________ and ensuring employees will not be in
(Equipment/M achine)
danger with the removal of the lockout control device.
1. Attempt to contact the above employee was made by calling
_______________________ at _______________am/pm
(Phone Number)
(Time)
If other means of contacting the employee was done, then please detail.
2. The area was checked to ensure it is clear and safe at _______________am/pm
(Time)
3. Permission to remove the lock was obtained from this member of management
__________________________________________
(M anagers Name)
4. The lockout control device was removed at ______________________am/pm
(Time)
5. Notify employee prior to return to work and discuss the seriousness of actions.
(Fill out the Notice of Violation Employee Safety Warning and submit to EHS Manager)
Authorized
Free Wheeling Equipment
Equipment which does not
stop within 5 seconds of being
shut off.
Equipment must have:
A Sticker or Sign>>>
On Guard
On Electrical Panel
On Lockout Procedure
FREE WHEELING
EQUIPMENT LIST
BRAKE PRESS #
BRAKE PRESS #
A Trained Employee
Employee has been trained within the last
12-13 months on the facilities lock-out/tag-out
procedure.
There is an approved, up to date (less than
1 year since last review) LOTO procedure for
that equipment.
Authorized Employee has demonstrated
within the past year, through an Audit of
Proficiency that he/she knows how to perform
LOTO properly on equipment.
Audit of Proficiency
CERTIFICATION OF PROFICIENCY BY DEMONSTRATION
Lockout procedure used: __________________________________
Did the employee know the following:
Know where Lockout program & procedures are located?
Follow the proper lockout and test procedures?
Lockout all the sources necessary?
Y N
Y N
Y N
Use proper lockout devices? Y N
Knowledge & performance meets program requirements?
Lockout procedure was correct?
Y N
Y N
Deficiencies found:
__________________________________________________________
Authorized
Discipline Policy

Minor or Major Violation (Employee)
• Working under another employee’s lock
• Forgetting to remove your lock
• Minimum- 3-day suspension / Maximum- termination
Minor
or Major Violation (Supervisor of
Employee)
•Minimum- 5-day suspension / Maximum- termination

Blatant & Willful


Employee knowingly disregards
lockout procedure.
Employee will be terminated.
Exceptions to Discipline Policy
If the investigation determines that the
employee who was injured had received
all the appropriate training and had
demonstrated how to lock out the
equipment but willingly violated lockout
without the supervisor’s knowledge,
then discipline can be reduced or
eliminated.
LOTO is IMPORTANT to
YOU!!
59% of all accidents caused by a release of
energy during maintenance procedures resulted in
DEATH.
12% of all lockout-related injuries resulted in
AMPUTATION of some part of the body.
BETTER SAFE THAN SORRY…