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The Lock-Out / Tag-Out Program

The Lock-Out / Tag-Out Program. A Simple Reason Why…. LOTO Protects You. Use proper Lock-Out / Tag-Out procedures Please be careful when working on equipment. Case Study #1. Killed By The Moving Parts Of A Saw.

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The Lock-Out / Tag-Out Program

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  1. The Lock-Out / Tag-Out Program

  2. A Simple Reason Why…

  3. LOTO Protects You • Use proper Lock-Out / Tag-Out procedures • Please be careful when working on equipment

  4. Case Study #1 Killed By The Moving Parts Of A Saw Narrative: 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. Citation: Failure to Shutdown or Turn off Equipment To Perform Maintenance.

  5. Circumstances of Injury How Most Injuries Occur In Order Of Occurrence • Injured by Moving Machinery Part. • Made Contact With Energized Part. • Injured by Physical Hazard (Heat, Chemicals). • Injured by Falling Machine Part.

  6. Circumstances of Injury Activity At Time Of Accident Frequency Of Occurrence 1. Unjamming Object(S) From Equipment 2. Cleaning Equipment 3. Repairing Equipment 4. Performing Routine Maintenance 5. Installing Equipment

  7. Circumstances of Injury Activity At Time Of Accident Frequency Of Occurrence 6. Adjusting Equipment 7. Doing Set-up Work 8. Performing Electrical Work 9. Inspecting Equipment 10. Testing Materials

  8. Circumstances of Injury Reasons For Equipment Not Being Turned Off • Afraid of Slow Down in Production. • Afraid It Would Take Too Long. • Not Required by Company Procedure. • Worker Didn't Know Power Was on. • Worker Didn't Know How to Turn Off. • Did Not Think It Was Necessary. • Task Could Not Be Done With Power Off. ON OFF SYSTEM CONTROL SWITCH

  9. Circumstances of Injury Reasons For Equipment Being Turned On • Accidentally Turned on by Injured Employee • Co-Worker Accidentally Turned Equipment On • Equipment Moved When Jam-up Cleared • Equipment Unexpectedly "Cycled" • Parts Still in Motion (Coasting) ON OFF SYSTEM CONTROL SWITCH

  10. Definition of Employees • Authorized Employee • The Person Who Locks or Tags Out Machines To Perform Servicing or Maintenance. • Affected Employee • An Employee Whose Job Requires Him or Her To Operate or Use a Machine or Piece of Equipment On Which Servicing or Maintenance Is Being Performed.

  11. Definitions • Lock-Out / Tag-Out • The placement of a lock/tag on an energy isolating device, in accordance with an established procedure, to ensure that the energy isolating device and the equipment being controlled cannot be operated until the lock and tag is removed . • In addition to tag/lock out, the equipment must be blocked against motion and any residual energy removed. • Lock-Out Device • A device that utilizes a positive means such as a key lock to hold an energy isolating device in the safe position and prevents the energizing of equipment

  12. Definitions • De-Energized • Disconnected from all energy sources so no residual or stored energy. • Risk Assessment • Comprehensive evaluationof likelihood & extent of possible injury or damage, undertaken to choose proper safety precautions. • Energy Isolating Device • A mechanical Device That Physically Prevents The Transmission or Release of Energy. Examples include: circuit breakers, disconnect switches, slide gates, valves, blocks, and blind flanges. E-Stops-push button selector switches are not includedin isolation devices.

  13. Training Requirements • Authorized Employee • Recognition of Hazardous Energy Sources. • Type and Magnitude Energy Sources. • Energy Isolation and Control Methods.

  14. Training Requirements • Affected Employee • Purpose and Use of The Energy Control Program.

  15. Training Requirements • All Other Employees • Procedures and Prohibitions Relating To Attempts to • Restart or Reenergize Machines or Equipment Which Are • Locked Out or Tagged Out..

  16. Retraining Requirements • Authorized and Affected Employees • Retraining Provided When There Is a: • Change in Job Assignment. • Change in Machines, Equipment or Processes. • Change in Energy Control Procedures. • Close-Call Event. • Failure in the Procedures. • Reason to Doubt Employee Proficiency.

  17. Three Elements To The Program: 1. Energy Control Procedures 2. Employee Training 3. Periodic Inspections Energy Control Program

  18. Definition of Lockout Lockout Is Defined as: The Placement of a Lockout Device on an Energy Isolating Device, in Accordance With an Established Procedure, Ensuring That the Energy Isolating Device and the Equipment Being Controlled Cannot Be Operated Until the Lockout Device Is Removed.

  19. Lockout • Prevents release of hazardous energy • Lock placed on appropriate energy isolating device that is in the off or closed position

  20. Energy Isolating Device • Block • Line Valve • Disconnecting Switch • Manually Operated Switch • Any Other Device That Isolates Energy

  21. Types of Energy Sources • HYDRAULIC • PNEUMATIC • MECHANICAL • RADIOACTIVE • THERMAL • ELECTRICAL • CHEMICAL • WATER/GAS

  22. Types of Energy States ACTIVE ENERGY STORED ENERGY 110 VOLTS AC HOT SURFACE

  23. Types of Energy States • ACTIVE ENERGY • VOLTAGES • EXTERNAL PRESSURIZED LINE FEEDS TO THE • MACHINE

  24. Types of Energy States • STORED ENERGY • INTERNAL LINE PRESSURES • CAPACITORS • SURFACE TEMPERATURES • MECHANICAL TENSION (SPRINGS, ETC.) • COASTING OF PARTS • CHEMICAL (OPPOSING pH) • GRAVITY

  25. Mechanical Energy • Kinetic - machinery in motion • Gears • Belts • Potential - stored energy • Weights (gravity) & springs • Pistons under pressure • Hydraulic controls

  26. Potential Energy (Gravity)

  27. Activities Covered • NORMAL OPERATIONS: 1. Covered If an Employee Must Remove or Bypass Guards or Devices 2. Covered Where Employees Are Required to Put A Body Part in a Machine Process Area 3. Covered Where Employees Are Required to Put A Body Part in a Machine Having a Danger Zone

  28. Tag-out Requirements

  29. Tag-Out • Identifies problem • Identifies lockout date • Identifies person • Used by itself only when cannot be locked out

  30. Requirements if Tag-Out is Used • SOME KEY POINTS ABOUT TAGS: • Tags Are Only Warning Devices! • Tags Must Be Securely Attached! • May Evoke False Sense of Security! • Tags Do Not Provide Physical Restraint! • Tags Must Never Be Defeated or Ignored! • Must Withstand Environmental Conditions! • Tags Must Be Legible and Understandable! • Tags Are Only Removed by the Responsible • Person.

  31. Lock-Out Sequence of Events 1. Preparation for Shutdown 2. Shutdown 3. Machine or Equipment Isolation 4. Application of Lockout/Tagout Devices 5. Testing of LO/TO 6. Servicing or Maintenance 7. Removal of LO/TO Devices 8. Re-energization 9. Equipment Reactivation

  32. 1. Prepare • Plan your work & locate instructions • Understand equipment hazards • Notify others of shutdown

  33. 2. Shutdown • Turn all switches to OFF • Normal shutdown procedure • Shut all control valves

  34. 3. Isolate Sources • Disable all energy sources • Shut valves • Open breakers & disconnects

  35. 4. Apply Locks • Valves • Breaker & electrical disconnects • Block or disconnect all lines

  36. Lockout Devices • Electrical • Hydraulic • Pneumatic • Plug locks • Ball valve • Gate valve • Hasp

  37. Use of Locks • Use only locks issued to you – lock all energy isolation gear • Never use another workers lock or tag • Tell supervisor if you need more LOTO equipment

  38. 5. Verification • Prior to servicing or maintenance, authorized employee must verify that equipment is isolated by turning it on • To Verify: The process of operating the start controls, engaging levers, measuring voltage, inspecting lockout devices valves,disconnect switches, blades, piping systems in an area to make sure that all energy sources have been isolated and controlled.

  39. 6. Control Stored Energy • Block or release springs or other tension • Block elevated parts • Stop rotating flywheels • Relieve system pressure • Drain fluids • Vent gases

  40. 7. Prepare for Startup • Put all guards back • Remove tools • Inform others of startup • Restore system connections • Remove locks & tags • Restore equipment to normal • Conduct normal startup

  41. Who Can Remove Locks/Tags? • Only the employee who placed the lock and/or tag • A supervisor, after obtaining permission from the worker who placed the tag

  42. Written Program Requirements All Employers Must: • Maintain a Written Program. • Review the Program on an Annual Basis. • Develop Detailed Energy Control Procedures. • Review Individual LO/TO Procedures Annually. • Make the Written Program Available to all Affected Employees During Each Work Shift.

  43. Energy Control Procedures Procedures Must Contain: 1. Statement of Intended Use. 2. Steps for Shut-Down and Energy Control. 3. Steps for LO/TO Device Placement, Transfer and Removal. 4. Determination of Responsibility. 5. Steps for Testing LO/TO.

  44. Exceptions to the Requirement Exceptions to the Requirement to have written LOTO Procedures All Of The Following Eight Conditions Must Exist: • No Potential for Residual, Stored or Reaccumulation of Energy. • Contains Only One Energy Source Which Is Readily Identified and Isolated. • Isolating & Locking Out Results in Complete De-Energization. • 4. The Machine or Equipment Is Isolated or Locked Out During Maintenance.

  45. Exceptions to the Requirement 6. The Lockout Device Is Under Exclusive Control Of An Authorized Employee 7. Servicing/Maintenance Does Not Produce Hazards For Other Employees 8. No Previous Energy Control Accident History Exists for the Employer

  46. Lock-Out Program Elements • ID hazardous energy covered by program • ID types of energy isolating/de-energizing devices

  47. Energy Control Procedures • Annual Inspections Must Include: • DATE OF INSPECTION • IDENTIFICATION OF MACHINE OR EQUIPMENT • EMPLOYEES INCLUDED IN INSPECTION • PERSON PERFORMING INSPECTION

  48. Release From Lock-Out/Tag-Out The Authorized Employee Must: 1. INSPECT WORK AREA FOR HAZARDS 2. CLEAR ALL EMPLOYEES 3. NOTIFY ALL AFFECTED EMPLOYEES 4. REMOVE ENERGY ISOLATING DEVICES

  49. Important Points to Remember • WHERE LOCKOUT CAN BE USED: • IT MUST BE* • WHERE LOCKOUT CANNOT BE USED: • TAGOUT PROCEDURES MUST BE INITIATED • * (Unless It Can Be Demonstrated That Full Protection Can Be Achieved by Other Means)

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