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Lockout - Tagout

Lockout - Tagout. Subpart J. Fatal Five. Failure to stop equipment Failure to disconnect from power source Failure to dissipate (bleed, neutralize) residual energy Accidental restarting of equipment Failure to clear work areas before restarting. Scope and Application.

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Lockout - Tagout

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  1. Lockout - Tagout Subpart J

  2. Fatal Five • Failure to stop equipment • Failure to disconnect from power source • Failure to dissipate (bleed, neutralize) residual energy • Accidental restarting of equipment • Failure to clear work areas before restarting

  3. Scope and Application • Applies to general industry • Covers operators and service personnel

  4. When is LOTO Required? • Servicing or maintaining equipment where: • Hazardous energy exists • Unexpected start-up could occur • Either of these could harm an employee

  5. LOTO Shall Be Used When: • Employees are required to remove or bypass a safety device • Employees are required to place any part of their body in harm’s way • Employees are exposed to hazardous energy

  6. LOTO Exceptions • Work where hazardous energy does not exist • Activities performed during routine production processes • Work on cord-controlled devices • Hot tap operations where shutdown is not feasible

  7. Typical Equipment Requiring LOTO • Presses • Saws • Conveyors • Pumps • Production Equipment • Trash Compactors • Ovens

  8. Mechanical Chemical Thermal Hydraulic Pneumatic Electrical Gas Water Other stored energy (i.e. springs, capacitors) Energy Sources

  9. Affected Employees Employees who: • Operate • Work around • Occasionally adjust equipment that is subject to lockout tagout

  10. Authorized Employee • Maintains equipment • Services equipment • Is trained to use lockout tagout procedures

  11. Energy Control Program • Energy control procedures • Periodic inspections • Employee training

  12. Procedures • Must clearly and specifically outline the: • Scope • Purpose • Authorization • Rules • Lockout-tagout techniques • Means to enforce compliance

  13. Procedures • Statement of intended use of the procedure • Specific energy control steps for • Shutting down • Isolating • Blocking • Securing equipment

  14. Procedures • Specific steps for LOTO device • Placement • Removal • Transfer • Responsibility

  15. Procedures • Requirements for testing equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures

  16. Where to Begin • Conduct a hazard assessment by identifying each piece of equipment that is used, serviced, or maintained • Include broken or stored equipment • Determine the requirements for lockout • If there is more than one primary energy source to the equipment, document each source

  17. Where to Begin • Document all energy sources • Hidden • Direct • The hazard posed • The magnitude or measurable degree of danger • Special or unusual conditions • Proper isolations and devices

  18. Types of Lockout Devices • Locks • Blocks • Chains • Multilock hasps • Wheel valve covers • Ball valve covers

  19. Requirements For Lockout/Tagout Devices • Durable • Standardized • Substantial • Identifiable

  20. Periodic Inspections • At least annually • Ensure procedures are implemented properly • Ensure employees are familiar with their responsibilities • Correct any deviations or inadequacies identified

  21. Designating an Inspector • Periodic inspections must be performed by an authorized employee other than the one(s) using the energy control procedure • Who can inspect • Department manager • Plant management • Safety manager • Others

  22. Employee Reviews • Lockout • Review between the inspector and each authorized employee • Review each employee’s responsibility • Tagout • Review between the inspector and each authorized and affected employee • Review each employee's responsibility • Review the limitations of tags

  23. Inspection Certification • Must certify that the required periodic inspections have been performed • Certification must identify the following: • Equipment on which the energy control procedure was used • Date of the inspection • Employee(s) included in the inspection • Person performing the inspection

  24. Training Requirements • Authorized employees • initially and at least annually • Affected employees • at least initially • Authorized and affected • whenever changes are made to jobs or procedures • when program deficiencies are noted • Certification

  25. Authorized Employee Training • Purpose of the procedure • Recognition of applicable hazardous energy sources • Type and magnitude of the energy available in the workplace • Means and methods necessary for energy isolation and control • Ways to verify that energy isolation is effective

  26. Affected Employee Training • Instruction on the the purpose and use of the energy control system • Awareness

  27. Other Employee Training • All other employees (including new hires) whose work operations are or may be in an area where lockout/tagout may be utilized • Instruction must include: • Purpose of the procedure • Prohibition of starting or reenergizing any locked-out or tagged-out equipment they encounter

  28. Retraining • Authorized and affected employees • Change in job assignment • Change in equipment, machinery, or processes that presents a new hazard • Change in the lockout/tagout procedure

  29. Retraining Shall be conducted whenever a periodic inspection reveals, or the employer has reason to believe, that there are deviations from or inadequacies in the employee's knowledge or use of the lockout-tagout procedures

  30. Group Lockout/Tagout Procedure must afford the employees a level of protection equivalent to that provided by the implementation of a personal lockout-tagout device

  31. Group Lockout/Tagout • Primary responsibility is vested in an authorized employee who must: • ascertain the exposure status of individual group members • coordinate affected work forces (i.e. crews, departments, crafts)

  32. Group Lockout/Tagout • Each authorized employee must: • Affix a personal lockout-tagout device to the group lockout device or box when he/she begins work • Remove those devices when he/she stops working on the equipment being serviced or maintained

  33. Shift or Personnel Changes • Procedures must ensure: • Continuity of lockout/tagout protection • Orderly hand-off of lockout of lockout/tagout devices

  34. Testing or Positioning of Machines OSHA allows the temporary removal of locks or tags and the re-energization of the equipment only when necessary under special conditions – • for example, when power is needed for the testing or positioning of equipment

  35. Testing or Positioning of Machines • Must be conducted in following sequence: • Clear the equipment of tools and material • Vacate employees from the equipment area • Remove the lockout-tagout device as specified in the standard (the authorized employee who applied it must remove it) • Energize the equipment and proceed with testing or positioning • De-energize all systems, isolate the equipment from the energy source, and reapply the lockout-tagout devices

  36. Contractors • Must inform each other of all applicable lockout/tagout procedures • Both employer and contractor must ensure that their employees understand and will respect the other’s Energy Control Program

  37. Typical Shutdown Procedure • Notify affected employees • Use the specific procedures as outlined for the appropriate situation • Shut off energy source(s) to affected equipment • Use normal stopping or running procedures for the machine • Isolate the equipment from the energy source

  38. Typical Shutdown Procedures • Affix locks and tags to each energy source controlling device • Relieve all stored energy from capacitor banks, springs, compressed air, steam, hydraulics, etc. • Verify isolation of energy has occurred by trying equipment

  39. Removal of Lockout/Tagout and Start-Up Procedures • Ensure that nonessential items are removed from equipment • Ensure that equipment components are intact • Check area to ensure that all affected employees are safely positioned or removed from the area

  40. Removal of Lockout/Tagout and Start-Up Procedures • Notify all affected employees and site supervisor before reenergizing the equipment • Remove lockout/tagout devices • Reenergize equipment to ensure safe operation

  41. Summary • Accidents will happen • Equipment will occasionally malfunction • People will still make mistakes There is no excuse for serious injury that results from ignorance, carelessness, complacency, or lack of an Energy Control Program

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