safety & health consultation office of safety & health consultation presents control of...

Safety & Health Consultation

Office of Safety & Health Consultation

presents

Control of Energy SourcesLockout/Tagout

(LOTO)

Control of Energy SourcesLockout/Tagout

(LOTO)

NUMBER OF SERIOUS VIOLATIONS – FY 2014

GENERAL ENVIRONMENT CONTROLS [1910.141 – 147]

LOCKOUT/TAGOUT – DEVELOPED PROCEDURES

LOCKOUT/TAGOUT – PROGRAM

LOCKOUT/TAGOUT – PERIODIC INSPECTIONS

SUBPART J

LOCKOUT/TAGOUT – GENERAL TRAINING

LOCKOUT/TAGOUT – SPECIFIC/ENFORCEMENT OF PROCEDURES147(c)(4)(ii)

147(c)(7)(i)

147(c)(6)(i)

147(c)(1)

147(c)(4)(i)

ScopeScope

• Covers the servicing and/or maintenance of machines where the unexpected start-up or release of stored energy could cause injury– Installation and set-up

– Adjustment or maintenance

– Inspection

– Modification

– Routine service1910.147(a)(1)

PurposePurpose

• Establish a program and utilize

procedures for affixing

appropriate lockout devices or

tagout devices to energy

isolating devices

• Prevent unexpected

energization, start up or release

of stored energy in order to

prevent injury to employees

1910.147(a)(3)

Safety & Health Consultation 5

ObjectiveObjective

• Participants will understand– Safe application, usage & removal of energy

controls– Prohibitions on restarting/reenergizing

machines– Selection & use of PPE

ExemptionsExemptions

• Construction, agriculture and maritime employment;

• Electrical Utilities;

• Exposure to electrical hazards from work on, near, or

with conductors or equipment in electric utilization

installations, which is covered by Subpart S of this

part; and

• Oil and gas well drilling and servicing

1910.147(a)(1)

General RequirementsGeneral Requirements• The employer shall establish a program consisting of:

– Energy control procedures,

– Employee training and,

– Periodic inspections

• To ensure that before any employee performs any

servicing or maintenance on a machine or equipment

where the unexpected energizing, startup or release of

stored energy could occur and cause injury, the machine

or equipment shall be isolated from the energy source and

rendered inoperative.1910.147(c)

General RequirementsGeneral Requirements

• "Energy control procedure.”

• Procedures shall be developed, documented and

utilized for the control of potentially hazardous

energy when employees are engaged in the activities

covered by this section.

1910.147(c)(4)

ExceptionException

The employer need not document the

required procedure for a particular

machine or equipment when all eight (8)

of the following elements exist:

1910.147(a)(2)

ExceptionException

1. The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees

2. The machine or equipment has a single energy source which can be readily identified and isolated

3. The isolation and locking out of that energy source will completely deenergize and deactivate the machine or

equipment 4. The machine or equipment is isolated from that energy source

and locked out during servicing or maintenance

1910.147(a)(2)

ExceptionException

5. A single lockout device will achieve a lock-out condition

6. The lockout device is under the exclusive control of the

authorized employee performing the servicing or maintenance

7. The servicing or maintenance does not create hazards for

other employees; and

8. The employer, in utilizing this exception, has no accidents

involving the unexpected activation or reenergization of the

machine or equipment during servicing or maintenance

1910.147(a)(2)

DefinitionsDefinitions

• Affected employee– Works in an area in which servicing or

maintenance operations are performed and LOTO is implemented

– Does not perform service or maintenance on equipment

– Is not responsible for LOTO

1910.147(b)

• Authorized employee– Performs LOTO in order to service or maintain

equipment

– Capable of being locked out

1910.147(b)

• Other employees – Other employees whose work operations are,

or may be, in area where energy control procedures may be utilized

1910.147(c)(7)

Protection Against HazardsProtection Against Hazards

• Three methods–Engineering Controls–Administrative Controls–Personal Protective Equipment

Note: Other OSHA regulations may be linked such as Electrical Safety, Confined Space, HAZCOM .

Lockout/TagoutLockout/Tagout

Energy control (LOTO) shall be used whenever authorized employees are servicing machines and equipment, in which the unexpected start-up or the release of stored energy could cause injury.

Lockout/TagoutLockout/Tagout

LOTO is not required when servicing or maintaining cord and plug connected equipment that is unplugged from the energy source during the servicing or maintenance operation, provided the cord/plug is under exclusive control of person performing the operation.

1910.147(a)(2)

Types of Hazardous EnergyTypes of Hazardous Energy

• Electrical

• Mechanical

• Pneumatic

• Hydraulic

• Chemical

• Thermal

• Force of Gravity

The “Fatal Five” Main Causes of Lockout/Tagout Injuries

• Failure to stop equipment• Failure to disconnect from all power sources• Failure to dissipate (bleed, neutralize) residual

energy

The “Fatal Five” Main Causes of Lockout/Tagout Injuries

• Accidental restarting of equipment• Failure to clear work areas before restarting

Lockout RequirementsLockout Requirements

• Lockout devices shall be:– Unique and readily identifiable as a LOTO

device.– Substantial enough to prevent removal without

excessive force or unusual techniques, such as the use of metal snips and/or bolt cutters.

1910.147(c)(5)

Tagout RequirementsTagout Requirements

• General use of Tagout– Tagout shall be used only when an energy-

isolating device cannot be physically locked out– When tagout is the only method, all the steps of

the LOTO method shall be observed except for the lock itself

1910.147(c)(2)

Tagout DevicesTagout Devices

• Tagout devices must be:– Substantial enough to prevent inadvertent

removal.– Readily identifiable as a LOTO device.– Weather resistant.– Attachable by hand and self-locking with a

break-away strength of 50 lbs.

1910.147(c)

General ApplicationGeneral Application

• Before starting the job, the following conditions must exist– The isolation of locking out of the equipment

will completely deenergize and deactivate the equipment

– The lockout device is under the exclusive control of the authorized employee performing the service

1910.147(d)

General ApplicationGeneral Application

– The servicing doesn’t create hazards for other employees

– The servicing has not caused any prior incidents at the facility

Note: If these conditions cannot be satisfied, a separate equipment specific LOTO procedure must be followed.

1910.147(d)

The LOTO ProcedureThe LOTO Procedure

• Notify all affected employees by the shutdown before the task is begun

• Shutdown the equipment• Isolate the equipment from any energy

source• Lockout/tagout the energy isolation devices

with approved locks/tags

1910.147(d)

• Release the stored energy– Valves, springs, capacitors, or other means

• Verify a “zero energy” state– Ensure that the means of releasing energy was

successful

• Perform required service– Remember to comply with other applicable safety

programs such as, Hot Work, Fire Protection Systems Impairment, Confined Space, etc.

1910.147(d)

• Lockout/tagout device removal– The authorized employee who attached the device must

remove it• Authorized employee not available, the Employer:

– Must verify that the authorized employee is not in facility.

– Make all reasonable efforts to contact him/her, – Must ensure that authorized employee will be informed

of the removal prior to beginning work at that facility upon their return.

1910.147(e)

• Remove unnecessary tools from the work area and make sure everyone is clear of the equipment

• Remove lockout/tagout devices and re-energize the system

• As soon as the energy is no longer needed, isolate the equipment and re-apply lockout/tagout, using the six step procedure.

1910.147(f)

The LOTO ProcedureThe LOTO Procedure• Notify affected employees after LOTO device is

removed, and they shall be notified that the equipment is being returned to service.

• Restoring equipment to service:– Check equipment and the immediate area to ensure

removal of non-essential items and tools.– Check work area to ensure all employees have been

removed or safely positioned.– Verify equipment controls are in neutral position.

1910.147(f)

Electrical LockoutElectrical Lockout

• All electrical circuits are considered “hot” until:– All sources of energy are removed.– The disconnecting means are locked/tagged out.– An approved device verifies the absence of voltage.– Temporary grounding is in place when there is

exposure to energized facilities

• Electrical circuits shall always be treated in a safe manner, using practices that match the voltage and energy level of the unit.

Electrical LockoutElectrical Lockout• Whenever electrical work is scheduled, the

following is required:– Identify the power source disconnect .– Deenergize the power source.– Attach a lock and a Red Danger Tag to the controlling

device.DANGER

DO NOTOPERATE

DANGER

DO NOTOPERATE

This lock/ tag may only beremoved by:

Name ____________________

Dept. _____________________

Expected Completion _______

The energy source has beenLOCKED OUT. Unauthorizedremoval of this lock / tag may resultin immediate discharge.

Remarks: _________________

_________________________________________________________________________________

Sect ion 9 .1 Cont rol of Ha zardous Energy (LOTO) Page 1 of 1

Re vision D8 R evi sion Date : 9-22-98

RED DANGER TAG

• If more than one authorized employee doing work:– Each employee attaches their own Red Danger Tag

before commencing work.

DANGER

DO NOTOPERATE

DANGER

DO NOTOPERATE

Name ____________________

Dept. _____________________

Remarks: _________________

_________________________________________________________________________________

Sect ion 9 .1 Cont rol of Ha zardous Energy (LOTO) Page 1 of 1

Re vision D8 R evi sion Date : 9-22-98

RED DANGER TAG

• Prior to beginning equipment work:– Test voltmeter on known circuit to verify working

order.– Test equipment on the downstream/tagged out side of

the controlling device.– If equipment is wired directly to breaker box, test

downstream of the box actuator device.

• Try to start equipment as a test• Inspect & test controls to verify that circuit

is locked and NOT just temporarily inoperative due to an electrical or mechanical interlock

Fixed Piping Systems LockoutFixed Piping Systems Lockout

• Breaking into a pressurized piping system:– Shutter valves must be locked out– Vent valves must be locked open– Pipes must be drained with the valves properly

tagged

• A valve is locked out when:– It has a valve handle locking device and/or,

– The valve chain is locked.

• Equipment systems powered by piping are considered locked out when the disconnect is:– Removed from the supply line.– Cleared and tested.– Tagged with a Red Danger Tag, as though a

lock is in use.DANGER

DO NOTOPERATE

DANGER

DO NOTOPERATE

Name ____________________

Dept. _____________________

Remarks: _________________

_________________________________________________________________________________

Sect ion 9 .1 Cont ro l of Ha zardous Energy (LOTO) Page 1 of 1

Re visi on D8 R evi sion Date : 9-22-98

RED DANGER TAG

When the system is down the deenergized equipment must be checked to ensure that it is inoperable or if pressurized it has been drained of contents on the downstream side.

• Pressurized systems must be:– Be flushed out with water if it contained

liquids.– Be flushed with an inert gas if it contained

compressed gases.

Note: MSDSs must be reviewed for any

additional safety procedures that may be required

Appropriate air testing must be done whenever the pressurized systems have contained hazardous gases or liquids, especially when welding or burning operations have been involved.

• When locking off a pressurized system:– Blanks are preferable to valving off– Double valves are preferred with drain cocks

between the valves

Note: MSDSs must be reviewed for any additional safety procedures that may be required when working with chemicals.

General InformationGeneral Information• Never attempt lockout/tagout procedures unless

you have been trained and certified by your employer under an approved Energy Control (LOTO) Program.

• Never loan or share your lock, combination, or key with anybody else.

• Always be sure all lockout/tagout devices are compatible with the environment in which they will be used i.e. corrosive, humid, etc.

Safety & Health Consultation 51

Review ObjectiveReview Objective

• Participants will understand– Safe application, usage & removal of energy

controls– Prohibitions on restarting/reenergizing

machines– Selection & use of PPE

Your Questions?Your Questions?

presents

Control of Energy SourcesLockout / Tagout

(LOTO)

Control of Energy SourcesLockout / Tagout

(LOTO)

safety & health consultation office of safety & health consultation presents control of...

residual energy

hazardous energy

release of stored energy

energy control procedures

single energy source

particular machine

employeesthe machine

single lockout device

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