Lockout / TagoutLockout / Tagout

““Control of Control of Hazardous Energy” Hazardous Energy” 29 CFR 1910.14729 CFR 1910.147

Cummins Rocky Cummins Rocky MountainMountain

Purpose of Purpose of Lockout/Tagout (LOTO)Lockout/Tagout (LOTO)

WHY LOCKOUT/TAGOUT?WHY LOCKOUT/TAGOUT?

Cummins Rocky Mountain LOTO Cummins Rocky Mountain LOTO procedures are designed to prevent procedures are designed to prevent accidents, to protect employees and accidents, to protect employees and equipment from accidental start-up.equipment from accidental start-up.

The “Fatal Five” Main The “Fatal Five” Main Causes of Causes of Lockout/Tagout InjuriesLockout/Tagout Injuries• Failure to stop equipmentFailure to stop equipment

• Failure to disconnect from power Failure to disconnect from power sourcesource

• Failure to dissipate (bleed, neutralize) Failure to dissipate (bleed, neutralize) residual energyresidual energy

• Accidental restarting of equipmentAccidental restarting of equipment

• Failure to clear work areas before Failure to clear work areas before restartingrestarting

Employee CategoriesEmployee CategoriesAUTHORIZED EMPLOYEESAUTHORIZED EMPLOYEES

These are employees who are allowed to perform energy control These are employees who are allowed to perform energy control procedures. Training will include company approved energy control procedures. Training will include company approved energy control procedures, recognition of energy sources, and methods for isolation procedures, recognition of energy sources, and methods for isolation and energy control.and energy control.

AFFECTED EMPLOYEESAFFECTED EMPLOYEES

These are employees that operate the equipment on which work is being These are employees that operate the equipment on which work is being performed. Training will include the purpose and use of the energy performed. Training will include the purpose and use of the energy control procedures.control procedures.

OTHER EMPLOYEESOTHER EMPLOYEES

These are all other employees that may work in an area where energy These are all other employees that may work in an area where energy control procedures may be used. Training will include instruction on the control procedures may be used. Training will include instruction on the energy control procedures and the restrictions relating to attempting to energy control procedures and the restrictions relating to attempting to restart or reenergize equipment that is either locked out or tagged out.restart or reenergize equipment that is either locked out or tagged out.

Hazardous Energy SourcesHazardous Energy Sources

• CHEMICAL – acids, corrosives, causticsCHEMICAL – acids, corrosives, caustics

• THERMAL – steam, hot, coldTHERMAL – steam, hot, cold

• HYDRAULIC – water, oil, liquidsHYDRAULIC – water, oil, liquids

• ELECTRICAL – AC/DC, generator, batteryELECTRICAL – AC/DC, generator, battery

• MECHANICAL – coiled springs, raised loads, MECHANICAL – coiled springs, raised loads, moving partsmoving parts

• PNEUMATIC – pressurized gas, compressed airPNEUMATIC – pressurized gas, compressed air

Equipment Requiring Equipment Requiring Lockout/Tagout at our Lockout/Tagout at our

FacilityFacility

• 5 Ton Crane5 Ton Crane

• Air CompressorAir Compressor

• Bead BlasterBead Blaster

• Chassis DynoChassis Dyno

• Drill PressDrill Press

• Fuel Pump Test StandFuel Pump Test Stand

• HotsyHotsy

• Injector Test StandInjector Test Stand

LOTO Definitions and LOTO Definitions and RequirementsRequirements

• LOTO is defined as the process of the LOTO is defined as the process of the authorized placement and administrative authorized placement and administrative control of locks and tags used to ensure control of locks and tags used to ensure the protection of employees, equipment, the protection of employees, equipment, and the environment.and the environment.

• LOTO locks are used for physical control LOTO locks are used for physical control over an energy isolation device.over an energy isolation device.

Energy Isolation DevicesEnergy Isolation Devices

• Used to control and isolate hazardous energy. They Used to control and isolate hazardous energy. They are mechanical devices that physically are mechanical devices that physically preventprevent the the transmission or release of energy.transmission or release of energy.

– circuit breakerscircuit breakers

– disconnect switchesdisconnect switches

– valvesvalves

• Energy isolation devices are where we place the Energy isolation devices are where we place the locks and tags. They are NOT locks or tags. These locks and tags. They are NOT locks or tags. These are the devices that prevent the transmission of are the devices that prevent the transmission of hazardous energy to the equipment that requires hazardous energy to the equipment that requires work to be performed.work to be performed.

ON OFF

SYSTEMCONTROLSWITCH

Only individual circuit breakers can be locked Only individual circuit breakers can be locked out in a circuit breaker. If the whole panel was out in a circuit breaker. If the whole panel was locked, circuits powering other equipment locked, circuits powering other equipment would be inaccessible.would be inaccessible.

LocksLocks

• All our locks and tags for LOTO are All our locks and tags for LOTO are standardized by shape, size or colorstandardized by shape, size or color

• Personally Controlled LockPersonally Controlled Lock– Owner has only keyOwner has only key

– No master key is allowedNo master key is allowed

Hardware for LOTOHardware for LOTO

• Locks/TagsLocks/Tags

• Locking plug capsLocking plug caps

• ChainsChains

• WedgesWedges

• BlocksBlocks

• BlanksBlanks

Locks vs TagsLocks vs Tags

• Locks are used to block the flow of Locks are used to block the flow of energy.energy.

• Tags are a warning to all employees Tags are a warning to all employees not to turn the power on.not to turn the power on.

Lockout vs TagoutLockout vs Tagout

• OSHA prefers lockout.OSHA prefers lockout.

• If an energy isolation device will accept a If an energy isolation device will accept a lock, you MUST use a lock.lock, you MUST use a lock.

• In situations where a lock cannot be used, In situations where a lock cannot be used, you may use a tag only. A tag does not you may use a tag only. A tag does not provide the positive control of a lock. So provide the positive control of a lock. So it is important that we are all aware of the it is important that we are all aware of the limitations of a tag. limitations of a tag.

TagoutTagout

• CAN BE USED in place of lockout if you can demonstrate CAN BE USED in place of lockout if you can demonstrate that it will offer employee protection that it will offer employee protection equivalentequivalent to that to that offered by lockout.offered by lockout.

• Equivalent protection is demonstrated by the following Equivalent protection is demonstrated by the following safety measures:safety measures:

– Removing an isolating circuit element;Removing an isolating circuit element;

– Blocking a control switch;Blocking a control switch;

– Opening an extra disconnecting device; orOpening an extra disconnecting device; or

– Removing a valve handle.Removing a valve handle.

• The tag must be attached at the same spot where the The tag must be attached at the same spot where the lockout device would have been found.lockout device would have been found.

LOCKEDOUT

This Lock/Tag mayonly be removed by

NAME: _______________DEPT : _______________EXPECTED COMPLETIONDATE: ________________TIME: _________________

DO NOT OPERATE

DANGER

Examples of tags we use.

Tag Characteristics:Tag Characteristics:•Withstand at least 50 pounds of forceWithstand at least 50 pounds of force•Not re-usable Not re-usable •Self lockingSelf locking•Attachable by handAttachable by hand

Applying Locks and TagsApplying Locks and Tags

• LOTO devices are to be attached by an authorized LOTO devices are to be attached by an authorized employee to each energy-isolating device.employee to each energy-isolating device.

• When a lockout device is used, it must be attached in When a lockout device is used, it must be attached in such a way that it secures the energy isolating device in such a way that it secures the energy isolating device in the “off” position.the “off” position.

• When a tagout device is used, it must be attached When a tagout device is used, it must be attached exactly where the lock would have been on the energy-exactly where the lock would have been on the energy-isolation device-or as close to that point and in as isolation device-or as close to that point and in as obvious a position as possible. The tag must clearly obvious a position as possible. The tag must clearly indicate that the energy-isolation device must not be indicate that the energy-isolation device must not be disturbed. (The tag should read DO NOT START, DO disturbed. (The tag should read DO NOT START, DO NOT OPEN, or DO NOT ACTIVATE)NOT OPEN, or DO NOT ACTIVATE)

LOTO is NOT Required LOTO is NOT Required When:When:• Work is performed in cord and plug electrical Work is performed in cord and plug electrical

equipment on which the plug is under equipment on which the plug is under EXCLUSIVE CONTROL of the employee EXCLUSIVE CONTROL of the employee performing the service or maintenance.performing the service or maintenance.

– Note: exclusive control means that the plug Note: exclusive control means that the plug is:is:• Physically in possession of or within Physically in possession of or within

arm’s reach of the person who performs arm’s reach of the person who performs the work, andthe work, and

• In that person’s line of sight.In that person’s line of sight.

• Minor tool changes, when the on/off switch is Minor tool changes, when the on/off switch is under EXCLUSIVE CONTROL of the operator. under EXCLUSIVE CONTROL of the operator.

• For Example…For Example…

…Pedestal grinders

However, if you cannot immediately repair the ‘plug However, if you cannot immediately repair the ‘plug and cord’ equipment, it should be LOTO to prevent and cord’ equipment, it should be LOTO to prevent unintended startup. The above picture shows the plug unintended startup. The above picture shows the plug to a pedestal grinder. Since the employee couldn’t to a pedestal grinder. Since the employee couldn’t repair it until the parts arrived, a LOTO plug cap placed repair it until the parts arrived, a LOTO plug cap placed was used.was used.

LOTO Shutdown LOTO Shutdown ProcedureProcedure

Steps to Apply LOTOSteps to Apply LOTO1.1. Notification of employees involved or in the area and Notification of employees involved or in the area and

you will be shutting equipment down.you will be shutting equipment down.

2.2. Shutdown of all power sources. You may need to Shutdown of all power sources. You may need to stop, block, or bleed the energy sources.stop, block, or bleed the energy sources.

3.3. Lockout and Tagout all energy sources. Verify the Lockout and Tagout all energy sources. Verify the controls do not start machine and check the voltage.controls do not start machine and check the voltage.

4.4. Verification among employees once the work has Verification among employees once the work has been completed.been completed.

• Inspect work area to ensure removal of non-essentialsInspect work area to ensure removal of non-essentials• Employees safely positioned and notifiedEmployees safely positioned and notified• Lockout/tagout removal (by employee who applied)Lockout/tagout removal (by employee who applied)

Removal of Locks/TagsRemoval of Locks/Tags

• Only the maintenance employee performing Only the maintenance employee performing the original repair can remove a lock.the original repair can remove a lock.

• If employee is off-site, the supervisor may If employee is off-site, the supervisor may remove the lock under the following remove the lock under the following conditions.conditions.– Verify that authorized employee is not at facilityVerify that authorized employee is not at facility

– Make reasonable efforts to inform him or herMake reasonable efforts to inform him or her

– Ensure that he/she knows of removal upon re-Ensure that he/she knows of removal upon re-enteringentering

Group LockoutGroup Lockout

• Each employee performing LOTO Each employee performing LOTO work on equipment will have his/her work on equipment will have his/her own lock and tag at the energy own lock and tag at the energy isolation devices.isolation devices.– When multiple employees are working When multiple employees are working

on the equipment, a hasp may be on the equipment, a hasp may be used.used.

Equipment Start-UpEquipment Start-Up

• Clear equipment of tools and Clear equipment of tools and materialsmaterials

• Re-install all guardsRe-install all guards

• Alert employees to stand clearAlert employees to stand clear

• Remove locks/tagsRemove locks/tags

• Energize equipmentEnergize equipment

Remember to re-Remember to re-install all guards install all guards after service is after service is complete!!!!! complete!!!!! Otherwise, a Otherwise, a serious hazard serious hazard may be created.may be created.

Lockout/TagoutLockout/Tagout

If you have any questions on If you have any questions on Lockout/Tagout, contact your Lockout/Tagout, contact your supervisor or submit a question supervisor or submit a question using the “ASK THE EXPERT” menu using the “ASK THE EXPERT” menu selection on this website.selection on this website.

All lockout/tagout procedures are All lockout/tagout procedures are found through the link to Lockout / found through the link to Lockout / Tagout link on the Cummin’s safety Tagout link on the Cummin’s safety website.website.