Lockout/TagoutLockout/Tagout

By: By:

Brice MoellerBrice Moeller

OverviewOverview What lockout is What lockout is

– Lockout is a technique used to prevent the release of hazardous Lockout is a technique used to prevent the release of hazardous energy, or to prevent the hazardous energy from escaping.energy, or to prevent the hazardous energy from escaping.

Go over a list of hazardous energy sources Go over a list of hazardous energy sources – Electrical Electrical – Mechanical Mechanical – Thermal Thermal – Potential Potential

Types of lockout devices Types of lockout devices – Plug Locks Plug Locks – Ball Valve LockoutBall Valve Lockout– Gate Valve LockoutGate Valve Lockout– Group Lockout HaspGroup Lockout Hasp– ElectricalElectrical

Overview Overview (continued)(continued)

When to lock out a machine When to lock out a machine – RepairsRepairs– ServicingServicing– MaintenanceMaintenance– Tool Changes Tool Changes

An example of what a placard will look like An example of what a placard will look like Special situations concerning lockout Special situations concerning lockout

– Servicing more than one shift Servicing more than one shift – Worker who applied the lock is not availableWorker who applied the lock is not available

Lockout/TagoutLockout/TagoutLockout/TagoutLockout/Tagout

Covers the servicing and maintenance of Covers the servicing and maintenance of equipment where the unexpected equipment where the unexpected energization or start up of equipment, or energization or start up of equipment, or release of stored energy could cause release of stored energy could cause injuryinjury

Establishes the OSHA minimum Establishes the OSHA minimum requirements for controlling hazardous requirements for controlling hazardous energyenergy

LockoutLockout

Lockout is a technique used to prevent the Lockout is a technique used to prevent the release of hazardous energy, or to prevent the release of hazardous energy, or to prevent the hazardous energy from escaping.hazardous energy from escaping.

A padlock is placed on the appropriate energy A padlock is placed on the appropriate energy isolating device that is in the off or closed isolating device that is in the off or closed position.position.

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

Failure to stop equipmentFailure to stop equipment Failure to disconnect from power sourceFailure to disconnect from power source Failure to dissipate (bleed, neutralize) residual Failure to dissipate (bleed, neutralize) residual

energyenergy Accidental restarting of equipmentAccidental restarting of equipment Failure to clear work areas before restartingFailure to clear work areas before restarting

Statistics Statistics on LOTO Injurieson LOTO Injuries

82% - Failure to completely isolate, block, 82% - Failure to completely isolate, block, and or dissipate the energy source(s)and or dissipate the energy source(s)

11% - Failure to lockout or tagout energy 11% - Failure to lockout or tagout energy control devices and isolation points after de-control devices and isolation points after de-energizationenergization

7% - Failure to verify that the energy source 7% - Failure to verify that the energy source was de-energized before beginning workwas de-energized before beginning work

DefinitionsDefinitions Authorized Employee:Authorized Employee:

One who locks out machines or equipment in order to One who locks out machines or equipment in order to perform the servicing or maintenance on that machine or perform the servicing or maintenance on that machine or equipment.equipment.

Affected Employee:Affected Employee: One whose job requires him/her to operate or use a One whose job requires him/her to operate or use a

machine or equipment on which servicing or maintenance machine or equipment on which servicing or maintenance is being performed under lockout, or whose job requires is being performed under lockout, or whose job requires him/her to work in an area in which such servicing or him/her to work in an area in which such servicing or maintenance is being performed.maintenance is being performed.

DefinitionsDefinitions (continued)(continued)DefinitionsDefinitions (continued)(continued)

Lockout device:Lockout device:– A device that utilizes a positive means such as a lock either A device that utilizes a positive means such as a lock either

key or combination type, to hold an energy isolating device key or combination type, to hold an energy isolating device in the safe position and prevents the energizing of a in the safe position and prevents the energizing of a equipmentequipment

Tagout device:Tagout device:– A warning device, such as a tag and a means of attachment A warning device, such as a tag and a means of attachment – Can be securely fastened to an energy isolating device in Can be securely fastened to an energy isolating device in

accordance with an established procedure to indicate that accordance with an established procedure to indicate that the energy isolating device and the equipment being the energy isolating device and the equipment being controlled can not be operated until the tag is removedcontrolled can not be operated until the tag is removed

Definitions Definitions (continued)(continued)

Lockout/Tagout Procedure - Safety program Lockout/Tagout Procedure - Safety program adopted by the employer that includes energy adopted by the employer that includes energy control procedures plus provisions for control procedures plus provisions for inspecting the procedures and training inspecting the procedures and training employees for lockout/tagout.employees for lockout/tagout.

Hazardous Energy Sources Found in Hazardous Energy Sources Found in the Workplacethe Workplace

ElectricalElectrical GeneratedGenerated StaticStatic

MechanicalMechanical TransitionalTransitional RotationalRotational

ThermalThermal Machines or EquipmentMachines or Equipment Chemical ReactionsChemical Reactions

PotentialPotential PressurePressure

HydraulicHydraulicPneumaticPneumaticVacuumVacuum

SpringsSprings GravityGravity

Types of Lockout DevicesTypes of Lockout Devices Plug LocksPlug Locks Ball Valve LockoutBall Valve Lockout Gate Valve LockoutGate Valve Lockout Group Lockout HaspGroup Lockout Hasp

ElectricalElectrical Hydraulic, pneumatic, Hydraulic, pneumatic,

and other pressurized and other pressurized systemssystems

Lockout/Tagout DevicesLockout/Tagout DevicesLockout/Tagout DevicesLockout/Tagout Devices

DurableDurable– All devices must be capable of withstanding the workplace All devices must be capable of withstanding the workplace

environment.environment.– All tags and their means of attachment must be sturdy All tags and their means of attachment must be sturdy

enough to prevent inadvertent removalenough to prevent inadvertent removal SubstantialSubstantial

– Removal of lockout devices should be extremely difficult Removal of lockout devices should be extremely difficult to remove, requiring the use of excessive force and the help to remove, requiring the use of excessive force and the help of tools such as bolt cuttersof tools such as bolt cutters

– Tagout devices and their attachments must be tough Tagout devices and their attachments must be tough enough so that they can’t be accidentally removedenough so that they can’t be accidentally removed

Lockout Lockout Lockout Lockout

Lockout is a more appropriate means of Lockout is a more appropriate means of ensuring deenergization of equipment than ensuring deenergization of equipment than tagouttagout

If an energy-isolating device can’t be locked If an energy-isolating device can’t be locked out, tagout may be usedout, tagout may be used– Tagout may be used in place of lockout if it can be Tagout may be used in place of lockout if it can be

demonstrated that it will offer equivalent demonstrated that it will offer equivalent protection to that offered by lockoutprotection to that offered by lockout

TagoutTagoutTagoutTagout

When only a tag is used because equipment When only a tag is used because equipment cannot be locked out, the following steps must cannot be locked out, the following steps must be taken:be taken:– Removing an isolating circuit element (fuses)Removing an isolating circuit element (fuses)– Block machine (control switch, die)Block machine (control switch, die)– Opening an extra disconnecting deviceOpening an extra disconnecting device– Other means of isolationOther means of isolation

Tagout Tagout (continued)(continued)Tagout Tagout (continued)(continued)

Tags must be placed where the lockout device Tags must be placed where the lockout device would have been placed would have been placed

A legend must be used such as: A legend must be used such as: – Do not startDo not start– Do not openDo not open– Do not closeDo not close– Do not energizeDo not energize– Do not operate Do not operate

Tagout LimitationsTagout LimitationsTagout LimitationsTagout Limitations

Tags are attached to energy isolation devices, Tags are attached to energy isolation devices, but they are but they are only warningsonly warnings. .

They do not provide the protection offered by They do not provide the protection offered by a lockout procedurea lockout procedure

A tag is never to be bypassed or ignored, and it A tag is never to be bypassed or ignored, and it may not be removed without the specific may not be removed without the specific authorization of person responsible for itauthorization of person responsible for it

Tagout LimitationsTagout Limitations (continued)(continued)Tagout LimitationsTagout Limitations (continued)(continued)

Tags must be clearly visible and easily Tags must be clearly visible and easily understandable by any employee who may be understandable by any employee who may be in the areain the area

Tags and their attaching materials must be able Tags and their attaching materials must be able to withstand any adverse environmental to withstand any adverse environmental conditions in the workplaceconditions in the workplace

When to Lockout a MachineWhen to Lockout a Machine

A machine must be locked out when doing any A machine must be locked out when doing any of the following: of the following: – RepairsRepairs– ServicingServicing– MaintenanceMaintenance– Tool Changes Tool Changes

Basic Basic Lockout ProcedureLockout Procedure

1.1. Inform Inform

2.2. Preparation for ShutdownPreparation for Shutdown

3.3. Equipment ShutdownEquipment Shutdown

4.4. Equipment IsolationEquipment Isolation

5.5. Application of Lockout DevicesApplication of Lockout Devices

6.6. Control of Stored EnergyControl of Stored Energy

7.7. Equipment Isolation-VerificationEquipment Isolation-Verification

1. Inform1. Inform

The authorized personnel notifies all affected The authorized personnel notifies all affected employees that a lockout/tagout system is employees that a lockout/tagout system is going to be utilized and the reason because of going to be utilized and the reason because of it it

2. Prepare for Shutdown2. Prepare for Shutdown

Before an authorized or affected employee Before an authorized or affected employee turns off a machine or equipment, the turns off a machine or equipment, the authorized employee shall have knowledge of authorized employee shall have knowledge of the type and magnitude of the energy, the the type and magnitude of the energy, the hazards of the energy to be controlled, and the hazards of the energy to be controlled, and the method or means to control the energy.method or means to control the energy.

3. Machine or Equipment Shutdown3. Machine or Equipment Shutdown

The machine or equipment shall be turned off The machine or equipment shall be turned off or shut down using the procedures established or shut down using the procedures established for the machine or equipment. An orderly for the machine or equipment. An orderly shutdown must be utilized to avoid any shutdown must be utilized to avoid any additional or increased hazard(s) to employees additional or increased hazard(s) to employees as a result of the equipment stoppage. as a result of the equipment stoppage.

4. Machine or Equipment Isolation4. Machine or Equipment Isolation

All energy isolating devices that are needed to All energy isolating devices that are needed to control the energy to the machine or control the energy to the machine or equipment shall be physically located and equipment shall be physically located and operated in such a manner as to isolate the operated in such a manner as to isolate the machine or equipment from the energy machine or equipment from the energy source(s) source(s)

5. Lockout/Tagout Device Application5. Lockout/Tagout Device Application

– Lockout or tagout devices shall be affixed to Lockout or tagout devices shall be affixed to each energy isolating device by authorized each energy isolating device by authorized employees. employees.

– Lockout devices, where used, shall be affixed in Lockout devices, where used, shall be affixed in a manner to that will hold the energy isolating a manner to that will hold the energy isolating devices in a “safe” or “off” position devices in a “safe” or “off” position

5. Tagout Device Application 5. Tagout Device Application (continued)(continued)

Tagout devices, where used, shall be affixed in such a Tagout devices, where used, shall be affixed in such a manner as will clearly indicate that the operation or manner as will clearly indicate that the operation or movement of energy isolating devices from the “safe” movement of energy isolating devices from the “safe” or “off” position is prohibited or “off” position is prohibited Where tagout devices are used with energy isolating Where tagout devices are used with energy isolating

devices designed with the capability of being locked, the devices designed with the capability of being locked, the tag attachment shall be fastened at the same point at which tag attachment shall be fastened at the same point at which the lock would have been attached. the lock would have been attached.

Where a tag cannot be affixed directly to the energy Where a tag cannot be affixed directly to the energy isolating device, the tag shall be located as close as safely isolating device, the tag shall be located as close as safely possible to the device, in a position that will be possible to the device, in a position that will be immediately obvious to anyone attempting to operate the immediately obvious to anyone attempting to operate the device.device.

6. Control of Stored Energy6. Control of Stored Energy

Following the application of lockout or tagout Following the application of lockout or tagout devices to energy isolating devices, all potentially devices to energy isolating devices, all potentially hazardous stored or residual energy shall be hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise relieved, disconnected, restrained, and otherwise rendered safe. rendered safe.

If there is a possibility of re-accumulation of stored If there is a possibility of re-accumulation of stored energy to a hazardous level, verification of isolation energy to a hazardous level, verification of isolation shall be continued until the servicing or shall be continued until the servicing or maintenance is completed, or until the possibility of maintenance is completed, or until the possibility of such accumulation no longer exists.such accumulation no longer exists.

7. Verification of Isolation7. Verification of Isolation

Prior to starting work on machines or Prior to starting work on machines or equipment that have been locked out or tagged equipment that have been locked out or tagged out; the authorized employee shall verify that out; the authorized employee shall verify that isolation and de-energization of the machine or isolation and de-energization of the machine or equipment have been accomplished. equipment have been accomplished.

Basic Basic Removal of LockoutRemoval of Lockout

1.1. Ensure equipment is safe to operateEnsure equipment is safe to operate2.2. Safeguard all employeesSafeguard all employees3.3. Remove lockout/tagout devices. Except in Remove lockout/tagout devices. Except in

emergencies, each device must be emergencies, each device must be removed removed by the person who put it on.by the person who put it on.

4.4. Test the equipment to ensure that it is Test the equipment to ensure that it is working properlyworking properly

5.5. Inform all affected employees that the Inform all affected employees that the machine is workingmachine is working

Temporarily Reactivating Temporarily Reactivating EquipmentEquipment

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

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

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

Special SituationsSpecial Situations Servicing lasts longer Servicing lasts longer

than one shift.than one shift. Contractors are Contractors are

performing service or performing service or maintenance at your maintenance at your workplaceworkplace

Worker who applied Worker who applied lock is not availablelock is not available

Annual InspectionsAnnual InspectionsAnnual InspectionsAnnual Inspections

Certain circumstances lend themselves to the Certain circumstances lend themselves to the opportunity for an inspectionopportunity for an inspection– Construction of new equipmentConstruction of new equipment– Installation of new equipmentInstallation of new equipment– Modification or adjustment of equipmentModification or adjustment of equipment– Routinely scheduled cleaning and maintenanceRoutinely scheduled cleaning and maintenance– Major repairsMajor repairs

Designating an InspectorDesignating an InspectorDesignating an InspectorDesignating an Inspector

Periodic inspections must be performed by an Periodic inspections must be performed by an authorized employee other than the one(s) authorized employee other than the one(s) using the energy control procedureusing the energy control procedure

Who can inspectWho can inspect– Department managerDepartment manager– Plant managementPlant management– Safety managerSafety manager– OthersOthers

Tidbits of Info.Tidbits of Info. Never attempt lockout/tagout procedures Never attempt lockout/tagout procedures

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

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

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

Georgia – 1999 - OSHA has cited Roger Woods Foods Inc. for a fatal accident resulting from a lockout violation. OSHA fined the company $237,000 as a result of investigating the accident. A maintenance worker was crushed by a mechanical meat vat dumper, which had not been locked out.

An employee was attempting to correct an electrical problem involving two non-operational lamps. He had not shut off the power at the circuit breaker panel nor had he tested the wires to see if they were live. He was electrocuted when he grabbed the two live wires with his left hand and then fell from the ladder.

Summary Summary Summary Summary

Accidents will happenAccidents will happen Equipment will occasionally malfunctionEquipment will occasionally malfunction People will still make mistakesPeople will still make mistakes

There is no excuse for serious injury that results There is no excuse for serious injury that results from ignorance, carelessness, complacency, or lack from ignorance, carelessness, complacency, or lack of an Lockout/Tagout Program of an Lockout/Tagout Program

Any Questions?Any Questions?