Lockout / Tagout

1. Lockout / Tagout “Control of Hazardous Energy” 29 CFR 1910.147 Cummins Rocky Mountain

2. Purpose of Lockout/Tagout (LOTO) WHY LOCKOUT/TAGOUT? Cummins Rocky Mountain LOTO procedures are designed to prevent accidents, to protect employees and equipment from accidental start-up.

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

4. Employee Categories AUTHORIZED EMPLOYEES These are employees who are allowed to perform energy control procedures. Training will include company approved energy control procedures, recognition of energy sources, and methods for isolation and energy control. AFFECTED EMPLOYEES These are employees that operate the equipment on which work is being performed. Training will include the purpose and use of the energy control procedures. OTHER EMPLOYEES These are all other employees that may work in an area where energy control procedures may be used. Training will include instruction on the energy control procedures and the restrictions relating to attempting to restart or reenergize equipment that is either locked out or tagged out.

5. Hazardous Energy Sources • CHEMICAL – acids, corrosives, caustics • THERMAL – steam, hot, cold • HYDRAULIC – water, oil, liquids • ELECTRICAL – AC/DC, generator, battery • MECHANICAL – coiled springs, raised loads, moving parts • PNEUMATIC – pressurized gas, compressed air

6. Equipment Requiring Lockout/Tagout at our Facility • Air Compressor • Alkota Pressure Washer • Chassis Dyno • Overhead 10 Ton Crane • Repair Shop Lathe • Zero Blasting Hood

7. LOTO Definitions and Requirements • LOTO is defined as the process of the authorized placement and administrative control of locks and tags used to ensure the protection of employees, equipment, and the environment. • LOTO locks are used for physical control over an energy isolation device.

8. ON OFF SYSTEM CONTROL SWITCH Energy Isolation Devices • Used to control and isolate hazardous energy. They are mechanical devices that physically prevent the transmission or release of energy. • circuit breakers • disconnect switches • valves • Energy isolation devices are where we place the locks and tags. They are NOT locks or tags. These are the devices that prevent the transmission of hazardous energy to the equipment that requires work to be performed.

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

10. Locks • All our locks and tags for LOTO are standardized by shape, size or color • Personally Controlled Lock • Owner has only key • No master key is allowed

11. Hardware for LOTO • Locks/Tags • Locking plug caps • Chains • Wedges • Blocks • Blanks

12. Locks vs Tags • Locks are used to block the flow of energy. • Tags are a warning to all employees not to turn the power on.

13. Lockout vs Tagout • OSHA prefers lockout. • If an energy isolation device will accept a lock, you MUST use a lock. • In situations where a lock cannot be used, you may use a tag only. A tag does not provide the positive control of a lock. So it is important that we are all aware of the limitations of a tag.

14. DANGER LOCKED OUT DO NOT OPERATE This Lock/Tag may only be removed by NAME: _______________ DEPT : _______________ EXPECTED COMPLETION DATE: ________________ TIME: _________________ Tagout • CAN BE USED in place of lockout if you can demonstrate that it will offer employee protection equivalent to that offered by lockout. • Equivalent protection is demonstrated by the following safety measures: • Removing an isolating circuit element; • Blocking a control switch; • Opening an extra disconnecting device; or • Removing a valve handle. • The tag must be attached at the same spot where the lockout device would have been found.

15. Examples of tags we use. Tag Characteristics: • Withstand at least 50 pounds of force • Not re-usable • Self locking • Attachable by hand

16. Applying Locks and Tags • LOTO devices are to be attached by an authorized employee to each energy-isolating device. • When a lockout device is used, it must be attached in such a way that it secures the energy isolating device in the “off” position. • When a tagout device is used, it must be attached exactly where the lock would have been on the energy-isolation device-or as close to that point and in as obvious a position as possible. The tag must clearly indicate that the energy-isolation device must not be disturbed. (The tag should read DO NOT START, DO NOT OPEN, or DO NOT ACTIVATE)

17. LOTO is NOT Required When: • Work is performed in cord and plug electrical equipment on which the plug is under EXCLUSIVE CONTROL of the employee performing the service or maintenance. • Note: exclusive control means that the plug is: • Physically in possession of or within arm’s reach of the person who performs the work, and • In that person’s line of sight. • Minor tool changes, when the on/off switch is under EXCLUSIVE CONTROL of the operator. • For Example…

18. …Pedestal grinders

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

20. LOTO Shutdown Procedure Steps to Apply LOTO • Notification of employees involved or in the area and you will be shutting equipment down. • Shutdown of all power sources. You may need to stop, block, or bleed the energy sources. • Lockout and Tagout all energy sources. Verify the controls do not start machine and check the voltage. • Verification among employees once the work has been completed. • Inspect work area to ensure removal of non-essentials • Employees safely positioned and notified • Lockout/tagout removal (by employee who applied)

21. Removal of Locks/Tags • Only the maintenance employee performing the original repair can remove a lock. • If employee is off-site, the supervisor may remove the lock under the following conditions. • Verify that authorized employee is not at facility • Make reasonable efforts to inform him or her • Ensure that he/she knows of removal upon re-entering

22. Group Lockout • Each employee performing LOTO work on equipment will have his/her own lock and tag at the energy isolation devices. • When multiple employees are working on the equipment, a hasp may be used.

23. Equipment Start-Up • Clear equipment of tools and materials • Re-install all guards • Alert employees to stand clear • Remove locks/tags • Energize equipment

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

25. Lockout/Tagout All lockout/tagout procedures are found through the link to Lockout / Tagout link on the Cummin’s safety website. If you have any questions on Lockout/Tagout, contact your supervisor or submit a question using the “ASK THE EXPERT” menu selection on this website.