Lockout/Tagout

1. Lockout/Tagout

2. Lockout - Tagout Control of Hazardous Energy OSHA Standard 1910.147

3. What Is Lockout/Tagout? • Referred to as LOTO • Blocks the flow of energy from power source to the equipment • Provides means of warning (tag)

4. Why is Lockout/Tagout Important? • OSHA’s Top 10 Most Cited Violations: • Lockout / Tagout has ranked 4th on the list for the last two years. • Over 4,000 violations per year.

5. Types of Energy • Electrical • Mechanical • Chemical • Thermal • Hydraulic • Pneumatic

6. Use Safe Electrical Practices • Use non-conducting tools. • Check circuits dead before working. • Ensure all control power is de-energized. • Discharge all capacitors after lockout.

7. Mechanical Energy Hazards Kinetic – energy in motion Potential - stored energy • Energy stored in machinery • Weights & Springs • Pistons under pressure • Hydraulic controls Stored potential energy can be released during work causing injury or death.

8. Chemical Energy Hazards Chemicals have energy that can: • start fires • cause skin burns • generate harmful gases or fumes Before working – release, drain or vent chemicals safely.

9. Thermal Energy Hazards Energy of Heat and Cold • Hot or cold equipment & fluids can burn you • Quick releases of compressed gases can freeze your skin Allow equipment to reach a safe temperature before starting work.

10. Hydraulic Energy Energy of Liquids Under Pressure • pressure can cause equipment to move • rapid release can cause injury or ejection of system parts Block energy or relieve pressure slowly into a proper container.

11. Pneumatic Energy Hazards Energy of Compressed Gases • uncontrolled release can cause injury • rapid de-pressurization creates extreme low temperature Properly vent all systems before starting work.

12. LOTO Procedure 1. Prepare for Shutdown 2. Shutdown Equipment 3. Isolate all energy sources 4. Place Locks & Tags 5. Release Stored Energy 6. Verify Equipment Isolation

13. 1. Prepare for Shutdown • Understand equipment hazards! • Notify other employees of shutdown.

14. 2. Shutdown Equipment • Follow normal shutdown procedure. • Turn all switches to the OFF position. • Shut all valves. • Disable all sources of energy!

15. 3. Isolate All Energy Sources • Shut valves • Open breakers & disconnects

16. 4. Place Locks & Tags • Valves • Breakers / electrical disconnects • Block or disconnect all lines

17. 5. Release or Block all Stored Energy • Discharge capacitors • Block or release springs • Block elevated parts • Stop rotating parts • Relieve system pressure • Drain fluids • Vent gases • Allow system to cool

18. 6. Verify Equipment Isolation • Check all other workers are clear of the equipment. • Check locking devices securely placed. • Check isolation. • Attempt normal startup. • Return Controls to OFF/Neutral.

19. Items needed for LOTO • Written LOTO procedures • Locks & Tags • Hasps --for multiple locks & tags • Breaker Lockouts • Gate Valve Lockouts • Ball Valve Lockouts

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

21. Requirements for Lockout/Tagout Devices • They must be: • Durable • Standardized • Substantial • Identifiable

22. Typical Equipment Requiring LOTO • Presses • Saws • Conveyors • Pumps • Production equipment • Trash compactors • Ovens

23. Affected Employees Employees who • Operate • Work around • Occasionally adjust equipment that is subject to LOTO

24. Affected Employee Responsibilities • Notify maintenance, etc., when equipment needs repair or adjustment • Leave all LOTO devices in place • Verify equipment is safe to operate following LOTO • Follow all safety rules while operating the equipment

25. Authorized Employee • Maintains equipment • Services equipment • Is trained to use LOTO

26. Authorized Employee Responsibilities • Repair or service equipment as needed • Ensure that all energy sources are locked out • Test equipment to verify residual energy is dissipated • Place a “Danger—Do Not Operate” tag on equipment • Obtain assistance when necessary • Remove locks and/or tags following LOTO • Coordinate multi-shift repair

27. 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 • Authorized and affected—when program deficiencies are noted

28. Company Responsibilities • Ensure de-energization of equipment • Ensure employee awareness • Provide appropriate levels of training • Review program effectiveness • Maintain and revise program • Administer appropriate disciplinary actions

29. When Must LOTO Be Used? When servicing or maintaining equipment where: • Hazardous energy exists • Unexpected start-up could occur • 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

30. 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

31. Releasing Equipment from LOTO • Inspect Area and Equipment. • Ensure all Machine Guards in place. • Move tools away from equipment. • Inform others of startup. • Restore system connections. • Remove Locks & Tags. • Restore equipment to normal. • Conduct normal startup.

32. Know the Equipment! • Hazards • Energy isolation points • Lockout/Tagout procedures Working on unfamiliar machinery is a hazard!

33. WhoCan Lockout Equipment? Only employees who have been trained and authorized by management.

34. Who can remove Locks & Tags? Only the employee who placed the tag or a supervisor, after obtaining permission from the worker who placed the tag.

35. Lockout-Tagout Protects YOU! ALWAYS Use Proper Lockout - Tagout Procedures They are for your protection!!!