Lockout/Tagout
Lockout - Tagout Control of Hazardous Energy OSHA Standard 1910.147
What Is Lockout/Tagout? Referred to as LOTO Blocks the flow of energy from power source to the equipment Provides means of warning (tag)
Why is Lockout/Tagout Important? OSHA s Top 10 Most Cited Violations: Lockout / Tagout has ranked 4 th on the list for the last two years. Over 4,000 violations per year.
Types of Energy Electrical Mechanical Chemical Thermal Hydraulic Pneumatic
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.
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.
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.
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.
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.
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.
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
1. Prepare for Shutdown Understand equipment hazards! Notify other employees of shutdown.
2. Shutdown Equipment Follow normal shutdown procedure. Turn all switches to the OFF position. Shut all valves. Disable all sources of energy!
3. Isolate All Energy Sources Shut valves Open breakers & disconnects
4. Place Locks & Tags Valves Breakers / electrical disconnects Block or disconnect all lines
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
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.
Items needed for LOTO Written LOTO procedures Locks & Tags Hasps --for multiple locks & tags Breaker Lockouts Gate Valve Lockouts Ball Valve Lockouts
Types of Lockout Devices Locks Blocks Chains Multilock hasps Wheel valve covers Ball valve covers
Requirements for Lockout/Tagout Devices They must be: Durable Standardized Substantial Identifiable
Presses Saws Conveyors Pumps Production equipment Trash compactors Ovens Typical Equipment Requiring LOTO
Affected Employees Employees who Operate Work around Occasionally adjust equipment that is subject to LOTO
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
Authorized Employee Maintains equipment Services equipment Is trained to use LOTO
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
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
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
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
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
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.
Know the Equipment! Hazards Energy isolation points Lockout/Tagout procedures Working on unfamiliar machinery is a hazard!
Who Can Lockout Equipment? Only employees who have been trained and authorized by management.
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.
Lockout-Tagout Protects YOU! ALWAYS Use Proper Lockout - Tagout Procedures They are for your protection!!!