EM 385-1-1 Section 12 Control of Hazardous Energy (Lockout/Tagout)
Lockout/Tagout References EM 385-1-1 Section 12 29 CFR 1926.600 (a) (3) i Heavy Equipment 29 CFR 1926.702 (j) (1) Concrete Tools 29 CFR 1926.417 Electrical Circuits 29 CFR 1910.147 ; Subpart J UFGS 01 35 29 (Latest) Accident Abstracts
Statistics Recent OSHA estimates indicate that each year 120 deaths and 60,000 injuries occur as the result of unexpected activation of machinery, and nearly 75% of these accidents occur on jobs of 15 minutes or less. OSHA webpage dated 5-6-04
Potential Mishap Outcomes Electric shock and electrocutions Thermal burns Struck by objects Crushed by and caught between Loss of limb Mechanical Entanglement Engulfment Leading to property damage, injury, death
Direct Causes Lack of notification prior to re-energizing. Not verifying de-energized state. Failure to adequately bleed pressurized system before disassembly. Unauthorized work Lack of communication between workers. Worker ignoring safety procedures.
Indirect Causes Lack of Lockout/tagout/tryout program. Specific SOPs not developed or utilized. Workers not adequately trained or supervised. Approved safety plan not implemented. Regular site safety inspections not performed. Lack of safety equipment and/or use.
Fatal Incident A 28 year old dump truck driver was crushed when pinned between the dump body and frame. The victim elevated the empty body and tried to lower it, but it had stuck in the elevated position. He left the cab leaned over the truck frame to look at the control valve. The dump body suddenly lowered pining him. He was found the next day by the company owner who was his father.
General 12.A.01 This Section shall apply to contractor-managed Hazardous Energy Control Programs (HECP) only, as well as all requirements of 1910.147, ANSI Z244.1, and ANSI A10.44. When a site is controlled by a contractor and USACE employees are affected by contractormanaged HECP (e.g., QA s on construction sites, etc.), they shall comply with the contractor s HECP.
Energy Sources Electricity Hydraulic Pneumatic Steam Thermal Chemical Gravity
Typical Equipment Requiring LOTO Presses Saws Conveyors Pumps Production equipment Trash compactors Ovens
Isolation Systems with energy isolating devices that are capable of being locked out shall be locked out. 12.A.04
Authorized Employee Lockout and tagout shall be performed only by Authorized employees. 12.A.08
Training Training shall be provided to ensure that the purpose and function of the HEC procedures are understood by employees and that employees possess the knowledge and skills required for the safe application, usage, and removal of HEC devices. 12.B.01
Training a. Each Authorized Employee shall receive training in the recognition of hazardous energy sources, the type and magnitude of energy available in the workplace, and the methods and means for energy isolation and control. b. Each Affected employee shall be instructed in the purpose and use of the HEC procedures. c. All incidental personnel shall be informed of the procedures and prohibitions relating to restarting or reenergizing systems which are locked or tagged out. 12.B.01
Types of Lockout Devices Locks Blocks Chains Multi-lock hasps Wheel valve covers Ball valve covers
Inspections Daily inspections shall be conducted to ensure that all requirements of the HEC procedures are being followed. 12.C.01
Periodic Inspections Periodic inspections shall be documented and shall specify the system where the HEC procedures were inspected, the date of inspection, the names of employees performing and any deficiencies in complying with the HEC procedures. 12.C.02
Locks and Tags Locks and tags shall: a. Be capable of withstanding the environment that they are exposed to for the maximum period of time the exposure is expected, and b. Indicate the identity of the employee applying the device. 12.D.01
Locks Locks shall, in addition to the requirements of section 12.D.01 be substantial enough to prevent removal without the use of excessive force or unusual techniques. 12.D.02
Tags Tags shall, in addition to 12.D.01 meet the following requirements: Have standardized print and format Constructed and printed to prevent UV light, wet locations, or corrosive environment will not deteriorate the tag Attached in a reusable method Warn against hazardous conditions 12.D.03
Application and Removal of Locks and Tags The authorized employee shall affix locks and/or tags to each energy isolating device in accordance with the HEC procedures. 12.E.03
Personal Protective Grounds Following the application of locks or tags to energy isolating devices, all potentially hazardous stored or residual energy shall be relieved, disconnected, restrained, discharged, or otherwise rendered safe. 12.E.05
Verification by Authorized Individual Before starting work on systems that have been locked/tagged out, the authorized individual shall verify that isolation and de-energization of the system have been successfully been accomplished. 12.E.07
Termination of Operation Before locks or tags are removed and energy restored to the system, the authorized individual shall ensure that the following actions have been taken: a. The work area has been inspected and all nonessential items (e.g., tools and materials) have been removed from the system, the system components are operationally intact, and all employees have been safely positioned or removed from the area; and b. All affected individuals have been notified that the locks or tags are about to be removed. 12.E.09
Removal of Tags/Locks When the employee who installed the lock/tag is not available, the device may be removed by another individual appointed by, and under the direction of the Contractor Project Manager or Contractor designated authority. 12.E.10
Are wheels chocks LOTO???
LOTO? Welding on Gas Tank
Summary Lockout/tagout/tryout program must be implemented. Specific SOPs must be developed and utilized. Workers must be trained and/or supervised. Approved safety plan AHA and ORM must be implemented. Regular site safety inspections must be conducted. Safety equipment must be used.