Lockout Tagout


Published on

Published in: Business, Technology
  • Be the first to comment

No Downloads
Total views
On SlideShare
From Embeds
Number of Embeds
Embeds 0
No embeds

No notes for slide
  • Lockout Tagout

    1. 1. The Control of Hazardous Energy Lockout/Tagout 1910.147
    2. 2. Control of Hazardous Energy <ul><li>29 CFR 1910.147 </li></ul><ul><li>The standard covers the servicing and maintenance of machines and equipment in which the unexpected energizing or start up of the machines or equipment , or release of stored energy could cause injury to employees. </li></ul>
    3. 3. What Is Hazardous Energy? <ul><ul><li>Often invisible </li></ul></ul><ul><ul><li>Live or stored electricity </li></ul></ul><ul><ul><li>Moving machine or equipment parts </li></ul></ul>
    4. 4. What Is Hazardous Energy? (cont.) <ul><li>Stored energy in equipment </li></ul><ul><ul><li>Heat </li></ul></ul><ul><ul><li>Gravity </li></ul></ul><ul><ul><li>Pneumatic, hydraulic, air and water pressure </li></ul></ul><ul><ul><li>Steam </li></ul></ul><ul><ul><li>Chemical </li></ul></ul>Photo credit: State of WA-WISHA Services
    5. 5. Hazardous Energy Injuries <ul><li>7,600 injuries per year </li></ul><ul><li>80% of workers fail to turn off equipment </li></ul><ul><li>Causes </li></ul><ul><ul><li>Unexpected startup </li></ul></ul><ul><ul><li>Release of stored </li></ul></ul><ul><ul><li>energy </li></ul></ul><ul><ul><li>Fail to Lockout/tagout </li></ul></ul>Photo credit: State of WA-WISHA Services
    6. 6. When does LOTO apply?
    7. 7. Application Of The Standard <ul><li>An employee is required to remove or bypass a guard or other safety device </li></ul><ul><li>An employee is required to place any part of their body in contact with the point of operation of the operational machine or piece of equipment </li></ul><ul><li>An employee is required to place any part of their body into a danger zone associated with a machine operating cycle </li></ul>
    8. 8. Purpose <ul><li>Establish a program of procedures for </li></ul><ul><li>appropriate energy isolation </li></ul><ul><li>Prevent unexpected energizing </li></ul>
    9. 9. General Requirements <ul><li>Employer shall establish a program consisting of </li></ul><ul><ul><li>Energy control procedures </li></ul></ul><ul><ul><li>Employee training </li></ul></ul><ul><ul><li>Periodic inspections </li></ul></ul><ul><li>To ensure energy is isolated </li></ul><ul><li>Energy control procedures </li></ul><ul><ul><li>Developed, documented, and utilized </li></ul></ul>
    10. 10. Scope and Exemptions <ul><li>Scope – Servicing and maintenance of machines and equipment </li></ul><ul><li>Exemptions </li></ul><ul><ul><li>Construction, agriculture, and maritime </li></ul></ul><ul><ul><li>Electrical utilities </li></ul></ul><ul><ul><li>Electrical utilization installations ( Subpart S ) </li></ul></ul><ul><ul><li>Oil and gas well drilling and servicing </li></ul></ul>
    11. 11. Exception <ul><li>Has no potential for stored or residual energy </li></ul><ul><li>Single energy source (ext cord) </li></ul><ul><li>Lockout completely de-energizes </li></ul><ul><li>Machine is isolated </li></ul><ul><li>Single lockout device achieves lockout </li></ul>
    12. 12. <ul><li>Lockout under exclusive control </li></ul><ul><li>Servicing does not create hazards </li></ul><ul><li>Hot Tap Operations Involving Utility Company Transmission and Distribution Systems </li></ul>Exception
    13. 13. Minor Servicing Tasks <ul><li>Employees performing minor tool changes and adjustments that are routine, repetitive, and integral to the use of the equipment and that occur during normal operations are not covered by the lockout/tagout standard, provided the work is performed using alternative measures that provide effective protection. </li></ul>
    14. 14. LOTO Does Not Apply To <ul><li>Installations Under the Control of Electric Utilities </li></ul><ul><li>If De-energizing Introduces Additional or Increased Hazards or is Infeasible Due to Design </li></ul>
    15. 15. Energy Control Procedure <ul><li>Procedures shall clearly specify </li></ul><ul><ul><li>Scope </li></ul></ul><ul><ul><li>Purpose </li></ul></ul><ul><ul><li>Authorization </li></ul></ul><ul><ul><li>Rules </li></ul></ul><ul><ul><li>Techniques </li></ul></ul>
    16. 16. Energy Control Procedure <ul><li>A specific statement of intended use </li></ul><ul><li>Specific procedural steps for shutting down, blocking, and securing </li></ul><ul><li>Specific procedural steps for placement, removal, and transfer </li></ul>
    17. 17. Safety Work Practices <ul><li>Selection and use of work practices ( 1910.333 ) </li></ul><ul><ul><li>Working on or near de-energized parts that are not locked out or tagged are treated as energized </li></ul></ul><ul><ul><li>Only qualified personnel can work on electrical circuits </li></ul></ul>
    18. 18. Both Standards Mandate <ul><li>Both standards mandate the use of locks and/or tags to control potential energy </li></ul><ul><ul><li>1910.147 </li></ul></ul><ul><ul><li>1910.333 </li></ul></ul><ul><ul><li>Subpart S </li></ul></ul>
    19. 19. Isolation and Verification <ul><li>Employees working on de-energized utilization systems covered under Subpart S allows both the authorized employee and qualified employee are permitted to verify </li></ul><ul><li>Employees working on a mechanical hazardous energy covered under 1910.147 can verify </li></ul>
    20. 20. Periodic Inspection <ul><li>Energy control program </li></ul><ul><li>Shall conduct periodic inspection </li></ul><ul><ul><li>Performed by authorized employee </li></ul></ul><ul><ul><li>Conducted to correct deviations or inadequacies </li></ul></ul><ul><ul><li>Lockout versus tagout </li></ul></ul><ul><ul><li>Certification required </li></ul></ul>
    21. 21. Periodic Inspection <ul><li>Shall be performed by an authorized employee other than the person(s) utilizing the energy control procedure being inspected </li></ul><ul><li>Shall be conducted to correct any deviations or inadequacies identified </li></ul>
    22. 22. Periodic Inspection <ul><li>Where lockout is used, the inspection shall include a review between the inspector and each authorized employee </li></ul><ul><li>Where tagout is used, the inspection shall include a review between the inspector and each authorized and affected employees </li></ul>
    23. 23. <ul><li>The employer shall: </li></ul><ul><ul><li>Certify that the periodic inspections have been performed </li></ul></ul><ul><ul><li>Identify the machine or equipment on which energy control procedures were used </li></ul></ul><ul><li>The employer shall also note: </li></ul><ul><ul><li>The date of the inspection </li></ul></ul><ul><ul><li>The employees included in the inspection </li></ul></ul><ul><ul><li>The person performing the inspection </li></ul></ul>Periodic Inspections
    24. 24. Definitions
    25. 25. <ul><li>The placement of a lockout device on an energy isolating device to ensure that the equipment being controlled cannot be operated until the lockout device is removed </li></ul>Lockout
    26. 26. <ul><li>The placement of a tagout device on an energy isolating device to indicate the equipment being controlled may not be operated until the tagout device is removed </li></ul>Tagout
    27. 27. <ul><li>Tags must also include a legend such as: </li></ul><ul><ul><li>Do not start </li></ul></ul><ul><ul><li>Do not open </li></ul></ul><ul><ul><li>Do not close </li></ul></ul><ul><ul><li>Do not energize </li></ul></ul><ul><ul><li>Do not operate </li></ul></ul>Tag Requirements
    28. 28. Tagout Tags
    29. 29. Tagout Tag
    30. 30. Authorized Employee <ul><li>Locks out/Tags out equipment in order to perform maintenance </li></ul><ul><li>Authorized by line mgmt </li></ul><ul><li>Qualified by training </li></ul><ul><li>and experience </li></ul><ul><li>Must determine if a written </li></ul><ul><li>procedure exists </li></ul><ul><li>Trained in written LOTO </li></ul><ul><li>procedure </li></ul>
    31. 31. Authorized Employee <ul><ul><li>Trained to perform locking or tagging procedures </li></ul></ul><ul><ul><li>No other employee can attach or remove lock or tag devices </li></ul></ul>
    32. 32. Authorized Employee Responsibilities <ul><ul><li>Obtain assistance when necessary </li></ul></ul><ul><ul><li>Remove locks and/or tags following lockout/tagout </li></ul></ul><ul><ul><li>Coordinate multi-shift repair </li></ul></ul>
    33. 33. Authorized Lead Employee <ul><li>Authorized employee who performs or coordinates one or more LOTO activity for multiple personnel </li></ul>
    34. 34. Affected Employee <ul><li>An Employee whose Job Requires Operation or Use of the Machine or Equipment on Which Servicing or Maintenance is to be Performed Under Lockout or Tagout </li></ul><ul><li>An Employee whose Job Requires Work in an Area where such Servicing or Maintenance is Being Performed </li></ul><ul><li>Aware of energy control procedure </li></ul>
    35. 35. Who is an Affected Employee? Everyone in the building
    36. 36. Affected Employee Responsibilities <ul><ul><li>Notify maintenance when equipment needs repair or adjustment </li></ul></ul><ul><ul><li>Leave all lockout/tagout devices in place </li></ul></ul><ul><ul><li>Verify equipment is safe to operate following lockout/tagout </li></ul></ul><ul><ul><li>Follow all safety rules while operating the equipment </li></ul></ul>
    37. 37. Training and Communication <ul><li>Each authorized employee shall receive training in: </li></ul><ul><ul><li>Recognition of applicable hazardous energy sources </li></ul></ul><ul><ul><li>Type and magnitude of the energy available in the workplace </li></ul></ul><ul><ul><li>Methods and means necessary for energy isolation and control </li></ul></ul>
    38. 38. <ul><li>Each affected employee shall be instructed in the purpose and use of the energy control procedure </li></ul><ul><li>All other employees shall be instructed about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out </li></ul>Training and Communication
    39. 39. <ul><li>The employer shall certify that employee training has been accomplished and is being kept up to date </li></ul><ul><li>Certification shall contain employee names and dates of training </li></ul>Training and Communication
    40. 40. Group Lockout or Tagout <ul><li>Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device </li></ul><ul><li>Each authorized employee shall affix a personal lockout or tagout device to the group lockout device </li></ul>
    41. 41. Outside Personnel <ul><li>Whenever outside servicing personnel are engaged in activities covered by lockout/tagout, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures </li></ul>
    42. 42. Energy Sources <ul><li>Electrical </li></ul><ul><li>Mechanical </li></ul><ul><li>Pressurized Fluids </li></ul><ul><li>Pressurized Gasses </li></ul><ul><ul><li>Including cryogens </li></ul></ul><ul><li>Radiation </li></ul><ul><li>Gravity </li></ul>
    43. 43. Lockout/Tagout <ul><li>The Placement of a Lockout and/or Tagout Device on an Energy Isolating Device </li></ul><ul><ul><li>In accordance with procedures </li></ul></ul><ul><ul><li>Ensures equipment cannot be operated until lockout device is removed </li></ul></ul>
    44. 44. Exclusive Control <ul><li>If Equipment is Under Exclusive Control, the Plug is Within Your Sight and Reach </li></ul>
    45. 45. Lockout/Tagout <ul><li>The Placement of a Lockout and/or Tagout Device on an Energy Isolating Device </li></ul><ul><ul><li>In accordance with procedures </li></ul></ul><ul><ul><li>Ensures equipment cannot be operated until lockout device is removed </li></ul></ul>
    46. 46. Interpretations <ul><li>Hazardous Energy 1910.147 </li></ul><ul><li>Machine Guarding 1910.212 </li></ul>
    47. 47. Company Responsibilities <ul><ul><li>Ensure de-energizing of equipment </li></ul></ul><ul><ul><li>Ensure employee awareness </li></ul></ul><ul><ul><li>Provide appropriate levels of training </li></ul></ul><ul><ul><li>Review program effectiveness </li></ul></ul><ul><ul><li>Maintain and revise program </li></ul></ul><ul><ul><li>Administer appropriate disciplinary actions </li></ul></ul>
    48. 48. Devices
    49. 49. Energy Isolation Device <ul><ul><li>Isolate the equipment from the energy source </li></ul></ul><ul><ul><li>Isolation device </li></ul></ul><ul><ul><ul><li>Circuit breaker </li></ul></ul></ul><ul><ul><ul><li>Pressure valve </li></ul></ul></ul><ul><ul><ul><li>Machine block </li></ul></ul></ul>Photo credit: State of WA-WISHA Services
    50. 50. Lockout and Tagout Devices <ul><li>LOTO Locks are RED </li></ul><ul><ul><li>Do not use red-colored locks for any other purpose </li></ul></ul><ul><li>1 Key per lock </li></ul><ul><ul><li>Destroy any other keys immediately </li></ul></ul><ul><li>Combination locks are Not Allowed </li></ul><ul><li>When multiple locks are required for a single LOTO activity, locks with a common key may be used </li></ul>
    51. 51. Lockout Device
    52. 52. Lockout and Tagout Devices <ul><li>Tagout device states “ DANGER - DO NOT OPERATE ”. </li></ul><ul><ul><li>Shall be white, black and red </li></ul></ul><ul><ul><li>Shall have a space for the authorized employee’s name. </li></ul></ul><ul><ul><li>Must have a reinforced eyelet capable of accepting a lock shackle of 0.25 inch diameter </li></ul></ul>
    53. 53. Lockout Device <ul><ul><li>Lock </li></ul></ul><ul><ul><li>Block </li></ul></ul><ul><ul><li>Chain </li></ul></ul><ul><ul><li>Multilock hasp </li></ul></ul><ul><ul><li>Wheel valve cover </li></ul></ul><ul><ul><li>Ball valve cover </li></ul></ul>
    54. 54. Requirements for Lockout/Tagout Devices <ul><li>They must be: </li></ul><ul><ul><li>Durable </li></ul></ul><ul><ul><li>Standardized </li></ul></ul><ul><ul><li>Substantial </li></ul></ul><ul><ul><li>Identifiable </li></ul></ul>Photo credit: State of WA-WISHA Services
    55. 55. Group Lockout
    56. 56. Lockout Signage
    57. 57. Device Application
    58. 58. Lockout/Tagout Device Application <ul><li>Each employee must apply their own locks. </li></ul><ul><li>Lockout devices are applied to hold the isolating device in a “safe” or “off” position. </li></ul><ul><li>The employee must maintain exclusive control of the key </li></ul>
    59. 59. Lockout/Tagout Device Application <ul><li>Only the authorized employee may remove his/her LOTO device </li></ul><ul><li>Supervisor may overlock for additional control </li></ul>
    60. 60. Lockout/Tagout Device Application <ul><li>A Tag must always accompany a lock. </li></ul><ul><li>The tag must be placed as close as possible to the lock </li></ul><ul><li>The tag must be securely attached </li></ul><ul><li>The tag must clearly display the name of the authorized employee </li></ul>
    61. 61. Lockout/Tagout Device Application <ul><li>The Tag may also display: </li></ul><ul><ul><li>a picture of the authorized employee </li></ul></ul><ul><ul><li>the date of application </li></ul></ul><ul><ul><li>Other pertinent information </li></ul></ul><ul><li>Do not use string or tape to apply tags </li></ul>
    62. 62. Lockout/Tagout Device Application <ul><li>A tagout device only is allowed when the energy isolating device is not capable of accepting a lockout device. </li></ul><ul><ul><li>The tag must clearly indicate that operation or movement is prohibited </li></ul></ul><ul><ul><li>Tags must be securely attached to prevent inadvertent detachment </li></ul></ul>
    63. 63. Typical Equipment Requiring Lockout/Tagout <ul><ul><li>Presses </li></ul></ul><ul><ul><li>Saws </li></ul></ul><ul><ul><li>Conveyors </li></ul></ul><ul><ul><li>Pumps </li></ul></ul><ul><ul><li>Production equipment </li></ul></ul><ul><ul><li>Trash compactors </li></ul></ul>
    64. 64. When to Use Lockout/Tagout Devices <ul><ul><li>Servicing or maintaining machinery or equipment </li></ul></ul><ul><ul><li>Hazardous energy exists </li></ul></ul><ul><ul><li>Unexpected start-up could occur </li></ul></ul>
    65. 65. Actions that Trigger Lockout/Tagout <ul><ul><li>Removing or bypassing a safety device </li></ul></ul><ul><ul><li>Any part of the body is placed in harm’s way </li></ul></ul><ul><ul><li>Exposure to hazardous energy </li></ul></ul>
    66. 66. Alternative Removal of Locks and Tags
    67. 67. Temporary Removal of Locks/Tags for Testing or Positioning <ul><li>Follow Five Steps for Return to Service </li></ul><ul><li>When done, use your procedure </li></ul><ul><ul><li>General or Written </li></ul></ul>
    68. 68. Removal of Lock & Tags: Authorized Employee Not Available <ul><li>Supervisory personnel shall: </li></ul><ul><ul><li>Make every effort to locate the Authorized Employee </li></ul></ul><ul><ul><li>Get written approval from Department Head/Supervisor </li></ul></ul><ul><ul><li>Follow Five Steps for Return to Service </li></ul></ul><ul><ul><li>Inform Authorized Employee before he/she resumes work activities </li></ul></ul><ul><ul><li>Keep copy of written approval on file </li></ul></ul>
    69. 69. Group LOTO Explained
    70. 70. GROUP Lockout/Tagout Two Types Type A Type B
    71. 71. Type A Group LOTO <ul><li>Lead Authorized Employee places lock & tag </li></ul><ul><li>Everyone else locks behind him </li></ul><ul><li>Everyone verifies equipment is de-energized </li></ul><ul><li>Each worker removes his/her lock </li></ul><ul><li>If there is a written procedure, only lead Authorized Employee needs to be trained </li></ul>
    72. 72. Type B Group LOTO <ul><li>More complex activities </li></ul><ul><li>Lead Authorized Employee performs LOTO </li></ul><ul><li>Key goes into lockbox </li></ul><ul><li>Everyone places lock on lockbox </li></ul><ul><li>If there is a written procedure, only lead Authorized Employee needs to be trained </li></ul>
    73. 73. Shift or Personnel Changes
    74. 74. Shift or Personnel Change <ul><li>If no one else will be working on system: </li></ul><ul><ul><li>Leave LOTO as is </li></ul></ul><ul><li>If someone else will be working on system: </li></ul><ul><ul><li>Transfer keys/locks </li></ul></ul><ul><ul><li>Off-going employee unlocks </li></ul></ul><ul><ul><li>On-coming employee locks </li></ul></ul><ul><ul><li>Verification is very important!! </li></ul></ul>
    75. 75. Shift or Personnel Change <ul><li>Group LOTO: </li></ul><ul><ul><li>Lead places his own lock to lock box. </li></ul></ul><ul><ul><li>The job lockbox and captured keys remain under the control of the lead authorized employee. </li></ul></ul><ul><ul><li>If absent, the lead authorized employee may designate someone else the lead while retaining control of job lockbox </li></ul></ul>
    76. 76. Shift or Personnel Change <ul><li>Group LOTO </li></ul><ul><ul><li>Special circumstances ,may warrant the complete transfer of responsibility </li></ul></ul><ul><ul><li>The off-going and on-coming leads would simultaneously remove and apply locks. </li></ul></ul>
    77. 77. Supervised LOTO
    78. 78. Supervised LOTO <ul><li>If an employee or non-employee needs to perform LOTO and training is unavailable, an authorized employee may supervise the application of LOTO </li></ul>
    79. 79. Supervised LOTO <ul><li>Conditions apply: </li></ul><ul><ul><li>System must be able to accept LOTO device </li></ul></ul><ul><ul><li>The individual is briefed by the authorized employee </li></ul></ul><ul><ul><li>If there is a written procedure, authorized employee follows procedure and applies LOTO – individual applies LOTO and verifies </li></ul></ul>
    80. 80. Lockout/Tagout Procedure <ul><ul><li>Notify affected employees </li></ul></ul><ul><ul><li>Shut down energized equipment </li></ul></ul><ul><ul><li>Isolate energy sources from equipment </li></ul></ul><ul><ul><li>Lockout or tagout the energy isolation device </li></ul></ul><ul><ul><li>Release stored energy </li></ul></ul><ul><ul><li>Test </li></ul></ul>
    81. 81. 5 Step Restart Procedure <ul><ul><li>1. Clean up and inspect work area </li></ul></ul><ul><ul><li>2. Clear personnel from the startup area </li></ul></ul><ul><ul><li>and notify affected employees of startup </li></ul></ul><ul><ul><li>3. Verify that the controls are in neutral </li></ul></ul><ul><ul><li>4. Remove lockout devices and reenergize </li></ul></ul><ul><ul><li>the machine </li></ul></ul><ul><ul><li>5. Start machinery or equipment </li></ul></ul>
    82. 82. Sub-Contractors
    83. 83. Subcontractors <ul><li>Required to have their own LOTO program </li></ul><ul><ul><li>Must share that information with Task Manager </li></ul></ul><ul><ul><li>Must attend LOTO training or prove they have been trained </li></ul></ul>
    84. 84. Subcontractors <ul><li>Overlocking is allowed </li></ul><ul><ul><li>Sub locks first, then the you overlock </li></ul></ul>
    85. 85. Configuration Control Locks and Tags
    86. 86. Configuration Control <ul><li>Used if equipment must remain unattended for long periods of time w/out being worked on </li></ul><ul><li>Provides management control </li></ul><ul><li>Removal of locks/tags may result in injury, damage, disruption of normal processes, or degradation of system </li></ul>
    87. 87. Configuration Control - Examples <ul><li>Locking out overhead crane electrical disconnect </li></ul><ul><li>Locking equipment while awaiting repair or parts </li></ul><ul><li>Locking a valve to control the flow of fluids </li></ul><ul><li>Locking radioactive waste container </li></ul>
    88. 88. Configuration Control Locks <ul><li>Can use any shape or color of lock EXCEPT RED. </li></ul><ul><li>Tags: YELLOW, MANILA or RED (w/o DO NOT OPERATE wording are allowed. </li></ul><ul><li>RED locks and DANGER: Do not Operate tags are used exclusively for LOTO </li></ul><ul><ul><li>Not for Configuration Control </li></ul></ul>
    89. 89. Configuration Control Locks <ul><li>Can use lock w/out tags if use is obvious </li></ul><ul><li>Combination locks are allowed </li></ul><ul><li>Keyed locks may have more than one key. </li></ul>
    90. 90. Configuration Control Locks <ul><li>Removal of lock is by person or group who applied it. </li></ul><ul><li>Removal by other authorized or qualified person permissible if there is assurance that removal will not create unsafe condition </li></ul>
    91. 91. SUMMARY
    92. 92. Key Points to Remember <ul><ul><li>Hazardous energy is dangerous and deadly </li></ul></ul><ul><ul><li>Use lockout/tagout wherever unexpected startup or stored energy release may occur </li></ul></ul><ul><ul><li>Adhere to lockout/tagout and restart procedures </li></ul></ul><ul><ul><li>Keep everyone informed </li></ul></ul>
    93. 93. 5 Step Restart Procedure <ul><ul><li>1. Clean up and inspect work area </li></ul></ul><ul><ul><li>2. Clear personnel from the startup area </li></ul></ul><ul><ul><li>and notify affected employees of startup </li></ul></ul><ul><ul><li>3. Verify that the controls are in neutral </li></ul></ul><ul><ul><li>4. Remove lockout devices and reenergize </li></ul></ul><ul><ul><li>the machine </li></ul></ul><ul><ul><li>5. Start machinery or equipment </li></ul></ul>
    94. 94. Questions? Ron Kravitz