Lockout/Tagout Training (OEM Version)


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This training presentation targeted at OEMs covers the importance of Lockout/Tagout as a form of mitigation, the necessary elements of an effective program for the control of hazardous energy along with the means of handling special cases within the program.

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Lockout/Tagout Training (OEM Version)

  1. 1. SM!
  2. 2. •  OSHA  standard  for  Lockout  /Tagout   •  Goal:  Control  the  release  of  hazardous  energy                                                 during  maintenance  and  servicing   •  Many  types  of  energy:   –  Mechanical   –  Hydraulic   –  Electrical   –  Gas   –  PneumaDc   –  Water   –  Chemical   –  Thermal   SM!
  3. 3. •  Why  We  Do  It?   •  What  is  required  for   compliance?   •  How  to  get  started  with   Lockout/Tagout?   •  References   SM!
  4. 4. Employee  Safety   Legal   Risk   Mi'ga'on   Financial   SM!
  5. 5. •  Approximately  3  million  workers  in  the   US  service  equipment  and  face  the   greatest  risk  of  injury  if  Lockout/Tagout   is  not  properly  implemented   •  Lockout/Tagout  prevents  an  esDmated   120  fataliDes  and  50,000  injuries  each   year  in  the  US.   SM! Source: http://www.osha.gov/SLTC/controlhazardousenergy/index.html
  6. 6. •   Created  under  the  OccupaDonal  Safety   and  Health  Act  of  1970   •   Only  government  regulatory  agency  for   workplace  safety   •   Instructs,  conducts  inspecDons  and   enforces  workplace  safety   •   Does  not  apply  to  government  faciliDes   SM!
  7. 7. OSHA  General  Duty  Clause  States:      “each  employer  shall  furnish  to  each  of  his  employees   employment  and  a  place  of  employment  which  are   free  from  recognized  hazards  that  are  causing  or  are   likely  to  cause  death  or  serious  physical  harm  to  his   employees.”   Source: OSHA 29 USC 654 SM!
  8. 8. OSHA Standard 29 CFR 1910.147: •  29  CFR  1910.147  was  adopted  in   1989  and  established  minimum   performance  requirements  for  the   control  of  hazardous  energy   •  The  lockout/tagout  standard  applies   to  general  industry  employment   •  It  covers  the  servicing  and   maintenance  of  machines  and   equipment  in  which  the  unexpected   start-­‐up  or  the  release  of  stored   energy  could  cause  injury   •  It  covers  about  39  million  workers   SM!
  9. 9. NFPA 70E – Chapter 1 Article 110 States:    “covers  electrical  safety-­‐related  work  pracDces  and   procedures  for  employees  who  work  on  or  near  exposed   energized  electrical  conductors  or  circuit  parts  in   workplaces  that  are  included  in  the  scope  of  this   standard”      “Intended  to  provide  for  employee  safety  relaDve  to   electrical  hazards  in  the  workplace”   Source: NFPA Regulations – Chapter 1, Article 110, 2004 SM!
  10. 10. •  Required  by  law  for  employers  to  follow   •  Requirements  in  General  Terms   •  Lots  of  details  but  also  rely  on  consensus   industry  standards  for  guidelines                          NFPA  70E  –  2004  (Originated  1976):   •  Details  –  safe  installaDon,  maintenance  and   work  pracDces,  signs,  PPE  (Personal   ProtecDve  Equipment)   SM!
  11. 11. •  DownDme   •  Personnel   •  Equipment   •  Legal  AcDon   •  Liability  and  Injury   •  Cost  of  outside  counsel   •  Fines  and  PenalDes:   •  LOTO  is  #3  most  cited  by  OSHA   •  Fiscal  Year  2006    38,579 federal OSHA site inspections  58,058 state OSHA site inspections Source: Occupational Hazards, February 2008  3,659 violations for LOTO totaling about $6M SM!
  12. 12. SM!
  13. 13. Conclusion:    “ The  costs  in  terms  of  human   suffering,  lost  producDvity,  worker’s   compensaDon  claims  and  lawsuits   can  far  outweigh  the  investment  in  a   comprehensive  program.”   Source: Occupational Health&Safety Volume 76, Number 10 SM!
  14. 14. Elements  of  an  effecDve  Lockout/Tagout   program:   •  Procedures   •  Training   •  Device  requirements   •  InspecDons   SM!
  15. 15. •  OSHA  1910.147(c)(4)(i)        “Procedures  shall  be  developed,  documented  and   uDlized  for  the  control  of  potenDally  hazardous  energy   when  employees  are  engaged  in  the  acDviDes  covered   by  this  secDon”   •  NFPA  70E    120.2  (F)  /  Ch.  5-­‐4        “ The  employer  shall  maintain  a  copy  of  the  procedures   required  by  this  secDon  and  shall  make  procedures   available  to  all  employees”   SM!
  16. 16. Procedures  shall  be  developed,  documented   and  uDlized  for  the  control  of  potenDally   hazardous  energy:   –  Steps  to  de-­‐energize  and  re-­‐energize   –  Lockout/Tagout  devices  to  uDlize   –  Drawings/diagrams  (equipment  specific)   –  What  employees  are  exposed  to  hazards?   –  Who  is  qualified  to  perform  LOTO?   –  Who  is  in  charge  of  the  LOTO  program?   Standards/Codes:    OSHA  1910.147(c)(4);  NFPA  70E  -­‐  ArDcle  120.2  (D)  &  (F),  and  Annex  G   SM!
  17. 17. Steps  for  equipment  shutdown   1.  Prepare  for  and  announce  shutdown   2.  Shutdown  equipment   3.  Disconnect  energy  sources  /  test  for  isolaDon   4.  Lockout  and/or  Tagout   5.  Release  stored  energy     6.  Verify  isolaDon   SM!
  18. 18. Steps  for  equipment  startup   1.  Verify  equipment  operaDonally  intact  -­‐  Clear  all   personnel  and  tools   2.  Ensure  employees  are  safely  posiDoned   3.  Remove  lockout/tagout  devices  from  each   energy-­‐isolaDng  device   4.  NoDfy  all  affected  employees  of  Lockout/ Tagout  removal  and  that  work  has  been   completed   5.  Start  equipment   SM!
  19. 19. OSHA  1910.147(c)(7)(i)        “ The  employer  shall  provide  training  to  ensure  that  the  purpose   and  funcDon  of  the  energy  control  program  are  understood  by   employees  and  that  the  knowledge  and  skills  required  for  the   safe  applicaDon,  usage,  and  removal  of  the  energy  controls  are   acquired  by  employees”   NFPA  70E  120.2  (B)  (2)        “Each  employer  shall  provide  training  as  required  to  ensure   employees’  understanding  of  the  lockout/tagout  procedure   content  and  their  duty  in  execuDng  such  procedures”   SM!
  20. 20.  Authorized  employees  –  person  who  locks  out  or   tags  out  machines  or  equipment  in  order  to   perform  servicing  or  maintenance  on  that  machine   or  equipment    Affected  employees  –  employee  whose  job  requires   him/her  to  operate  or  use  a  machine  or  equipment   on  which  servicing  or  maintenance  is  being   performed  under  Lockout  or  Tagout,  or  whose  job   requires  him/her  to  work  in  an  area  in  which  such   servicing  or  maintenance  is  being  performed   SM!
  21. 21. Authorized  employees:   •  RecogniDon  of  applicable  hazardous   energy  sources   •  Type  and  magnitude  of  energy   available  in  the  workplace   •  Methods  and  means  necessary  for   energy  isolaDon  and  control   •  Ways  to  verify  that  the  energy  isolaDon   is  effecDve   SM!
  22. 22. Affected  employees:   •  Instructed  in  the  purpose  and  use  of  energy  control   procedure   •  Should  never  anempt  to  restart  or  re-­‐energize   machines  or  equipment  which  are  locked  out  or   tagged  out   •  Respect  use  of  warning  tags     SM!
  23. 23. •  New  employees,  or  change  in  employee   responsibili'es   •  New  equipment,  or  change  in   machines,  equipment  or  processes  that   present  a  new  hazard  or  change  to   energy  control  procedures   •  Devia'ons  from,  or  inadequacies  in,  the   employee’s  knowledge  or  use  of  the   energy  control  procedure   SM!
  24. 24. OSHA  1910.147(c)(7)(i)        “Lockout  device  –  a  device  that  uDlizes  a  posiDve  means  such   as  a  lock,  either  key  or  combinaDon  type,  to  hold  an  energy   isolaDng  device  in  a  safe  posiDon  and  prevent  the  energizing   of  a  machine  or  equipment”   NFPA  70E  120.2  (E)  (2)        “Each  employer  shall  supply,  and  employees  shall  use,   lockout/tagout  devices  and  equipment  necessary  to  execute   the  requirements  of  120.3(E).    Locks  and  tags  used  for   control  of  exposure  to  electrical  energy  hazards  shall  be   unique,  shall  be  readily  idenDfiable  as  lockout/tagout   devices,  and  shall  be  used  for  no  other  purpose.”   SM!
  25. 25. Lockouts  must  be:   •  Used  only  to  control  energy   •  Durable  enough  for  use  in  their  environment   •  Standardized  by  either  color,  shape  or  size   •  Substan'al  –  withstand  all  but  excessive   force   •  Iden'fy  the  employee  applying  the  device   SM!
  26. 26. Tags  must  be:   •  Durable  enough  for  use  in  their   environment   •  Substan'al  –  enough  to  resist  accidental  or   inadvertent  removal   •  Standardized  by  either  color,  shape  or  size   •  Iden'fy  the  employee  responsible  for  the   Tagout   •  Non-­‐reusable  aNachment  device  &   aNachable  by  hand   •  Withstand  50  lbs  of  force   SM!
  27. 27. OSHA  1910.147(c)(6)(i)        “ The  employer  shall  conduct  a  periodic  inspecDon  of  the  energy   control  procedure  at  least  annually  to  ensure  that  the  procedure   and  the  requirements  of  this  standard  are  being  followed.”     NFPA  70E    120.2  (C)  (3)        “An  audit  shall  be  conducted  at  least  annually  by  a  qualified   person  and  shall  cover  at  least  one  Lockout/Tagout  in  progress   and  the  procedure  details.  The  audit  shall  be  designed  to  correct   deficiencies  in  the  procedure  or  in  employee  understanding.”   SM!
  28. 28. •  At  least  annually   •  Performed  by  authorized  employee,  other  than  the  one(s)   using  the  energy  control  procedure   •  Cover  Lockout/Tagout  in  progress     •  Between  inspector  and  authorized/affected  employees   •  Lockout  –  review  employees  responsibiliDes  under  the   energy  control  procedure  inspected   •  Tagout  –  review  employee  responsibiliDes  and  Tagout   limitaDons   •  Document  inspecDon   •  Correct  any  deviaDons  or  inadequacies  idenDfied   SM!
  29. 29. •  Example:  Contractors   •  “On-­‐site  employer  and  outside  employer  shall  inform  each   other  of  their  respecDve  lockout  or  tagout  procedures”   •  “On-­‐site  employer  shall  ensure  that  his/her  employees   understand  and  comply  with  the  restricDons  and  prohibiDons   of  the  outside  employer’s  energy  control  program”   SM!
  30. 30. OSHA  1910.147(f)(3)(i)        “When  servicing  or  maintenance  is  performed  by  a  crew,  crao,   department  or  other  group,  they  shall  uDlize  a  procedure   which  affords  the  employees  a  level  of  protecDon  equivalent   to  that  provided  by  the  implementaDon  of  a  personal  lockout   or  tagout  device”   !   ONE  authorized  employee  is   responsible  for  overall  procedure  in  the   crew.   !   If  mulDple  crews  are  involved,  there   must  sDll  be  an  overall  authorized   employee  responsible.   !   Group  Lockout  devices  such  as  Group   Lockboxes  and/or  hasps  must  be  used.   SM!
  31. 31. •  “Ensure  conDnuity  of  lockout   or  tagout  protecDon”   •  Employee  from  incoming   shio  MUST  apply  his/her   lockout  device  before   employee  from  outgoing   shio  removes  his/her  device.   •  Communicate  about  the   work  that  has  been  done   SM!
  32. 32. •  If  authorized  employee  is  not  available  to   remove  his  device,  then  the  employer  may   remove  it  IF:   –  Employer  has  procedures  and  training  for  such   removal  in  energy  control  program   –  VerificaDon  that  authorized  employee  is  not  at   the  facility   –  Making  all  reasonable  efforts  to  contact   authorized  employee  to  inform  him/her  that   lockout  device  has  been  removed   –  Ensuring  that  authorized  employee  is  aware   that  his  device  was  removed  before  resuming   work  at  that  facility   SM!
  33. 33. 1.  Conduct  a  hazard  assessment  by  iden'fying  all  equipment   that  is  used,  serviced,  maintained  or  stored   2.  Determine  Lockout/Tagout  requirements  for  all  equipment,   iden'fying  and  documen'ng  all  energy  sources:   •  Type  of  Hazard   •  LocaDon  on  the  equipment   •  Proper  isolaDon  and  lockout  device/procedure   •  How  to  dissipate  the  stored  energy   •  How  to  verify  the  isolaDon   3.  Create  procedures  and  procure  necessary  Lockout/Tagout   hardware   4.  Train  all  employees  in  facility  and  document  the  training   5.  Put  in  place  process  for  inspec'ons,  retraining...   SM!
  34. 34. 1.  Only  work  on  equipment  “hot”  or  “live”  if  it  absolutely   unavoidable   2.  Lockout  over  Tagout   3.  Facility  specific  and  machine  specific   4.  Don’t  forget  about  secondary  energy  sources  or  stored   energy   5.  Use  annual  inspecDons,  regular  training  (annually   suggested),  and  discipline  to  avoid  complacency   6.  Lockout/Tagout  is  only  one  part  of  a  complete  and  effecDve   safety  program  (safety  ID,  PPE,  etc.)   SM!
  35. 35. Watch  Lockout/Tagout   Training  Video   SM!
  36. 36. •  OSHA  1910.147   •  NFPA  70E  (2009)   •  NEC  2008   •  www.osha.gov   •  www.nfpa.org   •  Your  company  Lockout/Tagout  procedure   SM!