This document discusses lockout/tagout procedures for equipment maintenance at a concentrate plant. It defines key terms, outlines the steps for locking out equipment including verifying isolation and restoring energy. Special considerations for contractors, shift changes and abandoned locks are also reviewed. Quizzes are included to reinforce the proper lockout/tagout procedures.

1. Control of Hazardous EnergyControl of Hazardous Energy
LLOCKOCKOOUT/UT/TTAGAGOOUTUT
Plant Asset ProtectionPlant Asset Protection

2. Lockout/TagoutLockout/Tagout
If you have any questionsIf you have any questions
about the presentation,about the presentation,
please contact:please contact:
Plant Asset Protection (PAP)Plant Asset Protection (PAP)
 Local 388 - Plant Shift-in-ChargeLocal 388 - Plant Shift-in-Charge
 Local 375 - PAP ManagerLocal 375 - PAP Manager

3. Lockout/TagoutLockout/Tagout
 Purpose of Lockout/TagoutPurpose of Lockout/Tagout
 ScopeScope
 DefinitionsDefinitions
 Step by Step InstructionStep by Step Instruction

4. Lockout/Tagout – Common ExcusesLockout/Tagout – Common Excuses
 This job will only take a few minutes. I don’t need
to lock it out.
 I’ve done this work for 20 years. I know what I’m
doing. I don’t need to lock it out.
 I’m in a hurry. I’ve locked the equipment out. I’m
sure it’s okay. I don’t need to verify it.
 There are two of us working on the equipment.
There is no need for both of us to lock it out. I’ll
work under my partner’s lock.

5. Lockout/Tagout – Top 5 ReasonsLockout/Tagout – Top 5 Reasons
1.1. Your life is on the lineYour life is on the line
2.2. Your family and friends love and need youYour family and friends love and need you
3.3. Your co-workers depend on you being aroundYour co-workers depend on you being around
4.4. It’s a company requirementIt’s a company requirement
5.5. It’s a regulatory requirementIt’s a regulatory requirement

6. Lockout/Tagout – PurposeLockout/Tagout – Purpose
The Concentrate Plant has establishedThe Concentrate Plant has established
requirements for Lockout/Tagout ofrequirements for Lockout/Tagout of
equipment during servicing andequipment during servicing and
maintenance to ensure:maintenance to ensure:
 equipment is isolated & locked or taggedequipment is isolated & locked or tagged
out from all potentially hazardous energyout from all potentially hazardous energy
 where the unexpected energization orwhere the unexpected energization or
release of such energy could cause injury.release of such energy could cause injury.

7. Lockout/Tagout – ScopeLockout/Tagout – Scope
Lockout/Tagout covers:Lockout/Tagout covers:
SERVICING and MAINTENANCESERVICING and MAINTENANCE ofof
machines and equipment in whichmachines and equipment in which
the unexpected energization, start-the unexpected energization, start-
up or release of energy could causeup or release of energy could cause
injury to employees.injury to employees.

8. Lockout/Tagout – ScopeLockout/Tagout – Scope
SERVICING and MAINTENANCESERVICING and MAINTENANCE includes:includes:
•Constructing
•Installing
•Setting upSetting up
•AdjustingAdjusting
•Inspecting
•Modifying
•ServicingServicing
•MaintenanceMaintenance

9. Lockout/Tagout – ScopeLockout/Tagout – Scope
Lockout/Tagout is not requiredLockout/Tagout is not required
for maintenance or servicingfor maintenance or servicing
performed during normalperformed during normal
productionproduction unlessunless itit
requires:requires:
 Removal of a guardRemoval of a guard
 Bypass of a safety deviceBypass of a safety device
 Placement of any part of thePlacement of any part of the
body in point of operation orbody in point of operation or
other danger zoneother danger zone

10. Lockout/Tagout – DefinitionsLockout/Tagout – Definitions
LOCKOUTLOCKOUT
 Placement of a lockoutPlacement of a lockout
device on an energydevice on an energy
isolating device, inisolating device, in
accordance with anaccordance with an
established procedure.established procedure.

11. Lockout/Tagout – DefinitionsLockout/Tagout – Definitions
TAGOUTTAGOUT
 Placement of a tagoutPlacement of a tagout
device on an energydevice on an energy
isolating device, inisolating device, in
accordance with anaccordance with an
established procedure.established procedure.

12. Lockout/Tagout – DefinitionsLockout/Tagout – Definitions
AUTHORIZED PERSONAUTHORIZED PERSON
A duly trained personnelA duly trained personnel
who locks or tagswho locks or tags
machines or equipmentmachines or equipment
to perform maintenanceto perform maintenance
or servicingor servicing

13. Lockout/Tagout – DefinitionsLockout/Tagout – Definitions
AFFECTED PERSONAFFECTED PERSON
A person whose jobA person whose job
requires him/her torequires him/her to
operate or work in anoperate or work in an
area where servicing isarea where servicing is
being performed underbeing performed under
Lockout/Tagout.Lockout/Tagout.

14. Lockout/Tagout – DefinitionsLockout/Tagout – Definitions
SOURCES OF ENERGYSOURCES OF ENERGY
Energy needed to operateEnergy needed to operate
the machine or equipmentthe machine or equipment
 ElectricalElectrical
 HydraulicHydraulic
 PneumaticPneumatic
 MechanicalMechanical
 Process PipingProcess Piping
 ThermalThermal
 StoredStored

15. Lockout/Tagout – DefinitionsLockout/Tagout – Definitions
ENERGY ISOLATING DEVICEENERGY ISOLATING DEVICE
Mechanical device that prevents theMechanical device that prevents the
transmission or release of energytransmission or release of energy
 Electrical circuit breakerElectrical circuit breaker
 Disconnect switchDisconnect switch
 Line valveLine valve
 Slip blindSlip blind
Note: Push button, selector switches,Note: Push button, selector switches,
emergency stops and other control devicesemergency stops and other control devices
are NOT energy isolating devicesare NOT energy isolating devices

16. Lockout/Tagout – DefinitionsLockout/Tagout – Definitions
Lockout/Tagout Devices mustLockout/Tagout Devices must
be:be:
 DurableDurable
 StandardizedStandardized
 SubstantialSubstantial
 IdentifiableIdentifiable

17. Lockout/Tagout – InstructionsLockout/Tagout – Instructions
1.1. Know the EquipmentKnow the Equipment
2.2. Notify Affected PersonsNotify Affected Persons
3.3. Shutdown equipment byShutdown equipment by
normal procedures (Ifnormal procedures (If
possible)possible)
4.4. Isolate Equipment byIsolate Equipment by
operating energy isolatingoperating energy isolating
devices.devices.

18. Lockout/Tagout – InstructionsLockout/Tagout – Instructions
5.5. Apply locks to devicesApply locks to devices
6.6. Dissipate stored energyDissipate stored energy
7.7. VERIFY Lockout isVERIFY Lockout is
effectiveeffective

19. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
The next step after locking out theThe next step after locking out the
energy sources & dissipating theenergy sources & dissipating the
stored energy is:stored energy is:
a)a) Take a coffee breakTake a coffee break
b)b) Perform servicing/maintenancePerform servicing/maintenance
c)c) Verify the LockoutVerify the Lockout
d)d) None of the aboveNone of the above

20. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

21. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
VERY GOOD!VERY GOOD!
C. IS THE CORRECTC. IS THE CORRECT
ANSWER!ANSWER!
Always verify ifAlways verify if
lockout/tagoutlockout/tagout
performed isperformed is
effective.effective.

22. Lockout/Tagout – InstructionsLockout/Tagout – Instructions
Verification of Lockout includes:Verification of Lockout includes:
 Push controls buttons, turn knobs,Push controls buttons, turn knobs,
etc.etc.
 Use voltage meter for electricalUse voltage meter for electrical
work (If the employee could bework (If the employee could be
exposed to live circuits)exposed to live circuits)
 (For circuits above 600 volts, check(For circuits above 600 volts, check
meter against a known source,meter against a known source,
before & after use)before & after use)

23. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
When performing maintenance whereWhen performing maintenance where
the employee could be exposed tothe employee could be exposed to
live electrical circuits, verification islive electrical circuits, verification is
accomplished by turning/pushingaccomplished by turning/pushing
control knobs/buttons.control knobs/buttons.
TRUETRUE
FALSEFALSE

24. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

25. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
VERY GOOD!VERY GOOD!
The answer isThe answer is FalseFalse
Verification isVerification is
accomplished byaccomplished by
using a voltmeter.using a voltmeter.
This must beThis must be
performed by aperformed by a
qualified person.qualified person.

26. Lockout/Tagout – InstructionsLockout/Tagout – Instructions
ENERGY RESTORATIONENERGY RESTORATION
1.1. Check that tools/parts areCheck that tools/parts are
removedremoved
2.2. Check for people in hazardousCheck for people in hazardous
locationslocations
3.3. Replace guards & safety devicesReplace guards & safety devices
4.4. Notify all Affected employeesNotify all Affected employees

27. Lockout/Tagout – InstructionsLockout/Tagout – Instructions
ENERGY RESTORATIONENERGY RESTORATION
5.5. Ensure all controls are in theEnsure all controls are in the
“OFF” position“OFF” position
6.6. Remove Locks & TagsRemove Locks & Tags
7.7. Restore EnergyRestore Energy
8.8. Ensure Equipment isEnsure Equipment is
operationaloperational

28. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
During energy restoration the authorized personDuring energy restoration the authorized person
should:should:
a.a. Check that tools and people are clearedCheck that tools and people are cleared
b.b. Guards and safety devices have been replaced and arGuards and safety devices have been replaced and ar
c.c. All controls are in the “OFF” PositionAll controls are in the “OFF” Position
d.d. All of the aboveAll of the above

29. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

30. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
VERY GOOD!VERY GOOD!
D is the correctD is the correct
answeranswer

31. Lockout/Tagout – InstructionsLockout/Tagout – Instructions
IMPORTANT POINTS TO CONSIDERIMPORTANT POINTS TO CONSIDER
Lockout/Tagout is the requiredLockout/Tagout is the required
method of isolating machinesmethod of isolating machines
from the energy sourcefrom the energy source
Only Authorized EmployeesOnly Authorized Employees
may lock/tag out equipment.may lock/tag out equipment.

32. DO NOT ATTEMPT TO OPERATEDO NOT ATTEMPT TO OPERATE
ANY ENERGY ISOLATING DEVICEANY ENERGY ISOLATING DEVICE
WHERE IT IS LOCKED ANDWHERE IT IS LOCKED AND
TAGGED OUT.TAGGED OUT.
Lockout/Tagout – InstructionsLockout/Tagout – Instructions
IMPORTANT POINTS TO CONSIDERIMPORTANT POINTS TO CONSIDER
All equipment must be lockedAll equipment must be locked
and tagged out to protectand tagged out to protect
against accidental oragainst accidental or
inadvertent operation whichinadvertent operation which
could cause injury to personnel.could cause injury to personnel.

33. Lockout/Tagout – InstructionsLockout/Tagout – Instructions
CONTRACTORSCONTRACTORS
TCCEC and the contractor must inform eachTCCEC and the contractor must inform each
other of their respective lockout/tagoutother of their respective lockout/tagout
procedures.procedures.
The two parties must coordinate theThe two parties must coordinate the
implementation of the procedures.implementation of the procedures.
The contractor’s employees and TCCECThe contractor’s employees and TCCEC
engineering personnel must perform theengineering personnel must perform the
lockout/tagout and verificationlockout/tagout and verification

34. Lockout/Tagout – InstructionsLockout/Tagout – Instructions
SHIFT CHANGESHIFT CHANGE
There must be a procedure or methodThere must be a procedure or method
to ensure the continuity of theto ensure the continuity of the
Lockout during shift or personnelLockout during shift or personnel
changes.changes.

35. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
When an outside contractor’s work requires aWhen an outside contractor’s work requires a
lockout/tagout:lockout/tagout:
a.a. TCCEC and the contractor must inform eachTCCEC and the contractor must inform each
other of their Lockout/Tagout proceduresother of their Lockout/Tagout procedures
b.b. The two parties must coordinate theThe two parties must coordinate the
implementation of the procedures.implementation of the procedures.
c.c. Both a and bBoth a and b
d.d. None of the aboveNone of the above

36. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

37. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
VERY GOOD!VERY GOOD!
C is the correctC is the correct
answeranswer

38. Lockout/Tagout – InstructionsLockout/Tagout – Instructions
ABANDONED LOCKABANDONED LOCK
In general, only the person who applied theIn general, only the person who applied the
lock should remove it.lock should remove it.
The PAP Manager may have the lockThe PAP Manager may have the lock
removed by another authorized person,removed by another authorized person,
under the following conditions:under the following conditions:
 All reasonable attempts have beenAll reasonable attempts have been
made to contact the person whomade to contact the person who
abandoned the lockabandoned the lock
 It has been determined that theIt has been determined that the
equipment is safe to operateequipment is safe to operate

39. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
Who should normally remove the lock of anWho should normally remove the lock of an
authorized employee?authorized employee?
a.a. The Plant Asset Protection ManagerThe Plant Asset Protection Manager
b.b. The authorized employee performingThe authorized employee performing
lockoutlockout
c.c. Another Authorized employeeAnother Authorized employee
d.d. All of the aboveAll of the above

40. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
INCORRECT ANSWER, LET’S REVIEWINCORRECT ANSWER, LET’S REVIEW

41. Lockout/Tagout – REVIEWLockout/Tagout – REVIEW
VERY GOOD!VERY GOOD!
B is the correctB is the correct
answeranswer
Under normalUnder normal
conditions, only theconditions, only the
person who appliedperson who applied
the lock shouldthe lock should
remove it.remove it.

42. Lockout/TagoutLockout/Tagout
LOCK ITLOCK IT
TAG ITTAG IT
VERIFY ITVERIFY IT

43. Lockout/TagoutLockout/Tagout
QUESTIONS?QUESTIONS?
COMMENTS?COMMENTS?
SUGGESTIONS?SUGGESTIONS?
VIOLENT REACTIONS?VIOLENT REACTIONS?

44. Safety is Everyone’s Responsibility!Safety is Everyone’s Responsibility!
Safety
Safety