Lockout/Tagout

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Lockout/Tagout
What This Training Will Cover
Who needs training? What is hazardous
energy? What is lockout/tagout? What are the
different types of lockout devices? What is the
requirement for tags? What lockout/tagout
procedures are required?
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Who Needs Training?

• Authorized employees people who lock or tag out
  machines or equipment to perform servicing.
• Affected employees people who use machines or
  equipment on which servicing is performed under
  lockout/tagout.
• Other employees people who work in the area of
  locked out machinery or equipment

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What is Hazardous Energy?
Hazardous energy is any of the following
Electricity live or stored
Moving machinery parts
Stored mechanical movement in machinery
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What is Hazardous Energy?
Stored heat (steam lines or hot
liquids) Hazardous chemicals in pipelines under
pressure or force of gravity Any other active
or stored energy sources that could harm a
worker --such as
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Hazardous Energy Source Examples
Live electrical lines Electrical
capacitors Lasers Engines that move machinery
parts Hydraulic lifts Pneumatic (air pressure)
lines Pressurized water lines Springs
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Lockout/Tagout and Confined Spaces
Lockout/Tagout is important in confined spaces
since it is easy to get trapped and hard to
escape. Pipelines leading into tanks must be
blanked off before entering the space. All
electrical and mechanical hazardous energy must
be addressed and locked out or tagged as needed.
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Our Hazardous Energy Sources (examples)
The following hazardous energy sources require
lockout/tag-out procedures

• Examples
• Laboratory equipment (examples)
• Field equipment (examples)
• Inventory list example (handout)
• Please refresh the inventory list for your
  laboratory or site

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What kind of injuries can happen?
Electrocution from live parts Scalding from steam
or hot liquids Chemical burns or poisoning From
machinery - Deep cuts and gashes - Crushing
injuries - Amputations All of these can be fatal
when severe
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Fatality Example
A man working inside a supermarket cardboard
compactor was crushed when the
unblocked compactor suddenly came down on top of
him.
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More Examples
Three men were doing maintenance inside an
asphalt pug mill mixer. One employee was still
inside the mixer when the power was turned back
on, thereby starting the mixer. He was killed
instantly. Cause failure to disconnect power
source and lock out. A cotton gin operator
climbed into a jammed cotton cleaner/separator.
The toggle switch controlling the operation of
the gin was turned off but not locked out. For
some reason, someone accidentally turned the
machine back on, not knowing the gin operator was
inside the gin. His leg was pulled through the
feed rollers. Cause failure to disconnect power
source and lock out. A warehouseman was
repairing an air-operated valve which he had
turned off but not disconnected and locked out.
During the repair operation he slipped and
inadvertently turned on the switch which let air
into the valve. His hand was caught and crushed
in the valve. Cause failure to disconnect power
source and lock out.
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More Examples
A maintenance employee was changing V-belts on an
exhaust fan. He de-energized the fan before
starting work. However, he did not block the
blades of the fan. The suction in the duct work
turned the fan blades, and his hand was caught in
the V-belt drive. Cause failure to block out
potential energy sources. One study on servicing
equipment injuries found that 80 percent of the
workers surveyed failed to even turn off the
equipment before performing the service work.
There is a difference between turning off a
machine and actually disengaging or de-energizing
a piece of equipment. When you turn off a control
switch, you are opening a circuit. There is still
electrical energy at the switch, and a short in
the switch or someone inadvertently turning on
the machine may start the machine running
again. Of the 20 percent of the injured workers
who did turn off the machinery, about half of
them were injured when someone, generally a
coworker who was unaware that the machine was
being serviced, accidentally reactivated the
machinery.
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More Examples
Of those workers who turned off the control
switch, another 20 were injured by the energy
still in the machine which should have been
blocked. The moving parts of the machine either
continued to coast, or the parts moved when a jam
was cleared. In an accident in California, a
table saw was turned off, but the saw blade was
still silently coasting and had not come to a
complete stop. An employee began cleaning the
machine, and his finger was amputated by the
blade. Other accidents have occurred when the
control switch on a machine was turned off, but a
short in the switch restarted the
machine. Accidents have also occurred even when
workers did take the necessary steps of
disconnecting the main power source. But they did
not perform a crucial step for a complete lockout
procedure They did not test the equipment to
make sure the machinery was, in fact,
de-energized. One case, the lockout had been
done on the wrong power line. In another case, a
second power line had been spliced into the
wiring beyond the point of the lockout.
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When is Lockout/Tag-out required?
When someone will be servicing or repairing
machinery or equipment AND the unexpected
machinery start-up or release of stored energy
could cause injury
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Service and Maintenance Examples

• Installing, constructing,
• adjusting, modifying,
• unjamming, cleaning,
• lubrication, inspecting,
• setup - preparing for normal function

These activities often require a worker to place
all or part of their body into the machines
hazard zone (the line of fire).
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What is an energy-isolating device?
A device that physically prevents transmission or
release of energy such as
An electrical circuit breaker,
A pipeline valve,
A machine block,
Anything else that positively blocks or isolates
energy.
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What is a Lockout Device?
A device that positively prevents a machine
from being started up or turned on, prevents a
machinery part from moving, prevents electrical
energizing, blocks a pipeline, steam line or air
line
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Electrical Lockout Devices
Locked out circuit breaker
Locked out electrical panel
Locked out electrical plug
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Fluid Gas Lockout Devices
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Pipe Lockout Examples
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Pneumatic Lockout Examples
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Physical Blocks
Punch press blocks
Truck bed lockout
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Group Lockout Devices
Used when more than one person doing maintenance
or repair on same machine or equipment. Machinery
or equipment cant be started up until all locks
are removed. Each person places and removes
their own lock.
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Example of a bad lockout/tagout
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Lockout Devices We Use
Personally-identified lock E-Z Panel LocTM
snap-on breaker lockout device More examples?
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What is Tag-out?
Tags are warning devices only
They dont provide the same level of protection
as lockout devices. We only use for information,
along with a locked device. They can only be
removed by an authorized person. They must be
legible (use a sharpie), securely attached (e.g.,
zip-tie not string) and resistant to degradation.
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Energy Control Program

• Our energy control program consists of
• Training for Authorized and Affected employees
• A current inventory of equipment requiring
  lockout
• A description of general energy control
  procedures,
• Development and use of a specific written
  stepwise procedure for all equipment on the
  inventory and
• Periodic inspection of the implementation of the
  energy control procedures

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Lockout Procedures
Six Steps to Follow

• Notify affected employees (anybody in the area)
  that the machine or equipment will be shut down
  and locked out
• 2. Shut down the machinery or equipment using
  normal procedure
• 3. Isolate energy sources with energy-isolating
  devices

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Lockout Procedures
Six Steps
4. Lock out energy-isolating devices with
assigned locks. 5. Release or restrain stored
or residual energy (capacitors, pressure, vacuum,
blades, etc.) 6. Test machinery to make sure it
cant start up (use the normal start procedure)
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Single Breaker Lock Use
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Dual Breaker Lock Use
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Lockout Steps
Shutdown Equipment
Isolate Energy
Notify employees
Release Stored Energy
Attach Lockout Device
Verify Lockout
Service Maintenance
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Examples of Release of Stored Energy

• Slowly open the receiver tank port and bleed off
  any internal pressure.
• Loosen both line valves to relieve all pressure
  in the cooling circuit.
• Ground out capacitor

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Examples of Attempt to Operate

• adjust the temperature cycle thermostat to
  check that all electrical inputs have been shut
  off.
• Push the start function button to verify that
  electric power has been removed.
• Crack the steam inlet and discharge line outlet
  valves

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Start-up Procedures
Only Authorized employee can do startup
Warn everyone present to stay clear Remove all
tools, locks and tags Remove, reverse, open or
reactivate isolating devices Visual check that
all is clear Start up machine, process or line
flow
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