Control of Hazardous Energy

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Lockout / Tagout

• Control of Hazardous Energy
• OSHA Standard 29CFR1910.147
• MIOSHA PART 85 - The Control of Hazardous Energy
  Sources

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Case Study 1
An employee was cleaning the unguarded side of an
operating granite saw. The employee was caught
in the moving parts of the saw and pulled into a
nip point between the saw blade and the idler
wheel resulting in fatal injuries.
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Case Study 2
A trainee employee was cleaning a flour batch
mixer. The employee was reaching into the
machine when another worker activated the wrong
switch turning the machine on. The employee
cleaning the mixer suffered fatal crushing
injuries to his neck. There was an unwritten
company procedure for locking out during all
maintenance. The procedure was not followed.
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Case Study 3
An employee was cleaning scrap from beneath a
large shear when a fellow employee hit the
control button activating the blade. The blade
came down and decapitated the employee cleaning
the scrap.
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WHAT DO ALL OF THESE LOSSES HAVE IN COMMON?
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FAILURE TO
LOCKOUT / TAGOUT
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You will learn

• Four Es of LOTO
• Purpose of LOTO
• Requirements for LOTO
• Types of Hazardous Energy
• Procedures for LOTO

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Four Es of LOTO
E

• Energy
• Engineering
• Education
• Enforcement

E
E
E
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Energy

• More than just switching a machine on/off
• Energy is dangerous when it is strong enough to
  injure your body
• Types of energy include
• Kinetic
• Potential

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Types of Energy

• Electrical
• Mechanical
• Thermal
• Hydraulic
• Pneumatic

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Mechanical Energy Hazards

• 2 Types
• Kinetic - In Motion
• Potential - Stored

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Kinetic Energy Hazards

• Energy of moving machinery can cause
• Amputations
• Lacerations
• Fractures
• Loss of life

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Potential Energy Hazards

• Energy stored in machinery
• Weights Springs
• Pistons under pressure
• Hydraulic controls
• Stored potential energy can be released during
  work causing injury or death

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Chemical Hazards

• Some chemicals can
• Start fires
• Cause skin burns
• Generate harmful gases, vapors, or fumes
• Before working release, drain, or vent
  chemicals safely

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Thermal Energy Hazards

• Hazards of Heat and Cold
• Hot equipment and fluids can burn you
• Very cold fluids can cause injury
• Quick release of compressed gases can freeze your
  skin
• Allow equipment to reach a safe temperature
  before starting work

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Hydraulic Energy

• Energy of Liquids Under Pressure
• Pressure can cause equipment to move
• Rapid release can cause injury
• Rapid release can also cause the ejection of
  system parts
• Relieve pressure slowly into a proper container

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Pneumatic Energy Hazards

• Energy of Compressed Gases
• Uncontrolled release can cause injury
• Rapid depressurization can create extremely low
  temperatures
• Properly vent all systems before starting work

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Engineering

• Do not bypass safety devices - they are designed
  for your protection!
• Engineered mechanisms built into machines for
  your safety include
• Mechanical guards
• Mechanical stops (pins, valves)
• Point-of-Operation guards
• Interlocks
• Light curtains

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Education

• Know all places hazardous energy releases might
  occur on each machine you are working on.
• Make sure people in the area know were all energy
  sources are located.
• Review and follow the written OCC Lockout/Tagout
  Program.

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First Step In LOTO

• Know your equipment and systems
• Hazards
• Isolation points
• Machine-specific procedures for lockout / tagout
• Working on unfamiliar machinery is a hazard

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When is LOTO necessary?

• To prevent unexpected start-up during
  service/maintenance
• There is the potential for the hazardous release
  of stored energy
• Safety devices are bypassed for service
• Body is exposed to hazardous energy
• Clearing jams
• Electrical repairs

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Energy Isolation

• Machine specific LOTO instructions
• Required if more than one power source involved
• Identifies isolation points
• Many different scenarios possible
• LOTO devices are assigned to specific affected
  employees

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Use Safe Electrical Practices

• Use non-conducting tools
• Check that circuits are dead before working
• Lock Tag source breakers, not switches
• Ensure all control power is de-energized
• Discharge all capacitors after Lockout

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• Energy Isolation
• Identify potential sources of hazardous energy
  release
• Identify method(s) for isolating the energy
• Document procedures for each piece of equipment

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Enforcement

• Know the results of tampering with or not
  following complete LOTO procedures
• LOTO procedures have been established to protect
  OCC employees from serious injury or death.
• Failure to comply with OCC LOTO policies and
  procedures can result in disciplinary actions up
  to, and including, dismissal.

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Who Can Lockout Equipment?

• Employees who have been trained and authorized by
  management ONLY!

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Contractors

• All contract employees must follow OCC LOTO
  procedures!

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Items Needed for LOTO

• Written LOTO schedule
• Locks Tags - specific to the worker
• Hasps - for placing locks tags
• Breaker Clips - for electrical LOTO
• Blank Flanges (Pancakes) - for fluid lines
• Valve Covers - for LOTO of valves
• Plug Buckets - for electrical plugs

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Use of Locks and Tags

• Use only those issued to you
• Never use another workers lock or tag
• Ask your supervisor if you need more LOTO
  equipment

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Who Can Remove Locks and Tags?

• The employee who placed the tag
• or
• A supervisor, after obtaining permission from the
  worker who placed the tag
• NO EXCEPTIONS!

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Q A piece of equipment already has a lock and
tag.  Do I have to place my own locks and tags?
Frequently Asked Questions

• A YES.  Each person working on the equipment
  must place their own locks and tags to ensure
  their safety.

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Procedures for Lockout / Tagout

• Remember
• Know your equipment and systems before proceeding
• Hazards
• Isolation points
• Procedures for Lockout
• Working on unfamiliar machinery is a hazard!

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6 Step LOTO Procedure

• Prepare for shutdown
• Shut down equipment
• Isolate all energy sources
• Place Locks and Tags
• Release stored energy
• Verify equipment isolation

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1  Prepare for Shutdown

• Understand equipment hazards
• Notify other workers of shutdown

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2  Shutdown Equipment

• Use normal shutdown procedures
• Turn all switches to OFF
• Shut all control valves
• Disable all sources of energy

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3  Isolate All Energy Sources

• Shut valves
• Open breakers and disconnects

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4 Place Locks Tags On

• Shut off and lock valves
• Deactivate and lock breakers / electrical
  disconnects
• Block or disconnect all lines
• Lock and tag blank flanges

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5  Release or Block All Stored Energy

• Discharge capacitors
• Block or release springs
• Block elevated parts
• Stop rotating flywheels
• Relieve system pressure
• Drain fluids
• Vent gases
• Allow system to cool

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6  Verify Equipment Isolation

• Ensure that all other workers are clear
• Check that locking devices are securely placed
• Check isolation
• Attempt normal startup (should fail!)
• Return controls to OFF/Neutral

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Release from Locked Out / Tagged Out Status

• Inspect area and equipment
• Ensure all machine guards are in place
• Move tools away from equipment
• Inform others of startup
• Restore system connections
• Remove Locks Tags
• Restore equipment to normal operating parameters
• Conduct normal startup

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Lockout / Tagout Protects YOU!??

• Use Proper Lockout / Tagout Procedures