Lockout Tagout

1
Lockout - Tagout

• Subpart J

2
Fatal Five

• Failure to stop equipment
• Failure to disconnect from power source
• Failure to dissipate (bleed, neutralize) residual
  energy
• Accidental restarting of equipment
• Failure to clear work areas before restarting

3
Scope and Application

• Applies to general industry
• Covers operators and service personnel

4
When is LOTO Required?

• Servicing or maintaining equipment where
• Hazardous energy exists
• Unexpected start-up could occur
• Either of these could harm an employee

5
LOTO Shall Be Used When

• Employees are required to remove or bypass a
  safety device
• Employees are required to place any part of their
  body in harms way
• Employees are exposed to hazardous energy

6
LOTO Exceptions

• Work where hazardous energy does not exist
• Activities performed during routine production
  processes
• Work on cord-controlled devices
• Hot tap operations where shutdown is not feasible

7
Typical Equipment Requiring LOTO

• Presses
• Saws
• Conveyors
• Pumps
• Production Equipment
• Trash Compactors
• Ovens

8
Energy Sources

• Mechanical
• Chemical
• Thermal
• Hydraulic
• Pneumatic

• Electrical
• Gas
• Water
• Other stored energy
• (i.e. springs, capacitors)

9
Affected Employees

• Employees who
• Operate
• Work around
• Occasionally adjust equipment that is subject to
  lockout tagout

10
Authorized Employee

• Maintains equipment
• Services equipment
• Is trained to use lockout tagout procedures

11
Energy Control Program

• Energy control procedures
• Periodic inspections
• Employee training

12
Procedures

• Must clearly and specifically outline the
• Scope
• Purpose
• Authorization
• Rules
• Lockout-tagout techniques
• Means to enforce compliance

13
Procedures

• Statement of intended use of the procedure
• Specific energy control steps for
• Shutting down
• Isolating
• Blocking
• Securing equipment

14
Procedures

• Specific steps for LOTO device
• Placement
• Removal
• Transfer
• Responsibility

15
Procedures

• Requirements for testing equipment to determine
  and verify the effectiveness of lockout devices,
  tagout devices, and other energy control measures

16
Where to Begin

• Conduct a hazard assessment by identifying each
  piece of equipment that is used, serviced, or
  maintained
• Include broken or stored equipment
• Determine the requirements for lockout
• If there is more than one primary energy source
  to the equipment, document each source

17
Where to Begin

• Document all energy sources
• Hidden
• Direct
• The hazard posed
• The magnitude or measurable degree of danger
• Special or unusual conditions
• Proper isolations and devices

18
Types of Lockout Devices

• Locks
• Blocks
• Chains
• Multilock hasps
• Wheel valve covers
• Ball valve covers

19
Requirements For Lockout/Tagout Devices

• Durable
• Standardized
• Substantial
• Identifiable

20
Periodic Inspections

• At least annually
• Ensure procedures are implemented properly
• Ensure employees are familiar with their
  responsibilities
• Correct any deviations or inadequacies identified

21
Designating an Inspector

• Periodic inspections must be performed by an
  authorized employee other than the one(s) using
  the energy control procedure
• Who can inspect
• Department manager
• Plant management
• Safety manager
• Others

22
Employee Reviews

• Lockout
• Review between the inspector and each authorized
  employee
• Review each employees responsibility
• Tagout
• Review between the inspector and each authorized
  and affected employee
• Review each employee's responsibility
• Review the limitations of tags

23
Inspection Certification

• Must certify that the required periodic
  inspections have been performed
• Certification must identify the following
• Equipment on which the energy control procedure
  was used
• Date of the inspection
• Employee(s) included in the inspection
• Person performing the inspection

24
Training Requirements

• Authorized employees
• initially and at least annually
• Affected employees
• at least initially
• Authorized and affected
• whenever changes are made to jobs or procedures
• when program deficiencies are noted
• Certification

25
Authorized Employee Training

• Purpose of the procedure
• Recognition of applicable hazardous energy
  sources
• Type and magnitude of the energy available in the
  workplace
• Means and methods necessary for energy isolation
  and control
• Ways to verify that energy isolation is effective

26
Affected Employee Training

• Instruction on the the purpose and use of the
  energy control system
• Awareness

27
Other Employee Training

• All other employees (including new hires) whose
  work operations are or may be in an area where
  lockout/tagout may be utilized
• Instruction must include
• Purpose of the procedure
• Prohibition of starting or reenergizing any
  locked-out or tagged-out equipment they encounter
  

28
Retraining

• Authorized and affected employees
• Change in job assignment
• Change in equipment, machinery, or processes that
  presents a new hazard
• Change in the lockout/tagout procedure

29
Retraining

• Shall be conducted whenever a periodic inspection
  reveals, or the employer has reason to believe,
  that there are deviations from or inadequacies in
  the employee's knowledge or use of the
  lockout-tagout procedures

30
Group Lockout/Tagout

• Procedure must afford the employees a level of
  protection equivalent to that provided by the
  implementation of a personal lockout-tagout
  device

31
Group Lockout/Tagout

• Primary responsibility is vested in an authorized
  employee who must
• ascertain the exposure status of individual group
  members
• coordinate affected work forces (i.e. crews,
  departments, crafts)

32
Group Lockout/Tagout

• Each authorized employee must
• Affix a personal lockout-tagout device to the
  group lockout device or box when he/she begins
  work
• Remove those devices when he/she stops working on
  the equipment being serviced or maintained

33
Shift or Personnel Changes

• Procedures must ensure
• Continuity of lockout/tagout protection
• Orderly hand-off of lockout of lockout/tagout
  devices

34
Testing or Positioning of Machines

• OSHA allows the temporary removal of locks or
  tags and the re-energization of the equipment
  only when necessary under special conditions
• for example, when power is needed for the testing
  or positioning of equipment

35
Testing or Positioning of Machines

• Must be conducted in following sequence
• Clear the equipment of tools and material
• Vacate employees from the equipment area
• Remove the lockout-tagout device as specified in
  the standard (the authorized employee who applied
  it must remove it)
• Energize the equipment and proceed with testing
  or positioning
• De-energize all systems, isolate the equipment
  from the energy source, and reapply the
  lockout-tagout devices

36
Contractors

• Must inform each other of all applicable
  lockout/tagout procedures
• Both employer and contractor must ensure that
  their employees understand and will respect the
  others Energy Control Program

37
Typical Shutdown Procedure

• Notify affected employees
• Use the specific procedures as outlined for the
  appropriate situation
• Shut off energy source(s) to affected equipment
• Use normal stopping or running procedures for the
  machine
• Isolate the equipment from the energy source

38
Typical Shutdown Procedures

• Affix locks and tags to each energy source
  controlling device
• Relieve all stored energy from capacitor banks,
  springs, compressed air, steam, hydraulics, etc.
  
• Verify isolation of energy has occurred by trying
  equipment

39
Removal of Lockout/Tagout and Start-Up Procedures

• Ensure that nonessential items are removed from
  equipment
• Ensure that equipment components are intact
• Check area to ensure that all affected employees
  are safely positioned or removed from the area

40
Removal of Lockout/Tagout and Start-Up Procedures

• Notify all affected employees and site supervisor
  before reenergizing the equipment
• Remove lockout/tagout devices
• Reenergize equipment to ensure safe operation

41
Summary

• Accidents will happen
• Equipment will occasionally malfunction
• People will still make mistakes
• There is no excuse for serious injury that
  results from ignorance, carelessness,
  complacency, or lack of an Energy Control Program

42
(No Transcript)