Lock Out/Tag Out Training

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Lock Out/Tag Out Training

• OSHA 29 CFR 1910.147

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Why Lockout/Tagout?

• Approximately 3 million workers service equipment
  and face the greatest risk of injury if
  lockout/tag out is not properly implemented.
  Compliance with the lockout/tag out standard (29
  CFR 1910.147) prevents an estimated 120
  fatalities and 50,000 injuries each year. Workers
  injured on the job from exposure to hazardous
  energy lose an average of 24 workdays for
  recuperation.

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WHO MUST BE TRAINED?

• Anyone who may have reason to be in an area where
  energy control procedures are used.

LOTO

• Training must be completed on an annual basis.

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LOCKOUT

• Lockout is a technique used to block the flow of
  hazardous energy from the power source to the
  equipment.
• The placement of a lock and tag on an isolating
  device which ensures that the equipment being
  controlled cannot be re-energized until the
  locking device is removed.

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GOAL

• The ultimate goal of lockout/tag out is to
  protect the safety and health of employees.
• Secondary is the protection of equipment from
  damage.

Lock-Out/Tag-Out is a safety procedure mandated
by OSHA.
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The Fatal Five Main Causes of Lockout/Tag out
Injuries

• FAILURE TO DISSIPATE (BLEED, NEUTRALIZE) RESIDUAL
  ENERGY

• FAILURE TO STOP EQUIPMENT

• FAILURE TO DISCONNECT FROM POWER SOURCE

• FAILURE TO CLEAR WORK AREAS BEFORE RESTARTING
• ACCIDENTAL RESTARTING
• OF EQUIPMENT

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REQUIREMENTS

• Equipment Specific Lockout Procedures
• Authorized Affected Training
• Audits of Proficiency Supervisor Audits for
  Authorized Employees
• Type of Energy Isolating Devices
• Group Lockouts
• Start-Up Alarms

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Definitions

• Affected Employee - one whose job requires
  him/her to operate or use a machine or equipment
  on which servicing or maintenance is being
  performed under lockout, or whose job requires
  him/her to work in an area in which such
  servicing or maintenance is being performed.

• Authorized Employee - one who locks out machines
  or equipment in order to perform the servicing or
  maintenance on that machine or equipment. Must
  have an Audit of Proficiency annually.

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TAG INFORMATION

• Information that may be found on a tag may
  include
• Name of the worker who put it there
• The date and/or time the work began
• Type of work being done
• If you see a Lock-Out Tag that is not legible it
• should be reported immediately to your
• Supervisor.

Only the employee who attached the Lock/Tag can
remove it! No else is Authorized to remove
someone elses Lockout device. (IN only certain
instances can a lockout device be removed by
someone other than who locked out the equipment
originally and it must be Approved by a Manager).
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TAGs

• Tags are essentially warning devices affixed to
  energy-isolating devices, they are not to be
  removed except by the person who applied them.
• Tags must be legible and understandable by all
• employees.
• Tags and their means of attachment must be
• made of materials that will withstand the envir-
• -onmental conditions encountered in the work
• place.
• Tags must be securely attached to the energy-
• isolating devices so that they cannot be detached
  
• accidentally during use.

Authorized
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Locks

• One lock, one key rule.
• Cannot work under another employees lock.
• Any lock that gets damaged or lost should be
  reported immediately.

Authorized
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Hazardous Energy Sources Found in the Workplace

• Electrical
• Generated
• Static
• Mechanical
• Transitional
• Rotational
• Thermal
• Machines or Equipment
• Chemical Reactions

• Potential
• Pressure
• Hydraulic
• Pneumatic
• Vacuum
• Springs
• Gravity

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Types of Lockout Devices

• Plug Locks
• Ball Valve Lockout
• Gate Valve Lockout
• Group Lockout Hasp

• Electrical
• Hydraulic, pneumatic, and other pressurized
  systems

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Lockout Procedure

• Alert the operator (s) that power is being
  disconnected.
• Preparation for Shutdown
• Equipment Shutdown
• Equipment Isolation
• Application of Lockout Devices
• Control of Stored Energy
• Equipment Isolation-Verification

Authorized
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REMEMBER

• Always personally lock the energy-isolating
  device (disconnect, switch, valve, etc.)
• NEVER WORK UNDER ANOTHER PERSONS LOCK (except as
  described in systems lockout).

Authorized
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Energy Control Situations

• All employees including outside contractors must
  utilize energy control procedures prior to
  engaging in any work such as repair, setup,
  maintenance, inspection, installation, or
  adjustment on processes, systems or equipment.

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LOTO Procedure-Area Specific

• The plant will have a designated lock-out/tag-out
  box that contains all the supplies needed to
  safely perform LOTO.
• The plant will also have a LOTO Procedure book
  with all the procedures.
• This book must be signed in and out each time a
  LOTO is performed.

Authorized
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LOCK-OUT STATIONS

• KNOW WHERE THE LOCKOUT STATION IS LOCATED.

• LOCKOUT STATIONS ARE NOT TO BE USED FOR STORAGE
  OF ANYTHING BUT LOCKOUT SAFETY DEVICES AND
  PROCEDURES.

Authorized
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Servicing and/or Maintenance Operations

• If a servicing activity - such as lubricating,
  cleaning, or un-jamming the production equipment
  - takes place during production, the employee
  performing the servicing may be subjected to
  hazards that are not encountered as part of the
  production operation itself. Workers engaged in
  these operations are covered by lockout/tagout
  when any of the following conditions occurs
• The employee must either remove or bypass machine
  guards or other safety devices, resulting in
  exposure to hazards at the point of operation
• The employee is required to place any part of his
  or her body in contact with the point of
  operation of the operational machine or piece of
  equipment or
• The employee is required to place any part of his
  or her body into a danger zone associated with a
  machine operating cycle.

Authorized
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LOTO ProcedureEquipment Specific
MACHINE SPECIFIC

Authorized
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Using Lock-Out/Tag-Out
When normal servicing tasks - such as setting
equipment up, and/or making significant
adjustments to machines - do not occur during
normal production operations, employees
performing such tasks are required to lock-out/
tag-out if they can be injured by unexpected
energization of the equipment. Ask yourself the
question Can I be hurt if this machine starts up?

Authorized
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No Lock-Out/Tag-Out Required

• Always check the Standard Operating Procedure
  (SOP) for the equipment you are operating.

Employees performing minor tool changes and
adjustments and/or other minor service activities
during normal production operations that are
routine, repetitive, and integral to the use of
the production equipment are not covered by the
lock-out/tag-out standard, provided the work is
performed using alternative measures that give
effective protection.
Authorized
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Removal of Lockout

• Employees in the area shall be alerted by a
  clearly audible signal to start-up
• Visual inspection by the operator and a verbal
  warning is permissible on smaller equipment.
• Remove all tools and non-essential items from
  equipment.

Authorized
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Important Rulesto REMEMBER

• Never attempt lockout/tag out procedures unless
  you have been trained and certified by your
  employer under an approved Energy Control
  Program.
• Never loan or share your lock, combination, or
  key with anybody else.
• Always be sure all lockout/tag out devices are
  compatible with the environment in which they
  will be used i.e. corrosive, humid, etc.
• Never use a lockout lock for any other reason
  than lockout.

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Group Lock-Out/Tag-Out
During all group lockout/tagout operations where
the release of hazardous energy is possible, each
authorized employee performing service or
maintenance shall be protected by his/her
personal lockout or tagout device or comparable
mechanism that affords equivalent
protection. Examples of Group LOTO Conveyor
Line, Other

Authorized
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LOCK-OUT/TAG-OUT
STEPS To Effective Lockout

Authorized
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STEP 1- Before the Shutdown

• THE STANDARD (d)(1) "Preparation for Shutdown."
  Before an authorized or affected associate turns
  off a machine or equipment, the authorized
  associate shall have knowledge of the type and
  magnitude of the energy, the hazards of the
  energy to be controlled, and the method or means
  to control the energy

Authorized
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Step 2- Powering Down
THE STANDARD (d)(2) "Machine or Equipment
Shutdown." The machine or equipment shall be
turned off or shut down using the procedures
established for the machine or equipment. An
orderly shutdown must be utilized to avoid any
additional or increased hazard(s) to associates
as a result of the equipment stoppage.

Use the specific procedures for the individual
unit of equipment.
Authorized
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Step 3-Isolating the Power Source

• THE STANDARD (d)(3) "Machine or Equipment
  Isolation." All energy isolating devices that are
  needed to control the energy to the machine or
  equipment shall be physically located and
  operated in such a manner as to isolate the
  machine or equipment from the energy source(s).

This step involves flipping a power switch,
breaking a circuit, closing a valve, etc. If the
equipment has more than one shutdown point, be
sure that all are isolated from power.
Authorized
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Step 4-Applying the Lock/Tag
THE STANDARD (d)(4) "Lockout /Tagout Device
Application. (i) Lockout/tagout devices shall
be affixed to each energy isolating device by
authorized associates. (ii) Lockout devices,
where used, shall be affixed in a manner to that
will hold the energy isolating devices in a
"safe" or "off" position. (iii) Tagout devices,
where used, shall be affixed in such a manner as
will clearly indicate that the operation or
movement of energy isolating devices from the
"safe" or "off" position is prohibited.

Authorized
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Step 5-Releasing Residual Energy
THE STANDARD (d)(5) "Stored energy. (i)
Following the application of lockout or tagout
devices to energy isolating devices, all
potentially hazardous stored or residual energy
shall be relieved, disconnected, restrained, and
otherwise rendered safe. (ii) If there is a
possibility of re-accumulation of stored energy
to a hazardous level, verification of isolation
shall be continued until the servicing or
maintenance is completed, or until the
possibility of such accumulation no longer
exists.

Authorized
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Step 5contd -Releasing Residual Energy
After all LO/TO devices have been applied,
associates must ensure that no hazardous energy
is still stored in the equipment or machinery.
This kinetic energy may be found in flywheels,
steam lines, hydraulic systems, springs,
capacitors, etc. Energy may need bleeding from
capacitors or grounded from electrical circuits.
Steam lines and hydraulic and pneumatic systems
need activated to determine all energy has been
released. Additionally, any water, chemical,
sewer, or other liquid lines need emptied,
e.g. block and bleed.

Authorized
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Step 6-Try to Power Up

• THE STANDARD (d)(6) "Verification of isolation."
  Prior to starting work on machines or equipment
  that have been locked out or tagged out, the
  authorized associate shall verify that isolation
  and de-energization of the machine or equipment
  have been accomplished.

Authorized
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Step 6contd -Try to Power Up
This step requires the associate to turn all
controls of the equipment or machinery in the
"ON" position to ensure that all energy sources
have been isolated and that it will not start up
while work is being performed on it. Before
trying to power up, be sure that no one is near
the equipment or machinery in case the equipment
should operate. Lastly, the associate should
verify that the isolation point cannot be moved
to the "ON" position. The associate can then
perform his servicing or maintenance. .

Authorized
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Removal of Lockout/TagoutStep 1- Machine and/or
Equipment Inspection

• THE STANDARD (e)(1) "The machine or equipment."
  The work area shall be inspected to ensure that
  nonessential items have been removed and to
  ensure that machine or equipment components are
  operationally intact.

Authorized
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Removal of Lockout/TagoutStep 2- Give
Notification to All Associates

• THE STANDARD (e)(2) "associates."
• (i) The work area shall be checked to ensure
  that all associates have been safely positioned
  or removed.
• (ii) Before lockout /tagout devices are removed
  and before machines or equipment are energized,
  affected associates shall be notified that the
  lockout or tagout devices have been removed.
• (iii) After lockout /tagout devices have been
  removed and before a machine or equipment is
  started, affected associates shall be notified
  that the lockout or tagout device(s) have been
  removed.

Authorized
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Removal of Lockout/TagoutStep 3- Remove the
Lockout/Tagout Device
THE STANDARD (e)(3) "Lockout/Tagout Devices
Removal." Each lockout or tagout device shall be
removed from each energy isolating device by the
associate who applied the device. Exception to
paragraph (e)(3). When the authorized associate
who applied the lockout or tagout device is not
available to remove it, that device may be
removed under the direction of the employer,
provided that specific procedures and training
for such removal have been developed, documented
and incorporated into the employer's energy
control program.

Authorized
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Removal of Lockout/Tagout Step 3contd Remove
the Lockout/Tagout Device
The employer shall demonstrate that the specific
procedure shall include at least the following
elements (i) Verification by the employer that
the authorized associate who applied the device
is not at the facility (ii) Making all
reasonable efforts to contact the authorized
associate to inform him/her that his/her lockout
or tagout device has been removed and (iii)
Ensuring that the authorized associate has this
knowledge before he/she resumes work at that
facility.

Authorized
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What If You Forget to Remove Your
Lock-Out/Tag-Out Device?

• Employees who leave the facility without removing
  their locks will be called back at their own
  expense to remove them, and may result in a
  disciplinary action.
• Never use a lockout lock for any other reason
  than lockout.

Authorized
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Cutting Off a Lock

Authorized
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Free Wheeling Equipment

• Equipment which does not stop within 5 seconds of
  being shut off.

• Equipment must have
  
• A Sticker or Signgtgtgt
• On Guard
• On Electrical Panel
• On Lockout Procedure

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FREE WHEELING EQUIPMENT LIST
BRAKE PRESS BRAKE PRESS

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A Trained Employee

• Employee has been trained within the last 12-13
  months on the facilities lock-out/tag-out
  procedure.
• There is an approved, up to date (less than 1
  year since last review) LOTO procedure for that
  equipment.
• Authorized Employee has demonstrated within the
  past year, through an Audit of Proficiency that
  he/she knows how to perform LOTO properly on
  equipment.

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Audit of Proficiency
CERTIFICATION OF PROFICIENCY BY
DEMONSTRATION   Lockout procedure used
__________________________________   Did the
employee know the following   Know where Lockout
program procedures are located? Y N   Follow
the proper lockout and test procedures? Y
N   Lockout all the sources necessary? Y N   Use
proper lockout devices? Y N   Knowledge
performance meets program requirements? Y
N   Lockout procedure was correct? Y
N   Deficiencies found __________________________
________________________________

Authorized
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Discipline Policy

• Minor or Major Violation (Employee)
• Working under another employees lock
• Forgetting to remove your lock
• Minimum- 3-day suspension / Maximum- termination

• Minor or Major Violation (Supervisor of
  Employee)
• Minimum- 5-day suspension / Maximum- termination

• Blatant Willful
• Employee knowingly disregards lockout procedure.
• Employee will be terminated.

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Exceptions to Discipline Policy

• If the investigation determines that the
  employee who was injured had received all the
  appropriate training and had demonstrated how to
  lock out the equipment but willingly violated
  lockout without the supervisors knowledge, then
  discipline can be reduced or eliminated.

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LOTO is IMPORTANT to YOU!!

• 59 of all accidents caused by a release of
  energy during maintenance procedures resulted in
  DEATH.
• 12 of all lockout-related injuries resulted in
  AMPUTATION of some part of the body.

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BETTER SAFE THAN SORRY