Lockout/Tagout

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Lockout/Tagout

• By
• Brice Moeller

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Overview

• What lockout is
• Lockout is a technique used to prevent the
  release of hazardous energy, or to prevent the
  hazardous energy from escaping.
• Go over a list of hazardous energy sources
• Electrical
• Mechanical
• Thermal
• Potential
• Types of lockout devices
• Plug Locks
• Ball Valve Lockout
• Gate Valve Lockout
• Group Lockout Hasp
• Electrical

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Overview (continued)

• When to lock out a machine
• Repairs
• Servicing
• Maintenance
• Tool Changes
• An example of what a placard will look like
• Special situations concerning lockout
• Servicing more than one shift
• Worker who applied the lock is not available

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Lockout/Tagout

• Covers the servicing and maintenance of equipment
  where the unexpected energization or start up of
  equipment, or release of stored energy could
  cause injury
• Establishes the OSHA minimum requirements for
  controlling hazardous energy

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Lockout

• Lockout is a technique used to prevent the
  release of hazardous energy, or to prevent the
  hazardous energy from escaping.
• A padlock is placed on the appropriate energy
  isolating device that is in the off or closed
  position.

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The Fatal Five Main Causes of Lockout/Tagout
Injuries

• 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

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Statistics on LOTO Injuries

• 82 - Failure to completely isolate, block, and
  or dissipate the energy source(s)
• 11 - Failure to lockout or tagout energy control
  devices and isolation points after
  de-energization
• 7 - Failure to verify that the energy source was
  de-energized before beginning work

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Definitions

• Authorized Employee
• One who locks out machines or equipment in order
  to perform the servicing or maintenance on that
  machine or equipment.
• 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.

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Definitions (continued)

• Lockout device
• A device that utilizes a positive means such as a
  lock either key or combination type, to hold an
  energy isolating device in the safe position and
  prevents the energizing of a equipment
• Tagout device
• A warning device, such as a tag and a means of
  attachment
• Can be securely fastened to an energy isolating
  device in accordance with an established
  procedure to indicate that the energy isolating
  device and the equipment being controlled can not
  be operated until the tag is removed

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Definitions (continued)

• Lockout/Tagout Procedure - Safety program adopted
  by the employer that includes energy control
  procedures plus provisions for inspecting the
  procedures and training employees for
  lockout/tagout.

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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/Tagout Devices

• Durable
• All devices must be capable of withstanding the
  workplace environment.
• All tags and their means of attachment must be
  sturdy enough to prevent inadvertent removal
• Substantial
• Removal of lockout devices should be extremely
  difficult to remove, requiring the use of
  excessive force and the help of tools such as
  bolt cutters
• Tagout devices and their attachments must be
  tough enough so that they cant be accidentally
  removed

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Lockout

• Lockout is a more appropriate means of ensuring
  deenergization of equipment than tagout
• If an energy-isolating device cant be locked
  out, tagout may be used
• Tagout may be used in place of lockout if it can
  be demonstrated that it will offer equivalent
  protection to that offered by lockout

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Tagout

• When only a tag is used because equipment cannot
  be locked out, the following steps must be taken
• Removing an isolating circuit element (fuses)
• Block machine (control switch, die)
• Opening an extra disconnecting device
• Other means of isolation

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Tagout (continued)

• Tags must be placed where the lockout device
  would have been placed
• A legend must be used such as
• Do not start
• Do not open
• Do not close
• Do not energize
• Do not operate

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Tagout Limitations

• Tags are attached to energy isolation devices,
  but they are only warnings.
• They do not provide the protection offered by a
  lockout procedure
• A tag is never to be bypassed or ignored, and it
  may not be removed without the specific
  authorization of person responsible for it

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Tagout Limitations (continued)

• Tags must be clearly visible and easily
  understandable by any employee who may be in the
  area
• Tags and their attaching materials must be able
  to withstand any adverse environmental conditions
  in the workplace

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When to Lockout a Machine

• A machine must be locked out when doing any of
  the following
• Repairs
• Servicing
• Maintenance
• Tool Changes

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Basic Lockout Procedure

1. Inform
2. Preparation for Shutdown
3. Equipment Shutdown
4. Equipment Isolation
5. Application of Lockout Devices
6. Control of Stored Energy
7. Equipment Isolation-Verification

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1. Inform

• The authorized personnel notifies all affected
  employees that a lockout/tagout system is going
  to be utilized and the reason because of it

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2. Prepare for Shutdown

• Before an authorized or affected employee turns
  off a machine or equipment, the authorized
  employee 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.

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3. 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 employees as a result of
  the equipment stoppage.

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4. 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)

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5. Lockout/Tagout Device Application

• Lockout or tagout devices shall be affixed to
  each energy isolating device by authorized
  employees.
• Lockout devices, where used, shall be affixed in
  a manner to that will hold the energy isolating
  devices in a safe or off position

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5. Tagout Device Application (continued)

• 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
• Where tagout devices are used with energy
  isolating devices designed with the capability of
  being locked, the tag attachment shall be
  fastened at the same point at which the lock
  would have been attached.
• Where a tag cannot be affixed directly to the
  energy isolating device, the tag shall be located
  as close as safely possible to the device, in a
  position that will be immediately obvious to
  anyone attempting to operate the device.

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6. Control of Stored Energy

• 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.
• 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.

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7. Verification of Isolation

• Prior to starting work on machines or equipment
  that have been locked out or tagged out the
  authorized employee shall verify that isolation
  and de-energization of the machine or equipment
  have been accomplished.

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Basic Removal of Lockout

1. Ensure equipment is safe to operate
2. Safeguard all employees
3. Remove lockout/tagout devices. Except in
   emergencies, each device must be removed by the
   person who put it on.
4. Test the equipment to ensure that it is working
   properly
5. Inform all affected employees that the machine is
   working

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Temporarily Reactivating Equipment

• Remove unnecessary tools from the work area and
  make sure everyone is clear of the equipment
• Remove lockout/tagout devices and re-energize the
  system
• As soon as the energy is no longer needed,
  isolate the equipment and re-apply
  lockout/tagout, using the six step procedure.

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Special Situations

• Servicing lasts longer than one shift.
• Contractors are performing service or maintenance
  at your workplace

• Worker who applied lock is not available

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Annual Inspections

• Certain circumstances lend themselves to the
  opportunity for an inspection
• Construction of new equipment
• Installation of new equipment
• Modification or adjustment of equipment
• Routinely scheduled cleaning and maintenance
• Major repairs

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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

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Tidbits of Info.

• Never attempt lockout/tagout 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/tagout devices are
  compatible with the environment in which they
  will be used i.e. corrosive, humid, etc.

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Georgia 1999 - OSHA has cited Roger Woods Foods
Inc. for a fatal accident resulting from a
lockout violation. OSHA fined the company
237,000 as a result of investigating the
accident. A maintenance worker was crushed by a
mechanical meat vat dumper, which had not been
locked out.

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An employee was attempting to correct an
electrical problem involving two non-operational
lamps. He had not shut off the power at the
circuit breaker panel nor had he tested the wires
to see if they were live. He was electrocuted
when he grabbed the two live wires with his left
hand and then fell from the ladder.
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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 Lockout/Tagout Program

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Any Questions?