Lockout Tagout

The Control of Hazardous Energy

Lockout/Tagout

1910.147

Control of Hazardous Energy

29 CFR 1910.147 The standard covers the servicing and

maintenance of machines and equipment in which the unexpected energizing or start up of the machines or equipment , or release of stored energy could cause injury to employees.

What Is Hazardous Energy?

Often invisible

Live or stored electricity

Moving machine or equipment parts

Photo credit: State of WA-WISHA Services

What Is Hazardous Energy? (cont.)

Stored energy in equipment Heat Gravity Pneumatic,

hydraulic, air and water pressure

Steam Chemical

Photo credit: State of WA-WISHA Services

Hazardous Energy Injuries

7,600 injuries per year80% of workers fail to turn

off equipment

Causes Unexpected startup Release of stored energy Fail to Lockout/tagout

When does LOTO apply?

Application Of The Standard

An employee is required to remove or bypass a guard or other safety device

An employee is required to place any part of their body in contact with the point of operation of the operational machine or piece of equipment

An employee is required to place any part of their body into a danger zone associated with a machine operating cycle

Purpose

Establish a program of procedures for appropriate energy isolation

Prevent unexpected energizing

General Requirements

Employer shall establish a program consisting of Energy control procedures Employee training Periodic inspections

To ensure energy is isolatedEnergy control procedures

Developed, documented, and utilized

Scope and Exemptions

Scope – Servicing and maintenance of machines and equipment

Exemptions Construction, agriculture, and maritime Electrical utilities Electrical utilization installations (Subpart S

) Oil and gas well drilling and servicing

Exception

Has no potential for stored or residual energy

Single energy source (ext cord)

Lockout completely de-energizes

Machine is isolated

Single lockout device achieves lockout

Lockout under exclusive control

Servicing does not create hazards

Hot Tap Operations Involving Utility Company Transmission and Distribution Systems

Exception

Minor Servicing Tasks

Employees performing minor tool changes and adjustments that are routine, repetitive, and integral to the use of the equipment and that occur during normal operations are not covered by the lockout/tagout standard, provided the work is performed using alternative measures that provide effective protection.

LOTO Does Not Apply To

Installations Under the Control of Electric Utilities

If De-energizing Introduces Additional or Increased Hazards or is Infeasible Due to Design

Energy Control Procedure

Procedures shall clearly specify Scope Purpose Authorization Rules Techniques

Energy Control Procedure

A specific statement of intended use

Specific procedural steps for shutting down, blocking, and securing

Specific procedural steps for placement, removal, and transfer

Safety Work Practices

Selection and use of work practices (1910.333)

Working on or near de-energized parts that are not locked out or tagged are treated as energized

Only qualified personnel can work on electrical circuits

Both Standards Mandate

Both standards mandate the use of locks and/or tags to control potential energy

1910.147

1910.333 Subpart S

Isolation and Verification

Employees working on de-energized utilization systems covered under Subpart S allows both the authorized employee and qualified employee are permitted to verify

Employees working on a mechanical hazardous energy covered under 1910.147 can verify

Periodic Inspection

Energy control programShall conduct periodic inspection

Performed by authorized employee Conducted to correct deviations or

inadequacies Lockout versus tagout Certification required

Periodic Inspection

Shall be performed by an authorized employee other than the person(s) utilizing the energy control procedure being inspected

Shall be conducted to correct any deviations or inadequacies identified

Periodic Inspection

Where lockout is used, the inspection shall include a review between the inspector and each authorized employee

Where tagout is used, the inspection shall include a review between the inspector and each authorized and affected employees

The employer shall: Certify that the periodic inspections have

been performed Identify the machine or equipment on which

energy control procedures were used

The employer shall also note: The date of the inspection The employees included in the inspection The person performing the inspection

Periodic Inspections

The placement of a lockout device on an energy isolating device to ensure that the equipment being controlled cannot be operated until the lockout device is removed

Lockout

The placement of a tagout device on an energy isolating device to indicate the equipment being controlled may not be operated until the tagout device is removed

Tagout

Tags must also include a legend such as: Do not start Do not open Do not close Do not energize Do not operate

Tag Requirements

Tagout Tags

Tagout Tag

Authorized EmployeeLocks out/Tags out equipment in order to

perform maintenanceAuthorized by line mgmtQualified by training and experienceMust determine if a written procedure existsTrained in written LOTO procedure

Authorized Employee

Trained to perform locking or tagging procedures

No other employee can attach or remove lock or tag devices

Authorized Employee Responsibilities

Obtain assistance when necessary

Remove locks and/or tags following lockout/tagout

Coordinate multi-shift repair

Authorized Lead Employee

Authorized employee who performs or coordinates one or more LOTO activity for multiple personnel

Affected Employee

An Employee whose Job Requires Operation or Use of the Machine or Equipment on Which Servicing or Maintenance is to be Performed Under Lockout or Tagout

An Employee whose Job Requires Work in an Area where such Servicing or Maintenance is Being Performed

Aware of energy control procedure

Who is an Affected Employee?

Everyone in the building

Affected Employee Responsibilities

Notify maintenance when equipment needs repair or adjustment

Leave all lockout/tagout devices in place

Verify equipment is safe to operate following lockout/tagout

Follow all safety rules while operating the equipment

Training and Communication

Each authorized employee shall receive training in: Recognition of applicable hazardous

energy sources Type and magnitude of the energy

available in the workplace Methods and means necessary for

energy isolation and control

Each affected employee shall be instructed in the purpose and use of the energy control procedure

All other employees shall be instructed about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out

Training and Communication

The employer shall certify that employee training has been accomplished and is being kept up to date

Certification shall contain employee names and dates of training

Training and Communication

Group Lockout or Tagout

Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device

Each authorized employee shall affix a personal lockout or tagout device to the group lockout device

Outside Personnel

Whenever outside servicing personnel are engaged in activities covered by lockout/tagout, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures

Energy Sources

ElectricalMechanicalPressurized FluidsPressurized Gasses

Including cryogensRadiationGravity

Lockout/Tagout

The Placement of a Lockout and/or Tagout Device on an Energy Isolating Device In accordance with procedures Ensures equipment cannot be operated

until lockout device is removed

Exclusive Control

If Equipment is Under Exclusive Control, the Plug is Within Your Sight and Reach

Lockout/Tagout

The Placement of a Lockout and/or Tagout Device on an Energy Isolating Device In accordance with procedures Ensures equipment cannot be operated

until lockout device is removed

Interpretations

Hazardous Energy 1910.147

Machine Guarding 1910.212

Company Responsibilities

Ensure de-energizing of equipment Ensure employee awareness Provide appropriate levels of training Review program effectiveness Maintain and revise program Administer appropriate disciplinary actions

Photo credit: State of WA-WISHA Services

Energy Isolation Device

Isolate the equipment from the energy source

Isolation device• Circuit breaker• Pressure valve• Machine block

Lockout and Tagout DevicesLOTO Locks are RED

Do not use red-colored locks for any other purpose

1 Key per lock Destroy any other keys immediately

Combination locks are Not Allowed When multiple locks are required for a

single LOTO activity, locks with a common key may be used

Lockout Device

Lockout and Tagout DevicesTagout device states “DANGER - DO

NOT OPERATE”. Shall be white, black and red Shall have a space for the authorized

employee’s name. Must have a reinforced eyelet capable of

accepting a lock shackle of 0.25 inch diameter

Lockout Device

Lock Block Chain Multilock hasp Wheel valve

cover Ball valve cover

Requirements for Lockout/Tagout Devices

They must be: Durable Standardized Substantial Identifiable

Photo credit: State of WA-WISHA ServicesPhoto credit: State of WA-WISHA Services

Group Lockout

Lockout Signage

Lockout/Tagout Device Application

Each employee must apply their own locks.

Lockout devices are applied to hold the isolating device in a “safe” or “off” position.

The employee must maintain exclusive control of the key

Lockout/Tagout Device Application

Only the authorized employee may remove his/her LOTO device

Supervisor may overlock for additional control

Lockout/Tagout Device Application

A Tag must always accompany a lock. The tag must be placed as close as

possible to the lockThe tag must be securely attachedThe tag must clearly display the name

of the authorized employee

Lockout/Tagout Device Application

The Tag may also display: a picture of the authorized employee the date of application Other pertinent information

Do not use string or tape to apply tags

Lockout/Tagout Device Application

A tagout device only is allowed when the energy isolating device is not capable of accepting a lockout device.

The tag must clearly indicate that operation or movement is prohibited

Tags must be securely attached to prevent inadvertent detachment

Typical Equipment Requiring Lockout/Tagout

Presses Saws Conveyors Pumps Production

equipment Trash compactors

When to Use Lockout/Tagout Devices

Servicing or maintaining machinery or equipment

Hazardous energy exists

Unexpected start-up

could occur

Actions that Trigger Lockout/Tagout

Removing or bypassing a safety device

Any part of the body is placed in harm’s way

Exposure to hazardous energy

Alternative Removal of Locks and Tags

Alternative Removal of Locks and Tags

Temporary Removal of Locks/Tags for Testing or Positioning

Follow Five Steps for Return to Service

When done, use your procedure General or Written

Removal of Lock & Tags:Authorized Employee Not Available

Supervisory personnel shall: Make every effort to locate the Authorized

Employee Get written approval from Department

Head/Supervisor Follow Five Steps for Return to Service Inform Authorized Employee before he/she

resumes work activities Keep copy of written approval on file

GROUP Lockout/TagoutTwo Types

Type A

Type B

Type A Group LOTO

Lead Authorized Employee places lock & tag

Everyone else locks behind him

Everyone verifies equipment is de-energized

Each worker removes his/her lock

If there is a written procedure, only lead Authorized Employee needs to be trained

Type B Group LOTO

More complex activitiesLead Authorized Employee performs

LOTOKey goes into lockboxEveryone places lock on lockboxIf there is a written procedure, only lead

Authorized Employee needs to be trained

Shift or Personnel ChangeIf no one else will be working on

system: Leave LOTO as is

If someone else will be working on system: Transfer keys/locks Off-going employee unlocks On-coming employee locks Verification is very important!!

Shift or Personnel Change

Group LOTO: Lead places his own lock to lock box. The job lockbox and captured keys remain

under the control of the lead authorized employee.

If absent, the lead authorized employee may designate someone else the lead while retaining control of job lockbox

Shift or Personnel Change

Group LOTO Special circumstances ,may warrant the

complete transfer of responsibility

The off-going and on-coming leads would simultaneously remove and apply locks.

Supervised LOTO

If an employee or non-employee needs to perform LOTO and training is unavailable, an authorized employee may supervise the application of LOTO

Supervised LOTO Conditions apply:

1. System must be able to accept LOTO device

2. The individual is briefed by the authorized employee

3. If there is a written procedure, authorized employee follows procedure and applies LOTO – individual applies LOTO and verifies

Lockout/Tagout Procedure

Notify affected employees Shut down energized equipment Isolate energy sources from equipment Lockout or tagout the energy isolation

device Release stored energy Test

5 Step Restart Procedure

1. Clean up and inspect work area 2. Clear personnel from the startup area and notify affected employees of startup 3. Verify that the controls are in neutral 4. Remove lockout devices and reenergize the machine 5. Start machinery or equipment

Sub-Contractors

SubcontractorsRequired to have their own LOTO

program

Must share that information with Task Manager

Must attend LOTO training or prove they have been trained

Subcontractors

Overlocking is allowed

Sub locks first, then the you overlock

Configuration Control

Used if equipment must remain unattended for long periods of time w/out being worked on

Provides management controlRemoval of locks/tags may result in

injury, damage, disruption of normal processes, or degradation of system

Configuration Control - Examples

Locking out overhead crane electrical disconnect

Locking equipment while awaiting repair or parts

Locking a valve to control the flow of fluids

Locking radioactive waste container

Configuration Control Locks

Can use any shape or color of lock EXCEPT RED.

Tags: YELLOW, MANILA or RED (w/o DO NOT OPERATE wording are allowed.

RED locks and DANGER: Do not Operate tags are used exclusively for LOTO Not for Configuration Control

Configuration Control Locks

Can use lock w/out tags if use is obvious

Combination locks are allowed

Keyed locks may have more than one key.

Configuration Control Locks

Removal of lock is by person or group who applied it.

Removal by other authorized or qualified person permissible if there is assurance that removal will not create unsafe condition

Key Points to Remember

Hazardous energy is dangerous and deadly

Use lockout/tagout wherever unexpected startup or stored energy release may occur

Adhere to lockout/tagout and restart procedures

Keep everyone informed

5 Step Restart Procedure

1. Clean up and inspect work area 2. Clear personnel from the startup area and notify affected employees of startup 3. Verify that the controls are in neutral 4. Remove lockout devices and reenergize the machine 5. Start machinery or equipment

Questions?

Ron Kravitz