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LOCK OUT/TAG OUT: EACH TIME, EVERY TIME
Mini Module
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Introduction
Lockout/Tagout: Each Time, Every Time
mini-module is part of a curriculum series
addressing hazards found in areas of grain
handling facilities including grain bins and
their surrounding area. It is accompanied by
a video – Lockout, Tagout, Tryout – Each
Time, Every Time. It’s purpose is to assist
participants to identify and abate hazards in
the work place.
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Disclaimers
This material was revised under grant
number SH-26294-60-F-17 from the
Occupational Safety and Health
Administration OSHA), U. S. Department of
Labor. It does not necessarily reflect the
views or policies of the U. S. Department of
Labor, nor does mention of trade names,
commercial products, or organizations imply
endorsement by the U. S. Government.
Employee Rights
Employees are entitled to:
▪ Safe & healthy working conditions
▪ Fair compensation for all hours worked
▪ Report unsafe conditions without retaliation
• Call, write or email the OSHA area office within 30 days to report employer retaliation
Employers are responsible for providing a safe workplace.
Information www.osha.gov & www.whistleblowers.gov
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Learning Objectives
At the end of this module,
participants will be able to:
▪ Explain the purpose of LOTO and when it
should be used.
▪ Explain the concept of one lock, one key,
per person.
▪ Describe the basic steps of performing
LOTO.
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Reason for Lock Out/Tag Out
▪ OSHA 1910.147
▪ Protects Employees
▪ Written Procedures
▪ Affordable
▪ Best Practice – Farm
▪ Mandatory -
Commercial
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Lock Out/Tag Out = Protection
Protects
▪ Injury
▪ Unexpected startup
▪ During service or
maintenance
▪ Work near exposed
electrical
Keeps others from turning
machines on!
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LOTO Controls Energy Sources
▪ Control hazardous energy
▪ Isolate power sources-inoperable
▪ De-energize machines/equipment
▪ Use energy isolating device
▪ Stored & residual energy
Energy - electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, gravity, others
Property of
Master Lock®
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Lockout Isolates Energy
Lock Out - isolation
of energy from the
system (a machine,
equipment, or process)
which physically locks
the system in a safe
mode.
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Tag Out – Warns & Informs
Tag Out – WARNSLabeling system informs others of reason for
LOTO, why it cannot be operated, who did
LOTO.
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LOTO Requirements
▪ Authorized employees ONLY perform LOTO
▪ Train ALL employees
▪ Use proper locks & tags
▪ Written LOTO procedures
▪ Review procedures annually
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1 Lock, 1 Key, 1 Person
Your lock cannot be
opened with another key.
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Multiple People = Multiple Locks
More than 1 person needs LOTO on same
equipment or machine:
Lock for each person Group LOTO
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When LOTO Is Needed
▪ Service or maintenance
• Machines & equipment
▪ By-pass or remove guard
• Other safety devices
▪ Any body part in the point of operation
• Danger zone during the operating cycle
▪ Grain bin entry
• Tasks related to grain handling & storage
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NO LOTO – Same Protection!
Limited exceptions to not using LOTO:
▪ Exclusive control of power source
• Electric cord
▪ Minor tool changes, adjustments, service
• Documented procedures
▪ Can’t accept lock
• Tagout only
Must have same level of protection
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#1 Prepare for Shutdown
▪ Identify energy sources
▪ Notify affected persons of LOTO
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#2 Shut Down Machine
▪ Follow written procedures
▪ Turn off or shut down the equipment
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#3 Isolate Energy Sources
▪ Disconnect or otherwise isolate ALLenergy sources
▪ Release stored energy
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Stored Energy Needs Release
Stored (residual) energy – energy in system not being used. Provides power when released.
Types▪ Mechanical - item under tension
▪ Hydraulic - stored in pressurized liquid
▪ Pneumatic - stored in pressured air
▪ Gravitational - from something falling
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Stored Energy is All Around
Stored energy examples:
▪ Battery back-ups
▪ Springs
▪ Capacitors
▪ Flywheels
▪ Gravity – elevated
▪ Hydraulic lift systems
▪ Air, gas, steam, water pressure
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Release Energy:
Dissipate - use up the energy
Restrain - keep from use
Methods:
▪ Grounding
▪ Repositioning
▪ Bleeding
▪ Venting
▪ Blocking
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# 4 Lock Out & Tag Out
▪ Install locks on energy sources
▪ Attach tags to locks and/or the machine
▪ One lock & tag per person per
machine or equipment
Install Lock Attach Tag
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# 5 Try Out!
▪ Test machine
▪ Attempt to start
▪ Verify it is locked
out
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#6 Begin work
▪ Begin maintenance or
service work
▪ Complete work
▪ Remove tools & clean
up area
• Account for tools &
parts
▪ Equipment is intact
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# 7 Notify Others of Start-Up
▪ Notify persons affected
• Energy being restored
• Machine/equipment being
restarted
▪ Ensure others at safe
distance
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# 8 Release Lock Out/Tag Out
▪ Remove lockout &
tagout devices
• Only person who put it
on
▪ Start-up equipment
▪ Verify working properly
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Lock Out Devices Only for LOTO
▪ Only use - LOTO
▪ Employer provides
▪ Standardize – color, shape, size
▪ Durable - withstand environment
▪ Substantial – prevent removal
• Need force or tool to remove
▪ Identify person
Property of Master Lock®
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Type of LOTO Locks
Pole Breaker
Padlock
Valves
Wall Switch Breaker Lockout
Lockout Hasp
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Durable, Locking Tagout Devices
▪ Standardize – print & format
▪ Durable - withstand environment
• Legible & understandable
▪ Substantial – securely attached
• Non-reuseable
• Self locking
• Unlock strength ≥ 50 lbs.
• By hand
▪ Warn - Do Not Operate, etc.
▪ Identify person
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Tag Out Devices Durable, Lock
▪ Standardize – print & format
▪ Durable - withstand environment
• Legible & understandable
▪ Substantial – securely attached
• Non-reuseable
• Self locking
• Unlock strength ≥ 50 lbs.
• By hand
▪ Warn - Do Not Operate, etc.
▪ Identify person
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Emergency Lock Removal
Employer to remove lock ONLY when
employee is unavailable
▪ Employee NOT at facility
▪ Reasonable effort to inform employee
▪ Employee knows lock removed
• Must know BEFORE return to work
HINT: Keep written documentation
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Energy Control Program
LOTO Procedures
Employee Training
Periodic Inspections
Enforcement Policy
Written
Full Employee Protection
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Energy Control Procedures
▪ Scope & Purpose – how to use
▪ Steps to control energy
• Shut down, isolate, block, secure
▪ LOTO Devices
• place, remove, transfer
▪ ID responsible person
▪ Try out – specific steps
Try Out in LOTO procedure
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EXAMPLE
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Who needs LOTO training?
ALL workers need training according
to their exposure to LOTO
OSHA identifies:
Authorized employee performs LOTO
Affected employee operates equipment
or works in area where LOTO is done
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LOTO Training ALL Workers
ALL - must know, understand & be able
to follow LOTO procedures
▪ Purpose & function of LOTO
▪ Use of LOTO
▪ Procedures
▪ Prohibit restart - LOTO in place
▪ Limitations – Tag Out only system
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Limitations of Tag Out Only
Warning Only!
Does NOT provide physical restraint
▪ False sense of security
▪ Provide full employee protection
▪ Removal by owner ONLY
▪ Prohibit start up
▪ Hold isolating device in “off” position
• Easily seen
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Train to Perform LOTO
Authorized employee – Person who performs LOTO
Additional Training
▪ Recognize hazardous energy sources
▪ Type & magnitude of energy sources present
▪ How to isolate & control energy
• Methods
• Means
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Retrain When Change Occurs
Retrain employees when:
▪ Change occurs:
• Job assignments
• Equipment
• Procedures & Process
▪ Inspection - need or inadequacy
▪ Certify training – name & date
• Keep training up to date
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Periodic Inspection
▪ Annual documentation
▪ Review procedures
▪ Authorized employee conducts
▪ Identify & correct
• Deviations or inadequacies
▪ Review each authorized employee
▪ Review each LOTO procedure
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Why LOTO for Farms
• Father & son discussed need to check a cross
auger on top of a bin.
• No responsibility assigned.
• Dad checked auger; did not like what he heard.
• Dad got on top of bin & stuck his arm in the auger.
• Son decided to check the auger.
• Father lost his forearm.
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Implement LOTO for Farms
▪ Develop procedures
▪ Communicate
▪ Tag it – Warn others
▪ Use locks
▪ Other locking or secured
mechanism
Farms - Use of LOCKS & TAGS
strongly recommended
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GROUP ACTIVITY - LOTO
Lock Out/Tag Out:Each Time, Every Time
Protect the most valuable resource we have –
“Our Workers!”
QUESTIONS?
For more information visit www.grainsafety.org
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