11/2/2015

1

Control of Hazardous Energy LOCKOUT/ TAGOUT

1910.147

Today‟s Objectives •Participants will be able to explain the requirements for

•Written Program

•Equipment Specific Procedures

•Authorized Employees‟ Duties and Training Requirements

•Affected Employees‟ Duties and Training Requirements

•Special Provisions for Group Work, Shift Changes and Locks Left On

•Annual Required Assessments

11/2/2015

2

Why LOTO is Important

Picture yourself working inside a huge machine, tending to its maintenance. Suddenly the machine springs to life, powerful metal gears grinding around you, placing you in mortal danger. That is exactly the sort of terrifying scenario that lockout/tagout is meant to prevent. Lockout/tagout is a procedure to disable equipment to protect workers from either an unexpected release of energy or an accidental start-up while performing job activities.

Why LOTO is Critical Per OSHA

•average of 24 lost workdays per worker

•10% serious accidents

Outcomes ◦ Cuts

◦ Amputations

◦ Crushing injuries

◦ Fatalities

6th on Frequently Cited List for 2014

11/2/2015

3

How You Keep Your Employees Safe

By establishing an energy control program consisting of:

1. Written Program

2. Energy control procedures for every type and piece of equipment

3. Employee training as appropriate

4. Annual written assessments to ensure accuracy and compliance

What is Hazardous Energy? •Electrical

•Mechanical – springs, gravity, counterbalance, pressure

•Hydraulic

•Pneumatic

•Chemical

•Thermal – result from radiation, chemical, mechanical work, electrical resistance

•Others

•During the servicing and maintenance of machines and equipment, the unexpected startup or release of stored energy could cause injury to employees.

11/2/2015

4

Written Program •Scope

•Responsibilities

•Procedures • Equipment Specific

• Lockout/Tagout Equipment

• Special Provisions

•Training

•Annual Assessment

Equipment Specific Procedures •Equipment Specific

•All energy sources

•How to shutdown equipment

•How to de energize

•How to restart

•Include affected employee notification

11/2/2015

5

Machine Specific Example handout

Applying lockout/tagout

Applying Lockout/Tagout: An authorized worker should notify others in the area that lockout/tagout procedures will be taking place. After listening to instructions given by the authorized worker, all unauthorized personnel should move to a safe location, away from the equipment.

11/2/2015

6

Servicing and repair

Servicing and Repairing Equipment: Unauthorized personnel should stay away from the equipment while the authorized person is working on it. At this time, the equipment is at its most vulnerable to the unexpected release of hazardous energy.

Returning to operation Returning Equipment to Proper Operation:

During this phase, the authorized worker should tell others in the area when locks and tags will be removed. Workers should stay clear of the area while locks and tags are removed and the equipment is prepared for normal operation. All personnel should be informed when lockout/tagout is complete.

11/2/2015

7

Lockout/ Tagout Restarting Equipment

Inspect machine/equipment and make sure:

All tools and rags are removed

Machine fully reassembled

Guards and safety devices are in place

Verify that controls are in “neutral” position

Notify all affected employees, and make sure they are safely positioned

Remove lockout device and restart equipment

Lockout Locks & Procedures

Authorized Employees

Must have or have access to enough locks for all energy sources.

No sharing of locks/keys with other employees, contractors, etc.

The authorized employee must remove any locks they apply personally.

11/2/2015

8

Shift and Personnel Changes

During shift or personnel change

Personal locks must be changed.

Employee that is leaving MUST takes off lock.

Employee starting the shift applies lock.

Equipment Protection for Extended Time

Use asset locks not individual lockout tagout equipment.

Maintenance manager or department holds keys to asset locks.

Never leave individual workers LOTO equipment on the equipment for days, weeks or months.

11/2/2015

9

Energy Isolating Devices •Manually operated electrical circuit breaker

•Disconnect switch

•Line valve

•Bolted blank flange

•Bolted slip blinds

•Safety block

•PLC NOT energy isolating devices

Energy Isolating Devices

11/2/2015

10

More Energy Isolating Devices

Authorized Employees •Control energy release

•Service or maintain equipment • Constructing, installing, setting up,

adjusting, inspecting, modifying, maintaining, servicing, lubrication, cleaning, unjamming, making adjustments, tool changes,

•Exclusive control of energy control device

Training ◦ Recognize applicable hazardous

energy sources

◦ Type and magnitude of energy

◦ Means and methods of isolating energy

◦ Means of verifying effective energy control

•Initially, deficiency, change

•Documented

11/2/2015

11

Affected Employees Work in area where lockout tagout is occurring

Training ◦ Instructed on procedure

◦Understand prohibition of attempt to restart equipment

Special Provisions Group lockouts

Shift change

Locks left on

Contractors ◦OSHA will evaluate both employers‟ programs

11/2/2015

12

Annual Assessments Periodic inspections of energy control procedures

Deviations/inadequacy tracking

Conducted by Authorized Employee ◦Steps of procedure followed

◦Employees involved know responsibility

◦Procedure is adequate to protect

Lockout Tagout Failure Examples 1. Employee cleaned out chemical process knockout pot when it

became plugged. The pressurized vessel was not de energized.

2. Machine used in „inch mode‟ with light curtains. Light curtains weren‟t protective in inch mode.

3. Employee cleaning high speed unguarded rollers while in operation exposing employee to moving machine parts and in running nip points.

4. Employee cleaning tanks and equipment with knives, wasn‟t locked out resulting in leg amputation and two fingertips.

11/2/2015

13

Resources Ohio BWC Division of Safety & Hygiene ◦Lockout/Tagout and Safety-related Work Practices .5 day course

LOTO Program

https://www.bwc.ohio.gov/downloads/blankpdf/(G)%20Lockout%2099.pdf

Sample LOTO Procedure

https://www.bwc.ohio.gov/downloads/brochureware/publications/SWPrograms/LTProcedure.pdf

CDC NIOSH Self Inspection Checklist 2004-101

OSHA Sample LOTO Procedure

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9805

Q&A Time DGROTEADAMS@SAFEX.US