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