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Safety & Health Consultation
Office of Safety & Health Consultation
presents
Office of Safety & Health Consultation
presents
Control of Energy SourcesLockout/Tagout
(LOTO)
Control of Energy SourcesLockout/Tagout
(LOTO)
NUMBER OF SERIOUS VIOLATIONS – FY 2014
29CF
R 19
10 S
UBP
ARTS
GENERAL ENVIRONMENT CONTROLS [1910.141 – 147]
2
LOCKOUT/TAGOUT – DEVELOPED PROCEDURES
LOCKOUT/TAGOUT – PROGRAM
LOCKOUT/TAGOUT – PERIODIC INSPECTIONS
SUBPART J
LOCKOUT/TAGOUT – GENERAL TRAINING
LOCKOUT/TAGOUT – SPECIFIC/ENFORCEMENT OF PROCEDURES147(c)(4)(ii)
147(c)(7)(i)
147(c)(6)(i)
147(c)(1)
147(c)(4)(i)
173
258
432
508
579
ScopeScope
• Covers the servicing and/or maintenance of machines where the unexpected start-up or release of stored energy could cause injury– Installation and set-up
– Adjustment or maintenance
– Inspection
– Modification
– Routine service1910.147(a)(1)
Safety & Health Consultation
PurposePurpose
• Establish a program and utilize
procedures for affixing
appropriate lockout devices or
tagout devices to energy
isolating devices
• Prevent unexpected
energization, start up or release
of stored energy in order to
prevent injury to employees
1910.147(a)(3)
Safety & Health Consultation 5
ObjectiveObjective
• Participants will understand– Safe application, usage & removal of energy
controls– Prohibitions on restarting/reenergizing
machines– Selection & use of PPE
Safety & Health Consultation
ExemptionsExemptions
• Construction, agriculture and maritime employment;
• Electrical Utilities;
• Exposure to electrical hazards from work on, near, or
with conductors or equipment in electric utilization
installations, which is covered by Subpart S of this
part; and
• Oil and gas well drilling and servicing
1910.147(a)(1)
Safety & Health Consultation
General RequirementsGeneral Requirements• The employer shall establish a program consisting of:
– Energy control procedures,
– Employee training and,
– Periodic inspections
• To ensure that before any employee performs any
servicing or maintenance on a machine or equipment
where the unexpected energizing, startup or release of
stored energy could occur and cause injury, the machine
or equipment shall be isolated from the energy source and
rendered inoperative.1910.147(c)
Safety & Health Consultation
General RequirementsGeneral Requirements
• "Energy control procedure.”
• Procedures shall be developed, documented and
utilized for the control of potentially hazardous
energy when employees are engaged in the activities
covered by this section.
1910.147(c)(4)
Safety & Health Consultation
ExceptionException
The employer need not document the
required procedure for a particular
machine or equipment when all eight (8)
of the following elements exist:
1910.147(a)(2)
Safety & Health Consultation
ExceptionException
1. The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees
2. The machine or equipment has a single energy source which can be readily identified and isolated
3. The isolation and locking out of that energy source will completely deenergize and deactivate the machine or
equipment 4. The machine or equipment is isolated from that energy source
and locked out during servicing or maintenance
1910.147(a)(2)
Safety & Health Consultation
ExceptionException
5. A single lockout device will achieve a lock-out condition
6. The lockout device is under the exclusive control of the
authorized employee performing the servicing or maintenance
7. The servicing or maintenance does not create hazards for
other employees; and
8. The employer, in utilizing this exception, has no accidents
involving the unexpected activation or reenergization of the
machine or equipment during servicing or maintenance
1910.147(a)(2)
Safety & Health Consultation
DefinitionsDefinitions
• Affected employee– Works in an area in which servicing or
maintenance operations are performed and LOTO is implemented
– Does not perform service or maintenance on equipment
– Is not responsible for LOTO
1910.147(b)
Safety & Health Consultation
DefinitionsDefinitions
• Authorized employee– Performs LOTO in order to service or maintain
equipment
– Capable of being locked out
1910.147(b)
• Other employees – Other employees whose work operations are,
or may be, in area where energy control procedures may be utilized
DefinitionsDefinitions
1910.147(c)(7)
Safety & Health Consultation
Protection Against HazardsProtection Against Hazards
• Three methods–Engineering Controls–Administrative Controls–Personal Protective Equipment
Note: Other OSHA regulations may be linked such as Electrical Safety, Confined Space, HAZCOM .
Safety & Health Consultation
Lockout/TagoutLockout/Tagout
Energy control (LOTO) shall be used whenever authorized employees are servicing machines and equipment, in which the unexpected start-up or the release of stored energy could cause injury.
Safety & Health Consultation
Lockout/TagoutLockout/Tagout
LOTO is not required when servicing or maintaining cord and plug connected equipment that is unplugged from the energy source during the servicing or maintenance operation, provided the cord/plug is under exclusive control of person performing the operation.
1910.147(a)(2)
Safety & Health Consultation
Types of Hazardous EnergyTypes of Hazardous Energy
• Electrical
• Mechanical
• Pneumatic
• Hydraulic
• Chemical
• Thermal
• Force of Gravity
Safety & Health Consultation
The “Fatal Five” Main Causes of Lockout/Tagout Injuries
The “Fatal Five” Main Causes of Lockout/Tagout Injuries
• Failure to stop equipment• Failure to disconnect from all power sources• Failure to dissipate (bleed, neutralize) residual
energy
Safety & Health Consultation
The “Fatal Five” Main Causes of Lockout/Tagout Injuries
The “Fatal Five” Main Causes of Lockout/Tagout Injuries
• Accidental restarting of equipment• Failure to clear work areas before restarting
Safety & Health Consultation
Lockout RequirementsLockout Requirements
• Lockout devices shall be:– Unique and readily identifiable as a LOTO
device.– Substantial enough to prevent removal without
excessive force or unusual techniques, such as the use of metal snips and/or bolt cutters.
1910.147(c)(5)
Safety & Health Consultation
Tagout RequirementsTagout Requirements
• General use of Tagout– Tagout shall be used only when an energy-
isolating device cannot be physically locked out– When tagout is the only method, all the steps of
the LOTO method shall be observed except for the lock itself
1910.147(c)(2)
Safety & Health Consultation
Tagout DevicesTagout Devices
• Tagout devices must be:– Substantial enough to prevent inadvertent
removal.– Readily identifiable as a LOTO device.– Weather resistant.– Attachable by hand and self-locking with a
break-away strength of 50 lbs.
1910.147(c)
Safety & Health Consultation
General ApplicationGeneral Application
• Before starting the job, the following conditions must exist– The isolation of locking out of the equipment
will completely deenergize and deactivate the equipment
– The lockout device is under the exclusive control of the authorized employee performing the service
1910.147(d)
Safety & Health Consultation
General ApplicationGeneral Application
– The servicing doesn’t create hazards for other employees
– The servicing has not caused any prior incidents at the facility
Note: If these conditions cannot be satisfied, a separate equipment specific LOTO procedure must be followed.
1910.147(d)
Safety & Health Consultation
The LOTO ProcedureThe LOTO Procedure
• Notify all affected employees by the shutdown before the task is begun
• Shutdown the equipment• Isolate the equipment from any energy
source• Lockout/tagout the energy isolation devices
with approved locks/tags
1910.147(d)
Safety & Health Consultation
The LOTO ProcedureThe LOTO Procedure
• Release the stored energy– Valves, springs, capacitors, or other means
• Verify a “zero energy” state– Ensure that the means of releasing energy was
successful
• Perform required service– Remember to comply with other applicable safety
programs such as, Hot Work, Fire Protection Systems Impairment, Confined Space, etc.
1910.147(d)
Safety & Health Consultation
The LOTO ProcedureThe LOTO Procedure
• Lockout/tagout device removal– The authorized employee who attached the device must
remove it• Authorized employee not available, the Employer:
– Must verify that the authorized employee is not in facility.
– Make all reasonable efforts to contact him/her, – Must ensure that authorized employee will be informed
of the removal prior to beginning work at that facility upon their return.
1910.147(e)
Safety & Health Consultation
The LOTO ProcedureThe LOTO Procedure
• 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.
1910.147(f)
Safety & Health Consultation
The LOTO ProcedureThe LOTO Procedure• Notify affected employees after LOTO device is
removed, and they shall be notified that the equipment is being returned to service.
• Restoring equipment to service:– Check equipment and the immediate area to ensure
removal of non-essential items and tools.– Check work area to ensure all employees have been
removed or safely positioned.– Verify equipment controls are in neutral position.
1910.147(f)
Safety & Health Consultation
Electrical LockoutElectrical Lockout
• All electrical circuits are considered “hot” until:– All sources of energy are removed.– The disconnecting means are locked/tagged out.– An approved device verifies the absence of voltage.– Temporary grounding is in place when there is
exposure to energized facilities
• Electrical circuits shall always be treated in a safe manner, using practices that match the voltage and energy level of the unit.
Safety & Health Consultation
Electrical LockoutElectrical Lockout• Whenever electrical work is scheduled, the
following is required:– Identify the power source disconnect .– Deenergize the power source.– Attach a lock and a Red Danger Tag to the controlling
device.DANGER
DO NOTOPERATE
DANGER
DO NOTOPERATE
This lock/ tag may only beremoved by:
Name ____________________
Dept. _____________________
Expected Completion _______
The energy source has beenLOCKED OUT. Unauthorizedremoval of this lock / tag may resultin immediate discharge.
Remarks: _________________
_________________________________________________________________________________
Sect ion 9 .1 Cont rol of Ha zardous Energy (LOTO) Page 1 of 1
Re vision D8 R evi sion Date : 9-22-98
RED DANGER TAG
Safety & Health Consultation
Electrical LockoutElectrical Lockout
• If more than one authorized employee doing work:– Each employee attaches their own Red Danger Tag
before commencing work.
DANGER
DO NOTOPERATE
DANGER
DO NOTOPERATE
This lock/ tag may only beremoved by:
Name ____________________
Dept. _____________________
Expected Completion _______
The energy source has beenLOCKED OUT. Unauthorizedremoval of this lock / tag may resultin immediate discharge.
Remarks: _________________
_________________________________________________________________________________
Sect ion 9 .1 Cont rol of Ha zardous Energy (LOTO) Page 1 of 1
Re vision D8 R evi sion Date : 9-22-98
RED DANGER TAG
Safety & Health Consultation
Electrical LockoutElectrical Lockout
Safety & Health Consultation
Electrical LockoutElectrical Lockout
Safety & Health Consultation
Electrical LockoutElectrical Lockout
Safety & Health Consultation
Electrical LockoutElectrical Lockout
Safety & Health Consultation
Electrical LockoutElectrical Lockout
Safety & Health Consultation
Electrical LockoutElectrical Lockout
• Prior to beginning equipment work:– Test voltmeter on known circuit to verify working
order.– Test equipment on the downstream/tagged out side of
the controlling device.– If equipment is wired directly to breaker box, test
downstream of the box actuator device.
Safety & Health Consultation
Electrical LockoutElectrical Lockout
• Try to start equipment as a test• Inspect & test controls to verify that circuit
is locked and NOT just temporarily inoperative due to an electrical or mechanical interlock
Safety & Health Consultation
Fixed Piping Systems LockoutFixed Piping Systems Lockout
• Breaking into a pressurized piping system:– Shutter valves must be locked out– Vent valves must be locked open– Pipes must be drained with the valves properly
tagged
Safety & Health Consultation
Fixed Piping Systems LockoutFixed Piping Systems Lockout
• A valve is locked out when:– It has a valve handle locking device and/or,
– The valve chain is locked.
Safety & Health Consultation
Fixed Piping Systems LockoutFixed Piping Systems Lockout
• Equipment systems powered by piping are considered locked out when the disconnect is:– Removed from the supply line.– Cleared and tested.– Tagged with a Red Danger Tag, as though a
lock is in use.DANGER
DO NOTOPERATE
DANGER
DO NOTOPERATE
This lock/ tag may only beremoved by:
Name ____________________
Dept. _____________________
Expected Completion _______
The energy source has beenLOCKED OUT. Unauthorizedremoval of this lock / tag may resultin immediate discharge.
Remarks: _________________
_________________________________________________________________________________
Sect ion 9 .1 Cont ro l of Ha zardous Energy (LOTO) Page 1 of 1
Re visi on D8 R evi sion Date : 9-22-98
RED DANGER TAG
Safety & Health Consultation
Fixed Piping Systems LockoutFixed Piping Systems Lockout
Safety & Health Consultation
Fixed Piping Systems LockoutFixed Piping Systems Lockout
Safety & Health Consultation
Fixed Piping Systems LockoutFixed Piping Systems Lockout
When the system is down the deenergized equipment must be checked to ensure that it is inoperable or if pressurized it has been drained of contents on the downstream side.
Safety & Health Consultation
Fixed Piping Systems LockoutFixed Piping Systems Lockout
• Pressurized systems must be:– Be flushed out with water if it contained
liquids.– Be flushed with an inert gas if it contained
compressed gases.
Note: MSDSs must be reviewed for any
additional safety procedures that may be required
Safety & Health Consultation
Fixed Piping Systems LockoutFixed Piping Systems Lockout
Appropriate air testing must be done whenever the pressurized systems have contained hazardous gases or liquids, especially when welding or burning operations have been involved.
Safety & Health Consultation
Fixed Piping Systems LockoutFixed Piping Systems Lockout
• When locking off a pressurized system:– Blanks are preferable to valving off– Double valves are preferred with drain cocks
between the valves
Note: MSDSs must be reviewed for any additional safety procedures that may be required when working with chemicals.
Safety & Health Consultation
General InformationGeneral Information• Never attempt lockout/tagout procedures unless
you have been trained and certified by your employer under an approved Energy Control (LOTO) 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.
Safety & Health Consultation 51
Review ObjectiveReview Objective
• Participants will understand– Safe application, usage & removal of energy
controls– Prohibitions on restarting/reenergizing
machines– Selection & use of PPE
Safety & Health Consultation
Your Questions?Your Questions?
Safety & Health Consultation
Office of Safety & Health Consultation
presents
Office of Safety & Health Consultation
presents
Control of Energy SourcesLockout / Tagout
(LOTO)
Control of Energy SourcesLockout / Tagout
(LOTO)