Presenter: Bruce DelGrasso

Over 30 years in Safety and Risk Management Operations, maintenance, and production Construction, Infrastructure, Industry, Oil & Gas, Biotech Authorized OSHA Trainer Safety Consultant - 22 years National and International Clients Extensive experience developing and implementing safety

programs

contactme@bdelgrasso.com

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• Power sources• What is LOTO• Personnel, responsibilities and

requirements• Plans, policies, and procedures • Equipment and devices• Special Situations• Training • Audits• Questions

• Electrical • Hydraulic• Pneumatic• Steam• Mechanical• Potential (Gravity)

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• Procedure for a safe shut down and restart of equipment that is serviced or maintained

• Protects employees who service and maintain equipment

• Warns employees of the shut down

• 29 CFR Part 1910.147, 29 CFR Part 1910.333• 29 CFR 1926.416 and 29 CFR 1926.417

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• Equipment from unexpectedly starting-up• Co-workers from restarting equipment• Injury and death during servicing or maintenance

of equipment

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• Failure to shut off equipment• Failure to disconnect from power source• Unexpected restarting of equipment• Failure to clear work area before restarting

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Authorized Employee•An employee who performs servicing and/or maintenance on machines and equipment. •Identify all energy sources•Inform others of Lockout/Tagout in progress•Follow the Lockout/Tagout procedures

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Affected Employee•An employee who performs the duties of his or her job in an area in which lockout is implemented and servicing and/or maintenance operations are performed; however, the employee does not perform the servicing and/or maintenance on machines and equipment.•Operate or use equipment•Understand all Lockout/Tagout procedures•Never remove locks or tags•Never restart equipment with lock or tag

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Other Employees•Are not authorized or affected employees•Must be able to identify locks and tags•Must be aware of Lockout/Tagout procedures•Never remove a lock or tag•Never restart equipment with lock/tag

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Energized• Equipment is energized when it is connected to an

energy source or it contains residual or stored energy

Energy Isolating Device• Any mechanical device that physically prevents the

release or transmission of energyEnergy Source• Any source of electrical, mechanical, hydraulic,

pneumatic, chemical, thermal, or other energy

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Minor Tool Changes and Adjustments • Performed during normal production operations and

they are routine, repetitive, and integral to the use of production equipment, are not covered by the standard

• Alternate measures of effective employee protection must be in place

• Employer must provide effective protection for employees in power-on (trouble-shooting) conditions

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If the power is off, then a lockout procedure is required.

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If both of the following conditions are met, then the Lockout/Tagout standard does not apply to servicing and/or maintaining cord and plug connected equipment:

Hazardous energy sources must be controlled by unplugging the equipment from the energy source

The plug must be under the exclusive control of the employee performing the servicing and/or maintenance

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• Step One - Prepare for shutdown • Step Two - Shutdown equipment• Step Three - Disconnect power source using an

energy isolating device

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• Step Four - Apply Lockout/Tagout devicesOnly applied by authorized employeesLocks power source in “off” positionLocks must be used if equipment is capable

of being locked outIf locks cannot be used – tags must be used

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• Step Four…continued Devices must be:• Standardized• Identifiable• Durable• Not used for other purposes

Limitation of tags:• Only a warning device• Equipment can still be started-up• False sense of security

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• Step Five - Release stored energy

• Step Six - Verify machine is safe

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1.Lockout of equipment will only be carried out by authorized employees

2. Notify all affected employees that a lockout of machinery will be taking place

3. De-energize equipment using the written equipment specific procedures

4. Lockout the energy source in a position that will prevent further operation of the equipment and will hold the energy-isolating device in an off position

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5. Each employee involved in the lockout will place their own lockout device on each energy-isolating device

6. The lockout device will be fitted with a tag describing who placed the lock on the machinery

7. The lockout device key will remain in the possession of the employee locking out the affected equipment

8. All potentially hazardous stored or residual energy (air or water pressure, hydraulic systems, etc.) must be disconnected, reduced, or rendered safe, including gravity

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9. Prior to servicing and/or maintenance on the affected machinery, the lockout integrity must be verified:a. Clear all employees from the affected equipmentb. Attempt to operate the affected equipment using established start-up proceduresc. Return the affected equipment to the Off position after performing the lockout integrity test

d. Make any adjustments necessary and re-evaluate the lockout integrity

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10. To restart or test the affected equipment, the following steps to be followed:a. Visually inspect the servicing and/or maintenance areas to ensure that all tools, materials, and personnel are free from the machineryb. Remove all lockout devices and energize the affected equipment…NEVER remove another employee’s lockc. WARN all personnel and VERIFY area clear

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10. Continued…

d. Verify that the affected equipment is operating correctly

e. If the affected equipment is not operating correctly, then de-energize the equipment and ensure that all lockout devices were removedf. To continue servicing and/or maintenance on the affected equipment the authorized employee must conduct a new lockout procedure

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• When the energy supply cannot be locked out, the employer must use a Tagout procedure Investigate if, in the facility's best interest, you want to modify or replace the device to make it capable of being locked out

• If a Tagout is used, then the employer must follow all tagout- related provisions of 29 CFR 1910.147

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• The employer must provide additional training on the limitations of using a tag

• When a tag is attached to an energy supply, it is not to be removed except by the person who applied it,

and it is never to be by-passed, ignored, or otherwise defeated

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Tags are only warning devices and do not provide the physical restraint of a lock

• Tags must be legible and understandable by all employees… bi-lingual, multi-lingual

• Tags and their means of attachment must be made of materials that will withstand the environmental

conditions encountered in the workplace

• Tags must be securely attached to the energy-isolating device

so that they cannot be detached accidentally during use

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• Group lockout device used when more than one person services the equipment

• Each employee has own lock or tag• One primary employee responsible

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• If a lock or tag needs to be removed and the employee cannot be found:

Verify employee is not in facilityMake reasonable effort to contact employeeDetailed and Exacting procedureTell employee about removal

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DurabilityLockout devices must withstand the environment to

which they are exposed for the maximum duration of exposure.

StandardizedLockout devices must be standardized according to

either color, shape, or size.

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SubstantialLockout devices must be substantial enough to

minimize early or accidental removal. Locks must be substantial to prevent removal except by

excessive force of special tools such as bolt cutters or other metal cutting tools.

IdentifiableA lock must clearly identify the employee who

applied it.

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• Locks• Hasps• Circuit breaker

clamps• Switch lockout covers• Valve lockout devices• Tags• Pneumatic• Hoist

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Steering Wheel Multi Breaker Cable Lock Out Kits Lock Out Stations Bi / Multi Lingual Signs Hydraulic Aviation

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• For Group Lockout operations, each authorized employee must attach a personal lockout device to the group device with the servicing and/or maintenance coordinated by one designated employee. This designated employee is always the last to remove his lock

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Should the hasp not have enough holes for the required number of locks, insert a second hasp into the last hole and install additional locks on the second hasp

• If servicing and/or maintenance will continue for extended periods or across shifts, then the original lockout must be removed by the employees who installed it, and the incoming shift employees must complete a lockout from the initial step to ensure continuity

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• Outside contractors and the on-site employer must inform each other of their respective energy control programs; each employer must ensure that his/her personnel comply with the other employer's energy control programThe on-site (controlling) employer might consider training the contractor’s employees to the site’s LOTO program, furnish the locks and devices, and all employees follow the site’s program and policies

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• Employers must provide initial training and re-training as necessary

• Employers must certify that the training has been given and include the employee's name and dates of training

• AUTHORIZED employee training must include:a. The type and magnitude of hazardous energy sources presentb. The machine specific procedures needed to isolate and control those hazardous energy sources

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• AFFECTED employees training must include:a. How to recognize a lockoutb. Understand the purpose of lockout

c. Never attempt to start-up or use the machinery that has been locked out

d. Never remove or defeat a lockout / tag out

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• Re-training will be provided for all authorized and affected employees whenever there is a change in job assignment, machinery processes or a new hazard is present in the workplace

• Re-training will be provided whenever a periodic inspection identifies a deficiency or inadequacy in the Lockout/Tagout program

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• Periodically, (at least annually), the Safety Director or General Manager will assist Supervisors and

Foremen with an audit of the Lockout/Tagout program (employees

who utilize the energy control procedures cannot be

included in the audit team)

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• The periodic audit will be used to correct any anomalies or inadequacies in the Lockout/Tagout program and ensure employees are following energy control procedures

• The periodic audit shall include an interview with the employees utilizing the Lockout/Tagout program and

energy control procedures and their responsibilities

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• The periodic inspection will be certified with the following information:

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Date of inspectionEquipment on which the energy control procedure was being utilizedEmployees interviewed or included in the auditName(s), title(s), and signature(s) of person(s) performing the audit

• One lock for each worker• Never count on another employees lockout without

verifying and installing your own lock• Consider other sources of energy• Follow proper lock removal steps• Communicate with affected and other employees

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• Lockout/Tagout is a warning and prevention system• Failure to perform Lockout/Tagout can kill you• Know the six steps of Lockout/Tagout• Never remove another employee’s lock or tag• Develop, Train and Communicate

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THANK YOU FOR YOUR ATTENTION

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