LOTO - Lee auth

THE CONTROL OF HAZARDOUS ENERGY:LOCKOUT/TAGOUT : 

THE CONTROL OF HAZARDOUS ENERGY:LOCKOUT/TAGOUT

Lockout/Tagout Overview : 

Lockout/Tagout Overview Covers the servicing and maintenance of equipment where unexpected energization or release of stored energy could cause injury All equipment installed after January 2, 1990, must be designed to accept lockout devices

OSHA regulation 1910.147 : 

OSHA regulation 1910.147 Although OSHA made it “law” in 1990, lockout standards have been around much longer. Since 1990 it has saved many lives by preventing serious accidents.

What does lockout ask us to do? : 

What does lockout ask us to do? Safely eliminate all hazardous energy from machinery before working on it, by shutting down, disconnecting, dissipating, etc. Remove any doubt that it will return by isolating, blocking, locking out, etc.

If it needs to be turned off to be “safe”, it has to be locked out. : 

If it needs to be turned off to be “safe”, it has to be locked out. Lockout is required for any situations where an employee would be exposed to hazardous energy of any type. Where does Lockout/Tagout Apply? Any work where any employee, not just maintenance people, might be exposed to hazardous energy

What is hazardous energy? : 

What is hazardous energy? Hazardous energy sources include more than just the power sources to the machine. Rotating flywheels, hot parts, elevated components, and other sources can be dangers!

Hazardous energy sources : 

Hazardous energy sources Locking out an overhead door includes consideration of the weight of the door and tension in the counterbalance springs, along with electrical power to the motor. ? ? ? ? ? ? ?

Is common sense enough? : 

Is common sense enough? No, we need good machine-specific procedures that detail how to lockout individual machines. One generic lockout procedure is usually not enough for most machines.

Is one lock enough at all times? : 

Is one lock enough at all times? When more than one employee works on a machine, each employee must apply their own lock, or follow some other equivalent safe practice. Employees cannot share a single lock. One person, one lock, one key.

Why not just tag it? : 

Why not just tag it? Tagout is not as safe as lockout. Tagout has to include additional steps to hinder re-energization, and should only be used where lockout is not feasible.

Exemptions : 

Exemptions If work is routine, repetitive, and integral to the use of the equipment for production without any hazardous exposure Placing blank in, and removing finished part from, machine Minor tool changes and adjustments Other minor activities Work on cord and plug powered devices Must be able to disconnect cord Must be under the exclusive control of the employee Need written procedures unless extremely simple machine

Written Lockout Procedures : 

Written Lockout Procedures A written procedure is required for each machine (or type of machine when essentially identical) This covers practically all machines with some exceptions: very simple machines

The Written Procedure Exception : 

The Written Procedure Exception Machine has no potential for stored or residual energy, or re-accumulation of stored after shutdown Has a single source that can be easily identified and isolated Isolating and locking out the energy source will completely de-energize and deactivate the equipment The equipment is isolated from an energy source and locked out during maintenance A single lockout device will achieve a totally locked condition The lockout is under the exclusive control of and in the view of the authorized employee performing the servicing and maintenance The servicing or maintenance does not create hazards for other employees There have been no accidents involving unexpected energization of the equipment while taking advantage of this exception

Definitions : 

Definitions Authorized Employee: A person who locks or tags out equipment in order to perform servicing or maintenance

Definitions (continued) : 

Definitions (continued) Affected employee: Job requires employee to operate or use equipment on which servicing or maintenance is being performed under lockout and tagout conditions Job requires the employee to work in an area in which such servicing or maintenance is being performed

Definitions (continued) : 

Definitions (continued) Energy Sources are not always power sources. Sometimes are “hidden” sources: Mechanical: includes elevated weight, spinning flywheels, etc. Hydraulic Electrical Gas Pneumatic Water Chemical Thermal Other stored energy (Springs, capacitors, etc)

Energy Control Program : 

Energy Control Program Must clearly and specifically outline the: Scope Purpose Authorization Rules Techniques to be utilized for lockout/tagout, and means to enforce compliance

Energy Control Program (continued) : 

Energy Control Program (continued) Lockout Procedures must include: A statement of the intended uses of the procedure Specific steps for shutting down, isolating, blocking, and securing equipment to control hazardous energy Specific steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them Requirements for testing equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures

Lockout/Tagout Devices : 

Lockout/Tagout Devices Standardized Lockout/tagout devices must be Singularly identified The only device(s) used for controlling energy Not be used for other purposes Devices must have the same color, shape, or size. The format and print of tags should be standardized

Lockout/Tagout Devices (continued) : 

Lockout/Tagout Devices (continued) Substantial Removal of lockout devices should be extremely difficult to remove, requiring the use of excessive force and the help of tools such as bolt cutters One key per lock: employees should not have master keys Identified as to who put it on Can use a tag, engraving, or other means

Lockout vs. tagout : 

Lockout vs. tagout Lockout is a safer way to de-energize than tagout If an energy-isolating device can’t be locked out, tagout may be used only if It will offer equivalent protection to that offered by lockout When only a tag is used because equipment cannot be locked out, the following steps must be taken: Removing an isolating circuit element (fuses) Blocking the machine (control switch, die) Opening an extra disconnecting device Other means of isolation: A secondary step like pulling a fuse or turning off a main power supply is used

Lockout vs. Tagout (continued) : 

Lockout vs. Tagout (continued) Tags must be clearly visible and easily understandable by any employee who may be in the area Tags and their attaching materials must be able to withstand any adverse environmental conditions in the workplace Have to be held on with a cable tie or other non-removable device: 50 pounds of force or cut to remove

ANNUAL Inspections : 

ANNUAL Inspections Must certify in writing that the required periodic inspections have been performed Certification must identify the following: The equipment on which the energy control procedure was used The date of the inspection The employee included in the inspection The name of the person performing the inspection

Specific Requirements : 

Specific Requirements A training program must consist of: Effective initial training Periodic retraining as necessary Certification that training has been given to all employees covered by the standard Certification must become part of employee record and contain Employee's name Date of training

Group Lockout/Tagout : 

Group Lockout/Tagout When work is performed by a crew, they must use a procedure that affords a level of protection equivalent to that provided by the implementation of a personal lockout/tagout device Translation: One lock per person Example: Three people on one machine = three locks

Shift or personnel changes occur : 

Shift or personnel changes occur Must allow for the orderly hand-off of lockout of lockout/tagout devices over shift changes When someone leaves a lock on but is not at machine, must make attempt to contact them before removing. Follow the procedure for unusual lock removal.

Unusual Conditions : 

Unusual Conditions Machines usually need to be tested or repositioned during servicing When necessary, under special safe conditions, OSHA allows the temporary removal of locks or tags and the re-energization of the equipment Example, when power is needed for the testing or positioning of equipment Should be protected by some other means: guarding, distance, etc.

Contractors : 

Contractors Must inform each other of all applicable lockout/tagout procedures. Both employer and contractor must ensure that their employees understand and will respect the other’s Energy Control Program

Typical Shutdown Procedure : 

Typical Shutdown Procedure Notify affected employees Use the specific procedures as outlined for the appropriate situation Shut off energy source(s) to affected equipment Use normal stopping or running procedures for the machine Isolate the equipment from energy sources

Shutdown Procedures (continued) : 

Shutdown Procedures (continued) Affix lock(s) and tag(s) to energy controlling devices Relieve all stored energy from capacitor banks, springs, compressed air, hydraulics, steam, etc. Verify isolation of energy has occurred by trying equipment start button: Make sure to turn it back off! Now work can begin.

Removal of Lockout/Tagout, and Start-Up Procedures : 

Removal of Lockout/Tagout, and Start-Up Procedures Ensure that tools and other items are removed Ensure that guards are back on Check area to ensure that all employees are in a safe place Notify all nearby employees and supervisor before reenergizing the equipment Remove lockout/tagout device Reenergize equipment

Quiz : 

Quiz 1. The LOTO standard is designed to block the flow of energy to a piece of equipment. True or False 2. Types of LOTO devices include _______, _______, and _______. 3. It is not required that a company have written procedures for proper lockout/tagout. True or False 4. An authorized employee is one who _________ or _________ the equipment. 5. If a safety device is removed from a piece of equipment, LOTO is not required. True or False

Quiz (cont.) : 

Quiz (cont.) 6. Typical energy sources found on equipment include: _______, _______, and _______. 7. Affected employees are those who operate or work around a piece of equipment. True or False 8. As long as an employee has had training on LOTO, the employer or company has no additional responsibilities under 1910.147. True or False 9. Training for authorized employees must be conducted _________ and at least _________. 10. Locks should always stay on the equipment during a shift change. True or False

Quiz Answers : 

Quiz Answers 1. True. It should block the flow of energy and provide a means of warning. 2. Types of LOTO devices include locks, blocks, chains, hasps, wheel valve covers and ball valve covers. 3. False. If lockout is required, a company must have a written program and procedures. 4. An authorized employee is one who services or maintains the equipment. 5. False. LOTO is required when a safety device is removed, an employee is in harms way or when employees are exposed to hazardous energy.

Quiz Answers (cont.) : 

Quiz Answers (cont.) 6. Typical energy sources include: electricity, hydraulics, pneumatics, steam, thermal, chemical and gravity. 7. True. Affected employees are those who operate or work around the equipment. 8. False. Training is just one of the responsibilities of a company. 9. Training for authorized employees must be conducted initially and at least annually. 10. False. Locks should be removed during shift change and the shift coming on duty should place their locks on the equipment.