lockout/tagout standard

Lockout/Tagout Lockout/Tagout StandardStandard

Proper Lockout Proper Lockout ProcedureProcedure

LOCKOUT/TAGOUTLOCKOUT/TAGOUTContractorsContractors

The outside contractor and the on-The outside contractor and the on-site employer must exchange site employer must exchange lockout/tagout information.lockout/tagout information.

Employees on site must understand Employees on site must understand rules used by the contractor.rules used by the contractor.

Be alert for new types of lockout or Be alert for new types of lockout or tagout devices.tagout devices.

LOCKOUT/TAGOUTLOCKOUT/TAGOUTEquipment IsolationEquipment Isolation

Operate all energy-isolating devices Operate all energy-isolating devices so that the equipment is isolated so that the equipment is isolated from its energy sources.from its energy sources.

Be sure to isolate all energy sources Be sure to isolate all energy sources (secondary power supplies as well as (secondary power supplies as well as the primary supplies).the primary supplies).

Never remove a fuse instead of Never remove a fuse instead of disconnecting.disconnecting.

LOCKOUT/TAGOUTLOCKOUT/TAGOUTShutting Down the Shutting Down the EquipmentEquipment

Shut the system down by using Shut the system down by using operating controls.operating controls.

Follow whatever procedure is right Follow whatever procedure is right for the equipment to avoid for the equipment to avoid endangering anyone during endangering anyone during shutdown.shutdown.

LOCKOUT/TAGOUTLOCKOUT/TAGOUTPreparation for ShutdownPreparation for Shutdown

Know the types and amounts of Know the types and amounts of energy that power it.energy that power it.

Know the hazards of that energy.Know the hazards of that energy.

Know how the energy can be Know how the energy can be controlled.controlled.

LOCKOUT/TAGOUTLOCKOUT/TAGOUTWritten ProceduresWritten Procedures

Preparation for shutdownPreparation for shutdown

Shutting down the equipmentShutting down the equipment

Equipment isolationEquipment isolation

Application of Lockout/Tagout Application of Lockout/Tagout devicesdevices

Release of stored energyRelease of stored energy

Verifying equipment isolationVerifying equipment isolation

What is Lockout/Tagout?What is Lockout/Tagout?

• LOTOLOTO

• Blocks the flow of energy Blocks the flow of energy from power sources to the from power sources to the equipmentequipment

• Provides means of warning Provides means of warning (tag)(tag)

LockoutLockout

• Lockout is a technique used Lockout is a technique used to prevent the release of to prevent the release of hazardous energy, orhazardous energy, or

• to prevent the hazardous to prevent the hazardous energy from escaping. energy from escaping.

An Example of LockoutAn Example of Lockout

• A padlock is placed on the A padlock is placed on the appropriate energy isolating appropriate energy isolating device that is in the off or device that is in the off or closed position.closed position.

LOCKOUT/TAGOUTLOCKOUT/TAGOUTTypes of DevicesTypes of Devices

The “Fatal Five” Main The “Fatal Five” Main Causes of Lockout/Tagout Causes of Lockout/Tagout

InjuriesInjuries Failure to stop equipmentFailure to stop equipment Failure to disconnect from power sourceFailure to disconnect from power source Failure to dissipate (bleed, neutralize) Failure to dissipate (bleed, neutralize)

residual energyresidual energy Accidental restarting of equipmentAccidental restarting of equipment Failure to clear work areas before Failure to clear work areas before

restartingrestarting

LOCKOUT/TAGOUTLOCKOUT/TAGOUTApplication of DevicesApplication of DevicesAll energy-isolating devices are to be All energy-isolating devices are to be locked, tagged or both.locked, tagged or both.Only standardized devices can be used Only standardized devices can be used and they are not to be used for anything and they are not to be used for anything else.else.Use a lockout device if your lock cannot Use a lockout device if your lock cannot be placed directly on the energy control.be placed directly on the energy control.When lockout is used, every employee in When lockout is used, every employee in the work crew must attach his personal the work crew must attach his personal lock.lock.

Lockout/Tagout Regulatory Lockout/Tagout Regulatory RequirementsRequirements

29 CFR 1910.147 29 CFR 1910.147

• Control of Hazardous energy Control of Hazardous energy covers operators and service covers operators and service personnelpersonnel

• Requires training of employeesRequires training of employees

Proper Procedures for Proper Procedures for LOTOLOTO• Inspect carefully, locate and identify all Inspect carefully, locate and identify all

isolating devices. isolating devices.

• Be certain which switch (s), valve (s), or Be certain which switch (s), valve (s), or other energy isolating devices, control the other energy isolating devices, control the equipment to be locked or tagged out. More equipment to be locked or tagged out. More than one energy source (electrical, than one energy source (electrical, mechanical, or others) may be involved. mechanical, or others) may be involved.

• All types and locations (s) of energy isolating All types and locations (s) of energy isolating means must be found and managed. means must be found and managed.

LOCKOUT/TAGOUTLOCKOUT/TAGOUTPerforming the WorkPerforming the Work

Look ahead and avoid doing anything Look ahead and avoid doing anything that could reactivate the equipment.that could reactivate the equipment.

Don’t bypass the lockout when Don’t bypass the lockout when installing new piping or wiring.installing new piping or wiring.

LOCKOUT/TAGOUTLOCKOUT/TAGOUTRemoving Lockout/TagoutRemoving Lockout/Tagout

Make sure the equipment is safe to Make sure the equipment is safe to operate by removing all tools from the operate by removing all tools from the work area and making sure the system is work area and making sure the system is fully assembled.fully assembled.Safeguard all employees by conducting a Safeguard all employees by conducting a head count to make sure everyone is clear head count to make sure everyone is clear of the equipment. Also notify everyone in of the equipment. Also notify everyone in the work area that lockout/tagout is being the work area that lockout/tagout is being removed.removed.Remove the lockout/tagout devices. Each Remove the lockout/tagout devices. Each device must be removed by the person device must be removed by the person who put it on.who put it on.

DefinitionsDefinitions

• Authorized Employee - one Authorized Employee - one who locks out machines or who locks out machines or equipment in order to equipment in order to perform the servicing or perform the servicing or maintenance on that machine maintenance on that machine or equipment. or equipment.

Definitions, cont.Definitions, cont.

Authorized employees are Authorized employees are those who:those who:

• Maintain equipmentMaintain equipment

• Service equipmentService equipment

• Trained to use LOTOTrained to use LOTO

Authorized Employee Authorized Employee ResponsibilitiesResponsibilities

• Repair or service equipment as Repair or service equipment as neededneeded

• Ensure that all energy sources are Ensure that all energy sources are locked outlocked out

• Test equipment to verify residual Test equipment to verify residual energy is dissipatedenergy is dissipated

• Place a “Danger – DO NOT Operate” Place a “Danger – DO NOT Operate” tag on equipmenttag on equipment

Authorized Employee Authorized Employee Responsibilities cont.Responsibilities cont.

•Obtain assistance when Obtain assistance when necessarynecessary

•Remove locks and/or tags Remove locks and/or tags following LOTOfollowing LOTO

•Coordinate multi-shift repairCoordinate multi-shift repair

Definitions, cont.Definitions, cont. •Affected Employee - one whose job Affected Employee - one whose job

requires him/her to operate or use requires him/her to operate or use a machine or equipment on which a machine or equipment on which servicing or maintenance is being servicing or maintenance is being performed under lockout, or whose performed under lockout, or whose job requires him/her to work in an job requires him/her to work in an area in which such servicing or area in which such servicing or maintenance is being performed. maintenance is being performed.

Definitions, cont.Definitions, cont.Affected employees are those Affected employees are those

who:who:

• OperateOperate

• Work aroundWork around

• Occasionally adjust equipment Occasionally adjust equipment

that is subject to LOTOthat is subject to LOTO

Affected Employee Affected Employee ResponsibilitiesResponsibilities

• Notify maintenance, etc., when Notify maintenance, etc., when equipment needs repairequipment needs repair

• Leave all LOTO devices in placeLeave all LOTO devices in place

• Verify equipment is safe to operate Verify equipment is safe to operate following LOTOfollowing LOTO

• Follow all safety rules while operating Follow all safety rules while operating the equipmentthe equipment


Company Responsibilities are:Company Responsibilities are:

• Ensure de-energization of Ensure de-energization of

equipmentequipment

• Ensure employee awarenessEnsure employee awareness

• Provide appropriate levels of Provide appropriate levels of

trainingtraining

Company Company ResponsibilitiesResponsibilities

Training RequirementsTraining Requirements• Authorized employers – initially Authorized employers – initially and at least annuallyand at least annually

• Affected employees – at lease Affected employees – at lease initiallyinitially

• Authorized and affected – Authorized and affected – whenever changes are made to whenever changes are made to jobs or proceduresjobs or procedures

• Authorized and affected – when Authorized and affected – when program deficiencies are notedprogram deficiencies are noted

Definitions, cont.Definitions, cont.Company Company

ResponsibilitiesResponsibilities• Review program effectivenessReview program effectiveness

• Maintain and revise programMaintain and revise program

• Administer appropriate Administer appropriate

disciplinary actionsdisciplinary actions

Maintenance Maintenance ResponsibilitiesResponsibilities

• Lockout/Tagout prior to Lockout/Tagout prior to service or repairservice or repair

• Remove or cut locks off Remove or cut locks off isolation devicesisolation devices

• Ensure proper training of Ensure proper training of authorized employeesauthorized employees


• Energy Isolating Device – Energy Isolating Device – A mechanical device that A mechanical device that physically prevents the physically prevents the transmission or release of transmission or release of energy.energy.


Energy Control ProcedureEnergy Control Procedure

Safety program adopted by the Safety program adopted by the employer that includes:employer that includes:

1.1. energy control procedures energy control procedures

2.2. provisions for inspecting the provisions for inspecting the procedures procedures

3.3. training employees for lockout/tagout. training employees for lockout/tagout.

Hazardous Energy Hazardous Energy Sources Sources

Found in the WorkplaceFound in the WorkplaceMechanicalMechanical

TransitionalTransitionalRotationalRotational

ThermalThermalMachines or Machines or

EquipmentEquipmentChemical Chemical

ReactionsReactions

PotentialPotentialPressurePressure

HydraulicHydraulicPneumaticPneumaticVacuumVacuum

SpringsSpringsGravityGravity

ElectricalGeneratedStatic

LOTO is not just for LOTO is not just for electrical energy sources! electrical energy sources!

• Gases, liquid chemical, mechanical, Gases, liquid chemical, mechanical, water, etc. can all be hazardous energy water, etc. can all be hazardous energy sources. Procedures should address all sources. Procedures should address all sources of energy. sources of energy.

•Type of stored energy-means to Type of stored energy-means to

dissipate or restrain:dissipate or restrain:

• * Electrical 115 volt unplug* Electrical 115 volt unplug

• * Pressure 100-200 PSI bleed off.* Pressure 100-200 PSI bleed off.

• * Chemical #2897 Nalco wash * Chemical #2897 Nalco wash downdown

•MECHANICAL ENERGYMECHANICAL ENERGY

(Gravity activation, or stored in springs, (Gravity activation, or stored in springs, etc)etc)

• A. Block out or use die ram safety chain. A. Block out or use die ram safety chain. B. Lockout or tagout safety device. B. Lockout or tagout safety device. C. Shut off, lockout or tagout electrical C. Shut off, lockout or tagout electrical system. system. D. Check for zero energy state. D. Check for zero energy state. E. Return controls to safest position. E. Return controls to safest position.

HYDRAULIC/PNEUMATICHYDRAULIC/PNEUMATIC

• A. Shut off all energy sources (pumps A. Shut off all energy sources (pumps and compressors). If the pumps and and compressors). If the pumps and compressors supply energy to more compressors supply energy to more than one piece of equipment, lockout or than one piece of equipment, lockout or tagout the valve supplying energy to tagout the valve supplying energy to this piece of equipment. this piece of equipment.

• B. Stored pressure from B. Stored pressure from hydraulic/pneumatic lines shall be hydraulic/pneumatic lines shall be drained/bled when release of stored drained/bled when release of stored energy could cause injury to employees. energy could cause injury to employees.

• C. Make sure controls are returned to C. Make sure controls are returned to their safest position (off, stop, standby, their safest position (off, stop, standby, inch, jog, etc.). inch, jog, etc.).

LOCKOUT/TAGOUTLOCKOUT/TAGOUTScope and ApplicationScope and Application

Hot tap operations that involve Hot tap operations that involve transmission and distribution systems for transmission and distribution systems for gas, steam, water, or petroleum products gas, steam, water, or petroleum products on pressurized pipelines on pressurized pipelines ifif continuity of continuity of service is essential, shutdown of the service is essential, shutdown of the system is impractical, documented system is impractical, documented procedures are followed, and employees procedures are followed, and employees are effectively are effectively

protected by special equipment.protected by special equipment.

LOCKOUT/TAGOUTLOCKOUT/TAGOUTRelease of Stored EnergyRelease of Stored EnergyInspect the system to make sure all Inspect the system to make sure all parts have stopped moving.parts have stopped moving.Relieve trapped pressure.Relieve trapped pressure.Block or brace parts that could fall Block or brace parts that could fall due to gravity.due to gravity.Bleed lines and vent valves open.Bleed lines and vent valves open.If stored energy can reaccumulate, If stored energy can reaccumulate, monitor it to make sure it stays below monitor it to make sure it stays below hazardous levels.hazardous levels.

Lockout devices

Types of Lockout DevicesTypes of Lockout DevicesPlug LocksPlug LocksBall Valve Ball Valve

LockoutLockoutGate Valve Gate Valve

LockoutLockoutGroup Group

Lockout Lockout HaspHasp

ElectricalElectricalHydraulic, Hydraulic,

pneumatic, pneumatic, and other and other pressurized pressurized systemssystems

Lockout Procedure Lockout Procedure

• Alert the operator(s) that power is Alert the operator(s) that power is being disconnected. Preparation for being disconnected. Preparation for Shutdown Shutdown

• Equipment Shutdown Equipment Shutdown • Equipment Isolation Equipment Isolation • Application of Lockout Devices Application of Lockout Devices

Control of Stored Energy Control of Stored Energy • Equipment Isolation-VerificationEquipment Isolation-Verification

LOCKOUT/TAGOUTLOCKOUT/TAGOUTVerifying Equipment Verifying Equipment IsolationIsolation

Make sure all danger areas are clear of Make sure all danger areas are clear of personnel.personnel.

Verify that the main disconnect switch or Verify that the main disconnect switch or circuit breaker can’t be moved to the on circuit breaker can’t be moved to the on position.position.

Press all start buttons and other activating Press all start buttons and other activating controls on the equipment itself and return controls on the equipment itself and return controls to the off position when the controls to the off position when the testing is complete.testing is complete.

Removal of Lockout Removal of Lockout • Ensure equipment is safe to Ensure equipment is safe to

operate operate

• Safeguard all employees Safeguard all employees

• Remove lockout/tagout devices. Remove lockout/tagout devices.

• Except in emergencies, each Except in emergencies, each

device must be device must be removed by the removed by the

person who put it on. person who put it on.

• Last person to take off lock Last person to take off lock

• Follow checklistFollow checklist

Temporarily Reactivating Temporarily Reactivating Equipment Equipment

• Remove unnecessary tools from the work Remove unnecessary tools from the work area and make sure everyone is clear of area and make sure everyone is clear of the equipment the equipment

• Remove lockout/tagout devices and re-Remove lockout/tagout devices and re-energize the system energize the system

• As soon as the energy is no longer As soon as the energy is no longer needed, isolate the equipment and re-needed, isolate the equipment and re-apply lockout/tagout, using safety apply lockout/tagout, using safety procedures. procedures.

RELEASE FROM RELEASE FROM LOCKOUT/TAGOUTLOCKOUT/TAGOUT

• A. Inspection – A. Inspection – - Make certain the work is completed and inventory tools - Make certain the work is completed and inventory tools

and equipment used. and equipment used.

• B. Clean-up - - Remove all towels, rags, work-aids, etc. B. Clean-up - - Remove all towels, rags, work-aids, etc.

• C. Replace guards - - Replace all guards possible. C. Replace guards - - Replace all guards possible. Sometimes a particular guard may have to be left off until Sometimes a particular guard may have to be left off until the start sequence is over due to possible adjustments, the start sequence is over due to possible adjustments, however, all other guards should be put back into place. however, all other guards should be put back into place.

• D. Check controls - - All controls should be in their safest D. Check controls - - All controls should be in their safest position. position.

• E. The work area shall be checked to ensure that all E. The work area shall be checked to ensure that all employees have been safely positioned or removed and employees have been safely positioned or removed and notified that the lockout/tagout devices are being removed. notified that the lockout/tagout devices are being removed.

• F. Remove locks/tags - - Remove only your lock or tag. F. Remove locks/tags - - Remove only your lock or tag.

Special SituationsSpecial SituationsServicing lasts Servicing lasts

longer than longer than one shift.one shift.

Contractors Contractors are performing are performing service or service or maintenance maintenance at your at your workplaceworkplace

Worker who Worker who applied lock applied lock is not is not availableavailable

LOCKOUT/TAGOUTLOCKOUT/TAGOUTShift ChangesShift Changes

If servicing lasts more than one shift, If servicing lasts more than one shift, lockout/tagout protection must not lockout/tagout protection must not be interrupted.be interrupted.

When the employee who applied When the employee who applied device is not there to remove it, it device is not there to remove it, it can be removed only in an can be removed only in an emergency and only under the emergency and only under the direction of the supervisor.direction of the supervisor.

Perform LOTO SafelyPerform LOTO Safely

• Follow company safety procedures for Follow company safety procedures for LOTOLOTO

• Refer to procedures on how to lock out Refer to procedures on how to lock out specific equipmentspecific equipment

• Keep everyone informed when Keep everyone informed when equipment is repaired or servicedequipment is repaired or serviced

• Stay alertStay alert

• Use common senseUse common sense

Tidbits of Info.Tidbits of Info.

• Never attempt lockout/tagout Never attempt lockout/tagout procedures unless you have been procedures unless you have been trained and certified by your trained and certified by your employer under an approved Energy employer under an approved Energy Control Program.Control Program.

• Never loan or share your lock, Never loan or share your lock, combination, or key with anybody combination, or key with anybody else.else.

Tidbits of Info. cont.Tidbits of Info. cont.

•Always be sure all lockout/tagout Always be sure all lockout/tagout devices are compatible with the devices are compatible with the environment in which they will environment in which they will be used i.e. corrosive, humid, be used i.e. corrosive, humid, etc. etc.

Any Questions?Any Questions?

Lockout/Tagout QuizLockout/Tagout Quiz

1. The LOTO standard is designed to 1. The LOTO standard is designed to block the flow of energy to a piece of block the flow of energy to a piece of equipment. equipment. True or FalseTrue or False

2.2. Types of LOTO devices include Types of LOTO devices include ______________________________________________________

3.3. It is not required that a company It is not required that a company have written procedures for proper have written procedures for proper lockout/tagout. True or Falselockout/tagout. True or False


4.4. An authorized employee is one who An authorized employee is one who _______ or________ the equipment._______ or________ the equipment.

5. If a safety device is removed from a 5. If a safety device is removed from a piece of equipment, LOTO is not piece of equipment, LOTO is not required. True or Falserequired. True or False

6.6. Typical energy sources found on Typical energy sources found on equipment include equipment include ____________________________________________________


7.7. Affected employees are those Affected employees are those who operate or work around a piece who operate or work around a piece of equipment. True or Falseof equipment. True or False

8.8. As long as an employee has had As long as an employee has had training on LOTO, the employer or training on LOTO, the employer or company has no additional company has no additional responsibilities under 1910.147. responsibilities under 1910.147. True or False True or False


9.9. Training for authorized employees Training for authorized employees must be conducted ________________and must be conducted ________________and at least ______________________at least ______________________

10. Locks should always stay on the 10. Locks should always stay on the equipment during a shift change. equipment during a shift change.

True or FalseTrue or False


11.11.You may remove a lock or tag You may remove a lock or tag applied by someone else? applied by someone else? True or FalseTrue or False

Lockout/Tagout Quiz Lockout/Tagout Quiz AnswersAnswers

1. 1. TrueTrue. It should block the flow of energy . It should block the flow of energy and provide a means of warning.and provide a means of warning.

2. Types of LOTO devices include locks, 2. Types of LOTO devices include locks, blocks, chains, hasps, wheel valve blocks, chains, hasps, wheel valve covers, and ball valve covers.covers, and ball valve covers.

3. 3. FalseFalse. If lockout is required, a company . If lockout is required, a company must have a written program and must have a written program and procedures.procedures.


4. An authorized employee is one who 4. An authorized employee is one who services or maintains the equipment.services or maintains the equipment.

5. 5. FalseFalse. LOTO is required when a safety . LOTO is required when a safety device is removed; an employee is in device is removed; an employee is in harm’s way, or when employees are harm’s way, or when employees are exposed to hazardous energy.exposed to hazardous energy.

6. Typical energy sources include 6. Typical energy sources include hydraulics, pneumatics, steam, thermal, hydraulics, pneumatics, steam, thermal, chemical, electricity, and gravity.chemical, electricity, and gravity.


7. 7. TrueTrue. Affected employees are those . Affected employees are those who operate or work around the who operate or work around the equipment.equipment.

8.8. FalseFalse. Training is just one of . Training is just one of the responsibilities of a company.the responsibilities of a company.


9.9. Training for authorized Training for authorized employees must be conducted employees must be conducted initially and at least annually.initially and at least annually.

10. 10. FalseFalse. Locks should be removed . Locks should be removed during shift change and the shift during shift change and the shift coming on duty should place their coming on duty should place their locks on the equipment.locks on the equipment.


11 11 FALSE. FALSE. You may You may NOTNOT remove a remove a lock or tag applied by someone else. lock or tag applied by someone else. (some companies require removal of (some companies require removal of locks and tags at the end of each locks and tags at the end of each shift with replacement locks and tags shift with replacement locks and tags applied by oncoming employees)applied by oncoming employees)

lockout/tagout standard

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