Lockout - Tagout
Subpart J
Fatal Five
Failure to stop equipment Failure to disconnect from power source Failure to dissipate (bleed, neutralize) residual
energy Accidental restarting of equipment Failure to clear work areas before restarting
Scope and Application
Applies to general industry Covers operators and service personnel
When is LOTO Required?
Servicing or maintaining equipment
where:
Hazardous energy exists Unexpected start-up could occur Either of these could harm an employee
LOTO Shall Be Used When:
Employees are required to remove or
bypass a safety device Employees are required to place any part of their body in harms way Employees are exposed to hazardous energy
LOTO Exceptions
Work where hazardous energy does
not exist Activities performed during routine production processes Work on cord-controlled devices Hot tap operations where shutdown is not feasible
Typical Equipment Requiring LOTO
Presses
Saws
Conveyors Pumps Production Equipment Trash Compactors Ovens
Energy Sources
Mechanical Chemical Thermal Hydraulic Pneumatic Electrical Gas Water Other stored energy (i.e. springs, capacitors)
Affected Employees
Employees who: Operate Work around Occasionally adjust equipment that is subject to lockout tagout
Authorized Employee
Maintains equipment Services equipment
Is trained to use lockout tagout
procedures
Energy Control Program
Energy control procedures Periodic inspections
Employee training
Procedures
Must clearly and specifically outline the: Scope Purpose Authorization Rules Lockout-tagout techniques Means to enforce compliance
Procedures
Statement of intended use of the
procedure Specific energy control steps for
Shutting down Isolating Blocking Securing equipment
Procedures
Specific steps for LOTO device Placement Removal Transfer Responsibility
Procedures
Requirements for testing equipment to
determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures
Where to Begin
Conduct a hazard assessment by identifying
each piece of equipment that is used, serviced, or maintained
Include broken or stored equipment
Determine the requirements for lockout If there is more than one primary energy source to the equipment, document each source
Where to Begin
Document all energy sources Hidden Direct The hazard posed The magnitude or measurable degree of
danger Special or unusual conditions Proper isolations and devices
Types of Lockout Devices
Locks Blocks Chains Multilock hasps Wheel valve covers Ball valve covers
Requirements For Lockout/Tagout Devices
Durable
Standardized
Substantial Identifiable
Periodic Inspections
At least annually Ensure procedures are implemented
properly Ensure employees are familiar with their responsibilities Correct any deviations or inadequacies identified
Designating an Inspector
Periodic inspections must be performed by an
authorized employee other than the one(s) using the energy control procedure Who can inspect Department manager Plant management Safety manager Others
Employee Reviews
Lockout
Review between the inspector and each authorized employee Review each employees responsibility Review between the inspector and each authorized and affected employee Review each employee's responsibility Review the limitations of tags
Tagout
Inspection Certification
Must certify that the required periodic inspections
have been performed Certification must identify the following:
Equipment on which the energy control procedure was used Date of the inspection Employee(s) included in the inspection Person performing the inspection
Training Requirements
Authorized employees initially and at least annually Affected employees at least initially Authorized and affected whenever changes are made to jobs or procedures when program deficiencies are noted Certification
Authorized Employee Training
Purpose of the procedure Recognition of applicable hazardous energy
sources Type and magnitude of the energy available in the workplace Means and methods necessary for energy isolation and control Ways to verify that energy isolation is effective
Affected Employee Training
Instruction on the the purpose and use of the
energy control system Awareness
Other Employee Training
All other employees (including new hires)
whose work operations are or may be in an area where lockout/tagout may be utilized Instruction must include:
Purpose of the procedure Prohibition of starting or reenergizing any locked-out or tagged-out equipment they encounter
Retraining
Authorized and affected employees Change in job assignment Change in equipment, machinery, or processes that presents a new hazard Change in the lockout/tagout procedure
Retraining
Shall be conducted whenever a periodic inspection reveals, or the employer has reason to believe, that there are deviations from or inadequacies in the employee's knowledge or use of the lockout-tagout procedures
Group Lockout/Tagout
Procedure must afford the employees a level of protection equivalent to that provided by the implementation of a personal lockouttagout device
Group Lockout/Tagout
Primary responsibility is vested in an
authorized employee who must:
ascertain the exposure status of individual group members coordinate affected work forces (i.e. crews, departments, crafts)
Group Lockout/Tagout
Each authorized employee must: Affix a personal lockout-tagout device to the group lockout device or box when he/she begins work Remove those devices when he/she stops working on the equipment being serviced or maintained
Shift or Personnel Changes
Procedures must ensure: Continuity of lockout/tagout protection Orderly hand-off of lockout of lockout/tagout devices
Testing or Positioning of Machines
OSHA allows the temporary removal of locks or tags and the re-energization of the equipment only when necessary under special conditions
for example, when power is needed for the testing or positioning of equipment
Testing or Positioning of Machines
Must be conducted in following sequence: Clear the equipment of tools and material Vacate employees from the equipment area Remove the lockout-tagout device as specified in the standard (the authorized employee who applied it must remove it) Energize the equipment and proceed with testing or positioning De-energize all systems, isolate the equipment from the energy source, and reapply the lockout-tagout devices
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 others Energy Control Program
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 the energy source
Typical Shutdown Procedures
Affix locks and tags to each energy source
controlling device Relieve all stored energy from capacitor banks, springs, compressed air, steam, hydraulics, etc. Verify isolation of energy has occurred by trying equipment
Removal of Lockout/Tagout and Start-Up Procedures
Ensure that nonessential items are
removed from equipment Ensure that equipment components are intact Check area to ensure that all affected employees are safely positioned or removed from the area
Removal of Lockout/Tagout and Start-Up Procedures
Notify all affected employees and site
supervisor before reenergizing the equipment Remove lockout/tagout devices Reenergize equipment to ensure safe operation
Summary
Accidents will happen Equipment will occasionally malfunction People will still make mistakes
There is no excuse for serious injury that results from ignorance, carelessness, complacency, or lack of an Energy Control Program
