Lockout/Tagout: Hazardous Energy Control

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1. Slide 1

   Lock Out Tag Out

   • Hazardous Energy Control
2. Slide 2

   Sponsorship - Disclaimer

   • Department of Labor
   • Occupational Health and Safety Administration (OSHA)
   • Susan Harwood Training Grant
   • This material was produced by the SPI-OSHA Alliance, and distributed by the Occupational Safety and Health Administration, U.S. Department of Labor. The contents in this presentation do not necessarily reflect the views or policies of the U.S. Department of Labor, nor does the mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.
   • Revisions were made to this material under grant number SH-05059-SH8 from the Occupational Safety and Health Administration, U.S. Department of Labor.
3. Slide 3

   Learning Objectives

   • Understand the purpose of the energy control program
   • Recognition of hazardous energy sources, and the methods necessary for energy control
   • Discuss the primary causes of injury from hazardous energy
   • Understand the steps necessary to properly control hazardous energy when servicing equipment
   • Know the responsibilities of Authorized and Affected employee in terms of logout / tagout
4. Slide 4

   Preventing Unexpected Startup or Release of Energy

   • Energy isolation:
   • Minimize potential for inadvertent activation and/or release of stored energy
   • Ensure power to the machine is isolated and locked at control points
   • Use a method that cannot readily be removed, bypassed, overridden or otherwise defeated
5. Slide 5

   Types of Hazardous Energy

   • Mechanical – the potential energy and kinetic energy present in the components of a mechanical system
   • Kinetic – energy possessed by virtue of its motion
   • Potential – energy stored by the mechanical system
   • Electrical – energy as a result of a generated electrical power source or a static source
   • Thermal – energy as a result of mechanical work, radiation, chemical reaction or electrical resistance
6. Slide 6

   Types of Hazardous Energy, continued

   • Chemical – energy released as a result of chemical reactions
   • Hydraulic – energy released as a result liquids under pressure
   • Pneumatic – energy released as a result of compressed gasses under pressure
7. Slide 7

   Definitions

   • Servicing and/or maintenance where employees may be exposed to unexpected start-up or release of hazardous energy
   • Construction
   • Installing and setting up
   • Adjusting, inspecting, modifying
   • Lubricating, cleaning or unjamming
   • Tool changes
8. Slide 8

   Definitions (continued)

   • Set-up - Work to prepare a machine to perform its normal production operation
   • Lockout – Placement of lockout device on an energy isolating device
   • Lockout device – Device that uses a physical means to prevent operation of a machine or equipment
9. Slide 9

   Definitions (cont’d)

   • Energized - Connected to an energy source, or containing residual or stored energy
   • Energy isolating device - A mechanical device that physically prevents the transmission or release of energy
   • Energy source - Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy
10. Slide 10

    LOTO applies when:

    • Employees are performing servicing or maintenance and there is a potential for injury from unexpected start-up or release of stored energy
    • Service and maintenance that takes place during normal production if the employee:
    • Must remove or bypass a guard or safety device
    • Must place any part of their body into the danger zone
11. Slide 11

    Exception to LOTO

    • Minor servicing activities that takes place during normal production when alternative effective protection is used
12. Slide 12

    Minor Servicing during Normal Production Operations

    • Routine
    • Repetitive
    • Integral to the use of the equipment for production
13. Slide 13

    Alternative effective protection such as:

    • Remote lubricators or other remote devices
    • Interlocked gates and barriers
    • Other effective guarding devices as described in OSHA’s
    • Subpart O and the most current ANSI B 151.1 standard
14. Slide 14

    Core Components of an Energy Control Program

    • Energy control procedures for each type of machine
    • Training and retraining to ensure employees understand the program
    • Periodic inspection to ensure procedures are being followed
15. Slide 15

    Energy Control Procedures

    • Must be specific to each type of machine and equipment you are working on
    • Must include
    • Statement of intended use of the procedure
    • Steps for shutting down and securing machines and equipment
    • Steps for placing, removing, and transferring of lockout devices
    • Requirements for testing and verifying effectiveness of lockout devices
16. Slide 16

    Required Training

    • Authorized employees
    • Recognition of hazardous energy sources
    • Type and magnitude of energy in the workplace
    • Methods for energy isolation / control
    • Affected employees
    • Purpose and use of energy control procedures
    • Other employees in work area
    • Procedures related to restarting machines
17. Slide 17

    Retraining Requirements

    • Retraining is required if:
    • Change in job assignments
    • Change in machines
    • Change in energy control procedures
    • Equipment or processes present new hazards
    • Inspections reveal deficiencies in employee's knowledge of energy control procedures
    • Retraining must reestablish employee proficiency
18. Slide 18

    Periodic Inspections

    • Performed at least annually
    • Conducted by authorized employees
    • Intended to correct inadequacies identified in the program
    • Certified
19. Slide 19

    Certification Requirements

    • Identification of equipment or machinery
    • Date of inspection
    • Names of employees involved in the inspection
    • Name of person(s) performing inspection
20. Slide 20

    Steps of Lockout Procedure

    • 1. Prepare for shutdown
    • 2. Shut down equipment
    • 3. Isolate all energy sources
    • 4. Apply locks & tags
    • 5. Release stored energy
    • 6. Verify equipment isolation
    • 7. Perform the task
    • 8. Release from Lockout
21. Slide 21

    Step 1: Prepare for Shutdown

    • Understand equipment hazards
    • Notify other workers of shutdown
22. Slide 22

    Step 2: Shut down equipment

    • Use the normal shutdown procedures
    • Turn all switches to Off or Neutral
23. Slide 23

    Step 3: Isolate all Energy Sources

    • Use energy isolation devices in accordance with established procedures to prevent transmission or release of energy
    • Valve lockout device
24. Slide 24

    Step 4: Apply Locks & Tags

    • Apply locks and tags to:
    • Valves
    • Breakers/electrical disconnects
    • Mechanical blocks
25. Slide 25

    Step 5: Release or Block all Stored Energy

    • Discharge capacitors
    • Block/disconnect lines
    • Block or release springs
    • Block elevated parts
    • Relieve system pressure
    • Drain fluids
    • Vent gases
    • Allow system to cool (or use PPE)
    • Apply any additional locks and tags needed
26. Slide 26

    Step 6: Verify Equipment Isolation

    • Check that other workers are clear of potential hazards
    • Check that locking devices are secure
    • Attempt normal startup
    • Return control to Off or Neutral
27. Slide 27

    Step 7: Perform the Task

    • Perform maintenance or service
28. Slide 28

    Step 8: Release from Lockout

    • Ensure machinery is properly assembled and all tools removed
    • Ensure that employees are outside of danger zones and are notified that devices are being removed
    • Remove LOTO devices
    • Must be removed by authorized employee who applied it
29. Slide 29

    Summary

    • Lockout-Tagout prevents energy from accidentally being released while a machine or equipment is being serviced
    • There are 6 types of hazardous energy common to most work environments – Mechanical, Electrical, Thermal, Chemical, Hydraulic and Pneumatic
    • Most injuries and fatalities are a result of improper hazardous energy control procedures
    • If an energy-isolating device is capable of being locked out, a lock out system MUST be used
    • General energy control procedures follow an 8-step process
    • Only the authorized employee may attach and remove the logout / tagout device
    • Affected employees or any other employees should NEVER remove or tamper with a logout / tagout device
30. Slide 30

    Questions?