Lockout/Tagout

Lockout - Tagout

Control of Hazardous
Energy
OSHA Standard
1910.147
 What Is Lockout/Tagout?

 Referred to
as LOTO
 Blocks the flow
of energy from
power source to
the equipment
 Provides means
of warning (tag)
 Why is Lockout/Tagout
Important?

 OSHA’s Top 10 Most Cited Violations:

– Lockout / Tagout has ranked 4th on the list for
the last two years.
– Over 4,000 violations per year.
 Types of Energy

 Electrical
 Mechanical
 Chemical
 Thermal
 Hydraulic
 Pneumatic
 Use Safe Electrical Practices
 Use non-conducting
tools.
 Check circuits dead
before working.
 Ensure all control
power is de-energized.
 Discharge all
capacitors after
lockout.
 Mechanical Energy Hazards
Kinetic – energy in motion
Potential - stored energy
 Energy stored in machinery
 Weights & Springs
 Pistons under pressure
 Hydraulic controls

Stored potential energy can be

released during work causing
injury or death.
 Chemical Energy Hazards

Chemicals have energy that can:

 start fires
 cause skin burns
 generate harmful gases or fumes

Before working – release, drain or vent chemicals

safely.
 Thermal Energy Hazards

Energy of Heat and Cold

 Hot or cold equipment & fluids can burn you
 Quick releases of compressed gases can freeze
your skin

Allow equipment to reach a safe temperature

before starting work.
 Hydraulic Energy
Energy of Liquids Under Pressure
pressure can cause equipment to
move
rapid release can cause injury or ejection of
system parts

Block energy or relieve pressure slowly into a

proper container.
 Pneumatic Energy Hazards

Energy of Compressed Gases

– uncontrolled release can cause injury
– rapid de-pressurization creates extreme low
temperature

Properly vent all systems before starting work.

 LOTO Procedure

1. Prepare for Shutdown

2. Shutdown Equipment
3. Isolate all energy sources
4. Place Locks & Tags
5. Release Stored Energy
6. Verify Equipment Isolation
 1. Prepare for Shutdown

 Understand equipment hazards!

 Notify other employees of shutdown.
 2. Shutdown Equipment

 Follow normal
shutdown procedure.
 Turn all switches to
the OFF position.
 Shut all valves.
 Disable all sources of
energy!
 3. Isolate All Energy Sources

 Shut valves
 Open breakers &
disconnects
 4. Place Locks & Tags

 Valves
 Breakers / electrical
disconnects
 Block or disconnect
all lines
 5. Release or Block all Stored
Energy
 Discharge capacitors
 Block or release springs
 Block elevated parts
 Stop rotating parts
 Relieve system pressure
 Drain fluids
 Vent gases
 Allow system to cool
6. Verify Equipment Isolation

 Check all other workers are clear of the

equipment.
 Check locking devices securely placed.
 Check isolation.
 Attempt normal startup.
 Return Controls to OFF/Neutral.
 Items needed for LOTO

 Written LOTO procedures

 Locks & Tags
 Hasps --for multiple locks
& tags
 Breaker Lockouts
 Gate Valve Lockouts
 Ball Valve Lockouts
 Types of Lockout Devices

 Locks
 Blocks
 Chains
 Multilock hasps
 Wheel valve covers
 Ball valve covers
 Requirements for
Lockout/Tagout Devices

 They must be:

– Durable
– Standardized
– Substantial
– Identifiable
 Typical Equipment
Requiring LOTO
 Presses
 Saws
 Conveyors
 Pumps
 Production
equipment
 Trash
compactors
 Ovens
 Affected Employees

Employees who
 Operate

 Work around

 Occasionally
adjust equipment
that is subject
to LOTO
Affected Employee Responsibilities

 Notify maintenance, etc., when equipment

needs repair or adjustment
 Leave all LOTO devices in place
 Verify equipment is safe to operate
following LOTO
 Follow all safety rules while operating the
equipment
 Authorized Employee

 Maintains equipment
 Services equipment
 Is trained to use LOTO
 Authorized Employee
Responsibilities
 Repair or service equipment as needed
 Ensure that all energy sources are locked out
 Test equipment to verify residual energy is
dissipated
 Place a “Danger—Do Not Operate” tag on
equipment
 Obtain assistance when necessary
 Remove locks and/or tags following LOTO
 Coordinate multi-shift repair
 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
 Authorized and affected—when program
deficiencies are noted
 Company Responsibilities

 Ensure de-energization of equipment

 Ensure employee awareness

 Provide appropriate levels of training

 Review program effectiveness

 Maintain and revise program

 Administer appropriate disciplinary actions

 When Must LOTO Be Used?

When servicing or maintaining equipment where:

 Hazardous energy exists

 Unexpected start-up could occur

 Employees are required to remove or bypass a

safety device
 Employees are required to place any part
of their body in harm’s 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
Releasing Equipment from LOTO

 Inspect Area and Equipment.

 Ensure all Machine Guards in place.
 Move tools away from equipment.
 Inform others of startup.
 Restore system connections.
 Remove Locks & Tags.
 Restore equipment to normal.
 Conduct normal startup.
 Know the Equipment!

– Hazards
– Energy isolation points
– Lockout/Tagout
procedures

Working on unfamiliar
machinery is a hazard!
Who Can Lockout Equipment?

Only employees
who have
been trained
and
authorized by
management.
 Who can remove Locks &
Tags?

Only the employee who placed the tag

or
a supervisor, after obtaining permission
from the worker who placed the tag.
Lockout-Tagout Protects YOU!

ALWAYS Use
Proper Lockout -
Tagout Procedures
They are for your
protection!!!