Lockout / Tagout

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Lockout / Tagout

• Control of Hazardous Energy 29 CFR 1910.147
• Cummins Rocky Mountain

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Purpose of Lockout/Tagout (LOTO)

• WHY LOCKOUT/TAGOUT?
• Cummins Rocky Mountain LOTO procedures are
  designed to prevent accidents, to protect
  employees and equipment from accidental start-up.

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The Fatal Five Main Causes of Lockout/Tagout
Injuries

• 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

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Employee Categories

• AUTHORIZED EMPLOYEES
• These are employees who are allowed to perform
  energy control procedures. Training will include
  company approved energy control procedures,
  recognition of energy sources, and methods for
  isolation and energy control.
• AFFECTED EMPLOYEES
• These are employees that operate the equipment on
  which work is being performed. Training will
  include the purpose and use of the energy control
  procedures.
• OTHER EMPLOYEES
• These are all other employees that may work in
  an area where energy control procedures may be
  used. Training will include instruction on the
  energy control procedures and the restrictions
  relating to attempting to restart or reenergize
  equipment that is either locked out or tagged out.

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Hazardous Energy Sources

• CHEMICAL acids, corrosives, caustics
• THERMAL steam, hot, cold
• HYDRAULIC water, oil, liquids
• ELECTRICAL AC/DC, generator, battery
• MECHANICAL coiled springs, raised loads, moving
  parts
• PNEUMATIC pressurized gas, compressed air

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Equipment Requiring Lockout/Tagout at our Facility

• Air Compressor
• Alkota Cleaning System
• Allstar Pressure Washer
• Cummins Injector Test Stand
• Fuel Pump Test Stand
• Sump Pump

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LOTO Definitions and Requirements

• LOTO is defined as the process of the authorized
  placement and administrative control of locks and
  tags used to ensure the protection of employees,
  equipment, and the environment.
• LOTO locks are used for physical control over an
  energy isolation device.

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Energy Isolation Devices

• Used to control and isolate hazardous energy.
  They are mechanical devices that physically
  prevent the transmission or release of energy.
• circuit breakers
• disconnect switches
• valves
• Energy isolation devices are where we place the
  locks and tags. They are NOT locks or tags.
  These are the devices that prevent the
  transmission of hazardous energy to the equipment
  that requires work to be performed.

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Only individual circuit breakers can be locked
out in a circuit breaker. If the whole panel was
locked, circuits powering other equipment would
be inaccessible.
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Locks

• All our locks and tags for LOTO are standardized
  by shape, size or color
• Personally Controlled Lock
• Owner has only key
• No master key is allowed

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Hardware for LOTO

• Locks/Tags
• Locking plug caps
• Chains
• Wedges
• Blocks
• Blanks

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Locks vs Tags

• Locks are used to block the flow of energy.
• Tags are a warning to all employees not to turn
  the power on.

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Lockout vs Tagout

• OSHA prefers lockout.
• If an energy isolation device will accept a lock,
  you MUST use a lock.
• In situations where a lock cannot be used, you
  may use a tag only. A tag does not provide the
  positive control of a lock. So it is important
  that we are all aware of the limitations of a
  tag.

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Tagout

• CAN BE USED in place of lockout if you can
  demonstrate that it will offer employee
  protection equivalent to that offered by lockout.
• Equivalent protection is demonstrated by the
  following safety measures
• Removing an isolating circuit element
• Blocking a control switch
• Opening an extra disconnecting device or
• Removing a valve handle.
• The tag must be attached at the same spot where
  the lockout device would have been found.

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Examples of tags we use.

• Tag Characteristics
• Withstand at least 50 pounds of force
• Not re-usable
• Self locking
• Attachable by hand

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Applying Locks and Tags

• LOTO devices are to be attached by an authorized
  employee to each energy-isolating device.
• When a lockout device is used, it must be
  attached in such a way that it secures the energy
  isolating device in the off position.
• When a tagout device is used, it must be attached
  exactly where the lock would have been on the
  energy-isolation device-or as close to that point
  and in as obvious a position as possible. The
  tag must clearly indicate that the
  energy-isolation device must not be disturbed.
  (The tag should read DO NOT START, DO NOT OPEN,
  or DO NOT ACTIVATE)

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LOTO is NOT Required When

• Work is performed in cord and plug electrical
  equipment on which the plug is under EXCLUSIVE
  CONTROL of the employee performing the service or
  maintenance.
• Note exclusive control means that the plug is
• Physically in possession of or within arms reach
  of the person who performs the work, and
• In that persons line of sight.
• Minor tool changes, when the on/off switch is
  under EXCLUSIVE CONTROL of the operator.
• For Example

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Pedestal grinders
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However, if you cannot immediately repair the
plug and cord equipment, it should be LOTO to
prevent unintended startup. The above picture
shows the plug to a pedestal grinder. Since the
employee couldnt repair it until the parts
arrived, a LOTO plug cap placed was used.
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LOTO Shutdown Procedure

• Steps to Apply LOTO
• Notification of employees involved or in the area
  and you will be shutting equipment down.
• Shutdown of all power sources. You may need to
  stop, block, or bleed the energy sources.
• Lockout and Tagout all energy sources. Verify the
  controls do not start machine and check the
  voltage.
• Verification among employees once the work has
  been completed.
• Inspect work area to ensure removal of
  non-essentials
• Employees safely positioned and notified
• Lockout/tagout removal (by employee who applied)

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Removal of Locks/Tags

• Only the maintenance employee performing the
  original repair can remove a lock.
• If employee is off-site, the supervisor may
  remove the lock under the following conditions.
• Verify that authorized employee is not at
  facility
• Make reasonable efforts to inform him or her
• Ensure that he/she knows of removal upon
  re-entering

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Group Lockout

• Each employee performing LOTO work on equipment
  will have his/her own lock and tag at the energy
  isolation devices.
• When multiple employees are working on the
  equipment, a hasp may be used.

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Equipment Start-Up

• Clear equipment of tools and materials
• Re-install all guards
• Alert employees to stand clear
• Remove locks/tags
• Energize equipment

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Remember to re-install all guards after service
is complete!!!!! Otherwise, a serious hazard may
be created.
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Lockout/Tagout
All lockout/tagout procedures are found through
the link to Lockout / Tagout link on the Cummins
safety website.

• If you have any questions on Lockout/Tagout,
  contact your supervisor or submit a question
  using the ASK THE EXPERT menu selection on this
  website.