Lockout/Tag out

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Lockout/Tag out
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Definitions

• Lockout/Tagout (LOTO) - Risk to individuals
  working on powered equipment or machinery can be
  minimized by adhering to the six step process of
  LOTO.
• Lockout/Tagout gets its name from the equipment
  used
• Lockout/Tagout must be used whenever you are
  performing service or maintenance on any machine
  where you or someone else could be injured by the
  unexpected startup or release of stored energy
• LOTO DOES NOT APPLY to single source plug and
  cord equipment when the equipment is unplugged
  and under the exclusive control of the person
  performing the work

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Definitions

• LOTO Device - A device such as a lock, circuit
  breaker cover, etc. that secures an energy
  isolating device and prevents energization of a
  machine, equipment or process
• Caution Tag - Yellow Caution Tags are used to
  indicate that a machine, equipment, process or
  circuit is out of service or inoperable
• Energy Isolating Device - A mechanical device
  that physically prevents the transmission or
  release of energy, such as a circuit breaker or
  disconnect switch

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Definitions

• Individual LOTO Lock - A type of key lock that is
  used for no other purpose in the
  facility/operation, having one key, and for which
  master keys are not available. Such locks are
  individually assigned (personal lock) to
  Authorized Employees, or can be obtained from a
  central repository of LOTO devices, whereupon
  they become personal locks while in use by an
  individual. LOTO Locks are typically colored red.
• Individual LOTO Tags- These tags are used with
  every Personal LOTO Lock to indicate that the
  energy source is locked out and that an
  Authorized Employee is actively working on the
  machine, equipment, process, or circuit.

Show employee(s) the individual locks and tags
that are used on site.
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Definitions

• Supervisor Lock - A key lock for which multiple
  keys may be made available and which is used on
  equipment or processes when they are not actively
  being serviced. Key control or access must be
  limited to a small, closely controlled group of
  Authorized Employees. This lock must be used in
  combination with a Supervisor Tag to indicate the
  equipment is unsafe to operate.
• This lock must not be used as an Personal Lock
  and may never be used on equipment that is being
  actively serviced.
• Supervisor Tag - Must be yellow in color and are
  used to indicate that a machine, equipment,
  process or circuit is out of service or
  inoperable, but no one is actively working on the
  system. Supervisor Tags are not to be used in
  place of Red Tags. No activity to the machine,
  equipment, process or circuit may occur when a
  Supervisor Tag is placed.

Show employee(s) the Supervisor locks and tags
that are used on site
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Definitions

• General LOTO Lock - A key lock that is not
  assigned to an individual employee as an
  Individual LOTO Lock. This lock has only one key
  and master keys are not available. When a Group
  LOTO is used, this lock may be used to Lock Out
  individual Energy Isolating Devices or Energy
  Sources. This lock may be left on for durations
  of greater than one shift. This lock is unique
  within the facility and is to be used only for
  LOTO.

Show employee(s) the general LOTO locks that are
used on site
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Personnel Affected by Lockout Tagout

• Every employee who will be in close proximity to
  any machinery or equipment being worked on will
  be affected by Lockout/Tagout.
• Authorized Employee
• Affected Employee

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Personnel Affected by Lockout Tagout

• Authorized Employee - An employee who has the
  appropriate technical background, has completed
  Lockout/Tagout Authorized Training, has
  successfully demonstrated that they know how to
  apply EC/LOTO, and who will perform the work on
  the system. This could include an electrician,
  pipefitter or other specialist with knowledge of
  the equipment.
• Affected Employee - An employee who operates
  equipment that is being maintained or serviced
  under EC/LOTO, or an employee working in an area
  where the maintenance or servicing is being
  performed. This could include machine operators,
  janitors or any other worker whose job requires
  him/her to be in the area. Affected Employees are
  NOT authorized to perform EC/LOTO.

Discuss the employee(s) role with lockout tag out
and whether or not they are Affected or
Authorized employees.
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Energy Isolation Device

• A mechanical device that prevents transmission or
  release of hazardous energy
• Circuit Breakers
• Disconnect Switches
• Line Valves
• Block Valves
• Manually Operated Switches

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Types of Lockout/Tagout Devices

• Circuit breaker cover
• Gate valve locks
• Fuse cover
• Wall switch cover

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Types of Lockout/Tagout Devices

• Plug lock
• Hasp
• Ball valve locks
• Group lockbox

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Types of Hazardous Energy

• Mechanical
• Relating to springs, rotating parts, etc.
• Magnetic
• Can be found in capacitors and superconducting
  magnetic energy storage
• Gravity
• Can be found in machinery or equipment parts that
  might descend, slide or fall if left unblocked
• Electrical
• Relating to or operated by electricity AC or DC
• Hydraulic
• Involving, moved or operated by a fluid under
  pressure, either internal or external
• Pneumatic
• May be in cylinders, lines and pipes
• Thermal
• Can be hot or cold

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Types of Hazardous Energy

• Chemical
• Produced as a result of a chemical reaction
• Steam
• Water vapor kept under pressure so as to supply
  energy for heating or mechanical work

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Hazardous Energy

• Remember To proceed with any maintenance or
  servicing, hazardous energy must be identified
  and controlled to prevent injury.
• All energy sources must be identified and
  labeled.

• Show employees examples of the sites LOTO
  procedures including
• Where they are located
• How the LOTO points are labeled

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Employee Training

• Authorized Employees must
• Recognize hazardous energy sources including type
  and magnitude present in the work place
• Know the methods and means to isolate and control
  hazardous energy sources
• Perform an annual demonstration to show they know
  how to properly apply LOTO
• In addition to this training course, Authorized
  Employees must also go through the periodic
  inspection/certification form located in the
  Lockout/Tagout program. Your Supervisor is
  responsible for completing this addition
  requirement.
• Employee Retraining is required when
• There is a change in job assignment
• There is a change in energy control procedures
• Inspections indicate deviations in procedures
• Employer believes employee needs retraining

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Six Step Process

• Step 1 - Prepare for Shutdown
• Notify all affected employees in the area that
  the equipment is going to be shut down and locked
  out.
• Understand the problem
• What needs to be fixed?
• Plan
• Are the proper tools available?
• Prepare
• Is the area clear and are warnings posted?

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Six Step Process

• Step 2 Shut Down the Equipment
• Use established procedures
• Involve the worker who normally shuts down the
  equipment
• If the work is being performed at a customer
  site, the customer should shut down the equipment

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Six Step Process

• Step 3 - Isolate the Equipment
• Disconnect the equipment from each hazardous
  energy source and know the proper order of
  shutdown
• Remember to wear Personal Protective Equipment
  (PPE) appropriate for any hazards in the area 
• Use common isolation techniques including closing
  valves and opening electrical disconnects
• Remember to stand to one side when opening
  electrical disconnects in the event an electrical
  arc occurs

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Six Step Process

• Step 4 - Apply Lockout/Tagout Devices
• Only use approved colored locks and tags
  designated for lockout
• NO MASTER KEY is allowed for a personal lock
• Locks must be attached to the energy-isolating
  device
• There should be one lock per person working on
  equipment, at each energy source, unless a group
  lockbox is used
• If multiple employees a lockbox and/or multiple
  lock hasps may be used
• Never lend or borrow locks or keys
• Never use lockout locks for any other purpose

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Six Step Process

• Step 5 - Control Stored and Residual Energy
• Check that all moving parts have stopped.
• Relieve or disconnect any residual hazardous
  energy that could be present.
• Bleed-off all trapped pressure.
• Blank pipe flanges.
• Install ground wires to discharge electrical
  capacitors.
• Block or support elevated equipment.

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Six Step Process

• Step 6 - Verify Isolation/Zero Energy
• Start by verifying that all testing equipment
  (e.g., voltmeter, etc.) is working properly
• Try to turn the equipment on
• Test for voltage
• Check gauges
• Check Double Block and Bleed
• Check temperature with an independent device
• Check blocks and pins
• Return switches to the OFF
• Notify Affected Employees in the area that work
  is to begin

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Release of Lockout/Tagout

• Check for others. When the assigned repair or
  servicing task is completed and the machine is
  ready for testing or return to service, check the
  area surrounding the shut off unit to assure that
  no one will be exposed to danger when that
  machine is started up. Replace all guards and
  reactivate all interlocks.
• Notify all affected employees that locks/tags are
  going to be removed and the machine is ready for
  operation.
• Remove LOTO equipment. When the area is clear,
  remove all locks and de-activate all the energy
  isolating devices to restore energy and material
  to the machine. The same worker who installed
  the energy isolating devices and installed the
  locks must de-activate and remove them.
• Test the machine. Perform any necessary testing
  of the restored machine to ensure it is in
  operable condition.
• Notify the management that work is completed and
  the area has been returned to operational
  condition.

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Things We Cannot Do!

• DO NOT
• Rely on emergency stops
• Rely on interlocks and light curtains
• Rely on another worker to guard the power
  source
• Why cant we do these things
• Emergency stops and interlocks can fail
• Human error- people can get distracted
• Injuries are not caused intentionally, it happens
  when things are overlooked and things
  accidentally happen (doors shutting behind
  someone, accidentally pushing a button, etc.)
• The whole point of lockout tag out is so that it
  cannot be bypassed. It removes the factor of
  other countermeasures like e-stops and interlocks
  failing as well as removing the human error
  element!

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Special Situations

• Group Lockout
• Each authorized individual performing service
  and/or maintenance must apply his/her personal
  lock. Every authorized individual who applies a
  personal lock shall verify that the machine,
  equipment, process or circuit has attained a zero
  energy state or observe the verification process.
  Multiple lock application can be accomplished
  with the following
• Multiple lock devices (hasps) that accommodate
  several personal Iocks
• The use of general locks and a lock box. For
  example, if a machine with multiple energy
  sources is going to be serviced by multiple
  personnel, it may be useful to use general locks
  at the energy sources. Keys for the general locks
  are held in lock boxes to which employees attach
  their personal locks.

• Discuss the sites procedure for group lockout
  including
• Color of locks used
• When it is to be used (give examples of machines
  and specific jobs)

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Special Situations

• Specific procedures shall be utilized during
  shift or personnel changes to ensure the
  continuity of LOTO protection. This includes
  provisions for the orderly transfer of LOTO
  devices between off going and on coming
  authorized individuals. There are two distinct
  methods of shift or personnel change LOTO
  transition. These methods should never be mixed
  or combined.
• Option 1 The immediate hand-off of LOTO in
  progress. Authorized individuals of the outgoing
  shift remove their personal locks and tags.
  Authorized individuals of the next shift
  simultaneously apply and secure their personal
  locks and tags at the same energy-isolating
  device and verify that a zero energy state exists
  in the system.
• Option 2 Application of Supervisor Locks.
  Authorized individuals use this method when
  servicing and/or maintenance continues over
  multiple shifts, but there is no immediate
  hand-off of LOTO in progress.

• Discuss the sites procedure for shift change
  including
• Color of locks and tags used (show them the locks
  and tags that will be used)
• How and when to apply or remove shift change
  locks and tags

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Special Situations

• Unauthorized removal of locks and tags is
  prohibited. The Supervisor or qualified person
  shall use the following procedure when the
  employee is not available
• Verify that the authorized employee is not on
  site and available to remove his or her own tag.
• Check that employees are not exposed to hazards.
• Verify that the equipment is safe to operate,
  tools have been removed, and guards have been
  replaced.
• Remove lock/tag and energize equipment.
• Remain with affected equipment so that no one
  returns while equipment or process is being
  restarted.
• Require that the affected employee knows the
  lockout device has been removed before he/she
  resumes work.
• The Lockout/Tagout Removal Notice in the Lockout
  Tagout program must be completed.

Discuss the sites procedure for lock removal
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Special Situations

• New person(s) working on the system Any new
  person working on the system must follow all
  lockout procedures.
• Returning to do more work If you return to do
  more work, follow full lockout procedure to
  assure nothing has changed.
• Removing another persons lock NO ONE ELSE
  should remove an individuals lock and tag.

DO NOT ASSUME ALL IS SAFE ALWAYS RE-VERIFY
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Special Situations

• When power must be temporarily restored to a
  machine to test or position the machine,
  equipment or components, the following sequence
  of actions shall be followed. At no time should
  you place any body parts in a danger area!! This
  procedure is for observation purposes and
  adjustments that can be made outside of the
  danger area!!!!
• Clear the machine or equipment of tools and
  materials.
• Notify all affected employees that you are
  removing lockout/tag out device(s) and ensure
  that they are safely positioned or cleared from
  the area.
• Remove the lockout device as specified in the
  lockout removal section of this procedure.
• Energize and proceed with testing or positioning.
• When testing or positioning is completed,
  de-energize all systems and reapply the energy
  control measures in this procedure.

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QUESTIONS