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1 Rochester Institute of Technology Lock Out/Tag Out (LO/TO)

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1 1 Rochester Institute of Technology Lock Out/Tag Out (LO/TO)

2 2 Rochester Institute of Technology This material was produced under grant number 46B4-HT15 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.

3 3 LOCK OUT / TAG OUT (LO/TO) 29 CFR "Lockout/tagout" refers to specific practices and procedures to safeguard employees from the unexpected energization or startup of machinery and equipment, or the release of hazardous energy during service or maintenance activities.

4 4 Rochester Institute of Technology LO/TO Most incidents occur in workplace around machinery or equipment Most incidents occur in workplace around machinery or equipment Other incidents occur from electric shock or hazardous materials Other incidents occur from electric shock or hazardous materials This can be avoided by using Lock Out/Tag Out to contain hazardous energy This can be avoided by using Lock Out/Tag Out to contain hazardous energy

5 5 Rochester Institute of Technology LO/TO When To Use It For Service & Maintenance of EquipmentFor Service & Maintenance of Equipment Installation Installation Inspection Inspection Cleaning Cleaning Modification Modification Lubrication Lubrication Un-jamming Un-jamming If worker needs to remove safety guards If worker needs to remove safety guards When a worker needs to place any part of their body into machinery When a worker needs to place any part of their body into machinery To avoid an unexpected start-up To avoid an unexpected start-up

6 6 Rochester Institute of Technology LO/TO Energy Sources Electrical Electrical Hydraulic & pneumatic Hydraulic & pneumatic Potential energy from springs Potential energy from springs Gravity Gravity Chemical Chemical Radiation Radiation Pneumatic Pneumatic Thermal Thermal Mechanical (from sources other than springs) Mechanical (from sources other than springs)

7 7 Rochester Institute of Technology LO/TO Achieve Zero Energy Status Utilizing Lock Out/Tag Out Utilizing Lock Out/Tag Out No one may start the machinery or equipment while it is being repaired or cleaned No one may start the machinery or equipment while it is being repaired or cleaned

8 8 Rochester Institute of Technology LO/TO Three Classifications Authorized Personnel: perform service and maintenance, apply locks & tags Authorized Personnel: perform service and maintenance, apply locks & tags Affected Personnel: operate the machinery, prepare machines and/or equipment, and work within same area when lock out/ tag out occurs Affected Personnel: operate the machinery, prepare machines and/or equipment, and work within same area when lock out/ tag out occurs Other: may pass by an area where LO/TO is being used (example: an office worker) Other: may pass by an area where LO/TO is being used (example: an office worker)

9 9 Rochester Institute of Technology LO/TO Lock Out Devices Lock with one key and a tag Lock with one key and a tag Chain Chain Block Block Flange Flange Pipe blank or blind Pipe blank or blind

10 10 Rochester Institute of Technology LO/TO Tag Out Devices Tags are always attached to the lock or energy isolation device Tags are always attached to the lock or energy isolation device Serves as a communication device Serves as a communication device TAG STATES: DO NOT OPERATE TAG STATES: DO NOT OPERATE and securely fastened and securely fastened

11 11 Rochester Institute of Technology LO/TO Locks and Tags are to be used by each individual working on a machine (double check for extraneous power or stored energy), either on the hasp itself, or lockable to a box with alternate hasp Locks and Tags are to be used by each individual working on a machine (double check for extraneous power or stored energy), either on the hasp itself, or lockable to a box with alternate hasp –should only be removed by the individual, after work is complete or replaced by oncoming shift Tags without locks only allowed when as safe as lock and additional protection is taken – i.e. cap over start button with fuse removed in panel Tags without locks only allowed when as safe as lock and additional protection is taken – i.e. cap over start button with fuse removed in panel

12 12 Rochester Institute of Technology Lock & Tag with equipment lock

13 13 Rochester Institute of Technology Lock & Tag with personal tag

14 14 Rochester Institute of Technology LO/TO Six Steps of LO/TO 1. Preparation 2. Equipment Shutdown 3. Equipment Isolation 4. Application of LO/TO device 5. Release of stored energy 6. Verification

15 15 Rochester Institute of Technology LO/TO Six Steps of LO/TO (contd) 1. Preparation: identify and isolate hazardous energy sources, and understand how to use equipment 2. Equipment Shutdown: stop buttons, and follow shut down procedures 3. Equipment Isolation: install device to isolate hazardous energy sources

16 16 Rochester Institute of Technology LO/TO Six Steps of LO/TO (contd) 4. Apply Locks & Tags: if something can be locked, it MUST be locked; if it cant be locked it MUST be tagged 5. Release Stored Energy: guard against residual energy 6. Verification: try activating start button to ensure everything is off, check interlock, and be sure area is clear

17 17 Rochester Institute of Technology LO/TO When Work is Complete Remove tools & equipment Remove tools & equipment Keep a safe distance Keep a safe distance Remove LO/TO devices Remove LO/TO devices Restore energy Restore energy Notify operators and supervisors work is complete Notify operators and supervisors work is complete

18 18 Rochester Institute of Technology LO/TO Doesnt Apply When… Performing routine adjustments Performing routine adjustments Performing repetitive adjustments Performing repetitive adjustments Working on cord & plug equipment kept within sight Working on cord & plug equipment kept within sight Integral with production Integral with production Always use safe work practices

19 19 Rochester Institute of Technology LO/TO Employee Training Employer must provide initial training and retraining as necessary Employer must provide initial training and retraining as necessary Training must be certified with employees name and date of training Training must be certified with employees name and date of training

20 20 Rochester Institute of Technology LO/TO Written Procedures Routine lockouts require the company to maintain a written procedure for: Routine lockouts require the company to maintain a written procedure for: –Each individual machine or piece of equipment, or –Each group of similar machines or equipment Non-routine lockouts must have a specific written procedure for the lockout activity. Non-routine lockouts must have a specific written procedure for the lockout activity.

21 21 Rochester Institute of Technology LO/TO Written Procedures Procedures must have: 1. A statement of the intended use of the procedure 2. Procedural steps for the LOTO process for that type of equipment. Specific steps for testing a machine to determine if a zero energy state is achieved 3. Steps to release or remove the equipment from LOTO

22 22 Rochester Institute of Technology LO/TO Periodic Inspections Performed at least annually to assure that the energy control procedures are effective and continue to be implemented Performed at least annually to assure that the energy control procedures are effective and continue to be implemented Inspection must be certified; identify machinery and equipment, record the date, and note employees included in the inspection Inspection must be certified; identify machinery and equipment, record the date, and note employees included in the inspection Review with all authorized users Review with all authorized users

23 23 Rochester Institute of Technology LO/TO Tag-Only Situations When machine or equipment cannot be locked out When machine or equipment cannot be locked out Employer may choose to modify to allow 100% LO/TO Employer may choose to modify to allow 100% LO/TO Full protection includes complying with all Tag Out provisions, plus implementing additional safety measures Full protection includes complying with all Tag Out provisions, plus implementing additional safety measures

24 24 Rochester Institute of Technology LO/TO Group LO/TO Group LO/TO includes having each authorized employee place his/her lock and tag on equipment being locked out Group LO/TO includes having each authorized employee place his/her lock and tag on equipment being locked out –See for examples of group procedures Shift or Personnel Change – specific procedures are utilized during shift changes Shift or Personnel Change – specific procedures are utilized during shift changes

25 25 Rochester Institute of Technology LO/TO Absentee Lock Removal One person at the company is designated One person at the company is designated This designated person must: Make reasonable efforts to find the absentee individual Make reasonable efforts to find the absentee individual Ensure it is safe to remove the device Ensure it is safe to remove the device Absent Authorized Individual must be notified BEFORE resuming work at the facility. Absent Authorized Individual must be notified BEFORE resuming work at the facility.

26 26 Rochester Institute of Technology LO/TO Summary LO/TO provides for control of energy sources that could cause injury during service or maintenance of machinery and equipment LO/TO provides for control of energy sources that could cause injury during service or maintenance of machinery and equipment Devices must be unique and substantial Devices must be unique and substantial Authorized Individuals are the ONLY people who can apply locks, tags and other LO/TO devices Authorized Individuals are the ONLY people who can apply locks, tags and other LO/TO devices Tags must identify who applied the device Tags must identify who applied the device Six steps must be followed. Six steps must be followed. Written procedures must be developed Written procedures must be developed Group lockouts and Absentee lock removal processes defined Group lockouts and Absentee lock removal processes defined


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