Presentation on theme: "Lockout/Tagout (LOTO):"— Presentation transcript:
1 Lockout/Tagout (LOTO): Creating a Safer Workplace through the Control of Hazardous EnergyWelcome to today’s training where we will discuss Lockout/ Tagout. My name is Trey Brown and I am a Senior Loss Control Consultant for Summit and I will be the one presenting today. The purpose of today’s training is to discover ways in which we can create a safer workplace by controlling hazardous energy. It is to protect employees involved in the servicing or maintenance of equipment from injury due to the unexpected start up or release of stored energyLockout/Tagout procedures can be found present in virtually every workplace to some extent. That said, some industries do not see the need for these procedures to the extent that other industries do, however, understanding the principles of Lockout/ Tagout is extremely important. It is important to understand the when, where and why aspects so that the workplace can remain as safe as possible regardless of how often the hazard is encountered.With all of this said, let’s get started.
2 What does it mean to “Lockout” Lockout is a technique used to prevent the release of hazardous energy, or to prevent the hazardous energy from escaping.A padlock is placed on the appropriate energy isolating device that is in the off or closed position.So what does it mean to “Lockout” a device?Locking out a device describes a technique that is used to prevent the release of hazardous energy or to prevent the hazardous energy from escaping.The most common example of locking out a device is a padlock placed on an appropriate energy isolating device that is in the off or closed position. This simply means to turn off some type of equipment and then locking it in the off position so that it can only be turned back on by the person who locked it out..
3 What is Tagout?A method of securing a power source through use of a distinguishable danger tag.Now What is Tagout?Tagout is A method of securing a power source through use of a distinguishable danger tag.Essentially, Lock out refers to the physical lock or device used so that the machine or equipment can not be turned on and Tagout refers to the tag to inform as to who has locked it out as well as some additional information such as when it will be turned back on or energized.
4 The “Fatal Five” Main Causes of Lockout/Tagout Injuries Failure to stop equipmentFailure to disconnect from power sourceFailure to dissipate (bleed, neutralize) residual energyAccidental restarting of equipmentFailure to clear work areas before restartingSo let’s start by looking at the top five causes of injury relating to Lockout/ Tagout issues:1) Failure to stop equipment: It is simply not possible to safely work on any type of equipment while it is in operation. If a piece of equipment is still in operation, there are moving parts to possible account for and the exposure for electrical shock or electrocution is also present.2) Failure to disconnect from power source: Just like not stopping the equipment, failure to disconnect the equipment for the power source, typically but not limited to electricity, can result in contact with the power source which in the case of electricity can lead to everything from severe burns and even death from electrocution.3) Failure to dissipate (bleed, neutralize) residual energy: If a device has stored energy, such as a pneumatic or hydraulic device, the energy that is stored must be bled out so that the device can not discharge while being serviced. This discharge can cause a wide range of injuries including death.4) Accidental restarting of equipment: When other employees other than the employee working on the device or equipment have the ability to turn on or re-energize the device or equipment, there is a chance that the it could be turned back on without the employee working on the equipment knowing. Imagine working on a large mechanical press in a manufacturing environment and being under the press when someone turned it back on. These types of breakdowns in lockout tagout programs lead to countless preventable deaths each year.5) Failure to clear work areas before restarting: The final crucial component in a Lockout / Tagout program is how to properly restart an equipment or device. All work areas should be cleared so that no one finds themselves in an area where they could be hurt by the operation of that machine.
5 Key Terms What is an Authorized Employee ? What is an Affected Employee?What is an energy Isolating Device?What are energy control procedures?Let’s look now at some terms key in discussing Lockout/ Tagout programs.What is an Authorized Employee ?Authorized Employee – An authorized employee is the one who locks out machines or equipment in order to perform the servicing or maintenance on that machine or equipment.What is an Affected Employee?Affected Employee is one whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed.What is an energy Isolating Device?An Energy Isolating Device is A mechanical device that physically prevents the transmission or release of energy.What are energy control procedures?An Energy Control Procedure is A Safety program adopted by the employer that includes energy control procedures plus provisions for inspecting the procedures and training employees for lockout/tagout.
6 Sources of Hazardous Energy in the Workplace ElectricalGeneratedStaticMechanicalTransitionalRotationalThermalMachines or EquipmentChemical ReactionsPotentialPressureHydraulicPneumaticVacuumSpringsGravitySources of Hazardous Energy can be found in many places throughout the WorkplaceHazardous energy can come from:Electrical Sources such as Generated and StaticMechanical sources that are Transitional and RotationalThermal Sources from Machines or Equipment and from Chemical ReactionsPotential other sources include Pressure sources that are Hydraulic, Pneumatic, or even Vacuum or sources that use Springs or even using Gravity
7 Types of Lockout Devices Plug LocksBall Valve LockoutGate Valve LockoutGroup Lockout HaspElectricalHydraulic, pneumatic, and other pressurized systemsIf there is an energy source that has to be controlled, there is a lockout device that has been developed to control that energy sourcePlug LocksBall Valve LockoutGate Valve LockoutGroup Lockout HaspElectricalHydraulic, pneumatic, and other pressurized systemsYou can see by the pictures on the right some of the many different types of devices that are out there.
8 Steps to a Proper Lockout Procedure Alert the operator (s) that power is being disconnected.Preparation for ShutdownEquipment Shutdown and IsolationHere are the steps to properly locking out a piece of equipment.First, you must Alert the operator or operators that power is being disconnected. – Good communications will save lives and reduce injury.Once the operators have been informed, then you take the steps to Prepare for the Shutdown: You must Follow established procedures for shutting down the machine or piece of equipment.Next, it is time for the Equipment Shutdown and isolation: This is Officially turning “off” the equipment
9 Steps to a Proper Lockout Procedure Application of Lockout DevicesControl of Stored EnergyEquipment Isolation-VerificationNext we are going to place the Lockout Device or devices on the equipment so that the hazard is containedNext we have to make sure we have Control of the Stored Energy. What does this mean?This could be Bleeding the lines and leave vent valves openIt could be Draining piping systems and closing valves to prevent the flow of hazardous materialsIt could be Dissipating extreme cold or heat, or wear protective clothingIf stored energy can re-accumulate, it must be monitored and kept below hazardous levelsFinally we have the Equipment Isolation and VerificationThe Main disconnect switch or breaker must be fixed in off positionYou have to then Check any switches with a voltmeter. This takes out all uncertainty as to whether or not there is an electrical charge presentThen Press all equipment activating controls. Try to make the machine work to see if tries to operate. If any part tries to operate, then the lockout is not complete. You must Assure by testing that all machine controls are “off”
10 Removal of Lockout Ensure equipment is safe to operate Safeguard all employeesRemove lockout/tagout devices.Last person to take off lockFollow checklistPrior to removing the lockout device, you must Ensure equipment is safe to operateThe Next step it to Safeguard all employees. Just like operators are informed prior to the lockout, the must be informed when the equipment is coming back online so that they are prepared.Now you can Remove lockout/tagout devices. Except in emergencies, each device must be removed by the person who put it on.Last person to take off lockFollow a checklist regarding the steps to re-energizing the machine
11 Our critical safety rule Authorized and affected employee’s share one critical safety rule:The Person Who Applied the Lock is the Only Person allowed to Remove the LockAuthorized and affected employee’s share one critical safety rule:The Person Who Applied the Lock is the Only Person allowed to Remove the Lock
12 Machine Specific Procedures Required on equipment with more than one source of energyIdentify the equipment’s specific types of energy sourcesSpecify stepsLet’s now discuss machine specific procedures:Machine specific procedures are required on equipment with more than one source of energy (electrical, gas, hydraulic, pneumatic, chemical, steam, springs, raised equipment parts, etc.)Note: Procedures are not required for single energy equipment with a cord and plug, provided the equipment is unplugged and remains under the control of the employee performing the work.Identify the equipment’s specific types of energy sources (electric, gas, hydraulic, pneumatic, chemical, raised equipment parts, etc.)Specify steps for the release of stored energy and placement of lockout devices to prevent accidental start up
13 Procedures Must Be Written, Unless All Exist: Equipment has:No potential for stored or residual energyA single energy source, capable of isolation and lockout for deactivating equipmentBeen isolated from energy source and lockedLockout device under exclusive control of authorized employee performing maintenanceNo other hazards createdEmployer has had no related accidentsLOTO Procedures Must Be Written, Unless All of the following conditions Exist:The Equipment has:No potential for stored or residual energyA single energy source, capable of isolation and lockout for deactivating equipmentBeen isolated from energy source and lockedLockout device under exclusive control of authorized employee performing maintenanceNo other hazards createdEmployer has had no related accidents
14 Training Schedule For LO/TO Primary training planInitial, retraining, certification of trainingRetraining of authorized/affected staffChange in assignmentsIntroduction of new equipment or processChange in LO/TO protocolAudit results at least annuallyLet’s now talk a little about training in regards to loto.Primary training planInitial, retraining, certification of trainingRetraining of authorized/affected staffChange in assignmentsIntroduction of new equipment or processChange in LO/TO protocolAudit results at least annually
15 Temporarily Reactivating Equipment Remove unnecessary tools from the work area and make sure everyone is clear of the equipmentRemove lockout/tagout devices and re-energize the systemAs soon as the energy is no longer needed, isolate the equipment and re-apply lockout/tagout, using the seven step procedure.On occasion you may have to Temporarily Reactivate the Equipment. Here are some steps to follow.First, Remove any unnecessary tools from the work area and make sure everyone is clear of the equipmentThen Remove the lockout/tagout devices and re-energize the systemLastly, As soon as the energy is no longer needed, isolate the equipment and re-apply lockout/tagout, using the six step procedure that we discussed earlier.
16 Special Situations Servicing lasts longer than one shift. Contractors are performing service or maintenance at your workplaceWorker who applied lock is not availableSometimes Servicing lasts longer than one shift. When shift change or reassignment occurs during a lockout/tagout, the following rules apply:The off-going employee will review the job with the on-coming employeeThe off-going employee will remove his/her locks/tagsThe on-coming employee will place his locks/tagsThe on-coming employee will verify that all energy controls are in the off or safe positionAlways check your lockout/tagout after being away from the job, even after breaks and lunchIf Contractors are performing service or maintenance at your workplaceContractors are required to have a program equivalent to yoursContractor personnel will be made aware of your procedure, locks and tagsAll personnel who work with contractors will be made aware of the contractor procedure, locks and tagsAny problems that are observed should be immediately brought to the attention of the LOTO program administratorWhat if the Worker who applied lock is not availableThe decision to remove the lock must be made by a member of managementEvery effort must be made to contact the employee including calling her/him at homeA member of management will meet the employee at the entrance before the next scheduled work shift or The cut-off lock will be left with a note on the employee’s bench or tool box. The fact that the employee left without making arrangements requiring the lockout device, this uncertainty in itself created a hazard. The employee must be instructed of his error so that it can not happen again.
17 Words to Live By…Never attempt lockout/tagout procedures unless you have been trained and certified by your employer under an approved Energy Control Program.Never loan or share your lock, combination, or key with anybody else.Always be sure all lockout/tagout devices are compatible with the environment in which they will be used i.e. corrosive, humid, etc.In closing, here are some words to live by…Never attempt lockout/ tagout procedures unless you have been trained and certified by your employer under an approved Energy Control Program.I conducted a site survey for one of Summit’s insureds and saw for myself how a little information can be a very bad thing. The owner wanted to have a lockout/tagout program. So he went out, bought the locks and issued them to his employees. Where his big mistake came into play was that he had all of the locks keyed the same. The employees could open each others locks. This leaves the chance for the lock to be removed and the equipment re-energized without the employee who is working on the equipment knowledge which could result in serious injury. This leads us to our next words to live by.Never loan or share your lock, combination, or key with anybody else.Last but not least, Always be sure all lockout/tagout devices are compatible with the environment in which they will be used i.e. corrosive, humid, etc.
18 When in doubt…….. LOCKOUT! Words to Live By… When in doubt…….. Some final words to live by:When in doubt……..LOCKOUT!