1. Lockout/Tagout

2. Control of Hazardous Energy
Lockout - Tagout
Control of Hazardous Energy
OSHA Standard

3. What Is Lockout/Tagout?
Referred to as LOTO
Blocks the flow of energy from power source to the equipment
Provides means of warning (tag)

4. 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.

5. Types of Energy Electrical Mechanical Chemical Thermal Hydraulic
Pneumatic

6. 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.

7. 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.

8. 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.

9. 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.

10. Block energy or relieve pressure slowly into a proper container.
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.

11. 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.

12. 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

13. 1. Prepare for Shutdown Understand equipment hazards!
Notify other employees of shutdown.

14. 2. Shutdown Equipment Follow normal shutdown procedure.
Turn all switches to the OFF position.
Shut all valves.
Disable all sources of energy!

15. 3. Isolate All Energy Sources
Shut valves
Open breakers & disconnects

16. 4. Place Locks & Tags Valves Breakers / electrical disconnects
Block or disconnect all lines

17. 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

18. 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.

19. Items needed for LOTO Written LOTO procedures Locks & Tags
Hasps --for multiple locks & tags
Breaker Lockouts
Gate Valve Lockouts
Ball Valve Lockouts

20. Types of Lockout Devices
Locks
Blocks
Chains
Multilock hasps
Wheel valve covers
Ball valve covers

21. Requirements for Lockout/Tagout Devices
They must be:
Durable
Standardized
Substantial
Identifiable

22. Typical Equipment Requiring LOTO
Presses
Saws
Conveyors
Pumps
Production equipment
Trash compactors
Ovens

23. Affected Employees Employees who Operate Work around
Occasionally adjust equipment that is subject to LOTO

24. 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

25. Authorized Employee Maintains equipment Services equipment
Is trained to use LOTO

26. 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

27. 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

28. 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

29. 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

30. 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

31. 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.

32. Working on unfamiliar machinery is a hazard!
Know the Equipment!
Hazards
Energy isolation points
Lockout/Tagout procedures
Working on unfamiliar machinery is a hazard!

33. Who Can Lockout Equipment?
Only employees who have been trained and authorized by management.

34. 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.

35. Lockout-Tagout Protects YOU!
ALWAYS Use Proper Lockout - Tagout Procedures
They are for your protection!!!