How to Effectively & Efficiently Control LOCKOUT / TAGOUT How to Effectively & Efficiently Control Hazardous Energy

Frequency Of LOTO Accidents 10% of all industrial accidents are LOTO-related 250,000 LOTO-related accidents each year, resulting in approximately: 200 fatalities 60,000 injuries

Cost of LOTO Accidents Medical expenses, worker’s compensation OSHA fines Civil lawsuits Low employee morale Equipment damage, lost productivity Higher insurance premiums

OSHA LOTO Regulations OSHA Standard 29 CFR 1910.147 Does not cover: “Control of Hazardous Energy (Lockout/Tagout)” Does not cover: Work on electrical systems (1910.333) Electrical Power Generation (1910.269) Construction (1926.416-417) Oil / gas drilling and servicing Agriculture Maritime

LOTO Program Components 4 key components of a LOTO program: Documented policies and procedures Energy source ID Employee training Proper tools and devices

Energy Control Policy Purpose and scope of LOTO program Equipment covered under the program Who is authorized to perform LOTO Enforcement policy Group lockout procedures and shift transfers Procedures for lock removal Coordination with contractors

Lockout Procedures The KEY to a compliant, efficient lockout process Inadequately documented procedures is one of the most frequently cited failures in LOTO violations Additional benefits of good procedures: Simplifies training Helps prevent errors, enhancing safety Speeds lockout, shortens downtime

Procedure Requirements Separate procedure required for each piece of equipment to be locked out. Multiple machines can be grouped under one procedure only if they have: the same type and magnitude of hazardous energy the same or similar means of controlling that energy Documentation not needed for single-source equip. Procedures must be audited at least once per year.

Procedure Contents Application of lockout Release of lockout Notify & brief Shutdown De-energize Apply LOTO devices Release stored energy Verify zero energy state (Put warnings in place) Release of lockout Inspect machine / area Confirm people are clear Verify controls in neutral Remove LOTO devices Re-energize Notify Startup

Sample Lockout Procedure Equipment identified at top Provides clear step-by-step instructions Uses color, pictograms to highlight energy sources Use of photos ensures that workers can quickly find the correct control points, avoiding lost time and mistakes

Accessing Procedures Post at point of use Put in binders Access online or attach to work orders

Energy Source Identification Identify hazardous energy sources to prevent mistakes, speed lockout activity. Alternative Solutions: Stock labels and tags Do-it-yourself printing systems Custom printed or engraved tags

LOTO Training Authorized employees Affected / other employees Separate training must be provided for the following types of workers: Authorized employees Affected / other employees Employers must keep a record of all training Retraining for authorized & affected employees Additional training required for tagout

Training & Awareness Aids Training Videos Training Booklets Posters Signs & Labels Hard hat stickers

Lockout & Tagout Devices Lockout and tagout devices must: Be provided by employer Be standardized and distinguishable from locks and tags used for other purposes. Be used for LOTO purposes only Be capable of withstanding the usage environment Identify the person who applied the lock/tag

Exclusive Control Each employee must have exclusive control of the locks they use. No worker should be able to open another another worker’s lock!

Brady Safety Padlocks The Ultimate Lockout Lock! Compact & lightweight Non-corrosive Non-conductive Impact resistant Tamper resistant

Tags Requirements For Tagout: Tags can be used alone (as tagout devices) or in combination with locks (for ID purposes). Requirements For Tagout: Must be strong enough to prevent accidental or inadvertent removal. Use non-reusable nylon cable tie or equiv. that withstands 50-lb pull test Must include warnings and instructions (eg, Do Not Operate) understandable to all employees

Mechanical Lockout Devices Gate Valves Ball Valves Air & Gas

Universal Valve Lockout Gate valves Ball valves Butterfly valves

Electrical Lockout Devices Circuit breakers Fuses Wall Switches Plugs

EZ Panel Loc System

Cable Lockout Devices Mini Cable Lockout All Purpose Cable Lockout

Group Lockout

Lockout Storage & Transport

Visual Warnings