1 Lockout/Tagout MEETING THE STANDARD MEETING THE STANDARD

2 Purpose b The purpose of lockout/tagout is to prevent energy from accidentally being released while a machine or equipment is being serviced. b The ultimate goal of lockout/tagout is to protect the safety and health of employees. b Secondary is the protection of equipment from damage.

3 Scope & Application Scope & Application b The OSHA Standard for the Control of Hazardous Energy (Lockout/Tagout) 29 CFR covers the servicing and maintenance of machines and equipment in which the unexpected start-up of machinery or release of stored energy could possibly cause injury to employees

4 Types of Energy Types of Energy b Mechanical b Hydraulic b Pneumatic b Chemical b Thermal b Other

5 Lockout/Tagout Applies b Whenever the employee: - removes or bypasses machine guards or other safety devices, resulting in exposure to hazards at the point devices, resulting in exposure to hazards at the point of operation; of operation; - places any part of their body in contact with the point of operation of the machine or piece of equipment; of operation of the machine or piece of equipment; - places any part of their body into a danger zone associated with a machine operating cycle. associated with a machine operating cycle.

6 Does Not Apply b While servicing or maintaining cord and plug connected electrical equipment. The plug must be removed from the energy source and remain under the exclusive control of the employee performing the service or maintenance. b During hot tap operations that involve transmission and distribution systems for gas, steam, water, or petroleum products when they are performed on pressurized pipelines; when continuity of service is essential and shutdown impractical and an equivalent form of employee protection is provided.

7 Definitions b Affected Associate b Authorized Associate b Capable Of Being Locked Out

8 Definitions (cont’d) b Communications Network b Department Lock b Double Block and Bleed b Energized b Energy Isolating Device

9 Definitions (cont’d) b Energy Source b Energy Control Procedure b Energy Control Program b Line Blanking or Blinding b Lockout

10 Definitions (cont’d) b Lockout Boundary b Lockout Device b Lockout/Tagout Lock Box b Multiple Lockout Device b Normal Operations

11 Definitions (cont’d) b “Other” Associate b Tagout b Tagout Device b Unexpected Release Of Energy

12 Associate Training Initial training and retraining (as necessary) must be provided and must certify that such must be provided and must certify that such training has been given to all associates training has been given to all associates who work in or around lockout/tagout. who work in or around lockout/tagout.

13 Written Energy Control Procedures b A written procedure must identify the information the “Authorized” associates must know in order to control hazardous energy during servicing or maintenance.

14 Periodic Inspections b At least annually, the employer (supervisor or manager) shall conduct an inspection of the energy control procedure to ensure the requirements of the standard are being followed.

15 Serving or Maintenance Operations b If servicing activity such as lubricating, cleaning or un-jamming production equipment takes place during production, the associates performing the servicing may be subjected to hazards that are not encountered as part of the production operation itself.

16 Minor Servicing Tasks b Associates performing minor tool changes and adjustments or other minor activities during normal production operations that are routine, repetitive and integral to the use of the production equipment, are not covered by the lockout/tagout standard providing using alternative measures that give effective protection against unexpected machine cycling, for example.

17 Equipment Modifications b After October 31, 1989 whenever major replacement, repair, renovation or modification of machines is performed, and whenever new machines or equipment are installed, energy isolating devices for machines and equipment shall be designed or retrofitted to ensure that lockout devices may be placed on the equipment

18 Appendix B Appendix B – Machine Specific Shutdown Procedures will be used for ALL lockout tagout. No matter how small the job, this form should be used. After completion of the job, the completed form should be filed by the supervisor.

19 Application Of Controls And Lockout/Tagout Devices – Seven Basic Steps b The established procedure of applying energy controls includes the specific elements and actions that must be implemented in sequence. They are identified specifically in Appendix – B Machine Specific Shutdown Procedures.

20 Preparation for Shutdown - 1 b Understand the types and amounts of energy that power the equipment, discuss with your Supervisor – Establish boundary b Understand the hazards associated with the energy b Notify all affected persons

21 Equipment Shutdown - 2 b Shut the system down using available operating controls b Follow whatever procedure is appropriate for the equipment to avoid endangering anyone during the shutdown

22 b Be sure to isolate all energy sources, secondary power supplies as well as primary supplies b Never just remove a fuse when you can disconnect the equipment completely

23 Application of Devices - 3 b All energy isolating devices are to be locked, and tagged. Only tags are permissible – Why? b When lockout is used, every employee in the work crew must attach their personal lock to the lockout/tagout lockbox

24 Release of Stored Energy - 4 b Ensure all parts have stopped moving b Relieve trapped pressure b Block or brace parts that could fall b Bleed lines and vent valves open b If stored energy can re-accumulate, then monitor conditions to make sure it stays below hazardous levels

25 Verify Equipment Isolation -5 b Ensure all danger areas are clear of personnel b Verify disconnect switch or circuit breaker cannot be moved to the “on” position b Attempt to start equipment by engaging all activating controls and return controls to the “off” position when testing is complete

26 Secure The Keys - 6 b Once the lockout devices have been locked with department locks, place the department lock keys in the lockout/tagout lockbox and place your personal lock on the box.

27 Supervision Verification - 7 b Have your Supervisor verify that all procedures have been followed, all energy sources have been locked or tagged and that the boundary is correct. The Supervisor should sign Appendix B Machine Specific Shutdown Procedures

28 Typical Lockout/Tagout

29 Removal Of Locks and Tags Before lockout or tagout devices are removed and energy is restored to the machine or equipment, the authorized associate(s) must follow the Restoring To Service Procedures in Appendix B.

30 Additional Safety Requirements b Special circumstances may arise due to: 1. Machines need to be tested or repositioned during serving or repair 2. Outside (contractor) personnel perform work 3. Servicing or maintenance is performed by a group rather than one associate 4. Shifts or personnel change

31 Testing or Repositioning Machines b The temporary removal of locks or tags and the re-energization of the machine is allowed ONLY under special conditions for example, when power is needed for the testing or repositioning of machines, equipment or components.

32 Outside Contractors b When using an outside contractor to service a piece of equipment of perform any maintenance activity that requires lockout/tagout, the authorized associates or Supervisor must meet with the contractor and discuss the lcokout/tagout procedure. You must decide which procedure will be used and the requirements. If the outside contractor does not have a lockout/tagout procedure, locks, or isolating devices, you must administer your lockout/tagout program. b You could possibly be held liable if an accident occurs within your facility with a contractor.

33 Group Lockout/Tagout b During all group (two or more) lockout/tagout operations where the release of hazardous energy is possible, each authorized associate performing servicing or maintenance shall be protected by his/her personal lock placed on the lockout/tagout lock box and by a department lock on isolating devices.

34 Energy Isolating Devices b The primary tool for providing protection under the 1910 standard is the energy isolating device, which is the mechanism that prevents the transmission or release of energy to which all locks or tags are attached.

35 Tagout Devices b When an energy isolating device cannot be physically locked out, it must have at a minimum a tagout device (TAG) applied to it.

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37 Lockout vs. Tagout b If an energy isolating device is capable of being locked out, it must be locked out unless it can be shown that a tagout system provides full employee protection

38 Lockout/Tagout Devices b When attached to an energy isolating device, both lockout and tagout devices are tools that can be used to protect associates from hazardous energy. The lockout device provides protection by holding the energy isolating device in a safe position, thus preventing the machine or equipment from becoming energized. The lockout device provides protection by holding the energy isolating device in a safe position, thus preventing the machine or equipment from becoming energized.

39 Types Of Lockout Devices b Gate Valve Handle b Ball Valve Handle b Butterfly Valve b Single Pole b Multiple Pole b Cord and Plug

40 Types, cont. b Wall Switch b Chains b Scissor Lock Hasp b Blinds

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58 Keys & Locks b You will see two different colored locks in your program. (1) Red Lock – Department Lock (2) Yellow Lock – Personal Lock

59 Lockout/Tagout Lock Box b b The Lockout/Tagout lock box is a box used to secure the keys of department locks once a lockout device has been placed on an energy isolating device or a lockout device.

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62 Typical Lockout/Tagout Using a Hasp and Department Lock

63 Appendix A – Model Lockout Procedure b Purpose

64 Responsibilities b Management

65 Responsibilities, cont. b Authorized Associate

66 Responsibilities, cont. b General

67 Paperwork Procedure b Supervisor issues Appendix B to Associate b Associate completes each step of lockout sequence and signs and dates and times. b Associate returns Appendix B to Supervisor for verification. Supervisor verifies, signs and retains b Supervisor retains Appendix B until Associate finishes job or needs Appendix B to clear lockout for testing purposes. b Associate gets Appendix B from Supervisor to clear lockout, signs and returns to Supervisor.

68 Locking Out & Isolating The Power Source b Appendix B – Sequence Of Lockout

69 Removal Of Locks & Restoring Power Source b Appendix B – Restoring Equipment To Service Service

70 Emergency or Authorized Lock Removal b Supervision will be authorized to remove an associates personal lock or department lock under specific conditions.

71 Shift Changes b If service or maintenance activities last longer then one shift - lockout/tagout protection must not be interrupted b If the employee who applied the device is not there to remove it – then it can only be removed in an emergency and under the direction of the supervisor

72 Contractors b The outside contractor and the on-site employer must exchange lockout/tagout information b Employees on-site must understand the rules used by the contractor and attach a department lock on the energy source b Be alert for new types of lockout/tagout devices

73 Contractor & Department Lock

74 Acceptable Isolating Techniques b Cord and Plug Powered Equipment

75 Minor Adjustments b Printers, Printing Presses, Molding Machines, Stamping Machines, etc.

76 Acceptable Isolating Devices b Mechanical Repair Work

77 b Panel Breaker Boxes

78 b Minor Tool Change or Minor Adjustment

79 Appendix B b Appendix B - Machine Specific Shutdown Procedures Procedures

80 Appendix C Machine Specific Shutdown/Lockout Procedures

81 b Questions ?