1. Lockout Tagout Tryout (LOTO)

2. A recent incident…
An installer was dispatched out on Saturday to deliver a pump to a customer (City of Colfax).  This pump was to replace a pump that the customer said was "worn out".  It is a back up pump to the customers pump that was pumping treated sewage.  The customer met the RFR employee at the jobsite and asked him for assistance in swapping the pump out, so the employee decided to help him.  (the original project was just a delivery)  The customer stated that there should not have been any pressure on the line, but come to find out there was some pressure on the discharge line, so as soon as they took the wrench to the clamp, it sprayed out a small amount of the treated sewage.  The RFR employee got hit in the chest and face.  After a brief spray, the clamp was tightened, closing off hose. 

3. A recent incident…
Teammate grabbed the middle of the hose and another grabbed the end of the hose preparing to place the hose.   In the process the hose slipped from one Teammates  hands, striking the other in the face.  The injury was a laceration to the mouth requiring sutures.

4. It was one of us, and could have been any of us
It was one of us, and could have been any of us. It is about our family, our brothers and sisters, it is about going home safe!

6. The purpose of the Lockout Tagout Program is to protect you.
Rain for Rent incidents include employees being sprayed with untreated sewage, chlorine and other chemicals while working on systems they thought to be under no pressure.

7. Application of LOTO When an employee is doing any of the following:
Remove or bypass a guard or other safety device (i.e. bandsaw blade replacement)
Put any part of his or her body into an area on a machine or piece of equipment where work is performed (i.e. pump or engine maintenance)
Is in an associated danger zone during a machine operating cycle (i.e. installing or removing a piping system)

8. When Else to Consider Hazardous Energy
The Human Factor
What incidents have we had where the human factor was the energy source that caused injury?
One person holding a pipe when another lets go
We have had several injuries where one person drops the pipe when the other is not prepared
Other injuries include pulling a bend on a pipe and accidently letting go
Pushing hard on a wrench when it gives out
Attempting to lift or move a heavy or awkward load
What else can you think of?
What is our plan to protect ourselves?

9. Types of Energy Human Electrical Mechanical Chemical Thermal Hydraulic
Pneumatic
Gravity
Other pressurized systems

10. Use of Locks & Tags Use only items that have been issued to you
Never use another employees lock
Your name must be clearly marked on your LOTO Lock. This can be done by
Etching your name or employee number in the lock
Using a tag that is attached to the lock
It is recommended you also put your cell phone number on the lock as well.

11. 6 Step LO-TO-TO Procedure
Prepare for Shutdown
Shutdown Equipment
Isolate all Energy Sources
Place Locks & Tags (Lock-out/Tag-out)
Release Stored Energy
Verify Equipment Isolation (Try Out)

12. Exceptions to LOTO Cord & plug connected equipment
Plug is only source of energy
Plug is under continuous control of one person

13. LOTO Equipment

14. Kits Fastenal part number 10743-06370

15. Locks
Red Locks are for people. Every person who is working on the equipment or could be exposed to the hazard needs to be locked out using a red lock.
Yellow locks are for equipment when using a LOTO Box

16. Lock labels
Every personal lock (Red lock) must be labeled for who is using that lock.
This can be done using a tag attached to the lock or by writing/etching on the lock.
It is recommended that both a name and Phone number be placed on the lock

17. Group Lockout/Tagout
Frequently more than one person will work on a piece of equipment. In such cases each person should attach his or her lock to the equipment. Hasps can hold several locks at a time.
This protects everyone working on the equipment since the equipment can’t be energized until every lock has been removed.

18. Continued on next slide
Group Lockout/Tagout
Equipment can be locked out using a yellow equipment lock
Equipment keys can then be placed in a LOTO Box
Continued on next slide

19. Group Lockout/Tagout Personal locks can then be placed on the LOTO Box
Additional Keys may be added to the LOTO Box as needed
End result
All employees are locked out on all equipment who’s keys are in the box.
Each employee only needs one person lock to lock out several items

20. Cable System
Open device and insert cable in direction of arrow. Note cable can be tightened, but not loosened, with locks applied.

21. Locking out a Pump OR
The picture at bottom allows others to lock out without the need for the first lock to be removed.

22. Locking out a valve
Many valves are designed to be locked out easily.

23. Locking Out Valves

24. Locking Out Valves
Unable to get a hasp or lock in due to how far the hole is from the edge, a cable will work.

25. Valve Handle LO
It is important that this device slides over the angled part of the valve. If this device will not, another LOTO device needs to be used.

26. Too big for what was used in the last slide
Simple two piece device that slips over the handle

27. No place to lock out?
The cable systems allow for a variety of valves.

28. Where to lock out

29. Stored Energy For systems that do not vent to atmosphere:
Valves need to be installed to bleed off any residual energy
Relief valves need to be installed anywhere pressure can accumulate and is not automatically relieved when the system is secured

30. Where to lock out

31. Where to lock out

32. Release from LOTO Inspect Area & Equipment
Ensure all Machine Guards are in place
Move tools away from equipment
Inform others of pending startup
Restore system connections
Remove Locks & Tags
Conduct normal startup

33. Lock Removal An employee may leave for the day and accidently leave a lock on; what do we do now?
If a lock needs to be removed by anyone other than the owner of that lock Appendix C – Lock removal form MUST be used. (Recommended a copy of this form be kept in each vehicle)
The purpose of the form is to contact the employee and ensure their safety prior to removing their lock. (This is why a phone number on each lock is recommended)
Next slide has example of form

34. Lock Removal Form

35. Contractors
ALL contractors on Rain for Rent property must follow LOTO procedures!
Rain For Rent Employees must lockout before any contractor and must be the last to remove a lock.
This prevents a contractor from disconnecting or energizing systems without Rain for Rent knowledge or presence.

36. In the back of the policy is a flow chart on how to conduct LOTO

37. FAQs
If I need to reach into a fusion machine to clear out scraps, wipe the surfaces, or for some other reason do I need to lock out the machine? YES LOTO is required if you are going to be reaching into a pinch point on a fusion machine.

38. FAQs Can I just unplug a piece of electrical equipment?
In some cases YES, so long as the power cord is the ONLY source of energy and it is under the direct control of the person doing maintenance. Examples
Welder changing disk on 4’’ grinder
Changing disk on bench grinder
Maintaining portable drill press

39. FAQs
Why cant I just take off the neg. terminal on the battery and stuff it down the battery box? Most equipment (like pumps) is bonded to the metal frame. Any contact with metal parts can re-energize the system. Always disconnect and LOTO the positive terminal with the terminal block. This ensures isolation.

40. FAQ
What if I am the ONLY mechanic to work on a pump? Do I still need to LOTO? YES. All employees must be protected from hazardous energy. Including YOU.

41. FAQ Is LOTO ONLY for protecting people?
That is the primary concern, but LOTO is also useful to protect equipment and the environment.
Starting a vehicle or equipment without oil or missing parts
Breaking apart a pipeline and causing a spill
Starting a pump with pipeline unfinished and valves open

42. FAQ What does it mean to ‘Verify’ isolation?
After following your physical LOTO procedures, try the equipment to ‘verify’ they DO NOT operate.
Turn on the switches
Try the tools
Turn the keys
Try the valve handles

43. Appendix B – LOTO Form & Plan
For complex projects Appendix B is a tool to help plan and communicate what is needed for LOTO on that project.

44. Summary Locking out is a requirement!
All hazardous energy sources must be controlled and stored energy released
Control via energy isolation device (LOTO)
Only use designated locks for LOTO
All personal locks need to be labeled for whose lock it is
Remember to verify isolation
Ensure area is clear before restarting equipment

45. They are counting on YOU

46. Additional Resources LOTO hard hat stickers LOTO Posters
LOTO Posters