1. 29 CFR 1910.147 Subpart J Control of Hazardous Energy
Lockout/Tagout
29 CFR
Subpart J
Control of Hazardous Energy
Joe Bateman, ISRI Safety

2. Never let it happen to you.
A sad shredder story . . .
Never let it happen to you.
This is the Why: a young man performing maintenance on an automobile shredder crawled into the mill and got shredded. He left a wife and small child. It’s a job he’d been doing the same way for nearly 2 years. God only know why he decided to take a shortcut on the last day of his life.

3. Recyclable Material Merchant Wholesalers
Most Frequently Cited OSHA Standards NAICS Code: Recyclable Material Merchant Wholesalers Listed below are the standards which were cited by Federal OSHA for the specified NAICS Code during the period October 2013 through September Penalties shown reflect current rather than initial amounts.
Standard
Citations
Inspections
Penalty
Description
Total
629
148
$723,542
All Standards cited for
Recyclable Material Merchant Wholesalers 75 52
$91,591
#2($). Powered industrial trucks. 36
$33,206
#8($). Hazard Communication. 58 32
$47,574
#5($). Wiring methods, components, and equipment for general use. 39 21
$62,401
#3($). The control of hazardous energy (lockout/tagout). 37 31
$94,024
#1($). Machine guarding. 35 26
$48,740
#4($). General electrical requirements. 19
$42,780
#7($). Guarding floor and wall openings and holes.
5A0001 17
$45,443
#6($). OSHA Act General Duty Paragraph 18 11
$28,975
#9($). Lead. 16 8
$20,273
#10($).Occupational noise exposure. 15 13
$16,110
Walking/working surfaces/Housekeeping.
$13,171
Permit-required confined spaces 10
$14,040
Mechanical power-transmission apparatus.
$10,310
Personal protective equipment. 6 5
$19,620
Handling materials - general.
Lockout is consistently among the top 5 OSHA citations in our industry.

4. When is LOTO Required?
Servicing, maintaining, or un-jamming equipment where:
Hazardous energy exists
Unexpected start-up could occur
Either of these could injure a worker
If you are unsure to what equipment LOTO applies, perform a hazard analysis.
Make sure that all sources of energy are considered.
Do not jeopardize an employee by not requiring LOTO
When in doubt, lock it out

5. LOTO Shall Be Used When:
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.
Anytime an employee could be injured by the piece of equipment, it should be de-energized and locked out.

6. Remember: (Example of incomplete understanding from a recent visit.)
Lockout is not just for when things go wrong.
Lockout is not just for maintenance workers.
Make sure people understand AND use it.
(Example of incomplete understanding from a recent visit.)
One day at an auto shredder the shredder crew was changing hammers. They turned off the power, but applied no locks. They said the maintenance guys had locks, but not them. ALWAYS APPLY LOCKS DURING LOCKOUT TO PREVENT UNEXPECTED STARTUP OF A MACHINE. Don’t rely on just turning off the power.

7. What do we Lockout?
List the types of equipment we have to lockout.

8. Multiple Points on Same Machine
Some of your machines may have more than one lockout point.

9. What about this?
Do you lockout trailers at your docks?

10. A 47-year-old man was operating a forklift in the bed of a semi-trailer. As the truck driver was pulling away from the dock, the forklift fell from the trailer bed to the ground...The lift operator was able to get himself off the ground and enter the facility, where he was treated by medical personnel. Approximately 16 hours later he died as a result of the injuries he suffered.
Do you have a way to make sure this never happens at your facility?

11. Always Chock Your Wheels
Wheel chocks are an OSHA requirement.

12. And use GLADHAND LOCKS:
Gladhand locks keep the driver from pulling the trailer away before your operator is finished loading.

13. Make it Foolproof—
Placing a sign or bale in front of the truck adds a failsafe measure to the process.

14. Energy Sources Mechanical Thermal Electrical Hydraulic Gas Pneumatic
Magnetic
Gravity
Electrical
Gas
Water
Other stored energy
(i.e. springs, capacitors)
There are many different types of energy sources that may need lockout/tagout. Do not overlook any potential source of energy.
Many sources are invisible.
A job hazard analysis can help identify energy sources.
Make sure any and all sources of energy can be effectively isolated.

15. Authorized Employee Maintains equipment Services equipment
Is properly and thoroughly trained to use lockout/tagout procedures
Operates equipment (sometimes)
Authorized employees are these who are at risk while the equipment is being repaired or adjusted.
It is important that authorized employees inform affected employees of the work to be done.
The “danger tag” is an important communication device for the authorized employee.

16. Affected Employees Employees who: Operate (sometimes) Work around
Occasionally adjust equipment that is subject to lockout tagout
Affected employees can be almost anyone in a facility, except office workers.
An affected employee can have a significant impact on authorized employees if the affected employee starts the equipment prior to the completion of the work by the authorized employee.

17. Where to Begin
First, conduct a HAZARD ASSESSMENT by identifying each piece of equipment that is used, serviced, or maintained
Include broken or stored equipment
Then, determine the requirements for lockout
If there is more than one primary energy source to the equipment, document each source
Hazard Assessment is your first order of business.

18. Where to Begin Document all energy sources The hazard posed
Hidden
Direct
The hazard posed
The magnitude or measurable degree of danger
Special or unusual conditions
Proper isolations and devices

19. Types of Lockout Devices
Locks
Blocks
Chains
Multilock hasps
Wheel valve covers
Ball valve covers
Gladhand locks
Any type of lockout/tagout device that is used must be durable.
There are no requirements for the specific type of device as long as it can be locked.
It is a good idea to have a variety of devices available to fit all situations.
Tags should always accompany the use of any of these devices.
A tag is not a device, because it does not prevent the start-up of the equipment.

20. Overhead Crane Controls/Plugs
There’s a lockout device for every situation.

21. Breakers

22. Wall Switches

23. Air Lines

24. Gas Cylinders
For use with liquid nitrogen, acetylene, or any other compressed gas cylinder you need to keep secure.

25. Here’s an option for locking out mobile equipment:
Caterpillar makes a lockout switch that can be mounted to mobile equipment.

26. Here’s another option for locking out mobile equipment:
Lockout switches used in racing can also be mounted to our mobile equipment.

27. Requirements For Lockout/Tagout Devices
Durable
Standardized
Substantial
Identifiable
LOTO devices must be able to withstand the environment in which they are used.
They should also be standardized according to color, size, or shape and should be substantial enough so that they cannot be accidentally removed.
To be identifiable, they should have a legend that states phrases such as Do Not Operate, Do Not Start, Do Not Energize, etc.

28. One Man. One Lock. One Key. Remember:
No spare keys. Red lock means “stop” or “danger”.

29. Name & Cell Phone Number
Use a Tag—
A picture eliminates language barriers.
The phone number allows for immediate contact of authorized employee in his absence.
Name & Cell Phone Number
Joe Bateman

30. Make It Clear
Make it clear something bad could happen here if I don’t lockout.

31. Label your Lockout points:
Especially in the case of multiple lockout points, label them. Eliminate all guesswork.

32. 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
when program deficiencies are noted
when new equipment is installed
when equipment is modified
Documentation
OSHA spells out specific training requirements for LOTO. Every employer is required to provide training in accordance with these regulations.
Probably the single most difficult aspect of training is the retraining function, both when deficiencies are noted and on an annual basis for authorized employees.

33. Authorized Employee Training
Purpose of the procedure
Recognition of applicable hazardous energy sources
Type and magnitude of the energy available in the workplace
Means and methods necessary for energy isolation and control
Ways to verify that energy isolation is effective

34. Affected Employee Training
Instruction on the purpose and use of the energy control system
Awareness
BACK OFF!!!

35. Other Employee Training
All other employees (including new hires) whose work operations are or may be in an area where lockout/tagout may be utilized
Instruction must include:
Purpose of the procedure
Prohibition of starting or reenergizing any locked-out or tagged-out equipment they encounter

36. Retraining Authorized and affected employees Change in job assignment
Change in equipment, machinery, or processes that presents a new hazard
Change in the lockout/tagout procedure

37. Retraining
Shall be conducted whenever a periodic inspection reveals, or the employer has reason to believe, that there are deviations from or inadequacies in the employee's knowledge or use of the lockout-tagout procedures
If you see people are not locking out like they should, or they’re getting sloppy with your lockout procedure, retrain them.

38. Group Lockout/Tagout
Procedure must afford the employees a level of protection equivalent to that provided by the implementation of a personal lockout-tagout device
When servicing and/or maintenance is performed by a crew, craft, department or other group, they must utilize a procedure that affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout/tagout device

39. Group Lockout/Tagout
Primary responsibility is vested in an authorized employee who must:
ascertain the exposure status of individual group members
coordinate affected work forces (i.e. crews, departments, crafts)
A “Lead Lockout Man”
Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device
Provision for the authorized employee to ascertain the exposure status of individual group members with regard to the lockout/tagout of the equipment

40. Group Lockout/Tagout Each authorized employee must:
Affix a personal lockout-tagout device to the group lockout device or box when he/she begins work
Remove those devices when he/she stops working on the equipment being serviced or maintained

41. Shift or Personnel Changes
Procedures must ensure:
Continuity of lockout/tagout protection
Orderly hand-off of lockout of lockout/tagout devices
Continuity of lockout/tagout protection must be ensured by following specific procedures for shift and personnel changes, including the orderly hand-off of lockout of lockout/tagout devices

42. Testing or Positioning of Machines
OSHA allows the temporary removal of locks or tags and the re-energization of the equipment only when necessary under special conditions –
for example, when power is needed for the testing or positioning of equipment

43. Testing or Positioning of Machines
Must be conducted in following sequence:
Clear the equipment of tools and material
Vacate employees from the equipment area
Remove the lockout-tagout device as specified in the standard (the authorized employee who applied it must remove it)
Energize the equipment and proceed with testing or positioning
De-energize all systems, isolate the equipment from the energy source, and reapply the lockout-tagout devices

44. Contractors
Must inform each other of all applicable lockout/tagout procedures
Both employer and contractor must ensure that their employees understand and comply with the other’s Energy Control Program
Expect the same from your contractors as you expect from your own employees.

45. Typical Lockout Procedure
1. Notify affected employees
2. Use the specific steps as written in your own procedure manual
3. Shut off energy source(s) to affected equipment
--Use normal stopping or running procedures for the machine
4. Isolate the equipment from the energy source
Keep it simple.

46. Typical Lockout Procedure
5. Affix locks and tags to each energy source controlling device
6. Relieve all stored energy from capacitor banks, springs, compressed air, hydraulics, etc.
7. Verify isolation of energy has occurred by trying to start equipment
Always be sure and go back and hit the start button to make sure the machine is dead.

47. Removal of Lockout/Tagout and Start-Up Procedures
1. Ensure that nonessential items are removed from equipment
2. Ensure that equipment components are intact
3. Check area to ensure that all affected employees are safely positioned or removed from the area

48. Removal of Lockout/Tagout and Start-Up Procedures
4. Notify all affected employees and site supervisor before reenergizing the equipment
5. Remove lockout/tagout devices
6. Reenergize equipment to ensure safe operation

49. Periodic Inspections At least annually
Ensure procedures are implemented properly
Ensure employees are familiar with their responsibilities
Correct any deviations or inadequacies identified
Document (form, photo)

50. Give it some Teeth Cardinal Safety Rules Lockout/Clockout
Safety Absolutes
Would anything get me fired?
Would you fire me for stealing? Yet, the act of stealing will not hurt me physically. However, failing to properly lockout may kill me, and has killed other workers in our industry. Consider treating failure to lockout the same as stealing.

51. Questions?
Thank you!
Joe Bateman