1. Wade Behnke, MPH
Environmental, Health, and Safety Director
Colby College

2. Objectives Understand the reasons for LOTO
Legal/OSHA requirements for LOTO
Understand the Colby specific LOTO polices and procedures
Provide an opportunity to discuss concerns related to LOTO Program

3. LOTO Incident Case Study – Tribe Foods
Tribe Mediterranean Foods Fined $702,300 after a temporary worker was crushed to death while cleaning and sanitizing a machine used to make hummus. His body was pulled into the hummus machine between two rotating augers (December 2012)
He and other workers did not receive safety training, including LOTO training
He was 28 years old
OSHA issued 18 citations for willful and serious violations

4. What is LOTO
“LOTO is a technique used to prevent energy from being released during the servicing of equipment. This is accomplished by placing locks on energy isolation devices prior to starting work”
Note: Exception to documentation requirement:
The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist:
The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees;
The machine or equipment has a single energy source which can be readily identified and isolated;
The isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment;
The machine or equipment is isolated from that energy source and locked out during servicing or maintenance;
A single lockout device will achieve a locked-out condition;
The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance;
The servicing or maintenance does not create hazards for other employees; and
The employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance.

5. “The Fatal Five” (150-200 LOTO fatalities per year)
Failure to stop equipment
Failure to disconnect from power source
Failure to dissipate residual energy
Accidental restarting of equipment
Failure to clear work areas before starting

6. LOTO Injury Breakdown
BLS study on injuries while servicing equipment revealed:
–80% failed to turn off equipment
–10% equipment activated by someone else
–5% failed to control potential energy
–Most of remaining 5% disconnected power but failed to verify effectiveness

7. Legal Standards
OSHA 29 CFR (The control of hazardous energy) AKA the “Lockout/Tagout [LOTO] Standard”
Establishes the employer’s responsibility to protect employees from hazardous energy sources on machines and equipment during service and maintenance
Addresses the practices and procedures necessary to disable machinery or equipment in order to control hazardous energies
OSHA 29 CFR (Selection and use of work practices for electrical machine/equipment)
Establishes the employer’s responsibility to protect employees from electrical hazards while working on or near exposed deenergized parts

8. OSHA LOTO Basic Requirements
Employers must develop/implement/enforce written policies/procedures
Employee Training
Provide LOTO equipment/Devices
Employer must complete internal inspections to verify adequacy of the program
Note: Exception to documentation requirement:
The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist:
The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees;
The machine or equipment has a single energy source which can be readily identified and isolated;
The isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment;
The machine or equipment is isolated from that energy source and locked out during servicing or maintenance;
A single lockout device will achieve a locked-out condition;
The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance;
The servicing or maintenance does not create hazards for other employees; and
The employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance.

9. When does Lockout/Tagout Apply
During Servicing/Maintenance:
Erecting
Installing
Constructing
Repairing
Adjusting
Inspecting
During normal production operations LOTO applies when an employee is:
Required to remove or bypass a guard or other safety device
Required to place any part of their body in an area of a machine where work is performed on the material being processed (point of operation) or in a danger zone
Unjamming
Setting up
Trouble-shooting
Testing
Cleaning
Servicing and/or maintenance: Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or unjamming of machines or equipment and making adjustments or tool changes, where the employee may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy. 

10. When NOT to use Lockout/Tagout
The LOTO Standard does not apply to:
Minor part changes and servicing during routine operations unless machine guards are bypassed
Work on cord and plug-controlled devices
Hot tap operations (welding on a pressurized line) involving transmission and distribution systems for substances such as gas, steam, water or petroleum

11. LOTO Employee Designations
Authorized Employees
Apply LOTO and conduct maintenance
Affected Employees
Work on or around equipment being locked out
Other Employees
Not impacted by LOTO in workplace

12. Employee Responsibilities
Authorized employee:
Trained to perform energy control procedures
Implement the LOTO procedures
Perform repair and service requiring LOTO
Apply and remove lockout/tagout
Notify ALL employees
Coordinate groups lockout/tagout repair and outside personnel lockout/tagout repair
Affected employee:
Trained to be aware of energy control procedures
Notify maintenance of need for equipment repair requiring LOTO
Operate machinery or equipment , but not perform repair requiring LOTO
Leave all lockout/ tagout devices in place
Verify that it is safe after maintenance
Follow safety rules

13. Forms of Energy CHEMICAL MECHANICAL ELECTRICAL HYDRAULIC PNEUMATIC
Test: what is energy? The power to do work
Pneumatic: Power created by the compressive force or movement of air or gas in a confined area. Assembly tools often use pneumatic energy to force parts together.
Hydraulic: Power created by the compressive force or movement of a liquid in a confined area. Machines that lift objects often use hydraulic energy.
Mechanical: A combination of kinetic and potential energy resulting from the force of gravity or the movement or release of a machine component, such as a spring, clamp, or wheel.
Thermal: Energy transferred from one body to another as the result of a difference in temperature. Sources include mechanical work, radiation, chemical reactions, and electrical resistance. Heat can be retained in machine parts and cause burns.
Chemical: The capacity of a substance to do work or produce heat through a change in its composition. Chemical energy can be converted from gasses, liquids, solid chemicals, and vapors.
Electrical: Energy generated through the conversion of other forms such as mechanical, thermal, or chemical energy. Energy stored between plates of a charged capacitor is an example of potential electrical energy. Typical electrical energy sources include open busbars, motors, and generators.
PNEUMATIC
HYDRAULIC
THERMAL

14. Types of Hazardous Energy Injuries
Electrocution
Burns
Crushing
Cutting/Lacerating
Amputating
Fracturing

15. Written Program Colby’s LOTO Program
Employers must develop/implement/ enforce written policies/procedures
The written program consists of:
Energy Control Program/Plan
Equipment specific LOTO procedures
Colby’s LOTO Program
Note: Exception to documentation requirement:
The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist:
The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees;
The machine or equipment has a single energy source which can be readily identified and isolated;
The isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment;
The machine or equipment is isolated from that energy source and locked out during servicing or maintenance;
A single lockout device will achieve a locked-out condition;
The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance;
The servicing or maintenance does not create hazards for other employees; and
The employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance.

16. Written Program Equipment specific procedures
Procedures that go through the step by step process for locking out a specific piece of equipment.
Procedures identify the hazardous energy sources, disconnect points and lockout devices.
Need to improve these at Colby College

17. Written Program When is an equipment specific procedure not required?
The machine has a single energy source that completely de-energizes the equipment to be worked on.
The machine can be locked out with a single lockout device.
There is no potential for the machine to store or re-accumulate energy during the shutdown period.
There are no hazards posed to other employees.
The machine has no history of lockout/tagout accidents.
Note: Exception to documentation requirement:
The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist:
The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees;
The machine or equipment has a single energy source which can be readily identified and isolated;
The isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment;
The machine or equipment is isolated from that energy source and locked out during servicing or maintenance;
A single lockout device will achieve a locked-out condition;
The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance;
The servicing or maintenance does not create hazards for other employees; and
The employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance.

18. LOTO Devices Requirements for lockout and tagout devices:
Used only for controlling energy
Durable
Legible and understandable by all employees in the area
Standardized
Substantial
Identifiable
Note: Exception to documentation requirement:
The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist:
The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees;
The machine or equipment has a single energy source which can be readily identified and isolated;
The isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment;
The machine or equipment is isolated from that energy source and locked out during servicing or maintenance;
A single lockout device will achieve a locked-out condition;
The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance;
The servicing or maintenance does not create hazards for other employees; and
The employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance.

19. Inspections
Periodic observation of employees performing the procedures (i.e. procedure inspection) must be performed at least annually
Intended to identify and correct any deviations or inadequacies
Performed by an authorized employee other that the one utilizing the energy control procedure being inspected
Includes reviews of authorized employee responsibilities with the inspector and the affected employees
Certification (documentation): The inspection must be documented and include the following:
The identification of the machine or equipment
The date of the inspection
The employee(s) included in the inspection
The person performing the inspection
As best practice, it is recommended that records be maintained at least until the next equipment-specific and employee-specific inspection

20. Preparation for LOTO (authorized employees only)
Step #1: Notify (LOTO Coordinator)
Step #2: Survey machine/equipment
Step #3: Review the equipment-specific procedure
Step #4: Obtain the sufficient number of locks, tags and devices to perform the job.

21. LOTO Application (authorized employees only)
Step #1: Notify all affected employees
Step #2: Shut equipment down
Step #3: Deactivate the energy isolating device so that the machine/equipment is isolated from the energy source
Step #4: Apply the LOTO devices, using assigned locks, applicable devices and danger tags;

22. LOTO Application (authorized employees only)
Step #5: Release, restrain, or dissipate stored energy
Step#6: Verify that energy isolation is complete,
attempting to start the affected machinery or equipment in the normal manner.
when working on exposed electrical parts that operate at 50 or more volts a qualified person shall use an appropriately rated test meter and arcflash PPE to verify that all parts have been deenergized. If greater than 600 volts the meter will be checked for proper operation after use; and
Step #7: After testing, return all operation controls to the "neutral" or "off" positions.

23. Removal of LOTO Devices (authorized employees only)
Step #1: Ensure components are operationally and employees are safely positioned
Step #2: Remove all tools and repair equipment;
Step #3: Ensure that all guards have been replaced
Step #4: Verify that the operating controls are in the "off" or neutral position;
Step #5: Notify affected employees
Step #6: Remove all lockout and tagout devices
Step #7: Activate the energy isolation devices to restore energy.

24. Special Circumstances
What if the authorized employee who applied lockout/tagout is not available:
1. Remove only under the direction of the LOTO Coordinator 2. Verify that the employee who applied lockout/tagout is not at the facility 3. Contact the employee who applied lockout/tagout to inform him/her that his/her logout/tagout device has been removed 4. Ensure that the employee who applied lockout/tagout knows it was removed before he/she resumes work

25. Group lockout or tagout
Ensure that the group procedures affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout/tagout devices
If more than one group, the LOTO coordinator will oversee the LOTO activities to ensure continuity of protection
Each authorized employee shall affix a personal lockout/tagout to the group lockout/tagout
Delete slide if Soleras does not use group LOTO
A group LO/TO occurs when the servicing/maintenance of a machine/equipment requires more than one authorized employee.
If there are people performing maintenance/servicing on different machine/equipment simultaneously, then a Coordinator (which will be an authorized employee) is required.
You will need to implement a group LOTO procedure (who do what, when, steps, etc.). For example, you could have a form with LOTO steps and beside each step write the name of the person who performs the step…Add a spot for the maintenance: who service what?, etc.

26. Shift or personnel changes:
Ensure the continuity of lockout/tagout protection
Transfer orderly lockout/tagout device protection between off-going and oncoming employees
The departing workers must not remove their locks until the arriving workers attach theirs
Locks may be left in place overnight or over a weekend

27. Contractor LOTO:
Contractor LOTO on Colby operated equipment will be managed by the LOTO Coordinator.
LOTO Coordinator will verify complete the LOTO process and verify absence of power.
LOTO Coordinator will lockout equipment and place the lock key in a group lockout box.
Each contractor employee will place there lock on the outside of the Group box and verify absence of power

28. TAGS ONLY ARE NOT PERMITTED AT COLBY COLLEGE
Tagout Only
Tagout device:
Device to Warn and indicate that the machine may not be operated until the lockout device is removed
In the same place as the lockout device or close and obvious
Can be used if the machine is not capable of being locked out
Must include:
the identity of the worker
warnings of hazardous condition if the machine is energized, and
legends such as “Do Not Start”, “Do Not Open/Close”, etc.
After January 2, 1990, whenever replacement or major repair, renovation or modification of a machine or equipment is performed, and whenever new machines or equipment are installed, energy isolating devices for such machine or equipment shall be designed to accept a lockout device
Full employee protection: req’d if the machine can be locked out but the employer does not and just uses tagout
(c)(3)(i)When a tagout device is used on an energy isolating device which is capable of being locked out, the tagout device shall be attached at the same location that the lockout device would have been attached, and the employer shall demonstrate that the tagout program will provide a level of safety equivalent to that obtained by using a lockout program.
(c)(3)(ii)In demonstrating that a level of safety is achieved in the tagout program which is equivalent to the level of safety obtained by using a lockout program, the employer shall demonstrate full compliance with all tagout-related provisions of this standard together with such additional elements as are necessary to provide the equivalent safety available from the use of a lockout device. Additional means to be considered as part of the demonstration of full employee protection shall include the implementation of additional safety measures such as the removal of an isolating circuit element, blocking of a controlling switch, opening of an extra disconnecting device, or the removal of a valve handle to reduce the likelihood of inadvertent energization.
Electrical: Examples of additional safety measures include the removal of an isolating circuit element, blocking of a controlling switch, or opening of an extra disconnecting device.
TAGS ONLY ARE NOT PERMITTED AT COLBY COLLEGE

29. Tagout Limitations Essentially warning devices
Do not provide the physical restraint of a lock
Must not be removed without authorization of the authorized employee
Must not be bypassed, ignored, or otherwise defeated
Can evoke a false sense of security
They must be legible and their purpose understood by all employees

30. What You Need To Do
Understand and be familiar with the OSHA LOTO regulations and Colby procedures
Always follow LOTO procedures when working on equipment…no short cuts!!
Never remove a LOTO device that is not yours
Talk to your supervisor/EHS Director if you have questions or concerns with the program
Work safely!

31. Interactive Quiz

32. 1) The purpose of the LOTO standard is to:
a. Prevent injuries from the unexpected start-up of equipment
b. Prevent new employees from working on equipment until they have been trained
c. Prevent locks and tags from getting rusty

33. 2) Name a piece of equipment at Colby that requires a written equipment specific LOTO procedure.

34. 3) Where can you find the written equipment specific LOTO procedures?

35. 4) Which of the below is not an example of activities covered under the LOTO standard?
a. Repairing equipment
b. Starting equipment at the beginning of the shift
c. Unjamming objects during normal production operations

36. 5) True or False?
All Colby employees can perform lockout/tagout procedures.

37. 6) What must an employee do prior to shutting down equipment?
a. Notify affected and other personnel about the shut down
b. Become familiar with all energy sources
c. Both A & B

38. 7) An energy isolating device:
a. Determines the type of energy associated with a piece of equipment
b. Prevents the flow of energy from the power source to the equipment
c. Both A & B

39. 8) True or False?
Only authorized employees can attach or remove locks and tags.

40. 9) True or False?
One set of energy control procedures will work for all equipment .

41. 10) If you find a lock/tag on a piece of equipment you should
a. Avoid it
b. Remove it if you need to operate the equipment
c. Both A & B

42. 11) Which two of the following are requirements of LOTO devices?
a. They should have standardized color, shape and size
b. They should not be used for other purposes
c. They should be identical for everyone

43. 12) True or False?
The use of tags instead of locks is not allowed at Colby College

44. 13) After the LOTO procedure is complete, how can you verify the equipment is deenergized (safe)?
a. Attempt to turn the equipment on.
b. Place a tag on the equipment.
c. Ask another employee to watch the process

45. 14) Which two of the following should be done by authorized employees prior to removing locks and tags?
a. Inform other employees
b. Replace safety guards
c. Turn the power back on

46. 15) True or False?
In a group lockout/tagout situation, the LOTO Coordinator is the only one required to lockout the equipment.