Lockout/Tagout

Who needs training?

What is hazardous energy?

What is lockout/tagout?

What are the different types of lockoutdevices?

What is the requirement for tags?

What lockout/tagout procedures are required?

What This Training Will Cover:

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Who Needs Training?

•Authorized employees –people who lock or tag out machines or equipment to perform servicing.

•Affected employees –people who use machines or equipment on which servicing is performed under lockout/tagout.

•Other employees –people who work in the area of locked out machinery or equipment

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What is Hazardous Energy?

Hazardous energy is any of the following:

Electricity – live or stored

Moving machinery parts

Stored mechanical movement in machinery

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What is Hazardous Energy?

Stored heat (steam lines or hot liquids)

Hazardous chemicals in pipelines under pressure or force of gravity

Any other active or stored energy sources that could harm a worker

--such as:

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Hazardous Energy Source Examples

Live electrical lines

Electrical capacitors

Lasers

Engines that move machinery parts

Hydraulic lifts

Pneumatic (air pressure) lines

Pressurized water lines

Springs

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Lockout/Tagout and Confined Spaces

Lockout/Tagout is important in confined spaces since it is easy to get trapped and hard to escape.

Pipelines leading into tanks must be blanked off before entering the space.

All electrical and mechanical hazardous energy must be addressed and locked out or tagged as needed.

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Our Hazardous Energy Sources (examples)

Examples:

• Laboratory equipment (examples)

• Field equipment (examples)

Inventory list example (handout)

Please refresh the inventory list for your laboratory or site

The following hazardous energy sources require lockout/tag-out procedures:

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What kind of injuries can happen?

Electrocution from live parts

Scalding from steam or hot liquids

Chemical burns or poisoning

From machinery:

- Deep cuts and gashes

- Crushing injuries

- Amputations

All of these can be fatal when severe

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A man working inside a

supermarket cardboard compactor

was crushed when the unblocked

compactor suddenly came down on

top of him.

Fatality Example

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Three men were doing maintenance inside an asphalt pug mill mixer. One employee was still inside the mixer when the power was turned back on, thereby starting the mixer. He was killed instantly. Cause: failure to disconnect power source and lock out.

A cotton gin operator climbed into a jammed cotton cleaner/separator. The toggle switch controlling the operation of the gin was turned off but not locked out. For some reason, someone accidentally turned the machine back on, not knowing the gin operator was inside the gin. His leg was pulled through the feed rollers. Cause: failure to disconnect power source and lock out.

A warehouseman was repairing an air-operated valve which he had turned off but not disconnected and locked out. During the repair operation he slipped and inadvertently turned on the switch which let air into the valve. His hand was caught and crushed in the valve. Cause: failure to disconnect power source and lock out.

More Examples

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A maintenance employee was changing V-belts on an exhaust fan. He de-energized the fan before starting work. However, he did not block the blades of the fan. The suction in the duct work turned the fan blades, and his hand was caught in the V-belt drive. Cause: failure to block out potential energy sources.

One study on servicing equipment injuries found that 80 percent of the workers surveyed failed to even turn off the equipment before performing the service work. There is a difference between turning off a machine and actually disengaging or de-energizing a piece of equipment. When you turn off a control switch, you are opening a circuit. There is still electrical energy at the switch, and a short in the switch or someone inadvertently turning on the machine may start the machine running again.

Of the 20 percent of the injured workers who did turn off the machinery, about half of them were injured when someone, generally a coworker who was unaware that the machine was being serviced, accidentally reactivated the machinery.

More Examples

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Of those workers who turned off the control switch, another 20% were injured by the energy still in the machine which should have been blocked. The moving parts of the machine either continued to coast, or the parts moved when a jam was cleared.

In an accident in California, a table saw was turned off, but the saw blade was still silently coasting and had not come to a complete stop. An employee began cleaning the machine, and his finger was amputated by the blade. Other accidents have occurred when the control switch on a machine was turned off, but a short in the switch restarted the machine.

Accidents have also occurred even when workers did take the necessary steps of disconnecting the main power source. But they did not perform a crucial step for a complete lockout procedure: They did not test the equipment to make sure the machinery was, in fact, de-energized.

One case, the lockout had been done on the wrong power line. In another case, a second power line had been spliced into the wiring beyond the point of the lockout.

More Examples

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When is Lockout/Tag-out required?

When someone will be servicing or repairing machinery or equipment

AND

the unexpected machinery start-up or release of stored energy could cause injury

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Service and Maintenance Examples

Installing, constructing,

adjusting, modifying,

unjamming, cleaning,

lubrication, inspecting,

setup - preparing for normal function

These activities often require a worker to place all or part of their body into the machine’s hazard zone (“the line of fire”).

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What is an energy-isolating device?

An electrical circuit breaker,

A device that physically prevents transmission or release of energy such as:

A machine block,

A pipeline valve,

Anything else that positively blocks or isolates energy.

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What is a Lockout Device?

A device that positively:

prevents a machine from being started up or turned on,

prevents a machinery part from moving,

prevents electrical energizing,

blocks a pipeline, steam line or air line

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Electrical Lockout Devices

Locked out electrical panel

Locked out circuit breaker

Locked out electrical plug14

Fluid & Gas Lockout Devices

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Pipe Lockout Examples

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Pneumatic Lockout Examples

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Physical Blocks

Truck bed lockout Punch press blocks

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Group Lockout Devices

Used when more than one person doing maintenance or repair on same machine or equipment.

Machinery or equipment can’t be started up until all locks are removed.

Each person places and removes their own lock.

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Example of a bad lockout/tagout

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Lockout Devices We Use

Personally-identified lock

E-Z Panel LocTM snap-on breaker lockout device

More examples?

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What is Tag-out?

Tags are warning devices onlyThey don’t provide the same level of protection as lockout devices. We only use for information, along with a locked device.

They can only be removed by an authorized person.

They must be legible (use a sharpie), securely attached (e.g., zip-tie not string) and resistant to degradation.

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Energy Control Program

Our energy control program consists of:

1. Training for Authorized and Affected employees;

2. A current inventory of equipment requiring lockout;

3. A description of general energy control procedures,

4. Development and use of a specific written stepwise procedure for all equipment on the inventory; and

5. Periodic inspection of the implementation of the energy control procedures

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Lockout Procedures

Six Steps to Follow:

1. Notify affected employees (anybody in the area) that the machine or equipment will be shut down and locked out

2. Shut down the machinery or equipment using normal procedure

3. Isolate energy sources with energy-isolating devices

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Lockout Procedures

4. Lock out energy-isolating devices with assigned locks.

5. Release or restrain stored or residual energy (capacitors, pressure, vacuum, blades, etc.)

6. Test machinery to make sure it can’t start up (use the normal start procedure)

Six Steps

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Single Breaker Lock Use

Dual Breaker Lock Use

Lockout Steps

Notify employees

ShutdownEquipment

Isolate Energy

Attach LockoutDevice

Release Stored Energy

Verify Lockout

Service &Maintenance

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Examples of Release of Stored Energy

• “Slowly open the receiver tank port and bleed off any internal pressure.”

• “Loosen both line valves to relieve all pressure in the cooling circuit.”

• “Ground out capacitor…”

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Examples of Attempt to Operate

• “…adjust the temperature cycle thermostat to check that all electrical inputs have been shut off.”

• “Push the start function button to verify that electric power has been removed.”

• “Crack the steam inlet and discharge line outlet valves…”

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Start-up Procedures

Warn everyone present to stay clear

Remove all tools, locks and tags

Remove, reverse, open or reactivate isolating devices

Visual check that all is clear

Start up machine, process or line flow

Only Authorized employee can do startup

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