Sample presentation for online Lockout/Tagout class.

1. Lockout/Tagout

2. 1910.147(a)(1) Scope
• Covers servicing and maintenance of
machines and equipment in which
– Unexpected energization or start up or
– Release of stored energy could cause
– Injury to employees
• Normal operation is
covered in 1910
Subpart O

3. 1910.147(a)(1)(ii) Exemptions
• Construction, agriculture and maritime
employment;
• Electrical Utilities;
• Electrical equipment (covered by Subpart S)
• Oil and gas well drilling and servicing
• So why comply?

4. Control of Hazardous Energy
• Why use lockout/tagout?
– Protects maintenance personnel
from power being reapplied by
mistake
– Recommended by API RP 54 for
electrical systems in drilling and
servicing operations
– Recognized hazard

5. 1910.147(a)(2) Application
• Service and maintenance:
– Employee required to remove or bypass a guard
or safety device
– Employee required to place part of body into
area that would be a danger zone during
machine operation cycle

6. 1910.147(a)(2) Application
• Exception: Minor adjustments and servicing
activities during normal production if
– Routine
– Repetitive
– Integral to production
• Provided that alternative measures provide
effective protection

7. 1910.147(a)(2) Application
• Does not apply to cord and plug
connected equipment for which
– Exposure to hazard is controlled by
unplugging and
– Plug under exclusive control of
employee performing service or
maintenance

8. 1910.147(a)(2) Application
• Does not apply to hot tap operations in
transmission and distribution operations in
pressurized pipelines provided that:
– Continuity of service is essential,
– Shutdown of system is impractical, and
– Documented procedures and special equipment
provide proven effective protection for
employees

9. 1910.147(a)(3) Purpose
• Establish a program and utilize procedures
for affixing appropriate lockout devices or
tagout devices to energy isolating devices
• Prevent unexpected energization, start up or
release of stored energy in order to prevent
injury to employees
• Training and procedural requirements for other
sections’ LO/TO requirements

10. Affected employee
• Job requires employee to
– operate or use a machine or equipment on
which servicing or maintenance is being
performed under lockout or tagout, or
– work in an area in which such servicing or
maintenance is being performed

11. Authorized employee
• Locks out or tags out machines or equipment
in order to perform servicing or maintenance
on that machine or equipment
• Affected employee whose duties include
servicing or maintenance under this section

12. Energized
• Connected to an energy source OR
• Containing residual or stored energy

13. Energy isolating device
• A mechanical device that physically prevents
the transmission or release or energy
– Circuit breakers included
– NOT push buttons
– NOT selector switches
– NOT control circuits

14. Energy source
• Any source of:
– Electrical,
– Mechanical,
– Hydraulic,
– Pneumatic,
– Chemical,
– Thermal, or
– Other energy
What kind of energy
did the rock have?

15. Lockout
• Placement of a lockout device on an energy
isolating device, in accordance with an
established procedure, ensuring that energy
isolating device and equipment being
controlled cannot be operated until lockout
device is removed

16. Lockout device
• Device that uses a positive
means such as a lock, either
key or combination type, to
hold an energy isolating device
in the safe position and prevent
the energizing of a machine or
equipment
• Blank flanges and bolted slip
blinds included

17. Servicing and/or maintenance
• Workplace activities such as:
– Constructing,
– Installing,
– Setting up,
– Adjusting,
– Inspecting,
– Modifying, and
– Maintaining and/or servicing machines or
equipment

18. Tagout
• Placement of tagout device
– on an energy isolating device,
– in accordance with an established procedure,
– to indicate that energy
isolating device and
equipment being controlled
may not be operated until
tagout device is removed

19. General Requirements
1910.147(c)

20. Energy control program
• Energy control procedures
• Employee training
• Periodic inspections
• Any employee who services/maintains any
equipment where unexpected energizing or
stored energy release could cause injury
isolates and renders it inoperative first.

21. 1910.147(c)(ii) General Requirements
• If an energy isolating device is
capable of being locked out, the
employer's energy control
program shall utilize lockout,
unless the employer can
demonstrate that the utilization of
a tagout system will provide full
employee protection

22. 1910.147(c)(iii) General Requirements
• Energy isolating devices designed to accept
lockout devices whenever:
– Replacement or major repair, renovation or
modification of equipment is performed or
– New machines or equipment are installed

23. 1910.147(c)(3) Full employee protection
• When tagout device used on energy isolation
device capable of being locked out:
– Same location as potential lockout device
– Demonstrably equivalent program
• May require additional safety elements

24. 1910.147(c)(4) Energy control
procedure
• Procedures shall be developed, documented
and utilized for the control of potentially
hazardous energy when employees are
engaged in the activities covered by this
section.
– Exception with all 8 elements listed in standard

25. 1910.147(c)(4) Energy control
procedure
• Outline scope, purpose, authorization, rules,
techniques for control of hazardous energy,
including:
– Specific intended use of the procedure;
– Specific steps for shutting down, isolating,
blocking and securing equipment
– Specific steps for placement, removal, transfer
of lockout/tagout devices and responsibility for
them
– Specific requirements for testing equipment to
verify effectiveness of lockout devices, tagout
devices, and other energy control measures

26. 1910.147(c)(5) Protective materials and
hardware
• Locks, tags, chains, wedges, key blocks,
adapter pins, self-locking fasteners, or other
hardware shall be provided by the employer
for isolating, securing or blocking of equipment
from energy sources

27. 1910.147(c)(5) Protective materials and
hardware
• Lockout and tagout devices must be:
– Singularly identified
– The only device(s) used for controlling energy
– Not used for other purposes
– And shall meet the following
requirements:

28. 1910.147(c)(5) Protective materials and
hardware
• Capable of withstanding environment for
maximum time period
• Moisture or corrosives must not make tag
deteriorate
• Standardized:
– Color
– Shape
– Size
– Print/Format

29. 1910.147(c)(5) Protective materials and
hardware
• Lockout devices:
– Substantial enough to prevent removal without
excessive force or unusual techniques such as
bolt cutters
• Tagout devices:
– Substantial enough to prevent inadvertent or
accidental removal
– Non-reusable attachment means
– Attachable by hand, self-lockable
– At least equivalent to nylon cable tie

30. 1910.147(c)(5) Protective materials and
hardware
• Lockout and tagout devices indicate identity of
employee applying devices

31. 1910.147(c)(6) Periodic Inspection
• Energy control procedure inspected at least
annually:
– By authorized employee not using the procedure
being inspected
– Correct any deviations
– Review employee responsibilities with:
• each authorized employee – lockout
• each affected or authorized employee – tagout

32. 1910.147 (c)(7) Training and
communication
• Ensure employees understand purpose and
function of energy control program
• Ensure employees acquire skills required for
safe application, usage, removal of energy
controls

33. Employee Training Requirements
• Authorized employee:
– Recognition of hazardous energy sources
– Type and amount of energy in workplace
– Methods and means for energy isolation
• Affected employee:
– Purpose and use of procedure
• Other employees in area:
– Procedure and prohibition on restarting

34. Employee Training Requirements for
Tagout
• Train on limitations of tags:
– Warning devices do not provide physical
restraint that a lock would
– Tag not to be removed without owner’s
authorization, bypassed, ignored, defeated
– Must be legible / understandable to work
– Must withstand environmental conditions
– False sense of security
– Attach securely: avoid accidental removal

35. Employee Retraining
• For all authorized or affected employees when:
– Job assignment changes
– Equipment or processes present new hazard
– Energy control procedure changes
– Knowledge / use of program is inadequate
• Certify employee training up to date

36. 1910.147(c)(8) Energy Isolation
• Only the authorized employees performing the
servicing or maintenance may apply
lockout/tagout

37. 1910.147(c)(9) Notification of
Employees
• Affected employees must be notified
– By employer or authorized employee
– Of application and removal of lockout and
tagout devices
– Before controls are applied
– After controls are removed

38. Order of Operation for Application of
Control
1. Preparation for shutdown
2. Equipment shutdown – orderly
3. Equipment isolation
4. Lockout or tagout device application
5. Stored energy relieved; continue while
reaccumulating
6. Verification of isolation
– Test and return to “off” position

39. 1910.147(e) Release from Lockout
• Before lockout or tagout devices removed and
energy restored, ensure:
• Machine or equipment:
– Inspect area; remove nonessential items
– Ensure equipment components intact
• Employees:
– Ensure all employees safe or removed
– Before restart, notify affected employees of
removal

40. 1910.147(e) Release from Lockout
• Each lockout/tagout device removed by
employee who applied the device
– If not available, removed under employer
direction
– Specific procedures and training from energy
control program must be in use!
• Verify that applying employee is not at facility
• Make all reasonable efforts to contact/notify
• Ensure authorized employee knows of removal
before resuming work at facility

41. 1910.147(f)(1) Testing or Positioning
• Temporary removal of lockout/tagout devices
for testing/positioning:
– Clear tools and materials
– Remove employees from equipment area
– Remove lockout/tagout devices (as in (e))
– Energize and test or position
– Deenergize systems and reapply energy control
measures to continue servicing

42. 1910.147(f)(2) Outside Personnel
• Contractors and other outside personnel:
– On-site employer and outside employer inform
each other of lockout/tagout procedures
– On-site employer complies with outside
employer’s energy control program

43. 1910.147(f)(3) Group Lockout or Tagout
• Procedure must provide protection equivalent
to personal lockout/tagout device
• 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 (such as an
operations lock);

44. 1910.147(f)(3) Group Lockout or Tagout
• When more than one crew, craft, department,
etc. is involved:
– Designated authorized employee takes
lockout/tagout control responsibility
– Coordinates affected work forces
– Ensures continuity of protection

45. 1910.147(f)(3) Group Lockout or Tagout
• Each authorized employee affixes personal
lockout/tagout device to group lockout device
when beginning work
• Each removes personal device when stopping
work on this equipment

46. 1910.147(f)(4) Shift or Personnel
Changes
• Specific procedures in energy control plan
• Ensure continuity of lockout/tagout protection
• Orderly transfer of lockout/tagout device
protection between shifts
• Minimize exposure to hazards from
unexpected energization or release