LockoutTag out Definitions u LockoutTagout LOTO Risk to

Lockout/Tag out

Definitions u Lockout/Tagout (LOTO) - Risk to individuals working on powered equipment or machinery can be minimized by adhering to the six step process of LOTO. - Lockout/Tagout gets its name from the equipment used - Lockout/Tagout must be used whenever you are performing service or maintenance on any machine where you or someone else could be injured by the unexpected startup or release of stored energy - LOTO DOES NOT APPLY to single source plug and cord equipment when the equipment is unplugged and under the exclusive control of the person performing the work

Definitions u LOTO Device - A device such as a lock, circuit breaker cover, etc. that secures an energy isolating device and prevents energization of a machine, equipment or process u Caution Tag - Yellow Caution Tags are used to indicate that a machine, equipment, process or circuit is out of service or inoperable u Energy Isolating Device - A mechanical device that physically prevents the transmission or release of energy, such as a circuit breaker or disconnect switch

Definitions u Individual LOTO Lock - A type of key lock that is used for no other purpose in the facility/operation, having one key, and for which master keys are not available. Such locks are individually assigned (personal lock) to Authorized Employees, or can be obtained from a central repository of LOTO devices, whereupon they become personal locks while in use by an individual. LOTO Locks are typically colored red. u Individual LOTO Tags- These tags are used with every Personal LOTO Lock to indicate that the energy source is locked out and that an Authorized Employee is actively working on the machine, equipment, process, or circuit. Show employee(s) the individual locks and tags that are used on site.

Definitions u Supervisor Lock - A key lock for which multiple keys may be made available and which is used on equipment or processes when they are not actively being serviced. Key control or access must be limited to a small, closely controlled group of Authorized Employees. This lock must be used in combination with a Supervisor Tag to indicate the equipment is unsafe to operate. - This lock must not be used as an Personal Lock and may never be used on equipment that is being actively serviced. u Supervisor Tag - Must be yellow in color and are used to indicate that a machine, equipment, process or circuit is out of service or inoperable, but no one is actively working on the system. Supervisor Tags are not to be used in place of Red Tags. No activity to the machine, equipment, process or circuit may occur when a Supervisor Tag is placed. Show employee(s) the Supervisor locks and tags that are used on site

Definitions u General LOTO Lock - A key lock that is not assigned to an individual employee as an Individual LOTO Lock. This lock has only one key and master keys are not available. When a Group LOTO is used, this lock may be used to Lock Out individual Energy Isolating Devices or Energy Sources. This lock may be left on for durations of greater than one shift. This lock is unique within the facility and is to be used only for LOTO. Show employee(s) the general LOTO locks that are used on site

Personnel Affected by Lockout Tagout u Every employee who will be in close proximity to any machinery or equipment being worked on will be affected by Lockout/Tagout. - Authorized Employee - Affected Employee

Personnel Affected by Lockout Tagout u Authorized Employee - An employee who has the appropriate technical background, has completed Lockout/Tagout Authorized Training, has successfully demonstrated that they know how to apply EC/LOTO, and who will perform the work on the system. This could include an electrician, pipefitter or other specialist with knowledge of the equipment. u Affected Employee - An employee who operates equipment that is being maintained or serviced under EC/LOTO, or an employee working in an area where the maintenance or servicing is being performed. This could include machine operators, janitors or any other worker whose job requires him/her to be in the area. Affected Employees are NOT authorized to perform EC/LOTO. Discuss the employee(s) role with lockout tag out and whether or not they are Affected or Authorized employees.

Energy Isolation Device u A mechanical device that prevents transmission or release of hazardous energy - Circuit Breakers - Disconnect Switches - Line Valves - Block Valves - Manually Operated Switches

Types of Lockout/Tagout Devices u Circuit breaker cover u Gate valve locks u Fuse cover u Wall switch cover

Types of Lockout/Tagout Devices u Plug lock u Hasp u Ball valve locks u Group lockbox

Types of Hazardous Energy u Mechanical - Relating to springs, rotating parts, etc. u Magnetic • Can be found in capacitors and superconducting magnetic energy storage u Gravity • Can be found in machinery or equipment parts that might descend, slide or fall if left unblocked u Electrical • Relating to or operated by electricity – AC or DC u Hydraulic • Involving, moved or operated by a fluid under pressure, either internal or external u Pneumatic • May be in cylinders, lines and pipes u Thermal • Can be hot or cold

Types of Hazardous Energy u Chemical - Produced as a result of a chemical reaction u Steam - Water vapor kept under pressure so as to supply energy for heating or mechanical work

Hazardous Energy u Remember: To proceed with any maintenance or servicing, hazardous energy must be identified and controlled to prevent injury. u All energy sources must be identified and labeled. Show employees examples of the site’s LOTO procedures including: • Where they are located • How the LOTO points are labeled

Employee Training u Authorized Employees must: - Recognize hazardous energy sources including type and magnitude present in the work place - Know the methods and means to isolate and control hazardous energy sources - Perform an annual demonstration to show they know how to properly apply LOTO *In addition to this training course, Authorized Employee’s must also go through the periodic inspection/certification form located in the Lockout/Tagout program. Your Supervisor is responsible for completing this addition requirement. u Employee Retraining is required when: - There is a change in job assignment - There is a change in energy control procedures - Inspections indicate deviations in procedures - Employer believes employee needs retraining

Six Step Process u Step 1 - Prepare for Shutdown - Notify all affected employees in the area that the equipment is going to be shut down and locked out. - Understand the problem • What needs to be fixed? - Plan • Are the proper tools available? - Prepare • Is the area clear and are warnings posted?

Six Step Process u Step 2 – Shut Down the Equipment l l l Use established procedures Involve the worker who normally shuts down the equipment If the work is being performed at a customer site, the customer should shut down the equipment

Six Step Process u Step 3 - Isolate the Equipment - Disconnect the equipment from each hazardous energy source and know the proper order of shutdown - Remember to wear Personal Protective Equipment (PPE) appropriate for any hazards in the area - Use common isolation techniques including closing valves and opening electrical disconnects - Remember to stand to one side when opening electrical disconnects in the event an electrical arc occurs

Six Step Process u Step 4 - Apply Lockout/Tagout Devices - Only use approved colored locks and tags designated for lockout - NO MASTER KEY is allowed for a personal lock - Locks must be attached to the energy-isolating device - There should be one lock person working on equipment, at each energy source, unless a group lockbox is used - If multiple employees a lockbox and/or multiple lock hasps may be used - Never lend or borrow locks or keys - Never use lockout locks for any other purpose

Six Step Process u Step 5 - Control Stored and Residual Energy - Check that all moving parts have stopped. - Relieve or disconnect any residual hazardous energy that could be present. • Bleed-off all trapped pressure. • Blank pipe flanges. • Install ground wires to discharge electrical capacitors. • Block or support elevated equipment.

Six Step Process u Step 6 - Verify Isolation/Zero Energy - Start by verifying that all testing equipment (e. g. , voltmeter, etc. ) is working properly - Try to turn the equipment on - Test for voltage - Check gauges - Check Double Block and Bleed - Check temperature with an independent device - Check blocks and pins - Return switches to the “OFF” - Notify Affected Employees in the area that work is to begin

Release of Lockout/Tagout u Check for others. When the assigned repair or servicing task is completed and the machine is ready for testing or return to service, check the area surrounding the shut off unit to assure that no one will be exposed to danger when that machine is started up. Replace all guards and reactivate all interlocks. u Notify all affected employees that locks/tags are going to be removed and the machine is ready for operation. u Remove LOTO equipment. When the area is clear, remove all locks and deactivate all the energy isolating devices to restore energy and material to the machine. The same worker who installed the energy isolating devices and installed the locks must de-activate and remove them. u Test the machine. Perform any necessary testing of the restored machine to ensure it is in operable condition. u Notify the management that work is completed and the area has been returned to operational condition.

Things We Cannot Do! u u DO NOT • Rely on emergency stops • Rely on interlocks and light curtains • Rely on another worker to “guard the power source” Why can’t we do these things • Emergency stops and interlocks can fail • Human error- people can get distracted u Injuries are not caused intentionally, it happens when things are overlooked and things “accidentally” happen (doors shutting behind someone, accidentally pushing a button, etc. ) u THE WHOLE POINT OF LOCKOUT TAG OUT IS SO THAT IT CANNOT BE BYPASSED. IT REMOVES THE FACTOR OF OTHER COUNTERMEASURES LIKE E-STOPS AND INTERLOCKS FAILING AS WELL AS REMOVING THE “HUMAN ERROR” ELEMENT!

Special Situations u Group Lockout - Each authorized individual performing service and/or maintenance must apply his/her personal lock. Every authorized individual who applies a personal lock shall verify that the machine, equipment, process or circuit has attained a zero energy state or observe the verification process. Multiple lock application can be accomplished with the following: • Multiple lock devices (hasps) that accommodate several personal Iocks; • The use of general locks and a lock box. For example, if a machine with multiple energy sources is going to be serviced by multiple personnel, it may be useful to use general locks at the energy sources. Keys for the general locks are held in lock boxes to which employees attach their personal locks. Discuss the site’s procedure for group lockout including: • Color of locks used • When it is to be used (give examples of machines and specific jobs)

Special Situations u Specific procedures shall be utilized during shift or personnel changes to ensure the continuity of LOTO protection. This includes provisions for the orderly transfer of LOTO devices between off going and on coming authorized individuals. There are two distinct methods of shift or personnel change LOTO transition. These methods should never be mixed or combined. - Option 1: The immediate hand-off of LOTO in progress. Authorized individuals of the outgoing shift remove their personal locks and tags. Authorized individuals of the next shift simultaneously apply and secure their personal locks and tags at the same energy-isolating device and verify that a zero energy state exists in the system. - Option 2: Application of Supervisor Locks. Authorized individuals use this method when servicing and/or maintenance continues over multiple shifts, but there is no immediate hand-off of LOTO in progress. Discuss the site’s procedure for shift change including: • Color of locks and tags used (show them the locks and tags that will be used) • How and when to apply or remove shift change locks and tags

Special Situations u Unauthorized removal of locks and tags is prohibited. The Supervisor or qualified person shall use the following procedure when the employee is not available: - Verify that the authorized employee is not on site and available to remove his or her own tag. - Check that employees are not exposed to hazards. - Verify that the equipment is safe to operate, tools have been removed, and guards have been replaced. - Remove lock/tag and energize equipment. - Remain with affected equipment so that no one returns while equipment or process is being restarted. - Require that the affected employee knows the lockout device has been removed before he/she resumes work. - The “Lockout/Tagout Removal Notice in the Lockout Tagout program must be completed. Discuss the site’s procedure for lock removal

Special Situations u New person(s) working on the system: Any new person working on the system must follow all lockout procedures. u Returning to do more work: If you return to do more work, follow full lockout procedure to assure nothing has changed. u Removing another person’s lock: NO ONE ELSE should remove an individual’s lock and tag. DO NOT ASSUME ALL IS SAFE – ALWAYS RE-VERIFY

Special Situations u When power must be temporarily restored to a machine to test or position the machine, equipment or components, the following sequence of actions shall be followed. At no time should you place any body parts in a danger area!! This procedure is for observation purposes and adjustments that can be made outside of the danger area!!!! - Clear the machine or equipment of tools and materials. - Notify all affected employees that you are removing lockout/tag out device(s) and ensure that they are safely positioned or cleared from the area. - Remove the lockout device as specified in the lockout removal section of this procedure. - Energize and proceed with testing or positioning. - When testing or positioning is completed, de-energize all systems and reapply the energy control measures in this procedure.

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