University of Illinois Chicago Lockout/Tagout - The Control of Hazardous Energy 29 CFR 1910.147
Why Lockout Tagout ? ♦ Worker injuries, illnesses and fatalities 5,190 workers were killed on the job in 2016 on average, more than 99 a week or more than 14 deaths every day ♦ Lockout Tagout is the 5 th most cited standard that OSHA issues citations
Video – LOTO Accident
Requirements for LOTO The OSHA standard covers the “servicing and maintenance of machines and equipment in which the unexpected energization or start-up of the machines or equipment, or release of stored energy, could harm employees. This standard establishes minimum performance requirements for the control of such hazardous energy.”
When is LOTO required? Servicing or Maintenance activities that require any of the following: ♦ Removal of a guard or other safety device – A panel or a door is included in this list ♦ An employee is required to place any part of the body into a danger zone on a piece of equipment (point of operation, machine operating cycle)
Video – LOTO Overview
Exception – Cord and Plug OSHA allows for some exceptions: – Cord and plug connected equipment where the cord is in the exclusive control of the employee performing the servicing, when electricity is the ONLY form of hazardous energy to which employees may be exposed.
Exceptions – Hot Tap Hot tap operations involving transmission and distribution systems for substances such as gas, steam, or oil, when they are performed on pressurized pipe lines, provided that the employer demonstrates the following: – Continuity of service is essential – Shutdown of system is impractical; and – Documented procedures are followed, and special equipment is used which will provide proven effective protection for employees (NEC 70E is followed) • Steam • Hot Water • Electrical
Exception – Minor Tool Changes ♦ Lockout/Tagout is not required for minor tool changes or other minor servicing activities that are routine, repetitive, and integral to production, and that occur during normal production operations when employees have effective, alternative protection.
Employee Involvement - LOTO ♦ 3 types of employees under LOTO – Authorized - An employee who is qualified, through training, to lockout and tagout a machine or equipment in order to perform service or maintenance on the machine or equipment. – Affected - An employee who normally works on or near a machine that must be locked out for maintenance. – Other - An employee, other than the authorized or affected employee, whose work operations are, or may be, in an area where energy control procedures may be utilized.
Employee Involvement at UIC – LOTO (cont ntinue nued) d) ♦ Authorized Employees – Building Engineers, Utilities, Electrical, Plumbing and others ♦ Affected/Other –Building Occupants, Faculty, Management/Supervisors
Controlling Energy Sources Energy sources that require lockout/tagout ♦ Electrical ♦ Mechanical ♦ Pneumatic ♦ Hydraulic ♦ Chemical ♦ Thermal ♦ Water under pressure ♦ Gravity ♦ Potential
Controlling Energy Sources Some problems of hazardous energy: – Accidental start-ups – Electric shock – Release of stored, residual, potential energy
The Lockout/Tagout Procedure ♦ The scope and purpose of lockout/tagout ♦ How to perform a shutdown – Isolating – Blocking – Securing machines – Equipment ♦ How to place, remove, and transfer locks ♦ How to test the machine and make sure it’s locked out
Magnitude of energy ♦ What voltages are present in mechanical rooms? ♦ What pressures are steam, hot water, and oxygen lines at? ♦ Other?
Methods and Means for Isolation ♦ How are electrical feeds shut down? ♦ How are pressurized lines shut down or isolated? ♦ Other?
RULES – LOTO EQUIPMENT LOTO Devices (locks and tags) must: ♦ be unique to the individual using the device. The devices shall only be utilized for lockout purposes; ♦ clearly identify the individual who applied the device; ♦ be sturdy, durable, and able to withstand the environment they will be used in, and to prevent accidental removal; ♦ Be standardized according to shape, color, and size. Tags must be legible and understandable to all employees. They must warn employees about the hazards if the machine is energized, and offer employees clear instruction such as “DO NOT START, DO NOT OPEN, DO NOT ENERGIZE”
Built-in Locks – If an isolating device has a built-in locking mechanism, such as a Kirk-key lock, then it can be used as a locking device and it is not necessary to affix an additional padlock. – A personal tag properly dated, signed with name of authorized employee and department or company must be attached to the built-in lock to indicate that work is being done on the circuit or equipment. – If there is more than one person involved, the group lockout tagout procedures should be used.
Keys ♦ Each lock has two keys, primary and emergency. – primary key with authorized employee – emergency key must be kept in a secured area (e.g. a lock box) with access limited to the authorized employee only.
Prohibitions UNDER NO CIRCUMSTANCES SHOULD ANY EMPLOYEE ATTEMPT TO RESTART OR REENERGIZE MACHINES OR EQUIPMENT WHICH ARE LOCKED AND/OR TAGGED OUT.
Tags Only - PROHIBITED IF YOU ENCOUNTER EQUIPMENT THAT CANNOT BE LOCKED OUT, REPORT TO YOUR Chief Engineer, Manager: DO NOT PROCEED WITH WORK ♦ Limitations – Tags are warning devices only; they do not provide the physical restraint on those devices that is provided by a lock ♦ When a tag is attached to an energy isolating means, it can only be removed by the authorized person that installed it ♦ Tags must be made of material that can withstand the environment they’re in ♦ Tags must be secured well ♦ Tags evoke a false sense of security; their meaning must be understood .
Sequence of LOTO 1. Prepare for Shutdown 2. Shut down machine with normal stopping procedure 3. Disconnect or isolate the machine from the energy source 4. Apply the lockout and tagout device 5. Release or restrain all potential forms of hazardous or stored energy 6. Verify
Preparing for a Shutdown Before turning off machines you must know: ♦ The type and magnitude of energy involved ♦ Associated hazards ♦ Control methods
Performing a Shutdown 1. Notify affected employees of lockout procedure 2. Locate all energy sources 3. Follow procedures to shut down machine
Isolating Equipment and Applying Lockout Devices Every power source has its own procedure ♦ Lockout – Accomplished by pulling a plug – Opening a disconnect switch – Closing a valve – Bleeding a line – Placing a block in the equipment
Isolating Equipment and Applying Lockout Devices ♦ After completing the shutdown, turn off the energy at the main power source ♦ Using a designated lock, lock out all energy sources involved ♦ Attempt to restart the machine to guarantee power is shut off ♦ RETURN THE CONTROL KNOB TO THE OFF POSITION
Isolating Equipment and Applying Lockout Devices If several people are needed a MULTIPLE LOCKOUT DEVICE is used to accommodate several locks at once (see Group Lockout Procedures) AUTHORIZED EMPLOYEES MAY NEVER USE ANOTHER EMPLOYEE’S LOCK AND NEVER LEND THEIRS
Safe Release of Stored Energy Before servicing or maintenance begins ♦ Equipment must be at “Zero energy state” – Drain all valves – Bleed off air from system – Eliminate stored hydraulic pressure – Test the machine to make sure all energy was disconnected or released – Lower raised parts – Place blocks where needed
Restoring Power All tools removed Replace all machine guards Employees are clear of machine Notify affected employees the that the lockout has been removed Machine can be restarted
Lockout Tagout Device Removal ♦ Each lock and tag should be removed only by the employee that placed the lock. – WHY? ♦ EXCEPTION: when an employee that placed the lock is not available to remove the lock and tag, it may be removed under supervisor/manager control, with the following steps in place: – All attempts have been made to locate employee on site (check break areas) – The employee’s personal /home phone has been called – It is confirmed that the employee is no longer on site (badge, time clock, etc…) – The employee is notified that the lock/tag have been removed prior to resuming work at the facility. – ALL OF THIS MUST BE DOCUMENTED
Testing or Positioning of Machines If lockout or tagout devices must be temporarily removed to test or position the machine, the following sequence will be followed: 1. Clear the equipment of tools 2. Remove employees from the equipment 3. Remove the LOTO devices 4. Energize and proceed with testing 5. De-energize and follow LOTO procedures
Group LOTO or Procedures Involving More Than One Person: If more than one individual is required to lockout and tagout equipment: ♦ Each employee must be properly trained ♦ Each authorized employee must place his/her own personal lockout device and tagout device on the energy isolating device(s) ♦ Group LOTO and shift or personnel changes must be documented in Shop Log.
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