LOTO Training for construction and other industry

LOTO Training

1. Lockout/Tagout
MODULE 20

2. 2 ©2006 TEEX
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. 3 ©2006 TEEX
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. 4 ©2006 TEEX
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. 5 ©2006 TEEX
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. 6 ©2006 TEEX
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. 7 ©2006 TEEX
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. 8 ©2006 TEEX
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. 9 ©2006 TEEX
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. Definitions
1910.147(b)

11. 11 ©2006 TEEX
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

12. 12 ©2006 TEEX
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

13. 13 ©2006 TEEX
Energized
Connected to an energy source OR
Containing residual or stored energy

14. 14 ©2006 TEEX
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

15. 15 ©2006 TEEX
Energy source
Any source of:
Electrical,
Mechanical,
Hydraulic,
Pneumatic,
Chemical,
Thermal, or
Other energy
What kind of energy
did the rock have?

16. 16 ©2006 TEEX
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

17. 17 ©2006 TEEX
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

18. 18 ©2006 TEEX
Servicing and/or maintenance
Workplace activities such as:
Constructing,
Installing,
Setting up,
Adjusting,
Inspecting,
Modifying, and
Maintaining and/or servicing machines or
equipment

19. 19 ©2006 TEEX
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

20. General Requirements
1910.147(c)

21. 21 ©2006 TEEX
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.

22. 22 ©2006 TEEX
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

23. 23 ©2006 TEEX
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

24. 24 ©2006 TEEX
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

25. 25 ©2006 TEEX
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

26. 26 ©2006 TEEX
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

27. 27 ©2006 TEEX
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

28. 28 ©2006 TEEX
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:

29. 29 ©2006 TEEX
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

30. 30 ©2006 TEEX
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

31. 31 ©2006 TEEX
1910.147(c)(5) Protective
materials and hardware
Lockout and tagout devices indicate
identity of employee applying devices

32. 32 ©2006 TEEX
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

33. 33 ©2006 TEEX
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

34. 34 ©2006 TEEX
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

35. 35 ©2006 TEEX
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

36. 36 ©2006 TEEX
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

37. 37 ©2006 TEEX
1910.147(c)(8) Energy Isolation
Only the authorized employees
performing the servicing or maintenance
may apply lockout/tagout

38. 38 ©2006 TEEX
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

39. Application of Control
1910.147(d)

40. 40 ©2006 TEEX
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

41. Release from Lockout/Tagout
1910.147(e)

42. 42 ©2006 TEEX
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

43. 43 ©2006 TEEX
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

44. Additional Requirements
1910.147(f)

45. 45 ©2006 TEEX
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

46. 46 ©2006 TEEX
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

47. 47 ©2006 TEEX
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);

48. 48 ©2006 TEEX
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

49. 49 ©2006 TEEX
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

50. 50 ©2006 TEEX
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