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NWACC Business & Industry Workforce Development Institute
J- 1
CONTROL OF HAZARDOUS CONTROL OF HAZARDOUS ENERGY ENERGY
(LOCKOUT/TAGOUT) FOR (LOCKOUT/TAGOUT) FOR GENERAL INDUSTRYGENERAL INDUSTRY
NWACC Business & Industry Workforce Development Institute
J- 2
COMMON QUESTIONS ABOUT LOCKOUT/TAGOUT
WHAT IS LOCKOUT/TAGOUT? IS IT NECESSARY?
WHAT ARE LOCKS AND TAGS AND HOW ARE THEY USED? WHO IS RESPONSIBLE FOR THEM?
ARE WRITTEN PROCEDURES REQUIRED?
WHAT ABOUT TRAINING?
WHAT IS THE PROCEDURE FOR LOCKOUT/TAGOUT?
NWACC Business & Industry Workforce Development Institute
J- 3
LOCKOUT/TAGOUT IS THE CONTROL OF HAZARDOUS ENERGY DURING SERVICING AND MAINTENANCE OF OF MACHINES AND EQUIPMENT.
UNEXPECTED ENERGIZATION OR RELEASE OF STORED ENERGY CAN INJURE AND KILL.
29 CFR 1910.147(c) requires the employer to establish an energy control program if the danger of unexpected releaseof energy exists
NWACC Business & Industry Workforce Development Institute
J- 4
HUNDREDS OF WORKERS ARE KILLED AND HURTEACH YEAR MAINTAINING EQUIPMENT!
CASE STUDY: An employee cleaning scrap from beneath a large shear is is decapitated when another employee pushes the control button. There is no procedure for lockout of the shear.
CASE STUDY: An electrician is electrocuted while performing maintenance on a motor control circuit. A procedure existed but the electrician wanted to save time, and did not follow it.
NWACC Business & Industry Workforce Development Institute
J- 5
LOCKS: IN LOCKOUT/TAGOUT, A LOCK IS USEDFOR HOLDING AN ENERGY ISOLATING DEVICE SUCH AS A VALVE OR SWITCH, IN A POSITION THAT WILL PREVENT ACTIVATION.
LOCKS MUST USE KEYS OR COMBINATION LOCKS
LOCKS AND TAGS ARE UNDER THE EXCLUSIVECONTROL OF THE EMPLOYEES PERFORMING THE WORK !
NWACC Business & Industry Workforce Development Institute
J- 6
TAGS: IN LOCKOUT TAGOUT, A TAG IS A WARNINGPLACED ON OR NEAR THE ENERGY ISOLATING DEVICETO ALERT OTHERS NOT TO OPERATE THE DEVICE.
DO NOT STARTDO NOT OPENDO NOT CLOSEDO NOT ENERGIZEDO NOT OPERATE
DO NOTSTART
DANGER
NWACC Business & Industry Workforce Development Institute
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TAGS CANNOT BE USED WITHOUT LOCKS UNLESS IT IS INFEASIBLE OR HAZARDOUS TO LOCKOUT AN ISOLATING DEVICE.
SOME POINTS ABOUT TAGS
TAGS MUST BE STANDARDIZED AS TO AT LEASTONE OF THE FOLLOWING: FORMAT, COLOR, SHAPE,SIZE, TYPE.TAGS MUST BE CLEARLY VISIBLE AND DISTINCTIVE.
TAGS MUST BE DESIGNED TO DETER UNAUTHORIZED REMOVAL.ATTACHMENT MEANS MUST BE NON-REUSABLE.
NWACC Business & Industry Workforce Development Institute
J- 8
IF A LOCK CANNOT BE USED DUE TO INFEASIBILITY OR INCREASED HAZARD,ONE ADDITIONAL SAFETY MEASUREMUST BE USED.
EXAMPLES:REMOVE AN UPSTREAM DISCONNECT.BLOCK AN UPSTREAM DISCONNECT.LOCK OUT AND TAG UPSTREAM DISCONNECT.GROUND A CIRCUIT BEING WORKED ON.
NWACC Business & Industry Workforce Development Institute
J- 9
Are Written Procedures Are Written Procedures Required?Required?
Written procedures are generally required. Written procedures are generally required. 1910.147 (c)1910.147 (c)
Procedures must include scope, purpose, Procedures must include scope, purpose, authorization, techniques, rules, responsibilities authorization, techniques, rules, responsibilities and training. and training.
Annual audits and inspections are required to Annual audits and inspections are required to verify the effectiveness of the procedures unless verify the effectiveness of the procedures unless they are used. they are used. 1910.147(c)(6)1910.147(c)(6)
NWACC Business & Industry Workforce Development Institute
J- 10
EXCEPTIONS TO THE RULE:All the following must be true
•No potential for stored energy exists.•There is a single readily identifiable energy source.•Isolating and lockout completely deenergizes the equipment.•A single lock will lockout the equipment.•The equipment is isolated during the work performed.•The lock is controlled by the person doing the work.•No hazard is created for others.•No history of unexpected startup for the equipment exists.
NWACC Business & Industry Workforce Development Institute
J- 11
DEFINITION: AN AUTHORIZED EMPLOYEE IS ANEMPLOYEE WHO PERFORMS OR PARTICIPATES IN THE LOCKOUT/TAGOUT OPERATION
DEFINITION: AN AFFECTED EMPLOYEE IS AN EMPLOYEE WHO MUST OPERATE THE EQUIPMENTDURING LOCKOUT/TAGOUT OR WHO IS IN THE VICINITY
BOTH AUTHORIZED AND AFFECTED EMPLOYEES MUST BE APPROPRIATELY TRAINED.
NWACC Business & Industry Workforce Development Institute
J- 12
TRAINING AND COMMUNICATION1910.147(c)(10)
Training and communication must take place before Lockout/Tagout can begin.
All employees involved must have necessary skills.
Other employees in the area may require some training.
Training must cover: required parts of energy control program,elements of applicable procedures, applicable Safety RelatedWork Practices.
NWACC Business & Industry Workforce Development Institute
J- 13
LOCKOUT/ TAGOUT LOCKOUT/ TAGOUT PROCEDUREPROCEDURE
29 CFR 1910.147(c)
NWACC Business & Industry Workforce Development Institute
J- 14
Preplanning
Isolation & Control Procedure
Restart Procedure
GENERAL LOCKOUT/TAGOUT PROCEDURE
Step 1
Step 2
Step 3
NWACC Business & Industry Workforce Development Institute
J- 15
IDENTIFY TYPES & AMOUNTS OF ENERGY SOURCES
IDENTIFY INDIVIDUAL EQUIPMENT & LOCATION
LOCATE & IDENTIFY DISCONNECT & ISOLATING DEVICES
VERIFY/DETERMINE POWER SHUTDOWN & POWER UP PROCEDURES
NOTIFY ALL AFFECTED EMPLOYEES
PREPLANNINGBLOCK DIAGRAM
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
NWACC Business & Industry Workforce Development Institute
J- 16
STEP 1 IDENTIFY TYPES & AMOUNT OF ENERGY SOURCES
TYPES OF ENERGY: MECHANICAL, ELECTRICAL, HYDRAULIC, THERMAL, AIR, CHEMICAL, ETC.
STEP 2 IDENTIFY INDIVIDUAL EQUIPMENT & LOCATION
ELECTRICAL MOTORS, MACHINES, CONTROLLERS, DISTRIBUTION PANELS, ETC.
NWACC Business & Industry Workforce Development Institute
J- 17
STEP 3 LOCATE AND IDENTIFY DISCONNECTS AND ISOLATING DEVICES
CIRCUIT BREAKERS, SWITCHES, VALVES, BLOCKS, GATES, ETC.
STEP 4 POWER SHUTDOWN AND POWER UPPROCEDURES
SEQUENCE PROCEDURES, PROCESS CONTROL DIAGRAMS, SINGLE ELECTRICAL ONE LINE DIAGRAMS, ETC.
NWACC Business & Industry Workforce Development Institute
J- 18
STEP 5 NOTIFY ALL AFFECTED EMPLOYEES
ENSURE ALL PERSONNEL AND UNNECESSARY EQUIPMENT ARE REMOVED.
NWACC Business & Industry Workforce Development Institute
J- 19 SHUTDOWN, ISOLATION & CONTROL
PROCEDURE BLOCK DIAGRAM
PREPARATION FOR SHUTDOWN
EQUIPMENT SHUTDOWN
ISOLATE EQUIPMENT
APPLY LOTO DEVICES
CONTROL STORED ENERGY
VERIFY ISOLATION
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
NWACC Business & Industry Workforce Development Institute
J- 20
STEP 1 PREPARE FOR SHUTDOWNAUTHORIZED EMPLOYEE TO DIRECT EQUIPMENT SHUTDOWN
STEP 2 EQUIPMENT SHUTDOWN AUTHORIZED EMPLOYEE DIRECTS EQUIPMENT SHUTDOWNWITH AUTHORIZED PROCEDURES.
STEP 3 ISOLATE EQUIPMENTUSE THE DISCONNECTING MEANS TO REMOVE ENERGY SOURCES.
STEP 4 APPLY LOCKOUT/TAGOUT DEVICES
FOLLOW PROCEDURES FOR INDIVIDUAL, GROUP, OR CONTRACTOR LOCKOUT. WATCH FOR SHIFT CHANGES.
NWACC Business & Industry Workforce Development Institute
J- 21
STEP 5 CONTROL STORED ENERGY
DISCHARGE CAPACITORS, RELEASE PRESS FLYWHEELS,DOUBLE BLOCK & BLEED LINES, ETC.
STEP 6 VERIFY ISOLATIONACTIVATE CONTROLS, MAKE CIRCUIT MEASUREMENTS, ETC.
NWACC Business & Industry Workforce Development Institute
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FOLLOW PROCEDURES FOR RELEASE FROM LOCKOUT/TAGOUT
INSPECT AREA TO ENSURE NON-ESSENTIALS REMOVED & EQUIPMENT INTACT & EMPLOYEES IN “SAFE ZONES”.
NOTIFY AFFECTED EMPLOYEES.
INDIVIDUALS REMOVE THEIR LOCKS & TAGS.
TEST & POSITION EQUIPMENT AS REQUIRED BY PROCEDURES
INFORM REQUIRED PERSONNEL AND RELEASE EQUIPMENT FOR USE.