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Lockout/Tagout

Module 2
Identification and Evaluation of
Energy Sources and Related Hazards
Lockout/Tagout Definitions
• Energy Source - any source of electrical,
mechanical, hydraulic, pneumatic, chemical,
thermal or other means of power.
• Energized - connected to an energy source or
containing residual or stored energy.
• Normal Production Operations - the utilization
of a machine or equipment to perform its
intended production function.
Lockout/Tagout Definitions
• Setting Up - any work performed to
prepare a machine or equipment to
perform its normal production function.
• Hot Tap - a procedure which involves
welding on a piece of equipment under
pressure to install connections or
equipment.
Lockout/Tagout Definitions
• Other Employee - employees who enter an area
where lockout/tagout procedures are used.
• Affected Employee - a person whose job
requires him/her to
– Operate or use a machine or equipment on
which servicing or maintenance is being
performed under lockout or tagout; or
– Whose job requires him/her to work in an area
where servicing/maintenance is being
performed.
Lockout/Tagout Definitions
• Authorized Employee - a person who locks
or tags out machines or equipment in
order to perform servicing or maintenance
on that machine or equipment.
– An affected employee becomes an authorized
employee when that employee’s duties include
performing servicing or maintenance under
lockout or tagout conditions.
Identify Facility Employees
Impacted by Lockout/Tagout

• Who are your Authorized


Employees?
• Who are your Affected
Employees?
• Who are your Other Employees?
Lockout/Tagout Definitions
• Servicing and/or Maintenance - activities
such as constructing, installing, setting-
up, adjusting, component changing,
inspecting, modifying, lubricating,
cleaning or unjamming of machines or
equipment where the employee may be
exposed to the unexpected energization
or start-up of the machine or release of
hazardous energy.
Lockout/Tagout Definitions
• Normal Production - machine guarding is
the primary means that protect employees
from machine and equipment-related
hazards during normal production.
Lockout or tagout is required when:
– The employee is required to remove or by-
pass a machine safeguard; or
– The employee is required to place any part of
their body in a danger zone.
Lockout/Tagout Definitions
• Exception - an employee may remove or by-
pass a guard to make adjustments or
perform minor maintenance that is integral
to running the machine provided that
alternative measures for protection are
used.
• Cord and Plug Equipment - Lockout or
tagout is not required where the plug is
under the exclusive control of the operator.
Lockout/Tagout Decision Flow Chart

Lockout/ Start
Is this operation a
hot tap involving a
gas, stem or
N Is equipment or
machine to be
serviced or
N Is procedure part of
normal operations
Yes
No

Tagout
product line? maintained
Yes Yes

Are all three of Does employee No Is employee N LOTO

Decision
these conditions need to remove or required to place a does
met? by-pass a guard? body or part of body not
1) Continuity of Yes in harm’s way? apply
service is Yes
essential.

Flow
2) Shutdown of
system is Is this a minor tool No
impractical. change or
3) Documented Yes adjustment integral

Chart
procedures and to use for normal
special operation?
equipment will Yes
be used that No No
provide
effective Is alternative
protection effective protection
provided? No
Yes Yes

LOTO does not


Yes apply

LOTO does not Is equipment only


apply. Follow energy source a
specific hot top plug and electrical No
procedures connection No
Yes

Are all machine LOTO APPLIES


energy hazards No Follow LOTO
controlled by procedures
unplugging?
Yes

LOTO does not Y Is plug under the No


apply. Use power exclusive control
cord plug lockout of the service or
and lock. maintenance
employee?
Which Jobs Require Lockout?
• Replace a grinding wheel on a grinder.
• Open an interlocked door to remove a carton lodged in
the box feed arm.
• Perform maintenance on a conveyor belt.
• Remove a bottle lodged at the entrance to the
accumulation table.
• Open an interlocked door to remove multiple labels
that are wound around the label cutter.
• Replace a thermostat in an oven.
• Remove a fixed guard to replace a shutdown switch.
Types of Energy Sources
– Electric • Energized power
– Hydraulic sources must be
shut off and
– Pneumatic secured when an
– Steam employee must
place any part of
– Chemical their body in a
– Gravity danger zone.
Stored Energy in systems
– Mechanical motion – Steam
– Mechanical energy – Chemical
– Gravity • Stored energy in
– Thermal systems must be
– Electrical released, dissipated,
or secured before
– Hydraulic servicing or
– Pneumatic maintenance begins.
– Compressed Gas
Identify the Energy Control
Which forms of energy should be control by
dissipation (releasing energy) and which
should be controlled by restraint (storage
of energy)?
Air (pressure); Mechanical motion (flywheel);
Mechanical Energy (compressed springs);
Gravity; Thermal energy (heat); Live Electrical
energy; Electrical (capacitor), Water (pressure);
Chemicals (pressure); Gas (pressure); or Steam
(pressure).
Perform a Hazard Assessment

Develop Equipment-specific Energy Control


Procedures:
• Conduct a Hazard Assessment (Inventory
of Hazards) for each machine or system.
• Evaluate the Hazards and Energy Sources
Hazard Assessment
• Be systematic. Conduct an assessment for
each machine or system.
• Identify machines, systems, processes that
have hazards and identify the related energy
sources.
• Make a list of energy sources for each hazard.
• Identify operator controls for each energy
source.
Evaluate Hazards and
Energy Sources
• What is the magnitude of the identified
energy?
• What hazards are created by the
energized system?
• How and where is the energy source
controlled or isolated?
• How can any stored energy be released?
Name of Authorized person:

__________________________________________
Hazard Assessment for Lockout/Tagout Date: ________________________
a. Machine/Equipment b. Type of Energy and Magnitude
and Location Enter the highest magnitude of energy for each applicable energy type below (i.e., 440 v, 50 psi, etc.). d. Hazard(s) e. Isolation Device/Location
____________________ Electrical Hydraulic Pneumatic Thermal Chemical* Potential* Residual* Other

____________________

b. Components

*Chemical (any raw material line: solid, liquid, slurry, gas, etc.); Potential (Mechanical motion, compressed springs, elevated components, etc.); Residual (unreleased air, gas, steam, chemical, water, oil, stored electrical, etc.)
Name of Authorized person:

__________________________________________
Hazard Assessment for Lockout/Tagout Date: ________________________
a. Machine/Equipment b. Type of Energy and Magnitude
and Location Enter the highest magnitude of energy for each applicable energy type below (i.e., 440 v, 50 psi, etc.). d. Hazard(s) e. Isolation Device (Location)
Electrical Hydraulic Pneumatic Thermal Chemical* Potential* Residual* Other Accidental restart,, Circuit Breaker (1)
Packaging Machine activation, electrocution, Main air valve (1)
Line 3 110 v 100 shock, pinch point, struck Air dump valves (3)
AC psi by reject arm/kick out Disconnect switch(1)
b. Components
Accidental restart, shock, Circuit break on the back of
Check weight scale and 110v electrocution. the indicator head.
conveyor motor AC

Main air valve (blue) and


Check weight scale and Accidental activation, pinch yellow dump valve by the
conveyor reject arm 100 point, struck by reject arm Allen Bradley motor start
psi control box.
Yellow air dump valve on
the frame of the conveyor
next to the reject arm.

Accidental restart, shock, Grey motor KW disconnect


Metal detector conveyor 110v electrocution switch by the Allen Bradley
motor AC motor start control box.

Main air valve (blue) and


Accidental activation, pinch yellow dumb valve by the
Metal detector Kick-out 100 point, struck by kick out Allen Bradley motor start
psi control box.
Yellow air dump valve
located on the air supply
line under the conveyor
frame at the kick out.

*Chemical (any raw material line: solid, liquid, slurry, gas, etc.); Potential (Mechanical motion, compressed springs, elevated components, etc.); Residual (unreleased air, gas, steam, chemical, water, oil, stored electrical, etc.)

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