BLR s Safety Training Presentations

1. BLR’sSafety Training Presentations Control of Hazardous Energy (Lockout/Tagout) 29 CFR 1910.147 I. Speaker’s Notes: Today’s session is on OSHA’s Control of Hazardous Energy Standard, or “lockout/tagout.”I. Speaker’s Notes: Today’s session is on OSHA’s Control of Hazardous Energy Standard, or “lockout/tagout.”

2. 11006115 Copyright ã1999 Business & Legal Reports, Inc. I. Background for the Trainer: Discuss the types of equipment the company has that may need to be locked out. Ask if anyone has had an incident or near miss when equipment inadvertently started. I. Background for the Trainer: Discuss the types of equipment the company has that may need to be locked out. Ask if anyone has had an incident or near miss when equipment inadvertently started.

3. 11006115 Copyright ã1999 Business & Legal Reports, Inc. 29 CFR 1910.147–Control of Hazardous Energy Covers operators and service personnel Requires training of employees Regulatory Requirements I. Speaker’s Notes: This program is required by federal law. All employees are affected by lockout/tagout. Any employee who operates equipment is an “affected” employee. Any employee who maintains or services equipment is an “authorized” employee. Training must be provided for authorized employees initially and at least annually.I. Speaker’s Notes: This program is required by federal law. All employees are affected by lockout/tagout. Any employee who operates equipment is an “affected” employee. Any employee who maintains or services equipment is an “authorized” employee. Training must be provided for authorized employees initially and at least annually.

4. Locks Blocks Chains Multilock hasps Wheel valve covers Ball valve covers Types of Lockout Devices I. Background for the Trainer: Show some examples of lockout/tagout devices if they are available to you. II. Speaker’s Notes: Any type of lockout/tagout device that is used must be durable. There are no requirements for the specific type of device as long as it can be locked. It is a good idea to have a variety of devices available to fit all situations. Tags should always accompany the use of any of these devices. A tag is not a device, because it does not prevent the start-up of the equipment. I. Background for the Trainer: Show some examples of lockout/tagout devices if they are available to you. II. Speaker’s Notes: Any type of lockout/tagout device that is used must be durable. There are no requirements for the specific type of device as long as it can be locked. It is a good idea to have a variety of devices available to fit all situations. Tags should always accompany the use of any of these devices. A tag is not a device, because it does not prevent the start-up of the equipment.

5. 11006115 Copyright ã1999 Business & Legal Reports, Inc. Requirements For Lockout/Tagout Devices They must be: Durable Standardized Substantial Identifiable I. Speaker’s Notes: LOTO devices must be able to withstand the environment in which they are used. They should also be standardized according to color, size, or shape and should be substantial enough so that they cannot be accidentally removed. To be identifiable, they should have a legend that states phrases such as Do Not Operate, Do Not Start, Do Not Energize, etc.I. Speaker’s Notes: LOTO devices must be able to withstand the environment in which they are used. They should also be standardized according to color, size, or shape and should be substantial enough so that they cannot be accidentally removed. To be identifiable, they should have a legend that states phrases such as Do Not Operate, Do Not Start, Do Not Energize, etc.

6. 11006115 Copyright ã1999 Business & Legal Reports, Inc. Energy Sources Electricity Hydraulic Pneumatic Steam Thermal Chemical Gravity I. Speaker’s Notes: There are many different types of energy sources that may need lockout/tagout. Do not overlook any potential source of energy. Many sources are invisible. A job hazard analysis can help identify energy sources. Make sure any and all sources of energy can be effectively isolated.I. Speaker’s Notes: There are many different types of energy sources that may need lockout/tagout. Do not overlook any potential source of energy. Many sources are invisible. A job hazard analysis can help identify energy sources. Make sure any and all sources of energy can be effectively isolated.

7. Typical Equipment Requiring LOTO Presses Saws Conveyors Pumps Production Equipment Trash Compactors Ovens I. Background for the Trainer: It would be advantageous to take a tour and review equipment if feasible. Performing an audit of your facility will help to identify all applicable equipment. II. Speaker’s Notes: Basically, any equipment with hazardous energy is subject to LOTO. This list is obviously not all-inclusive. When in doubt, check it out; don’t take any equipment for granted.I. Background for the Trainer: It would be advantageous to take a tour and review equipment if feasible. Performing an audit of your facility will help to identify all applicable equipment. II. Speaker’s Notes: Basically, any equipment with hazardous energy is subject to LOTO. This list is obviously not all-inclusive. When in doubt, check it out; don’t take any equipment for granted.

8. 11006115 Copyright ã1999 Business & Legal Reports, Inc. When Must LOTO Be Used? When servicing or maintaining equipment where: Hazardous energy exists Unexpected start-up could occur Either of these could harm an employee I. Speaker’s Notes: This slide lists when lockout/tagout must be used. If you are unsure to what equipment LOTO applies, perform a hazard analysis. Make sure that all sources of energy are considered. Do not under any circumstances jeopardize an employee by not requiring LOTO—when in doubt, lock it out!!I. Speaker’s Notes: This slide lists when lockout/tagout must be used. If you are unsure to what equipment LOTO applies, perform a hazard analysis. Make sure that all sources of energy are considered. Do not under any circumstances jeopardize an employee by not requiring LOTO—when in doubt, lock it out!!

9. 11006115 Copyright ã1999 Business & Legal Reports, Inc. LOTO Shall Be Used When: Employees are required to remove or bypass a safety device Employees are required to place any part of their body in harm’s way Employees are exposed to hazardous energy I. Speaker’s Notes: If any of these occur, the equipment must be locked out. If a guard is removed from a piece of equipment, it should be locked out. Basically, any time an employee could be injured by the piece of equipment, it should be de-energized and locked out.I. Speaker’s Notes: If any of these occur, the equipment must be locked out. If a guard is removed from a piece of equipment, it should be locked out. Basically, any time an employee could be injured by the piece of equipment, it should be de-energized and locked out.

10. 11006115 Copyright ã1999 Business & Legal Reports, Inc. LOTO Exceptions Work where hazardous energy does not exist Activities performed during routine production processes Work on cord-controlled devices Hot tap operations where shutdown is not feasible I. Speaker’s Notes: No energy means no need for LOTO. If routine adjustments such as those made to a printing press must occur, then the equipment does not have to be locked out. However, it is a good idea to have a second employee nearby a disconnect to shut down the equipment while the other employee works on it. Cord-controlled devices do not require LOTO because it is assumed that for these items, the person performing the repair has control of the plug. Companies do make lockout devices for the male end of an electrical plug. It is always a good idea to use these as needed. Hot tap operations that could conceivably shut down a plant (e.g., boilers) are not subject to LOTO if they will adversely affect the operation of the plant as a whole.I. Speaker’s Notes: No energy means no need for LOTO. If routine adjustments such as those made to a printing press must occur, then the equipment does not have to be locked out. However, it is a good idea to have a second employee nearby a disconnect to shut down the equipment while the other employee works on it. Cord-controlled devices do not require LOTO because it is assumed that for these items, the person performing the repair has control of the plug. Companies do make lockout devices for the male end of an electrical plug. It is always a good idea to use these as needed. Hot tap operations that could conceivably shut down a plant (e.g., boilers) are not subject to LOTO if they will adversely affect the operation of the plant as a whole.

11. 11006115 Copyright ã1999 Business & Legal Reports, Inc. Typical LOTO Procedures Performing a shutdown Isolating equipment Applying and removing lockout devices Safely releasing stored energy I. Background for the Trainer: Distribute examples of these types of procedure. II. Speaker’s Notes: Procedures for appropriate lockout should be documented. It is helpful to post these procedures at the equipment location. These procedures can follow any format that is pertinent to your company. Using these procedures allows for consistency throughout a facility. I. Background for the Trainer: Distribute examples of these types of procedure. II. Speaker’s Notes: Procedures for appropriate lockout should be documented. It is helpful to post these procedures at the equipment location. These procedures can follow any format that is pertinent to your company. Using these procedures allows for consistency throughout a facility.

12. 11006115 Copyright ã1999 Business & Legal Reports, Inc. Affected Employees Employees who Operate Work around Occasionally adjust equipment that is subject to LOTO I. Speaker’s Notes: There are two categories of employees covered by 1910.147: 1. Affected employees 2. Authorized employees Affected employees can be almost anyone in a facility, except office workers. An affected employee can have a significant impact on authorized employees if the affected employee starts the equipment prior to the completion of the work by the authorized employee.I. Speaker’s Notes: There are two categories of employees covered by 1910.147: 1. Affected employees 2. Authorized employees Affected employees can be almost anyone in a facility, except office workers. An affected employee can have a significant impact on authorized employees if the affected employee starts the equipment prior to the completion of the work by the authorized employee.

13. Authorized Employee Maintains equipment Services equipment Is trained to use LOTO I. Speaker’s Notes: Authorized employees are these who are at risk while the equipment is being repaired or adjusted. It is important that authorized employees inform affected employees of the work to be done. The “danger tag” is an important communication device for the authorized employee.I. Speaker’s Notes: Authorized employees are these who are at risk while the equipment is being repaired or adjusted. It is important that authorized employees inform affected employees of the work to be done. The “danger tag” is an important communication device for the authorized employee.

14. 11006115 Copyright ã1999 Business & Legal Reports, Inc. Company Responsibilities Ensure de-energization of equipment Ensure employee awareness Provide appropriate levels of training Review program effectiveness Maintain and revise program Administer appropriate disciplinary actions I. Speaker’s Notes: It is important that a company lives up to its regulatory responsibility. LOTO is a major cause of industrial fatalities and must be taken seriously. If you intentionally violate LOTO rules, appropriate disciplinary actions will be taken to avoid future incidents. Annual reviews will be conducted to ensure that the written LOTO program is followed.I. Speaker’s Notes: It is important that a company lives up to its regulatory responsibility. LOTO is a major cause of industrial fatalities and must be taken seriously. If you intentionally violate LOTO rules, appropriate disciplinary actions will be taken to avoid future incidents. Annual reviews will be conducted to ensure that the written LOTO program is followed.

15. Maintenance Responsibilities Lockout/Tagout prior to service or repair Remove or cut locks off isolation devices Ensure proper training of authorized employees I. Speaker’s Notes: Responsibilities of the maintenance organization may vary from facility to facility. However, these responsibilities should be taken into consideration for each establishment. The LOTO program should delineate the responsibilities of each department. The maintenance department has the heaviest responsibility because it generally has the most authorized employees within the facility.I. Speaker’s Notes: Responsibilities of the maintenance organization may vary from facility to facility. However, these responsibilities should be taken into consideration for each establishment. The LOTO program should delineate the responsibilities of each department. The maintenance department has the heaviest responsibility because it generally has the most authorized employees within the facility.

16. 11006115 Copyright ã1999 Business & Legal Reports, Inc. Affected Employee Responsibilities Notify maintenance, etc., when equipment needs repair or adjustment Leave all LOTO devices in place Verify equipment is safe to operate following LOTO Follow all safety rules while operating the equipment I. Speaker’s Notes: Since affected employees can impact the authorized employees, it is imperative that they follow these rules. Affected employees should not be ultimately responsible for the placement of locks and tags unless they are also working on the equipment. The more that an affected employee knows about the equipment that is being locked out, the safer the lockout operation will be. Proper training is of the utmost importance.I. Speaker’s Notes: Since affected employees can impact the authorized employees, it is imperative that they follow these rules. Affected employees should not be ultimately responsible for the placement of locks and tags unless they are also working on the equipment. The more that an affected employee knows about the equipment that is being locked out, the safer the lockout operation will be. Proper training is of the utmost importance.

17. 11006115 Copyright ã1999 Business & Legal Reports, Inc. Authorized Employee Responsibilities Repair or service equipment as needed Ensure that all energy sources are locked out Test equipment to verify residual energy is dissipated Place a “Danger—Do Not Operate” tag on equipment I. Speaker’s Notes: Because authorized employees are in harm’s way, they must follow all appropriate procedures to ensure their own protection. If a device cannot be physically locked, the buddy system should be used to ensure that equipment remains de-energized. A second person can keep the emergency stop button or disconnect employed. The tag should be located as close as possible to the control panel so that anyone who tries to operate the equipment is aware of the potential danger.I. Speaker’s Notes: Because authorized employees are in harm’s way, they must follow all appropriate procedures to ensure their own protection. If a device cannot be physically locked, the buddy system should be used to ensure that equipment remains de-energized. A second person can keep the emergency stop button or disconnect employed. The tag should be located as close as possible to the control panel so that anyone who tries to operate the equipment is aware of the potential danger.

18. Authorized Employee  Responsibilities (cont.) Obtain assistance when necessary Remove locks and/or tags following LOTO Coordinate multi-shift repair I. Speaker’s Notes: Never hesitate to ask for assistance when repairing a piece of equipment. Extra eyes and ears are always an important safety aid. Authorized employees should always remove locks and tags, at the same time communicating to affected employees that the repair is complete and the equipment is safe to operate. If work needs to continue into the next shift, the authorized employee from the first repair shift should remove LOTO devices and have the shift coming on duty place their own locks and tags on the equipment. Only people working on a particular piece of equipment should have locks on the subject equipment.I. Speaker’s Notes: Never hesitate to ask for assistance when repairing a piece of equipment. Extra eyes and ears are always an important safety aid. Authorized employees should always remove locks and tags, at the same time communicating to affected employees that the repair is complete and the equipment is safe to operate. If work needs to continue into the next shift, the authorized employee from the first repair shift should remove LOTO devices and have the shift coming on duty place their own locks and tags on the equipment. Only people working on a particular piece of equipment should have locks on the subject equipment.

19. 11006115 Copyright ã1999 Business & Legal Reports, Inc. Training Requirements Authorized employees—initially and at least annually Affected employees—at least initially Authorized and affected—whenever changes are made to jobs or procedures Authorized and affected—when program deficiencies are noted I. Speaker’s Notes: OSHA spells out specific training requirements for LOTO. Every employer is required to provide training in accordance with these regulations. Probably the single most difficult aspect of training is the retraining function, both when deficiencies are noted and on an annual basis for authorized employees.I. Speaker’s Notes: OSHA spells out specific training requirements for LOTO. Every employer is required to provide training in accordance with these regulations. Probably the single most difficult aspect of training is the retraining function, both when deficiencies are noted and on an annual basis for authorized employees.

20. 11006115 Copyright ã1999 Business & Legal Reports, Inc. How to Perform LOTO Safely Follow company safety procedures for LOTO Refer to procedures on how to lockout specific equipment Keep everyone informed when equipment is repaired or serviced Stay alert Use common sense I. Speaker’s Notes: Remember that failure to lockout equipment is a leading cause of injuries and fatalities in industry. Employees must really stay on their toes and avoid shortcuts that could cost them their lives. Ignorance of LOTO procedures cannot be tolerated under any circumstances. Simply put, the program must be in place, the training must be conducted, and evaluations for effectiveness must follow.I. Speaker’s Notes: Remember that failure to lockout equipment is a leading cause of injuries and fatalities in industry. Employees must really stay on their toes and avoid shortcuts that could cost them their lives. Ignorance of LOTO procedures cannot be tolerated under any circumstances. Simply put, the program must be in place, the training must be conducted, and evaluations for effectiveness must follow.

21. Quiz 1. The LOTO standard is designed to block the flow of energy to a piece of equipment. True or False 2. Types of LOTO devices include _______, _______, and _______. 3. It is not required that a company have written procedures for proper lockout/tagout. True or False 4. An authorized employee is one who _________ or _________ the equipment. 5. If a safety device is removed from a piece of equipment, LOTO is not required. True or False I. Background for the Trainer: Hand out the quiz copies. Go over the questions orally and have the employees write their answers on their quiz sheets.I. Background for the Trainer: Hand out the quiz copies. Go over the questions orally and have the employees write their answers on their quiz sheets.

22. Quiz (cont.) 6. Typical energy sources found on equipment include: _______, _______, and _______. 7. Affected employees are those who operate or work around a piece of equipment. True or False 8. As long as an employee has had training on LOTO, the employer or company has no additional responsibilities under 1910.147. True or False 9. Training for authorized employees must be conducted _________ and at least _________. 10. Locks should always stay on the equipment during a shift change. True or False

23. Quiz Answers 1. True. It should block the flow of energy and provide a means of warning. 2. Types of LOTO devices include locks, blocks, chains, hasps, wheel valve covers and ball valve covers. 3. False. If lockout is required, a company must have a written program and procedures. 4. An authorized employee is one who services or maintains the equipment. 5. False. LOTO is required when a safety device is removed, an employee is in harms way or when employees are exposed to hazardous energy.

24. Quiz Answers (cont.) 6. Typical energy sources include: electricity, hydraulics, pneumatics, steam, thermal, chemical and gravity. 7. True. Affected employees are those who operate or work around the equipment. 8. False. Training is just one of the responsibilities of a company. 9. Training for authorized employees must be conducted initially and at least annually. 10. False. Locks should be removed during shift change and the shift coming on duty should place their locks on the equipment.