Lockout / Tagout

 Lockout Hasp

• A LOCKOUT is a method of keeping equipment from being set in motion and endangering workers.
• A disconnect switch, circuit breaker, valve or other energy isolation mechanism is put in the safe or off position.
  
• A device is often placed over the energy-isolating mechanism to hold it in the safe position.
• This is where LOCKOUT / TAGOUT products are essential
• A lock is attached so that the equipment can’t be energized. In a TAGOUT, the energy-isolating device is placed in the safe position and a written warning is attached to it. All lockout and tagout materials are supplied by the employer.

LOCKOUT / TAGOUT is necessary whenever you are performing service or maintenance in proximity to a machine where you could be injured by:

• Unexpected start up of the equipment.
• Release of stored energy.
  Two situations are most likely to need LOCKOUT / TAGOUT
  
• When you must remove or bypass a guard or other safety device.
• When you must place any part of your body where you could be caught by moving machinery.

• Repairing electrical circuits.
• Cleaning or oiling machinery with moving parts.
• Clearing jammed mechanisms.
  OSHA lets each employer use LOCKOUT / TAGOUT or both. It’s your responsibility to follow whichever system has been chosen for your workplace. Locks and Tags by themselves do not de-energize equipment. Attach them only after the machinery has been isolated from its energy sources.

• Energy isolation and LOCKOUT / TAGOUT are to be applied only by trained employees authorized to perform service or maintenance.
• Before LOCKOUT / TAGOUT is applied, all employees who work in the affected area must be notified.
• OSHA requires that control of hazardous energy be done according to a six-step procedure.

Before you turn off any equipment in order to lock or tag it out, you must know:

• The types and amounts of energy that power it.
• The hazards of that energy.
• How the energy can be controlled.

• Shut the system down by using its operating controls.
• Follow whatever procedure is applicable for the equipment, so that you don’t endanger anyone during shutdown.

• Install all energy-isolating devices so that the equipment is isolated from its energy sources.
• Be sure to isolate all energy sources and secondary power supplies as well as the main one.
• Never pull an electrical switch while it is under load.
• Never remove a fuse instead of disconnecting the energy or power.

• All energy-isolating devices are to be locked, tagged or bothaccording to your company LOCKOUT/TAGOUT procedures.
• Only the standardized devices supplied by your employer are to be used for LOCKOUT / TAGOUT, and they are not to be used for anything else.
• Use a LOCKOUT device if your lock cannot be placed directly on the energy control.
• When LOCKOUT is used, every employee can lock out a single energy-isolating device by using a multiple-lock hasp.
• For big jobs, a LOCKOUT box can be used to maintain control over a large number of padlocks and keys.
• If tags are used instead of locks, attach them at the same point as you would a lock, or as close to it as possible.
• Fill tags out completely and correctly.

• Take any of the following steps that are necessary to guard against energy left in the equipment after it has been isolated from its energy sources.
• Inspect the system to make sure all parts have stopped moving.
• Install ground wires.
• Relieve trapped pressure.
• Release the tension on springs, or block the movement of spring-driven parts.
• Block or brace parts that could fall because of gravity.
• Block parts in hydraulic and pneumatic systems that could move from the loss of pressure.
• Bleed the lines and leave vent valves open.
• Drain process piping systems and close valves to prevent the flow of hazardous materials.
• If a line must be blocked where there is no valve, use a blank flange.
• Purge reactor tanks and process lines.
• Dissipate extreme cold or heat, or wear protective clothing.
• If stored energy can reaccumulate, monitor it to make sure it stays below hazardous levels.

Take any of the following steps that fit your company’s equipment and energy control program.

• Make sure all danger areas are clear of personnel.
• Verify that the main disconnect switch or circuit breaker can’t be moved to the “on” position.
• Use a voltmeter or other equipment to check the switch.
• Press all start buttons and other activating controls on the equipment itself to ensure
  that it is isolated.
• Shut off all machine controls when the testing is finished.

PERFORMING THE WORK

• Look ahead, and avoid doing anything that could re-activate the equipment.
• Don’t bypass the lockout when putting in new piping or wiring

“LOCKOUT” means to physically neutralize all energies in a piece of equipment before beginning any maintenance or repair work. Lockouts generally involve:

• Stopping all energy flows (for example, by turning off switches, or valves on supply lines);
• Locking switches and valves;
• Securing the machine, device, or power transmission line in a de-energized state (forexample, by applying blocks or blanks, or bleeding hydraulic or pneumatic pressure from lines).

“TAGOUT” means placing a warning tag or sign (a tagout device)on an energy isolating device warning not to operate the machinery until the tagout device is removed.

It alerts other employees as to the status of a machine or system, about why it has been taken out of service, and the identity of the individual who has applied the lockout.

If a Lockout is not performed, uncontrolled energies could cause:

• Electrocution (contact with live circuits);
• Cuts, bruises, crushing, amputations, death, resulting from:
• Entanglement with belts, chains, conveyors, rollers, shafts, impellers;
• Entrapment by bulk materials from bins, silos or hoppers;
• Drowning in liquids in vats or tanks;
• Burns (contact with hot parts, materials, or equipment such as furnaces);
• Fires and explosions;
• Chemical exposures (gases or liquids released from pipelines).

Often power sources are inadvertently turned on, or valves opened mistakenly before the work is completed, resulting in serious injuries and fatalities. Therefore, it is important not only to ensure that all energies are properly locked out, but also that they remain locked out until the work is completed.

For lockouts to be effective, a clear, well-defined lockout policy supported by administrative and control procedures, and proper training, is essential. A systematic approach would be to:

• Develop a lockout policy;
• Identify lockout situations;
• Develop procedures;
• Train workers; and
• Enforce and update your policy.

Your written Lockout policy should make reference to your company's general occupational health and safety policy. It should clearly outline responsibilities, and refer to procedures to be followed. It should state your company's intent to protect all employees by:

• Identifying all activities and machines, equipment, and processes which require Lockouts (for example, repairs, maintenance, and cleaning of pipelines, tanks, and machines);
• Making the appropriate persons responsible for Lockouts;
• Ensuring that Lockouts are performed by authorized persons only;
• Developing procedures for each specific Lockout situation;
• Training those who will perform Lockouts;
• Verifying the effectiveness of such training;
• Reviewing, updating, and enforcing the lockout policy.

• Assess all processes, machinery, energies, and work activities to identify where and when Lockouts are needed.
• Maintenance work will probably be the major focus of Lockout needs.
• A useful source of information may be workplace inspections, and recommendations from your joint health and safety committee or health and safety representative.
• List every machine, device, or process that will require a Lockout. Against each, list the energy forms involved.
• Different energy forms will require different procedures. More than one lockout may be required for a single machine or system.

Procedures should be in writing and communicated to all employees and departments. Administrative procedures for lockouts in general should include the following:

• Supervisors to be notified of lockouts in their areas;
• All lockouts to be authorized by a work permit;
• Lockout to stay in effect if work is not completed at the end of the shift;
• Completed work to be reported to the person in charge for signing off the work permit.

Control procedures involve developing separate, detailed, written lockout procedures for each identified machine, device or process that may require to be locked out at some time.
The procedure should identify:

• The person responsible for performing the lockout (for example, operator, millwright, electrician);
• The person responsible for ensuring that the lockout is properly performed (for example, maintenance supervisor and/or site supervisor);
• The energy sources to be controlled by the lockout;
• The location of control panels, power sources (including electrical power boxes), switches, interlocks, valves, blocking points, relief valves and/or blanking and bleeding points (review schematics);
• Special hazards (for example, a flywheel that spins for minutes after power is removed, electrical capacitors);
• The personal protective equipment that must be used or worn (for example, eye protection, electrically insulated foot protection);
• The step by step Lockout procedure (that is, who does what, and when);
• The testing procedure to ensure that all energy sources are controlled;
• The step by step procedure for removing the lockout.

All workers performing Lockouts and their supervisors must receive training. The training should address:

• 
  Importance of Lockouts;
• Legal requirements for lockouts;
• Company policy on lockouts;
• The energy forms, hazards and procedures (administrative and work-related) that must be followed;
• The importance of following procedures;
• Lockout errors to be avoided (for example, assuming the equipment is inoperable or that the job is too small to warrant a lockout);
• The use and care of personal protective equipment;
• Proper use of all tools.

Review Lockout procedures periodically (semiannually) and revise them in light of any problems that may have been identified. When you change a process or equipment, Lockout requirements may also change. Review and revise your Lockout procedures whenever changes are made.

• LOTO products,
• Details of Lockout/Tagout programs & procedures,
• C D presentation,
• Various necessary forms required in process of lockout/tagout,
• Small booklets for your supervisors and Health and Safety Manager,
  Shop floor workers / employees etc.