Environmental Health and Safety Director Colby College Understand the reasons for LOTO LegalOSHA requirements for LOTO Understand the Colby specific LOTO polices and procedures Provide an opportunity to discuss ID: 432874
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Slide1
Wade Behnke, MPH
Environmental, Health, and Safety Director
Colby CollegeSlide2
Understand the reasons for LOTO
Legal/OSHA requirements for LOTOUnderstand the Colby specific LOTO polices and procedures
Provide
an opportunity to discuss concerns related to LOTO Program
ObjectivesSlide3
LOTO Incident Case Study – Tribe Foods
Tribe Mediterranean Foods Fined
$702,300
after a temporary worker was crushed to death while c
leaning and sanitizing a machine used to make hummus. His body was pulled into the hummus machine between two rotating augers (December 2012)He and other workers did not receive safety training, including LOTO trainingHe was 28 years oldOSHA issued 18 citations for willful and serious violationsSlide4
“LOTO is a technique used to prevent energy from being released during the servicing
of equipment. This is accomplished by placing locks on energy isolation devices prior to starting work”
What is LOTOSlide5
“The Fatal Five” (150-200 LOTO fatalities per year)
Failure to stop equipment
Failure to disconnect from power source
Failure to dissipate residual energy
Accidental restarting of equipmentFailure to clear work areas before startingSlide6
BLS study on injuries while servicing equipment revealed:
–80% failed to turn off equipment–10% equipment activated by someone else–5% failed to control potential energy
–Most of remaining 5% disconnected power but failed to verify effectiveness
LOTO Injury BreakdownSlide7
Legal Standards
OSHA 29 CFR 1910.147 (The control of hazardous energy) AKA the “Lockout/Tagout [LOTO] Standard”
Establishes the employer’s responsibility to protect employees from hazardous energy sources on machines and equipment
during service and maintenance
Addresses the practices and procedures necessary to disable machinery or equipment in order to control hazardous energiesOSHA 29 CFR 1910.333 (Selection and use of work practices for electrical machine/equipment)Establishes the employer’s responsibility to protect employees from electrical hazards while working on or near exposed deenergized partsSlide8
OSHA LOTO Basic Requirements
Employers must develop/implement/enforce written policies/procedures
Employee Training
Provide LOTO equipment/Devices
Employer must complete internal inspections to verify adequacy of the programSlide9
When does Lockout/Tagout Apply
During Servicing/Maintenance:
Erecting
Installing
ConstructingRepairingAdjustingInspectingDuring normal production operations LOTO applies when an employee is:
Required to remove or bypass a guard or other safety device
Required
to place any part of their
body
in an area of a machine
where work
is performed on the material
being
processed (point of operation)
or
in
a danger
zone
Unjamming
S
etting
up
T
rouble-shooting
Testing
C
leaningSlide10
When NOT to use Lockout/Tagout
The LOTO Standard does not apply to:
Minor part changes and servicing during routine operations unless machine guards are bypassed
Work on cord and plug-controlled devices
Hot tap operations (welding on a pressurized line) involving transmission and distribution systems for substances such as gas, steam, water or petroleumSlide11
LOTO Employee Designations
Authorized EmployeesApply LOTO and conduct maintenanceAffected Employees
Work on or around equipment being locked out
Other Employees
Not impacted by LOTO in workplaceSlide12
Employee Responsibilities
Authorized employee:
Trained to perform energy control procedures
Implement the LOTO procedures
Perform repair and service requiring LOTOApply and remove lockout/tagoutNotify ALL employees Coordinate groups lockout/tagout repair and outside personnel lockout/tagout repair
Affected employee:
Trained to be aware of energy control procedures
Notify maintenance of need for equipment repair requiring LOTO
Operate machinery or equipment , but not perform repair requiring LOTO
Leave all lockout/ tagout devices in place
Verify that
it is
safe after maintenance
Follow
safety rules Slide13
Forms of Energy
MECHANICAL
ELECTRICAL
THERMAL
PNEUMATIC
HYDRAULIC
CHEMICALSlide14
Types of Hazardous Energy Injuries
ElectrocutionBurns
Crushing
Cutting/LaceratingAmputating
FracturingSlide15
Written Program
Employers must develop/implement/ enforce written policies/procedures
The written program consists of:
Energy Control Program/Plan
Equipment specific LOTO procedures
Colby’s LOTO ProgramSlide16
Written Program
Equipment specific procedures
Procedures that go through the step by step process for locking out a specific piece of equipment.
Procedures identify the hazardous energy sources, disconnect points and lockout devices.
Need to improve these at Colby CollegeSlide17
Written Program
When is an equipment specific procedure not required
?
The machine has a single energy source that completely de-energizes the equipment to be worked on.
The machine can be locked out with a single lockout device.There is no potential for the machine to store or re-accumulate energy during the shutdown period.There are no hazards posed to other employees.The machine has no history of lockout/tagout accidents.Slide18
LOTO Devices
Requirements for lockout and tagout devices:
Used only for controlling energy
Durable
Legible and understandable
by all employees in the area
Standardized
Substantial
IdentifiableSlide19
Inspections
Periodic observation of employees performing the procedures (i.e. procedure inspection) must be performed at least annually
Intended to identify and correct any deviations or inadequacies
Performed by an authorized employee other that
the
one utilizing the energy control procedure being inspectedIncludes reviews of authorized employee responsibilities with the inspector and the affected employees
Certification (documentation): The inspection must be documented and include the following:
The identification of the machine or equipment
The date of the inspection
The employee(s) included in the inspection
The person performing the inspectionSlide20
Preparation for LOTO
(authorized employees only)
Step
#1: Notify (LOTO Coordinator)
Step #2: Survey machine/equipmentStep #3: Review the equipment-specific procedureStep #4: Obtain the sufficient number of locks, tags and devices to perform the job.Slide21
LOTO Application
(authorized employees only)Step #1
: Notify all affected
employeesStep #2: S
hut equipment down Step #3: Deactivate the energy isolating device so that the machine/equipment is isolated from the energy sourceStep #4: Apply the LOTO devices, using assigned locks, applicable devices and danger tags;Slide22
LOTO Application (authorized employees only)
Step #5: Release, restrain, or dissipate stored
energy
Step#6: Verify that energy isolation is complete,
attempting to start the affected machinery or equipment in the normal manner. when working on exposed electrical parts that operate at 50 or more volts a qualified person shall use an appropriately rated test meter and arcflash PPE to verify that all parts have been deenergized. If greater than 600 volts the meter will be checked for proper operation after use; andStep #7: After testing, return all operation controls to the "neutral" or "off" positions.Slide23
Removal of LOTO Devices (authorized employees only)
Step #1: Ensure components are operationally and
employees are safely
positionedStep #2: Remove all tools and repair equipment;
Step #3: Ensure that all guards have been replacedStep #4: Verify that the operating controls are in the "off" or neutral position; Step #5: Notify affected employeesStep #6: Remove all lockout and tagout devicesStep #7: Activate the energy isolation devices to restore energy.Slide24
Special Circumstances
1. Remove only under the direction of the LOTO Coordinator 2. Verify that the employee who applied lockout/tagout is not at the facility
3. Contact the employee who applied lockout/tagout to inform him/her that his/her logout/tagout device has been removed
4. Ensure that the employee who applied lockout/tagout knows it was removed before he/she resumes work
What if the authorized employee who applied lockout/tagout is not available:Slide25
Group lockout or tagout
Ensure that the group procedures affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout/tagout devices
If more than one group, the LOTO coordinator will oversee the LOTO activities to ensure continuity of protection
Each authorized employee shall
affix a personal lockout/tagout to the group lockout/tagoutSlide26
Shift or personnel changes: Ensure
the continuity of lockout/tagout protectionTransfer orderly lockout/tagout device protection between off-going and oncoming employees
The departing workers must not remove their locks until the arriving workers attach theirs
Locks may be left in place overnight or over a weekend
Slide27
Contractor LOTO: Contractor LOTO on Colby operated equipment will be managed by the LOTO Coordinator.
LOTO Coordinator will verify complete the LOTO process and verify absence of power.LOTO Coordinator will lockout equipment and place the lock key in a group lockout box.
Each contractor employee will place there lock on the outside of the Group box and verify absence of power
Slide28
Tagout Only
Tagout device:
Device to
Warn and indicate that the machine may
not be operated until the lockout device is removedIn the same place as the lockout device or close and obviousCan be used if the machine is not capable of being locked outMust include:the identity of the worker
warnings of hazardous condition if the machine is energized, and legends
such as “Do Not Start”, “Do Not Open/Close”, etc.
TAGS ONLY ARE NOT PERMITTED AT COLBY COLLEGESlide29
Tagout Limitations
Essentially warning devices
Do not provide the physical restraint of a lock
Must not be removed without authorization of the authorized employee
Must not be bypassed, ignored, or otherwise defeatedCan evoke a false sense of securityThey must be legible and their purpose understood by all employeesSlide30
What You Need To Do
Understand and be familiar with
the OSHA LOTO
regulations and Colby procedures
Always follow LOTO procedures when working on equipment…no short cuts!!Never remove a LOTO device that is not yoursTalk to your supervisor/EHS Director if you have questions or concerns with the programWork safely!Slide31
Interactive QuizSlide32
1) The purpose of the LOTO standard is to:a. Prevent injuries from the unexpected start-up of equipment
b. Prevent new employees from working on equipment until they have been trainedc. Prevent locks and tags from getting rustySlide33
2) Name a piece of equipment at Colby that requires a written equipment specific LOTO procedure.Slide34
3) Where can you find the written equipment specific LOTO procedures?Slide35
4) Which of the below is not an example of activities covered under the LOTO standard?a. Repairing equipment
b. Starting equipment at the beginning of the shiftc. Unjamming objects during normal production operationsSlide36
5) True or False?All Colby employees can perform lockout/tagout procedures.Slide37
6) What must an employee do prior to shutting down equipment?a. Notify affected and other personnel about the shut down
b. Become familiar with all energy sourcesc. Both A & BSlide38
7) An energy isolating device:a. Determines the type of energy associated with a piece of equipment
b. Prevents the flow of energy from the power source to the equipmentc. Both A & BSlide39
8) True or False?Only authorized employees can attach or remove locks and tags.Slide40
9) True or False?One set of energy control procedures will work for all equipment
.Slide41
10) If you find a lock/tag on a piece of equipment you shoulda. Avoid it
b. Remove it if you need to operate the equipmentc. Both A & BSlide42
11) Which two of the following are requirements of LOTO devices?a. They should have standardized color, shape and size
b. They should not be used for other purposesc. They should be identical for everyoneSlide43
12) True or False?The use of tags instead of locks is not allowed at Colby CollegeSlide44
13) After the LOTO procedure is complete, how can you verify the equipment is deenergized (safe)?
a. Attempt to turn the equipment on.b. Place a tag on the equipment.c. Ask another employee to watch the processSlide45
14) Which two of the following should be done by authorized employees prior to removing locks and tags?
a. Inform other employeesb. Replace safety guardsc. Turn the power back onSlide46
15) True or False?In a group lockout/tagout situation, the LOTO Coordinator is the only one required to lockout the equipment.