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y Wade Behnke, MPHEnvironmental, Health, and Safety DirectorColby College

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Understand the reasons for LOTO Legal/OSHA requirements for LOTO Understand the Colby specific LOTO

polices and procedures Provide an opportunity to discuss

concerns related to LOTO Program

Objectives

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LOTO Incident Case Study – Tribe Foods

• Tribe Mediterranean Foods Fined $702,300 after a temporary worker was crushed to death while cleaning 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 training

• He was 28 years old• OSHA issued 18 citations for willful and serious violations

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“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 LOTO

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“The Fatal Five” (150-200 LOTO fatalities per year)

1. Failure to stop equipment

2. Failure to disconnect from power source

3. Failure to dissipate residual energy

4. Accidental restarting of equipment

5. Failure to clear work areas before starting

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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 Breakdown

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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 energies

OSHA 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 parts

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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 program

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When does Lockout/Tagout ApplyDuring Servicing/Maintenance:

• Erecting• Installing• Constructing• Repairing• Adjusting• Inspecting

During 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• Setting up• Trouble-shooting• Testing• Cleaning

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When NOT to use Lockout/TagoutThe 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 petroleum

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LOTO Employee Designations

• Authorized EmployeesApply LOTO and conduct maintenance

• Affected EmployeesWork on or around equipment being locked

out• Other Employees

Not impacted by LOTO in workplace

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Employee Responsibilities Authorized employee:

Trained to perform energy control procedures

Implement the LOTO procedures Perform repair and service requiring

LOTO Apply and remove lockout/tagout Notify 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

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Forms of Energy

MECHANICAL

ELECTRICAL

THERMAL PNEUMATIC HYDRAULIC

CHEMICAL

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Types of Hazardous Energy Injuries Electrocution Burns Crushing Cutting/Lacerating Amputating Fracturing

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Written Program Employers must

develop/implement/ enforce written policies/procedures

The written program consists of:

o Energy Control Program/Plan

o Equipment specific LOTO procedures

Rev. A: 02/2014

Hazardous Energy Control Program (Lockout/Tagout)

Colby’s LOTO Program

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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 College

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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.

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LOTO DevicesRequirements for lockout and tagout devices:

Used only for controlling energy Durable Legible and understandable

by all employees in the area Standardized Substantial Identifiable

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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 inspected

Includes 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 inspection

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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.

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LOTO Application (authorized employees only)

Step #1: Notify all affected employeesStep #2: Shut equipment down Step #3: Deactivate the energy isolating device so

that the machine/equipment is isolated from the energy source

Step #4: Apply the LOTO devices, using assigned locks, applicable devices and danger tags;

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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; and

Step #7: After testing, return all operation controls to the "neutral" or "off" positions.

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Removal of LOTO Devices (authorized employees only)

Step #1: Ensure components are operationally and employees are safely positioned

Step #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.

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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:

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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/tagout

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Shift or personnel changes: Ensure the continuity of lockout/tagout protection Transfer 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

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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

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Tagout OnlyTagout device:

Device to Warn and indicate that the machine may not be operated until the lockout device is removed

In the same place as the lockout device or close and obvious

Can be used if the machine is not capable of being locked out

Must include:o the identity of the workero warnings of hazardous condition

if the machine is energized, and o legends such as “Do Not Start”, “Do

Not Open/Close”, etc.

TAGS ONLY ARE NOT PERMITTED AT COLBY COLLEGE

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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

defeated Can evoke a false sense of security They must be legible and their purpose

understood by all employees

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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 yours• Talk to your supervisor/EHS Director if you

have questions or concerns with the program• Work safely!

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1) The purpose of the LOTO standard is to:a. Prevent injuries from the unexpected start-up of

equipmentb. Prevent new employees from working on equipment

until they have been trainedc. Prevent locks and tags from getting rusty

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2) Name a piece of equipment at Colby that requires a written equipment specific LOTO procedure.

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3) Where can you find the written equipment specific LOTO procedures?

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4) Which of the below is not an example of activities covered under the LOTO standard?a. Repairing equipmentb. Starting equipment at the beginning of the shiftc. Unjamming objects during normal production

operations

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5) True or False?All Colby employees can perform lockout/tagout procedures.

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6) What must an employee do prior to shutting down equipment?a. Notify affected and other personnel about the shut

downb. Become familiar with all energy sourcesc. Both A & B

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7) An energy isolating device:a. Determines the type of energy associated with a

piece of equipmentb. Prevents the flow of energy from the power source to

the equipmentc. Both A & B

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8) True or False?Only authorized employees can attach or remove locks and tags.

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9) True or False?One set of energy control procedures will work for all equipment.

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10) If you find a lock/tag on a piece of equipment you shoulda. Avoid itb. Remove it if you need to operate the equipmentc. Both A & B

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11) Which two of the following are requirements of LOTO devices?a. They should have standardized color, shape and sizeb. They should not be used for other purposesc. They should be identical for everyone

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12) True or False?The use of tags instead of locks is not allowed at Colby College

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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 process

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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 on

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15) True or False?In a group lockout/tagout situation, the LOTO Coordinator is the only one required to lockout the equipment.