LOCK OUT TAG OUT Aegean Oil Terminal Corporation 1 Training - - PowerPoint PPT Presentation

Aegean Oil Terminal Corporation Training Program

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AEGEAN

LOCK OUT TAG OUT

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LOTO is necessary for the protection of personal from the unexpected energization / startup

• f machinery and equipment or

the release of hazardous energy during installation, demolition or service maintenance activities

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Learning Objectives

• Understand the purpose of the energy control program
• Recognition of applicable hazardous energy sources, and the

methods necessary for energy control

• Discuss the primary causes of injury from hazardous energy
• Understand the steps necessary to properly control hazardous energy

when servicing equipment

• Know the responsibilities of Authorized and Affected employee in

terms of lockout / tag out

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The “Fatal Five”

• Main Causes of Lockout/Tagout Injuries:

1.

Failure to stop equipment before servicing

2.

Failure to disconnect equipment from power source

3.

Failure to dissipate (bleed, neutralize) residual energy

4.

Accidental restarting of equipment

5.

Failure to clear work areas before restarting

• All injuries resulting from inadequate hazardous energy

control procedures can be prevented

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Types of Hazardous Energy

• Mechanical – the potential energy and kinetic energy present

in the components of a mechanical system

• Kinetic – energy possessed by virtue of its motion
• Common injuries: fracture, contusion, laceration, and amputation
• Potential – energy stored by the mechanical system
• Common injuries: fracture, contusion, laceration, and amputation
• Electrical – energy as a result of a generated electrical power

source or a static source

• Common injuries: shock, burns, and electrocution
• Thermal – energy as a result of mechanical work, radiation,

chemical reaction or electrical resistance

• Common injuries: burns

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Types of Hazardous Energy, continued

• Chemical -- energy released as a result of chemical

reactions

• Common injuries: burns
• Hydraulic – energy released as a result liquids under

pressure

• Common injuries: and contusions
• Pneumatic – energy released as a result of compressed

gasses under pressure

• Common injuries: burns and contusions

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What is Lockout-Tagout?

• Lockout-Tagout is a hazard avoidance technique used to prevent energy

from being accidentally released during the servicing of equipment

• The Lockout-Tagout standard requires the adoption and

implementation of written practices and procedures to:

• Shut down equipment
• Isolate it from its energy source or sources
• Prevent the release of potentially hazardous energy while maintenance and

servicing activities are being performed

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Energy Control Program – 3 Core Components

• Energy control procedures that detail the scope, purpose, authorization

rules and techniques to be utilized for the control of hazardous energy

• Periodic inspections of the energy control procedures to ensure that the

procedures and the requirements are being followed

• Employee training and ongoing retraining to ensure that the energy

control programs are understood

Written Procedures Inspections Training

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Lockout-Tagout Procedures are Required IF…

• A worker must remove or bypass machine guards or other

safety devices, or

• A worker is required to place any part of their body into a

point of operation or into the danger zone associated with the machine's operation

• Examples of activities where proper Lockout-Tagout

procedures would be required include

• Installing
• Lubricating
• Cleaning and un-jamming machines or equipment, and
• Making adjustments or tool changes

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Definition of Players

❑Authorized employee: An employee who locks or tags machines or equipment in order to perform servicing or maintenance ❑Affected employee: An employee who is required to use machines or equipment on which servicing is performed under the Lockout/Tagout standard or who performs

• ther job responsibilities in an area where

such servicing is performed ❑Other employees: All employees who are or may be in an area where energy control procedures may be utilized

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Responsibilities of Authorized Employees

• Identify all energy sources
• Notify all affected employees in the area of work
• Shut down the equipment at the operating controls
• Isolate all energy sources to equipment
• Lock and tag all isolating devices
• Dissipate all stored or residual energy sources.
• Verify the isolation
• Remove lock and tag when repair and testing are

complete

• Notify all affected employees that lock and tag were

removed

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Responsibilities of Affected Employees

• Never interfere or tamper with a lock or tag
• Stay clear of the area as much as possible
• Never attempt to assist
• Report any unusual situation or unsafe condition to your

supervisor

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Energy Isolation Devices A mechanical device that physically prevents the transmission or release of energy such as…

• Circuit breakers;
• Disconnect switches
• Line valves
• Slide gates
• Blind flanges

NOTE: Push buttons, selector switches and other control circuit type devices are not energy isolating devices

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Types of Lockout Devices

• Keyed and combination locks
• Ball valve locks
• Gate valve locks
• Group lockout hasp
• Circuit breaker locks
• Valve hand wheel cover

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Lockout Device Requirements

Devices Must...

• Be capable of withstanding the environment

to which they are exposed

• Be singularly identified
• Be the only devices used for controlling

energy

• Not be used for other purposes
• Be standardized within the facility in terms of

color, shape, or size.

• Indicate the identity of the employee applying

the devices

• Prevent removal without the use of excessive

force or unusual techniques

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Tagout Requirements Tagout must be…

• Be capable of withstanding the environment to

which they are exposed

• Able to withstand corrosive environments such as

areas where acid and alkali chemicals are handled and stored

• Standardized in print and format
• Substantial in order to prevent inadvertent or

accidental removal

• Able to be attachable by hand, self-locking, and

non-releasable with a minimum unlocking strength of no less than 50 pounds

• Inclusive of a legend such as: Do Not Start, Do

Not Open, Do Not Close, Do Not Energize, Do Not Operate.

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Lockout vs. Tagout

• If an energy-isolating device is capable of being locked
• ut, a lock out system must be used
• If an energy-isolating device is not capable of being

locked out tagout may be used, provided training and more rigorous periodic inspections are implemented

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General Energy Control Procedures

Step 1 Identify Energy Sources Step 2 Notify Others Step 3 Shut Down Equipment Step 4 Isolate Equipment Step 5

Lockout-Tagout

Equipment Step 6 Release Stored Energy Step 7 Verify Isolation Step 8 Service Equipment Step 9 Release From LOTO

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General Energy Control Procedures

Step 1: Identify Energy Sources

• Understand the types and magnitude of

the specific energy associated with equipment being serviced

• Hazards of energy being controlled
• Method or means to control the energy
• Identify all energy sources feeding the

equipment including potential energy

• Identify and obtain the appropriate

control devices

• Clarify any questionable identification of

energy sources before proceeding

Step 1 Identify Energy Sources

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General Energy Control Procedures

Step 2: Notify Others

• Verbally notify all “affected” and

“other” employees of impending shutdown

• Remember that not all equipment will

have someone “assigned” to it

Step 2 Notify Others

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General Energy Control Procedures

Step 3: Shut Down Equipment

• Use standard equipment operating

procedures to shut down equipment

• Push “Stop” button
• Open Toggle switches
• Close valve

Step 3 Shut Down Equipment

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General Energy Control Procedures Step 4: Isolate Equipment Energy Sources

• Operate all energy-isolating devices so that the

equipment is isolated from its energy sources

• Be sure to isolate ALL energy sources!
• Primary supplies
• Any secondary energy sources

Step 4 Isolate Equipment

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General Energy Control Procedures Step 5: Lockout – Tagout the Equipment

• Locks or tags must be applied to each

device

• Must be applied by an Authorized

employee

• Locks must be affixed in a manner that

will hold the energy isolating devices in a "safe" or "off" position

• Tags must be affixed in a manner that will

clearly indicate that the operation or movement of energy isolating devices is prohibited

Step 5

Lockout-Tagout

Equipment

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General Energy Control Procedures Step 6: Release Stored Energy

• Ensure all potential or residual energy

is controlled

• Block or brace springs and any

elevated parts that could fall due to gravity

• Relieve trapped system pressure
• Bleed lines and vent valves to drain

fluids and gasses

• Discharge capacitors
• If stored energy can re-accumulate,

monitor it to make sure it stays below hazardous levels

Step 6 Release Stored Energy

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General Energy Control Procedures

Step 7: Verify Isolation

• Before work begins, an authorized employee

must verify that the machine has been properly isolated and de-energized

• 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 normal starting procedure or otherwise

verify the system is completely de-energized

• Return controls to “OFF” position after testing
• Verification is the step which is most frequently

skipped during evaluations

Step 7 Verify Isolation

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General Energy Control Procedures

Step 8: Service Equipment

• Complete required service work

according to manufacturer’s recommendations

• Avoid doing anything that could

potentially reactivate the equipment

• Do not bypass the lockout if installing

new piping or wiring

Step 8 Service Equipment

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General Energy Control Procedures Step 9: Release From Lockout-Tagout

• Inspect work area to ensure that all tools

and spare parts have been removed and that all of the equipment components are

• perationally intact
• Replace all machine guards
• Ensure that all employees have been safely

positioned or have cleared the area.

• Each lockout / tagout device must be

removed from the energy-isolating device by the employee who applied the device.

• Notify “affected” and “other” employees

that the lockout / tagout devices have been removed before the equipment is started

Step 9 Release From LOTO

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General Energy Control Procedures Special Circumstances For Release - Testing

• Lockout-tagout devices may be removed

temporarily to test and /or reposition the equipment under the following procedures:

• The equipment must be cleared of tools and

materials

• Employees must be removed from the

machine or equipment area

• All lockout / tagout devices may then be

removed

• Authorized employees may then energize and

test or position the equipment

• Following testing or positioning, all systems

must be de-energized and energy control measures reapplied

Special Circumstances For Release

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General Energy Control Procedures Special Circumstances For Release – Shift Change

• If servicing lasts more than one shift,

lockout/tagout protection must not be interrupted

• When the authorized employee who applied

the LOTO device is not available to remove it, the device can only in an emergency and only under the direction of the supervisor

• Must verify the authorized employee is not in

the facility

• Must make all reasonable efforts to contact

employee who applied the device

• Must ensure that the authorized employee

knows the LOTO device has been removed

Special Circumstances For Release

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General Energy Control Procedures Special Circumstances – Group Lockout-Tagout

• Group lockout / tagout must afford

protection for each employee equivalent to that provided by a personal lockout or tagout device

• Each authorized employee must affix a

personal lockout / tagout when work begins and remove it when work is completed

• Group must designate a single authorized

employee to serve as overall supervisor

Special Circumstances For Release

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Summary

• Lockout-Tagout prevents energy from accidentally being

released while a machine or equipment is being serviced

• There are 6 types of hazardous energy common to most work

environments – Mechanical, Electrical, Thermal, Chemical, Hydraulic and Pneumatic

• Most injuries and fatalities are a result of improper hazardous

energy control procedures

• If an energy-isolating device is capable of being locked out, a

lock out system MUST be used

• General energy control procedures follow a 9-step process
• Only the authorized employee may attach and remove the

lockout / tagout device

• Affected employees or any other employees should NEVER

remove or tamper with a lockout / tagout device

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