Lockout / Tagout Program
Lockout / Tagout or " LOTO "refers to specific practices and procedures to safeguard employees from the unexpected energization or startup of machinery and equipment, or the release of hazardous energy during service or maintenance activities. This requires that a designated individual turns off and disconnects the machinery or equipment from its energy source(s) before performing service or maintenance and that the authorized employee(s) either lock or tag the energy-isolating device(s) to prevent the release of hazardous energy and take steps to verify that the energy has been isolated effectively.
Approximately 3 million workers service equipment and face the greatest risk of injury if lockout/tagout is not properly implemented. Compliance with the lockout/tagout standard (29 CFR 1910.147) prevents an estimated 120 fatalities and 50,000 injuries each year. Workers injured on the job from exposure to hazardous energy lose an average of 24 workdays for recuperation. In a study conducted by the United Auto Workers (UAW), 20% of the fatalities (83 of 414) that occurred among their members between 1973 and 1995 were attributed to inadequate hazardous energy control procedures specifically, lockout/tagout procedures.
OSHA CFR 29 1910.147 provides regulations on LOTO and 25 states have their own approved LOTO programs.
The Martin Technical LOTO program is designed to help prevent injuries and accidents with associated with equipment that should be locked-out / tagged-out and help companies meet OSHA and their state regulations for LOTO.
objectives of lockout / tagout ( loto )program
- Identify Equipment that is subject to LOTO
- Develop written LOTO procedures for each specific piece of equipment
- Attach LOTO procedures on all required equipment
- Inform management and workers of the results
- Provide LOTO training to those that need it
scope of work
Lockout / Tagout procedures to be developed includes the isolation of any prime movers, machinery and equipment from mechanical, hydraulic, pneumatic, chemical, electrical, thermal or other energy sources.
Lockout / Tagout procedures are to be developed in compliance with OSHA CFR 29 1910.147 and with any state OSHA regulations, including:
• The hazardous energy control procedures shall be documented in writing.
• The hazardous energy control procedure shall include separate procedural steps for the safe lockout/tagout of each machine or piece of equipment affected by the hazardous energy control procedure.
• The procedural steps for the safe lockout/tagout of prime movers, machinery or equipment may be used for a group or type of machinery or equipment, when either of the following two conditions exist:
(A) The operational controls named in the procedural steps are configured in a similar manner, and
(B) The locations of disconnect points (energy isolating devices) are identified, and
(C) The sequence of steps to safely lockout or tagout the machinery or equipment are similar.
2. The machinery or equipment has a single energy supply that is readily identified and isolated and has no stored or residual hazardous energy.
PHASE I – EQUIPMENT & ENERGY SOURCE IDENTIFICATION
The first phase of any Lockout / Tagout program is to identify all equipment subject to LOTO regulations and the energy sources that feed the equipment. Phase I is the labor intensive phase of the LOTO program, typically taking at least half of the total effort required to complete the program.
Equipment is surveyed on-site by a Martin Technical lockout / tagout field engineer experienced and knowledgeable of LOTO processes as well as electrical, mechanical, hydraulic, pneumatic and thermal equipment. The field engineer will:
||• Identify and document each piece of equipment requiring Lockout / Tagout procedures
• Take photographs of the equipment
• Identify and document all power sources and isolation points feeding the equipment
• Take photographs of the feed equipment and isolation points as needed.
• Identify and document proper process for turning off / disconnecting power sources to the equipment.
Generally all survey can be collected without disturbing any facility operations.
PHASE II – DEVELOPMENT of LOTO PROCEDURES
Using the information from the survey in Phase I, Lockout / Tagout procedures are developed of each piece of equipment in accordance with OSHA CFR 29 1910.147 and applicable state regulations.
The procedures for each piece of equipment shall clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance, including but not limited to, the following:
(A) A statement of the intended use of the Lockout / Tagout procedure;
(B) The procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy;
(C) The procedural steps for the placement, removal and transfer of lockout devices and tagout devices and responsibilities; and,
(D) The requirements for testing a machine or equipment, to determine and verify the effectiveness of lockout devices, tagout devices and other hazardous energy control devices.
Most procedures shall be accompanied by photographs for visual instruction and identification.
The procedures are written and implemented into one of the following programs that can be modified by the customer:
||• Word document with Martin Technical Lockout / Tagout template
• Lockout / Tagout software programs as determined by the customer.
PHASE III – CUSTOMER REVIEW
After the completion of Phase II, the Lockout / Tagout procedures will be sent to the customer for review and sign-off before completing and printing the procedures.
PHASE IV – PRINTING OF LOCKOUT / TAGOUT PROCEDURES
After the Lockout / Tagout procedures have been reviewed and approved by the customer, they will be printed using one or more different types of labels or media.
PHASE V – LOCKOUT / TAGOUT LABELING
Lockout / Tagout process placards / informational sheets will be applied to the appropriate equipment by the Martin Technical field engineer
PHASE VI – LOCKOUT / TAGOUT TRAINING & CONSULTATION
After the Lockout / Tagout procedures have been implemented, your Martin Technical field engineer will provide Lockout / Tagout training for those who need it and will consult with management on any of the Lockout / Tagout program requirements.
lockout / tagout DELIVERABLES
The following are the deliverables upon completion of the Lockout / Tagout program:
||• Equipment Specific LOTO procedures printed on agreed media
• Application of LOTO procedure placards
• Electronic files of all LOTO procedures for each equipment
• Martin Technical LOTOprocedure template (if not using LOTO software)
• LOTO training to those that need it
• Help with OSHA, NFPA and State LOTO compliance
Contact Us for a Free Consultation on How We Can Help You with Your Lockout / Tagout ( LOTO ) and Electrical Safety Program Needs.