Lockout / Tagout
“Control of Hazardous
Energy” 29 CFR
1910.147
Cummins Rocky
Mountain
Purpose of Lockout/Tagout
(LOTO)
WHY LOCKOUT/TAGOUT?
Cummins Rocky Mountain LOTO
procedures are designed to prevent
accidents, to protect employees and
equipment from accidental start-up.
The “Fatal Five” Main
Causes of Lockout/Tagout
Injuries
• Failure to stop equipment
• Failure to disconnect from power source
• Failure to dissipate (bleed, neutralize)
residual energy
• Accidental restarting of equipment
• Failure to clear work areas before
restarting
Employee Categories
AUTHORIZED EMPLOYEES
These are employees who are allowed to perform energy control
procedures. Training will include company approved energy
control procedures, recognition of energy sources, and methods
for isolation and energy control.
AFFECTED EMPLOYEES
These are employees that operate the equipment on which work is
being performed. Training will include the purpose and use of
the energy control procedures.
OTHER EMPLOYEES
These are all other employees that may work in an area where
energy control procedures may be used. Training will include
instruction on the energy control procedures and the restrictions
relating to attempting to restart or reenergize equipment that is
either locked out or tagged out.
Hazardous Energy Sources
• CHEMICAL – acids, corrosives, caustics
• THERMAL – steam, hot, cold
• HYDRAULIC – water, oil, liquids
• ELECTRICAL – AC/DC, generator, battery
• MECHANICAL – coiled springs, raised loads,
moving parts
• PNEUMATIC – pressurized gas, compressed air
Equipment Requiring
Lockout/Tagout at our Facility
• 2 Ton Hoist
• 21” drill
• 1000 lb. Hoist
• Air Compressor
• Engine dyno
• Fuel Pump Test Stand
• Hotsy
• Injector Test Stand
• Overhead Bridge Crane
• Ventilation Units in Dyno
LOTO Definitions and
Requirements
• LOTO is defined as the process of the
authorized placement and administrative
control of locks and tags used to ensure the
protection of employees, equipment, and the
environment.
• LOTO locks are used for physical control over
an energy isolation device.
Energy Isolation Devices
• Used to control and isolate hazardous energy. They are
mechanical devices that physically prevent the
ON OFF
transmission or release of energy.
– circuit breakers
– disconnect switches SYSTEM
CONTROL
– valves SWITCH
• Energy isolation devices are where we place the locks and
tags. They are NOT locks or tags. These are the devices
that prevent the transmission of hazardous energy to the
equipment that requires work to be performed.
Only individual circuit breakers can be locked out in
a circuit breaker. If the whole panel was locked,
circuits powering other equipment would be
inaccessible.
Locks
• All our locks and tags for LOTO are
standardized by shape, size or color
• Personally Controlled Lock
– Owner has only key
– No master key is allowed
Hardware for LOTO
• Locks/Tags
• Locking plug caps
• Chains
• Wedges
• Blocks
• Blanks
Locks vs Tags
• Locks are used to block the flow of
energy.
• Tags are a warning to all employees not
to turn the power on.
Lockout vs Tagout
• OSHA prefers lockout.
• If an energy isolation device will accept a lock,
you MUST use a lock.
• In situations where a lock cannot be used, you
may use a tag only. A tag does not provide the
positive control of a lock. So it is important
that we are all aware of the limitations of a tag.
DANGER
LOCKED
Tagout
OUT
DO NOT OPERATE
This Lock/Tag may
only be removed by
NAME: _______________
DEPT : _______________
EXPECTED COMPLETION
DATE: ________________
TIME: _________________
• CAN BE USED in place of lockout if you can demonstrate that
it will offer employee protection equivalent to that offered by
lockout.
• Equivalent protection is demonstrated by the following safety
measures:
– Removing an isolating circuit element;
– Blocking a control switch;
– Opening an extra disconnecting device; or
– Removing a valve handle.
• The tag must be attached at the same spot where the lockout
device would have been found.
Examples of tags we use.
Tag Characteristics:
•Withstand at least 50 pounds of force
•Not re-usable
•Self locking
•Attachable by hand
Applying Locks and Tags
• LOTO devices are to be attached by an authorized
employee to each energy-isolating device.
• When a lockout device is used, it must be attached in
such a way that it secures the energy isolating device in
the “off” position.
• When a tagout device is used, it must be attached
exactly where the lock would have been on the energy-
isolation device-or as close to that point and in as
obvious a position as possible. The tag must clearly
indicate that the energy-isolation device must not be
disturbed. (The tag should read DO NOT START, DO
NOT OPEN, or DO NOT ACTIVATE)
LOTO is NOT Required When:
• Work is performed in cord and plug electrical
equipment on which the plug is under EXCLUSIVE
CONTROL of the employee performing the service
or maintenance.
– Note: exclusive control means that the plug is:
• Physically in possession of or within arm‟s
reach of the person who performs the work,
and
• In that person‟s line of sight.
• Minor tool changes, when the on/off switch is under
EXCLUSIVE CONTROL of the operator.
• For Example…
…Pedestal grinders
However, if you cannot immediately repair the „plug and cord‟
equipment, it should be LOTO to prevent unintended startup.
The above picture shows the plug to a pedestal grinder. Since
the employee couldn‟t repair it until the parts arrived, a LOTO
plug cap placed was used.
LOTO Shutdown Procedure
Steps to Apply LOTO
1. Notification of employees involved or in the area and you
will be shutting equipment down.
2. Shutdown of all power sources. You may need to stop,
block, or bleed the energy sources.
3. Lockout and Tagout all energy sources. Verify the controls
do not start machine and check the voltage.
4. Verification among employees once the work has been
completed.
• Inspect work area to ensure removal of non-essentials
• Employees safely positioned and notified
• Lockout/tagout removal (by employee who applied)
Removal of Locks/Tags
• Only the maintenance employee performing the
original repair can remove a lock.
• If employee is off-site, the supervisor may
remove the lock under the following conditions.
– Verify that authorized employee is not at facility
– Make reasonable efforts to inform him or her
– Ensure that he/she knows of removal upon re-
entering
Group Lockout
• Each employee performing LOTO work
on equipment will have his/her own lock
and tag at the energy isolation devices.
– When multiple employees are working on the
equipment, a hasp may be used.
Equipment Start-Up
• Clear equipment of tools and materials
• Re-install all guards
• Alert employees to stand clear
• Remove locks/tags
• Energize equipment
Remember to re-
install all guards
after service is
complete!!!!!
Otherwise, a serious
hazard may be
created.
Lockout/Tagout
All lockout/tagout procedures are found
through the link to Lockout / Tagout link
on the Cummin‟s safety website.
If you have any questions on
Lockout/Tagout, contact your supervisor
or submit a question using the “ASK THE
EXPERT” menu selection on this website.