Welcome

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Lockout / Tagout Commonwealth of Massachusetts Informational/Awareness Seminar

Bob Clarke ~ Sr. Territory Manager New England BRADY

bob_clarke@bradycorp.com Maureen Grillo ~ Government Sales Manager

Grainger Maureen.Grillo@Grainger.com

Lisa Wolf ~ Field Safety Special Grainger

Lisa.Wolf@Grainger.com

LO/TO Informational Seminar Agenda I. Introductions II. Why Lockout/Tagout?

– OSHA Focus; Best Practice – Save Lives & Reduce Costs

III. Lockout / Tagout Facts IV. 4-step plan for creating an effective Lockout/Tagout program:

(1) Create energy control policy and procedures (2) Identify all energy control points (3) Equip employees with the proper lockout tools & warning devices (4) Train employees and promote awareness of safe work practices

V. Questions & Actions

To protect workers from injury during the maintenance and servicing of equipment.

Isolating Hazardous Energy

• De-energize circuits

• Block moving parts

• Release pressure

• Neutralize extreme temps

• Prevent chemical exposure

Why Lockout / Tagout?

Why Lockout / Tagout? • Lockout / Tagout is the #1 most frequently cited OSHA

regulation for general industry, and OSHA is focusing on LO/TO violators.

• OSHA citations run from several thousand to several hundred thousand dollars and beyond!

October, 2007; OSHA proposed $112,500 in penalties to a large employer for repeat violations, including failure to develop proper energy control procedures. Less than three months earlier, the same organization was cited for $2.78 million in proposed fines for 42 willful violations of the lockout/tagout standard,

Why Lockout / Tagout? Even more importantly, comprehensive and thoroughly

followed Lockout programs:

• SAVE LIVES – Up to 50,000 injuries & 120 lives each year

• CUT COSTS – Avoiding accidents also avoids lost employee time, insurance costs and legal fees

• IMPROVE PRODUCTIVITY – Speeds equipment maintenance, minimizing downtime

• Are BEST PRACTICE in industry

• Top 5 OSHA LO/TO violations: Surprisingly, the use of the proper tools and devices, including

safety padlocks, is NOT one of the 5 most frequently cited OSHA lockout violations!

Lockout / Tagout Facts

“So what are the top 5 violations?”

• Top 5 OSHA LO/TO violations: – Failure to establish and implement a

written lockout PROGRAM – Failure to develop, document and

utilize MACHINE-SPECIFIC PROCEDURES

– Failure to conduct a PERIODIC INSPECTION of the energy control procedure

– Failure to provide TRAINING as described by OSHA

– Failure to clearly OUTLINE the SCOPE and rules to be utilized, and the means to ENFORCE compliance

Lockout / Tagout Facts

Machine-Specific Procedures

Employee Training

The 4-Step Plan for Creating an Effective Lockout Program:

(1) Create energy control policy & procedures

(2) Identify all energy control points

(3) Equip employees with the proper lockout tools and warning devices

(4) Train employees and promote awareness of safe work practices

LO/TO: A Lot More Than Just Devices!

Per OSHA: LOTO Policy Must Include*: • Purpose and scope • Personnel authorized • Enforcement policy • Training methods • Group lockout procedures • Shift transfer procedures • Lock removal procedures • Method for auditing procedures • Coordination of outside contractors

Create Energy Control Policy & Procedures Step1

Also Per OSHA: LOTO Procedures: • Must be documented and identify the

equipment covered • A separate procedure must be created

for each distinct piece of equipment to be locked out

• The procedure must include specific steps for shutting down, isolating, blocking and securing equipment to control hazardous energy

• Includes specific steps for the placement, removal and transfer of LO/TO devices

• Employer shall conduct and certify periodic inspections at least yearly

Create Energy Control Policy & Procedures Step1

On-Site Visual Lockout Procedure Service: • Complete lockout assessment by Engineers • Image-supported lockout procedures for each piece of equipment • Creation and installation of energy source ID tags Benefits include: • Accuracy and completeness of your lockout procedures • Visually instructive procedures are easy to understand and follow • Improves productivity; reduce time to safely lock out, and re-

energize

Energy Control Service Solutions Step1

Lockout Pro™ Graphical Procedure Writing Software: Create clear, easy-to-follow procedures in minutes Create, maintain, train and update: • Develop your own lockout program • Create machine-specific procedures • Manage and update your procedures • Access current OSHA lockout standard

On-Site Awareness Seminar: A great supplement to your standard training program Purchase instructional training kit; with samples

Internet-Based Lockout Overview Webinars:

Energy Control Products & Services Step1

Summary of OSHA Requirements: • Electrical disconnecting means shall identify the energy

magnitude and purpose, unless this is evident. • Per ANSI, all energy isolating devices should be adequately

labeled or marked (unless the purpose is evident). Identification shall include:

• Machine, equipment, process supplied • Energy type and magnitude

Identify All Energy Control Points Step2

Tags, Signs & Labels: • A variety of materials, sizes and messages;

Energy Source ID Messages: • Stock messages help you comply with OSHA • Custom messages to meet your specific needs

Industrial Label Makers: • Designed to help you satisfy your OSHA Lockout,

HazCom, Arc Flash and General Equipment Identification Requirements

• Produce the energy source ID tags that you create with Lockout Pro™

Energy Control Point ID Solutions Step2

OSHA Lockout Device Requirements: Lockout Devices must in-part: • Be provided by the employer • Be standardized by size, shape or color • Be distinguishable from locks used for other purposes.

Lockout locks should only be used for lockout. • Identify the individual who applied the lock (tags are

acceptable) • Be durable, and capable of withstanding the usage

environment • Be strong enough to prevent removal except by using

excessive force • Remain under the exclusive control of the individual who

attached them

Provide the Proper Lockout Tools & Warning Devices Step3

• Versatility

• Durability

• Ease of use

• Portability / compact storage

• Security (positive restraint)

Lockout Tool & Warning Device Solutions

Key Usage Concerns:

Step3

The Ultimate Lockout Lock! • Compact & lightweight • Superior rust resistance • Enhanced shock protection;

nonconductive body • More rugged, durable • Keyed differently (KD) • KA sets for individual employees • Enables exclusive control • Key charting available • Laser engraving available

Proper Tools - Safety Padlocks Step3

Each employee must have exclusive control of the locks they use. No worker should be able to open another another worker’s lock!

B A C D E F

A A A A A A

B A C D E F Keyed differently for each authorized employee (worker A vs. B, etc.)

Keyed alike sets for each individual authorized employee (worker A’s locks open by the same key)

Same key can operate more than one employee’s lock(s) – PROHIBITED for Lockout

Proper Tools - Safety Padlocks Step3

Labeled Lockout Hasp: • Combination Lockout Tag

and Safety Lockout • Constructed from tough

anodized aluminum alloy • Write-on label accepts pencil,

pen and marker Steel Lockout Hasps: • Vinyl-coated high tensile steel

with rust-resistant plating

Proper Tools - Safety Hasps Step3

Three standard materials:

• Heavy duty (encapsulated, erasable) • Polyester • Cardstock

• HD and Poly tags meet OSHA’s 50 lb. pull test for use as Tagout devices

• Various legends, bilingual available

• Photo ID tags are also available

Proper Tools - LO/TO Tags Step3

Single Pole Lockouts Multipole Lockouts

Proper Tools - Electrical Lockouts Circuit Breaker Lockouts: • Fit a wide range of breaker sizes • Easy application – thumbwheel operation • More secure – feature a serrated blade & foot

Step3

Proper Tools - Electrical Lockouts Circuit Breaker Lockouts (cont’d): • The broadest line available • Patented features • Field tested; Helpful circuit breaker reference guide

Step3

Universal locks out small, medium & large plugs!

Proper Tools – Additional Electrical Lockouts Plug Lockouts: • Distinct fit & universal versions available Wall Switch Lockouts: • Hinged and clear cover options

Step3

Conventional sizes

Adjustable Lockout

Fits 1” to 6½” valves; replaces 3 conventional gate valve lockouts All includes Danger labels

Proper Tools - Valve Lockouts Gate Valve Lockouts: • Distinct fit & universal versions • Rugged construction • Withstand chemicals and temperature extremes

Step3

1-piece triangular design

Ball Valve Lockouts: • Single piece triangular design – two sizes fit valves to 3” diameter • Versatile 2-piece design – two sizes fit valves to 8” • Patented designs; assured fit lockouts

Versatile 2-piece design

Proper Tools - Valve Lockouts Step3

Butterfly valves

Gate valves

Ball valves

Universal Valve Lockout: • One device locks out most valve types & sizes

Proper Tools - Valve Lockouts Step3

All Purpose Cable Lockout Mini Cable Lockout

Multi-Purpose Cable Lockouts: • Great flexibility for use on gate valves, electrical disconnect switches, panels and more • Push button self-winding mechanism on mini-cable lockout retracts into body; cinches cable tight

Proper Tools - Valve Lockouts Step3

Proper Tools – Portable Lockout Kits Kits are available by lockout application: • Circuit Breaker • Electrical • Valve • Combination valve & electrical

Step3

Padlock Station

Proper Tools – Lockout Stations Ready Access Storage Stations: • Ensure that lockout devices remain accessible • Space-saving designs • Portable & Wall-Mountable • Lockable see-through covers

Lockout Station

Step3

Proper Tools - Group Lockouts Group Lock Boxes: Broad line for wide array of preferences:

• Portable and wall-mount versions • Powder-coated steel and molded plastic • Clear windows and models with key holders

Portable Lock Box

Step3

OSHA Training and Communication Requirements: • The employer shall provide training to ensure that

the purpose and function of the energy control program are understood by employees …

• The employer shall certify that the employee training has been accomplished and is being kept up-to-date …

Train Employees & Promote Awareness Step4

Effective Training & Communication: • Training Kit & Videos • Safety Poster • Procedure Station • Warning Signs • Floor Stands • Barricades

Training & Awareness Solutions Step4

Questions?