Safety and risk management

This course covers the procedures for handling hazardous energy, isolation, lockout & tagout (LOTO), and LOTO removal in manufacturing and construction industries.

This course is ‘Industry Approved’ since it’s been built in collaboration with industry experts at SafetyCulture to meet your operational needs. 

Controlling Hazardous Energy
Lockout/Tagout & Hazardous Energy


1
Electrocution
2
Amputation
3
Burns
4
Crushing
5
Fractures


Common Injuries  from Hazardous Energy


Lockout/Tagout Procedures
Before starting any LO/TO procedure, make sure you are familiar with all aspects of the plant.


2
Identify all energy sources and other hazards.


3
Identify all isolation points & deactivate all energy sources.


4
De-energize all stored energies.
Check your equipment for the proper procedures in de-energizing.


5
Lock out all isolation points.
Always double-check afterward to ensure each energy source is effectively locked out.


6
Tag out.
The process of attaching more information onto the lockout device.
Common tags include danger tags and out-of-service tags.


7
Test the isolation procedure.
Check that the plant is safe for maintenance. Make sure that re-activating the plant is impossible during this period.
Using the appropriate, and properly calibrated testing equipment to check that all the the parts have been de-energized.


Electrical Hazards
It can often cause shock and/or fire.


Mechanical Hazards
Two types of hazards can occur, with the most being moving parts but don't forget that many machines also store energy, and when suddenly released, can cause injuries.


Hydraulic Hazards
The energy of liquids under pressure can pose several hazards, such as causing plant parts to move.
The rapid release of energy can cause serious injuries, and hydraulic fluid can cause burns.


Pneumatic Hazards
Compressed gases, when uncontrollably released, can cause injury.
All systems must be properly vented before starting maintenance.


Chemical Hazards
Chemical energy can start fires, cause skin burns and generate harmful gases or fumes.


Thermal Hazards
Hot equipment & fluids can burn, while cold fluids can cause severe injuries.


What should you do after you have locked out and tagged out a piece of equipment?


In general, LOTO is required for planned or emergency maintenance activities that take longer to complete.
However, if a risk assessment finds an activity high risk, LOTO procedures must still be followed to avoid potential accidents.
Examples of these cases are the following:
When the task requires bypassing machine guards and other safety devices
A part of your body will be in an unsafe zone or near the operating part of the machine.


IMPORTANT NOTE


Lockout/Tagout & Hazardous Energy

Controlling Hazardous Energy
Lockout Procedures


Safety Lockouts Jaws or Hasps that can be used in conjunction with multiple locks


Lockouts for Circuit Breakers, Fuses, and Valves


Which of the following can you use to lockout machines and equipment?


Who's in charge of holding onto the key?


Plants with multiple energy sources or hazards undergo the same procedure.
Only the person that applied the lock should hold the key to unlock it.


What happens with multiple energy sources?


Lockout Procedures

Controlling Hazardous Energy
Tagout Procedures


Check in with your workplace isolation procedure to see what you need to do if a person does not remove a personal danger tag before leaving the worksite.
Generally speaking, if the plant is to remain isolated, then the  personal danger tag should be replaced with a out of service tag.
The tag should be applied to each isolation point before the personal tags are removed.
If maintenance is to continue over to the next shift, then a handover briefing should be given to the team taking over.
Briefing information should include: the status of the work and the removal or replacement of personal danger tags and locks


What happens if the maintenance work isn't complete at the end of my shift?


Tagout Procedure

Controlling Hazardous Energy
Removal Procedure


STEP 1: Inspect equipment.
Thoroughly inspect if the equipment is operating as intended and its parts are in their right places , especially the covers and safeguards.


STEP 2: Clear the area.
Remove wastes and all unnecessary items from the area.
Check that everyone is out of the danger zone.


STEP 3: Inform others.
Inform all concerned employees that re-energizing is about to take place.


STEP 5: Re-energize the equipment.
Reconnect the equipment to the energy source and restart.


STEP 6: Verify safe operation.
Confirm that everything is done safely and no new hazard is created.


Check in with your workplace isolation procedure to see what you need to do if a person does not remove a personal danger tag before leaving the worksite.
Generally speaking, if the equipment is to remain isolated, then the personal danger tag should be replaced with an out-of-service tag.
The tag should be applied to each isolation point before the personal tags are removed.
If maintenance is to continue over to the next shift then a handover briefing should be given to the team taking over.
Briefing information should include the status of the work and the removal or replacement of personal danger tags and locks.


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Controlling Hazardous Energy: Lockout/Tagout

Controlling Hazardous Energy: Lockout/Tagout Lessons

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