Control of Hazardous Energy

Lockout Tagout

PSC Industries has a (LOTO) control of hazardous energy program. This program addresses all other forms of energy that can impact a machine or process. Additional forms of energy can include fluid under pressure, air under pressure, stored energy in elevated machine members, temperature extremes (hot/cold), etc.

There are three classifications of individuals outlined in this safety program. Authorized, affected and other.

An authorized individual has received education on the control of hazardous energy, been thoroughly trained in the process of rendering a machine/process in zero mechanical state, been tested to confirm knowledge and understanding and been authorized by PSC to place the machine in zero mechanical state.

An affected individual is similar to the authorized with one exception. They have NOT been authorized to place the machine in zero mechanical state. They have had education and training but are not allowed to place the machine in zero mechanical state.

Other individuals – are folks that do not encounter or work directly/indirectly with a machine or process that does or has the potential to contact energy.

Our safety program includes work instructions to state how to place the machine in Zero Mechanical state. This work instruction is called a LOTO placard and looks like what you see below.

Each machine is required to have a LOTO placard affixed on it. Both the operator and affected individual are required to review this prior to placing the machine in Zero Mechanical State.

Lockout Locks

Individual Lockout Locks have 1 purpose – TO LOCKOUT. They can not be used for anything else.

Each lock is to be under the control of the owner – no one can place another individuals lock on, or remove the lock on their behalf.

Lockout Locks must be identified with the following 5 things:

1) Legible Name of the owner

2) Company Name

3) Owner’s phone number

4) The Word “Danger”

5) The statement – Do not remove, do not operate, do not remove or the like.

The following SIX STEPS are a review of basic steps for safely de-energizing equipment.

1. Notify all “affected employees” that the equipment will be shut down.

2. Shut down the equipment by normal stopping procedures.

3. “Isolate” all the equipment’s energy sources.

4. Lockout and/or tag out the energy isolating devices with assigned, individual locks.

5. Release or restrain any stored energy by grounding, blocking, bleeding down, etc.

6. Assure that no personnel are exposed, then test the equipment to assure it will not operate.

Instructor Notes:

Control of hazardous energy is an emphasis program from OSHA

Please ensure the following:

1. Know and understand the difference between the 3 classifications of individuals identified in the plan (Authorized, Affected,

and Other).

2. Maintain a list of individuals who are classified as Authorized.

• Generally, this would be supervisors, maintenance, and individuals who are required to place a machine in Zero Mechanical

State while performing routine maintenance, service, die change, etc.

3. Ensure each machine has a LOTO placard that is accurate and legible.

4. LOTO Locks – no sharing of keys, no using a LOTO lock for other than it’s intended purpose.

• A lockout may require 1-3 locks depending on the equipment and task per individual.

5. Secure the LOTO Keys – limit access to keys, do not leave locks with keys left in them.

6. Understand the 6-step process for placing a machine in Zero Mechanical state and returning it back to operation.