LockoutTagout

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Lockout/Tagout
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• When its time for maintenance, repairs or
  retooling of a machine, simply turning the
  machine off or unplugging it while it is being
  worked on does not give enough protection for
  workers. Many serious accidents happen when
  someone thought the machine or all of the energy
  was safely turned off.

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Lockout/Tagout CFR 1910.147

• The Lockout / Tagout standard covers the
  servicing and maintenance of machines and
  equipment in which the unexpected energizing or
  startup of the machines or equipment, or release
  of stored energy could cause injury to employees
  
• The standard is to help prevent unexpected
  energizing, start-up or release of stored energy
  in order to prevent injury to employees.

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Situations, other than maintenance, are also
Covered

• An employee is required to remove or bypass a
  guard or other safety device
• An employee is required to be placed in a danger
  zone.

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Example Situations related to Machines or
Equipment

• 1. has potential for stored or residual energy
• 2. has potential for re-accumulation of stored
  energy after shutdown
• 3. has more than a single energy source
• 4. isolation and locking out of any single energy
  source will not completely de-energize and
  deactivate the machine or equipment

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Example Situations related to Machines or
Equipment

• 5. lockout device is not under exclusive control
  of an authorized employee performing the
  servicing or maintenance
• 6. the servicing or maintenance work creates
  hazards for other employees
• 7. employer has had accidents involving the
  unexpected activation or re-energizing of the
  machine or equipment during servicing or
  maintenance.

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• Lockout Placement of a lockout device on an
  energy isolating device. Equipment being
  controlled cannot be operated until the lockout
  device is removed.
• Tagout Placement of a tagout device on an
  energy isolating device. Indicate the energy
  isolating device and the equipment being
  controlled may not be operated until lockout
  device is removed by authorized personnel.

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• Lockout Physical Device
• Tagout Written/Printed
• Warning Tag

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Lockout Devices

• 1. Used to secure energy isolating devices unless
  the machinery or equipment is not capable of
  being locked out.
• Only authorized employees will affix
  lockout/tagout devices.
• Lockout devices must be able to hold energy
  isolation devices in a safe or off position.

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Tagout

• Tags will clearly state that moving energy
  isolation devices from the safe or off
  position is strictly prohibited.
• If a tag cannot be affixed to the energy
  isolating device, it will be located as close as
  safely possible to the device so that the tag is
  obvious to anyone attempting to operate the
  device.
• Clearly identify the authorized person

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Tagout

• Tags are warning devices only and do not provide
  a physical restraint that lockout devices
  provide.
• Tags must not be removed by anyone other that the
  authorized employee who used the tag.
• Tags must be legible, and understandable by all
  employees.
• Tags must be able to withstand environmental
  conditions in the workplace.
• Tags may give employees a false sense of
  security.
• Tags must be securely attached to prevent being
  accidentally detached during use.

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Authorized Employee

• Person who services or performs maintenance on
  machines or equipment.
• Employee who is properly trained and certified on
  equipment maintenance and lockout/tagout
  procedures, and
• Person approved by the project manager.

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Affected Employee

• Person who operates or uses a machine or
  equipment which is being serviced or has
  maintenance being performed on it.

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Other Employee

• Person who works in an area where lockout/tagout
  procedures are being used.

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Training

• The need for training is evident

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Basic Requirements

• Authorized employees must be able to recognize
  hazardous energy sources, types and magnitudes of
  energy in the workplace, and methods and means
  necessary to isolate and control the energy.
• Affected employees must be able to recognize the
  purpose and use of energy control procedures.
• Other employees must be able to recognize
  procedures and prohibitions of the energy control
  program.

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After Lockout and Tagging

• Authorized employee will ensure all potentially
  hazardous stored or residual energy is relieved,
  disconnected, restrained, and otherwise rendered
  safe.
• Authorized employee to verify that the machinery
  or equipment is actually isolated and de-energized

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Types of Work where unexpected startup or energy
might be released

• The following types of work on machines,
  equipment, etc. Adjusting inspecting
  modifying constructing re-tooling lubricating
  removing components cleaning replacing
  components, etc.

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Lockout/Tagout ProgramElements

• Proper Training
• Effective Supervision
• Proper Procedures

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Data on Lockout/Tagout Accidents

• Data on 5 year period of 1990-1995
• 132 incidents or cases
• 144 victims
• 73 fatalities
• 54 hospitalizations
• 17 non-hospitalized
• Note data excludes accident w/87 victims.

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Example

• While installing an overhead light, an
  electrician received an electric shock.
• He asked a worker to open the light switch.
• The electrician was electrocuted.
• The junction box for the lighting circuit was
  improperly wired.

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Example

• A worker was balancing a 48-inch diameter vent
  shift fan.
• The worker used an adjusting electrical
  connections on the testing equipment while the
  fan was operating.
• The worker lost balance and fell into the moving
  blades and was decapitated.

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Example

• Maintenance employees went to repair and replace
  a leaking hydraulic line.
• The incoming hydraulic line separated at a point
  approximately 60 inches above the concrete floor.
  
• Hydraulic fluid, at a high pressure (800-1200
  psi), escaped.
• Hydraulic fluid being sprayed against the floor
  and onto a natural gas fueled cooker.
• No lockout/tagout procedures were being followed.
  
• This resulted in the rapid dispersal of products
  of combustion throughout, which caused the death
  of 25 employees with many more injured.
• Inadequate means of egress.

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Example

• Employee was in the process of repairing or
  replacing a shear pin on the main drive of a
  deboning machine
• Another employee activated the machine,
• Fingers were amputated.
• No lockout was performed.

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Types of Systems Involved in Lockout/Tagout
Accidents

• Electrical 48 fatal 8 hospitalized
• Mechanical 22 44
• Pneumatic 1 0
• Hydraulic 1 0
• Steam 0 1
• Chemical 0 1
• also, Gravity Pressure Radiation

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Types of Injuries By System

• Injury Type Electrical Mechanical
• Electrical Shock 53 0
• Amputation 0 26
• Caught In/Between 0 17
• Fracture 0 11
• Struck By 4 7
• Poisoning 0 7
• Burn 6 2
• Run-Over 1 2
• Fall 0 1
• Asphyxia 0 1
• 64 74

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Electrical System Involved in Lockout/Tagout
Accidents

• Electrical Apparatus/Wiring 8
• Lighting Circuit 8
• Conductor 7
• Busbar 5
• Breaker 4
• Switchgear 4
• Transformer 4
• Power Line 4
• Switch Box 3
• Others (Air Conditioner, 17
• Machine Sign, Etc.)

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Policy on Lockout/Tagout

• Compliance with lockout/tagout procedures is
  mandatory.
• Non-compliance with these procedures is
  considered a violation of an employees condition
  of employment and will result in the initiation
  of serious disciplinary procedures to include
  possible termination of employment.

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Authorized employee will follow certain steps
related to lockout/tagout

• Review the lockout/tagout information for the
  machine or equipment that is to be worked on.
• Types and magnitudes of energy
• Hazards posed by the energy and
• Methods to effectively control the energy
• Pay particularly close attention to the type of
  energy such as gravity, electrical, high
  pressure, mechanical, etc.

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Release from Lockout/tagout

• Make sure all employees are safely positioned
  outside danger zones. Notify affected employees
  that lockout/tagout devices have been removed and
  that energy is going to be reapplied.
• Only the authorized employee who applied the
  lockout/tagout device may remove that device.

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Removal of lockout/tagout devices

• Clear the machine or equipment of tools and
  materials
• Remove employees safely away from danger zone
• Remove lockout/tagout devices
• Energize and proceed with testing or positioning

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Lockout/Tagout

• Energy can be stored in many forms
• Supervisors and workers should be trained to
  recognize conditions where energy might suddenly
  be released
• Always follows established safety procedures with
  regard to lockout/tagout

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Lockout/tagout

• Always be aware of and in control of the energy
  they exists around the construction site

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