CONTROL OF HAZARDOUS ENERGY LOCKOUTTAGOUT

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CONTROL OF HAZARDOUS ENERGY
(LOCK-OUT/TAG-OUT)
Hydraulic
Electrical
Steam
Spring Loaded
Gravity
Chemical
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Developed by Garold L. Russell Joseph P.
Flick Mark C. Radomsky Raja V. Ramani Department
of Energy Geo-Engineering The Pennsylvania
State University 126 Hosler Building University
Park, PA 16802 [phone] June, 2001
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Energy Weve harnessed it, tamed it and put it to
work for us. But, energy is always ready to
escape. And if it is not kept under control, it
can hurt you----even kill you
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• The objectives of this program is to assist
  miner(s) to become more aware of
• Electrical hazards
• Types of electrical hazards
• MSHA regulations
• Prudent safe work procedures

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Consequences of Lock-Out/Tag-Out
Incidents Unexpectedly getting caught in
machinery Unplanned startup of
machinery Unexpected movement of machine
parts Unexpected release of stored energy
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Consequences of Lock-Out/Tag-Out Incidents Loss
of life Personal injury Property damage Loss
of production Loss of jobs
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Types of Hazardous Energy Live energy Stored
energy
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Live Energy Electrical energy Moving
machine parts
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Stored Energy Hydraulic or pneumatic pressure
that could be released Electric energy stored
in electric components
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Steam pressure that could be released Spring
loaded mechanisms that could be released
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Chemicals Gravitational force that pulls
on equipment, parts, or objects
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• Common Factors in Lock-Out/Tag-Out Incidents
• Accidental start up
• Release of stored energy
• Working on energized equipment
• Removal of guards

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Accidental Start Up Equipment being accidentally
started by someone who did not know that work was
being performed Electrical energy from an
alternative source providing power for a machine
or equipment to start
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Release of Stored Energy Hydraulic or
pneumatic pressure being released and allowing a
raised component to fall or drift onto a worker
Electric energy stored in electric components
causing electrical shock or even allowing a
machine to start up Steam pressure being
released when a pipeline is disconnected
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Release of Stored Energy Spring loaded
mechanisms that fly or are projected and hit a
worker Chemicals in pipelines that flow onto
workers Gravitational pulling force on
equipment, parts, or objects that allows parts or
components to roll, drift, or turn onto a worker
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Working on Energized Equipment Failing to
deenergize and secure equipment against start up
or movement Failing to deenergize and
secure all energy sources-one energy source was
locked out, but the equipment moved or started
from another energy source
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Removal of Guards Removing a guard from active
machinery for cleanup or repair and being caught
in or by the unguarded, active machinery
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MSHA Regulations, Part 56 (highlights and
overview only--not complete for all
regulations) Electrically powered equipment
shall be deenergized before work is done on such
equipment--power switches shall be locked out or
other measures taken which shall prevent the
equipment from being energized without the
knowledge of the individuals working on
it--Suitable warning notices shall be posted at
the power switch and signed by the individuals
who are to do the work--such locks or preventive
devices shall be removed only by the persons who
installed them or by authorized personnel
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MSHA Regulations, Part 56 (highlights and
overview only--not complete for all
regulations) Power circuits shall be deenergized
before work is done on such circuits unless
hot-line tools are used--suitable warning signs
shall be posted by the individuals who are to do
the work--switches shall be locked out or other
measures taken which shall prevent the power
circuits from being energized without the
knowledge of the individuals working on
them--such locks, signs, or preventative devices
shall be removed only by the persons who
installed them or by authorized
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MSHA Regulations, Part 56 (highlights and
overview only--not complete for all
regulations) Repairs or maintenance of machinery
or equipment shall be performed only after the
power is off, and the machinery or equipment is
blocked against hazardous motion Persons
shall not work on top of, under, or work from
mobile equipment in a raised position until the
equipment has been blocked or mechanically
secured to prevent it from rolling, falling, or
being accidentally lowered
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Factors Affecting Hazardous Energy Control
Lock-Out Program
Employee Training
Types of Equipment
Multiple Energy Sources
Types of Work Performed
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Lock-Out Program An organized program must be in
effect to identify and control all energy
sources The plan must be consistently used
during all types of work involving the control of
hazardous energy
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Employee Training MSHA-required task training
should address all parts of hazardous energy
control If you do not know how to perform
lock-out/tag-out--dont attempt to do so until
you have been trained
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Employee Training If you are asked to
participate in the lock out of any machinery or
equipment and do not know the correct and proper
procedures--stop--advise the supervisor
immediately If you are going to be part of the
work, you must be part of the lock-out--if you
dont know, arent sure, or have any doubts or
questions--stop--advise the supervisor
immediately
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Types of Equipment Electrically powered equipment
needs to be properly deenergized, and locked out
prior to work being done Some electrically
powered equipment may have more than one energy
source, if so, all energy sources have to be
identified, deenergized, and locked out Bucket
elevators, crusher counter-weights, truck beds,
and other such parts and components need to be
secured against movement as part of the lock-out
procedure
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All feed belts, lines, bins, etc. need to be
isolated, locked out, and secured to prevent any
process material from feeding or falling into the
work area All parts that may be under load,
force, or pressure that could spring out, or fly,
need to be secured as part of the lock out
process
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Hydraulic and pneumatically supported components
need to be secured against movement as part of
the lock-out procedure Pipelines need to be bled
off and blanked or disconnected as part of the
lock out process
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Types of Work Performed All forms of
construction, maintenance, repair, clean up,
adjustment or modification work require control
of hazardous energy Any type of work that places
you in any location or position where you may be
exposed to live or stored energy requires control
of hazardous energy
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Many jobs require more than one person--if you
are part of the work, you must be part of the
lock-out Energy control is vitally important in
any type of confined space work, and should also
be part of the confined space entry procedures
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Multiple Energy Sources There may be more than
one form of hazardous energy in any type of
machine Do not assume that electricity is the
only form of hazardous energy Evaluate each work
task to identify and control all forms of
hazardous energy
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• Control of Hazardous Energy
• Hazard identification and correction
• Notification of impending work
• Identification/isolation of all energy sources
• Lock-out/tag-out/block-out of all energy sources
• Verification/testing of all energy sources
• Replacement of all guards and safety devices
• Accounting of all personnel following work
• Sounding of all appropriate alarms/warning
  devices prior to restart
• Company-specific procedures

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Hazard Identification and Correction The
lock-out process begins before the actual work
starts All sources of energy and all potential
hazards must be identified and controlled before
any work begins
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The lock-out process includes a visual
inspection, mental inspection, and physical
inspection of the work area The electrician will
be helpful in identifying all electrical energy
sources--you cant see whats going through a
wire--dont take chances--have all energy sources
verified and confirmed You cant lock-out an
accident after it starts--the time to take all
precautions is before the work begins
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Notification of Impending Work Notify any and
all employees who may be affected by the
impending shut down of equipment of what is about
to occur--you do not need to cause any upstream
or downstream surprises (or accidents) Have a
team meeting with all other employees who will
be part of the work to standardize and confirm
what is to be done and why
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Identification/Isolation of All Energy
Sources All energy sources (both live and stored
energy) must be identified, located, and targeted
for lock-out
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• Lock-Out/Tag-Out
• All Energy Sources
• All energy sources must be deenergized and
  locked out
• Lock electrical energy sources at main sources
• If there is more than one energy source, it
  needs to be locked-out

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All persons participating in the work must attach
their own personal lock to all energy
sources--that may mean each person needs more
than one lock Lock-out hasps are a practical and
convenient way for more than one person to attach
his/her lock to an energy source Each persons
lock should have a unique and individual key--no
common keys
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Each energy source that is locked out, must be
tagged, advising of the work, and the dangers of
trying to start the machine--the tag must be
signed by all persons who have a lock
attached The key(s) to the lock should be kept
in the personal possession and under the personal
control of the person who attached the lock
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Verification/Testing of All Energy
Sources Verify that all electrical energy is
controlled by attempting to start the machine
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Control Stored Energy

• Stored energy sources must be bled off,
  supported, blocked, or otherwise neutralized to
  prevent any and all movement, motion, or other
  hazard

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Replacement of All Guards and Safety
Devices Replace all guards after work is
completed and before the equipment is reenergized
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Accounting of All Personnel Following
Work Physically account for all persons who were
part of the work before reenergizing Advise
co-workers that the equipment is about to be
restarted Only the person who attached the lock
may remove his/her lock
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Sounding of All Appropriate Alarms/Warning
Devices Prior to Restart After all guards have
been replaced, all persons have been accounted
for, and all upstream and downstream workers
advised of the impending restart, sound all
warning or start-up alarms before actually
restarting the equipment
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Company-Specific Procedures The way you obtain
your own personal lock is Lock-out hasps are
located The procedure to follow at this
facility to prepare for a lock-out is The types
of equipment at this facility that require energy
control are
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Equipment at this facility that has more than one
electrical energy source is The actual lock-out
procedure at this facility is The procedure to
follow at this facility if you are relieving
someone and that person has a lock attached
is The procedure to follow at this facility
if/when using a box-system lock-out is
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Analysis of Lock-Out Incidents
Causes
Corrections/ Lessons Learned
Prudent Safe Work Practices
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• Causes
• Review of MSHA fatalgram or fatal accident report
  involving energy control
• Review of company incident reports

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• Corrections/Lessons Learned
• Analysis of MSHA fatalgram or fatal accident
  reports involving energy control
• Review of company incident reports

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• Prudent Safe Work Practices
• If you have the slightest doubt, concern, or
  confusion about any part of the lock-out
  process--STOP--do not continue--ASK the
  supervisor--have your issues addressed to YOUR
  satisfaction before continuing
• Once a piece of machinery has you in its grasp,
  its very difficult to start the lock-out
  process--that is why all energy must be
  controlled before starting work
• Hazardous energy control is not a gray-area
  subject--it is not debatable--it must, and it
  will, be part of regular work procedures at this
  facility because it is literally a matter of life
  and death

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• If you will be part of the work, you must be part
  of the lock-out process
• You must have your own personal lock(s) and
  key(s)
• Never pass your lock or key off to somebody else,
  or accept theirs
• You and you alone must put on and take off your
  own lock
• Keep your key(s) in your own personal control and
  possession

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• Never remove any lock that belongs to anyone
  else--you are in control of your lock--they are
  in control of their lock
• Remember that there may be numerous types of
  energy to control on one piece of equipment
• Consult the electrician to identify all
  electrical energy sources
• Lock-out and tag-out all electrical energy
  sources--this may mean that you need more than
  one personal lock

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• Have a team meeting with coworkers to review the
  lock-out procedure before starting the job
• Block and support any and all parts and
  components that could fall, slide, or roll onto
  you
• Test all energy sources to verify that they are
  deenergized
• Do not remove guards for any reason without
  locking out
• Replace all guards and sound all warning alarms
  before reenergizing

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• Regularly review your company energy control
  procedures--always be alert for ways to improve
  the program--lives are on the line
• Ask questions--get answers--know, understand and
  follow energy control procedures at all times
• Instead of thinking about the time you may save
  by not locking out, think about the time you may
  lose--forever is a long, long time

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• Several possible last words regarding hazardous
  energy control
• I thought someone else locked it out
• I never thought it would start
• Weve done it before without locking out
• Lock out takes too much time

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I was only going in there for a few
seconds They should have known I was working
on it Why didnt the start-up alarm
sound I locked out but forgot the hydraulic
pressure The odds were a million to one that
Id get hurt
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References Florida Department of Environmental
Protection, U.S. Department of Labor. Mine Safety
and Health Administration. Lock out and Tag Out
for Safety. Videotape. Cat. No. VC-852. Beckley,
WV National Mine Health and Safety Academy,
1994. Title 30 Code of Federal Regulations. Part
56, Subpart C, Fire Prevention and Control.
Washington U.S. Government Printing Office. U.
S. Department of Health and Human Services.
Center for Disease Control and Prevention.
National Institute for Occupational Safety and
Health. Preventing Worker Deaths From
Uncontrolled Release of Electrical, Mechanical
and Other Types of Hazardous Energy. NIOSH
Publications 99-110. Cincinnati NIOSH, 1999.
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References U.S. Department of Labor. Mine Safety
and Health Administration. Electrical Hazards
Awareness Program. Cat. No. IG-65. Beckley, WV
National Mine Health and Safety Academy,
1988. U.S. Department of Labor.Occupational
Safety and Health Administration. Control of
Hazardous Energy Sources (Lockout/Tagout). OSHA
Factsheet. Washington OSHA. U.S. Department of
Labor.Occupational Safety and Health
Administration. Control of Hazardous Energy
Sources (Lockout/Tagout). OSHA Publication
Unnumbered. Washington OSHA Rev.1997. Graphics
Safety Services of Texas, Safety Clipart.
Austin, TX 2000.U. S. Department of Labor. Mine
Safety and Health Administration.