CONTROL OF HAZARDOUS ENERGY

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CONTROL OF HAZARDOUS ENERGY
LOCKOUT/TAGOUT
OSHA 29 CFR 1910.147
WELCOME
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COURSE OBJECTIVES

• Teach The Student to Recognize Where
  Lockout/Tagout Is Needed.
• Allow the Student to Develop an Understanding of
  the the Local Lockout/Tagout Policy.
• Introduce Techniques Needed to Select the
  Appropriate Lockout/Tagout Devices.
• Teach the Student to Successfully Conduct
  Lockout/Tagout Operations.
• Introduce the Rules for Safe Lockout/Tagout.

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REGULATORY STANDARD
CONTROL OF HAZARDOUS ENERGY
29CFR - 1910 - 147
29CFR - Safety and Health Standards
1910 - General Industry
147 - Lockout Tagout Standard
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REGULATORY STANDARD
29CFR 1910.147

• Title - Control of Hazardous Energy
• September 1, 1989 - Final Rule Issued
• January 2, 1990 - Final Rule Took Effect

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CIRCUMSTANCES OF INJURY
HOW MOST INJURIES OCCUR IN ORDER OF OCCURRENCE

• Injured by Moving Machinery Part.
• Made Contact With Energized Part.
• Injured by Physical Hazard (Heat, Chemicals).
• Injured by Falling Machine Part.

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CIRCUMSTANCES OF INJURY
ACTIVITY AT TIME OF ACCIDENT FREQUENCY OF
OCCURRENCE
1. Unjamming Object(S) From Equipment 2.
Cleaning Equipment 3. Repairing Equipment 4.
Performing Routine Maintenance 5. Installing
Equipment
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CIRCUMSTANCES OF INJURY
ACTIVITY AT TIME OF ACCIDENT FREQUENCY OF
OCCURRENCE
6. Adjusting Equipment 7. Doing Set-up Work 8.
Performing Electrical Work 9. Inspecting
Equipment 10. Testing Materials
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CIRCUMSTANCES OF INJURY
REASONS FOR EQUIPMENT NOT BEING TURNED OFF

• Afraid of Slow Down in Production.
• Afraid It Would Take Too Long.
• Not Required by Company Procedure.
• Worker Didn't Know Power Was on.
• Worker Didn't Know How to Turn Off.
• Did Not Think It Was Necessary.
• Task Could Not Be Done With Power Off.

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CIRCUMSTANCES OF INJURY
REASONS FOR EQUIPMENT BEING TURNED ON

• Accidentally Turned on by Injured Employee
• Co-Worker Accidentally Turned Equipment On
• Equipment Moved When Jam-up Cleared
• Equipment Unexpectedly "Cycled"
• Parts Still in Motion (Coasting)

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CASE STUDY 1 KILLED BY THE MOVING PARTS OF A SAW
Narrative An Employee Was Cleaning the
Unguarded Side of an Operating Granite Saw. The
Employee Was Caught in the Moving Parts Of The
Saw and Pulled Into a Nip Point Between The Saw
Blade and the Idler Wheel, Resulting In Fatal
Injuries.
Citation Failure to Shutdown or Turn off
Equipment To Perform Maintenance.
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CASE STUDY 2 DECAPITATED BY SHEARING MACHINE
Narrative An Employee Was Removing Scrap From
Beneath a Large Shear When a Fellow Employee Hit
the Control Button Activating The Blade. The
Blade Cycled and Decapitated The Employee
Cleaning Scrap.
Citation Failure to Shutdown or Turn off
Equipment To Perform Maintenance.
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CASE STUDY 3 KILLED BY PNEUMATIC DOOR
Narrative An Employee Was Partially Inside of
an Asphalt Mixing Machine Changing Its Paddles.
Another Employee, While Dusting in The Control
Room, Accidentally Hit a Toggle Switch Which
Caused the Door of the Mixer to Close, Striking
the First Employee on the Head and Killing Him.
Citation Failure to Isolate Equipment From
Energy Sources Before Attempting Any Repair,
Maintenance or Servicing.
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DEFINITION OF EMPLOYEES

• Authorized Employee
• The Person Who Locks or Tags Out Machines To
  Perform Servicing or Maintenance.
• Affected Employee
• An Employee Whose Job Requires Him or Her To
  Operate or Use a Machine or Piece of Equipment On
  Which Servicing or Maintenance Is Being
  Performed.

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DEFINITION OF EMPLOYEES

• Designated Inspector

• Does Not Utilize the Specific Procedure.
• The Person Who Inspects the LO/TO Procedure.
• Is an Authorized Employee.

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TRAINING REQUIREMENTS

• Authorized Employee
• Recognition of Hazardous Energy Sources.
• Type and Magnitude Energy Sources.
• Energy Isolation and Control Methods.

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TRAINING REQUIREMENTS

• Affected Employee
• Purpose and Use of The Energy Control Program.

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TRAINING REQUIREMENTS

• All Other Employees
• Procedures and Prohibitions Relating To Attempts
  to Restart or Reenergize Machines or Equipment
  Which Are Locked Out or Tagged Out..

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RETRAINING REQUIREMENTS

• Authorized and Affected Employees
• Retraining Provided When There Is a
• Change in Job Assignment.
• Change in Machines, Equipment or Processes.
• Change in Energy Control Procedures.
• Close-Call Event.
• Failure in the Procedures.
• Reason to Doubt Employee Proficiency.

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ENERGY CONTROL PROGRAM
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DEFINITION OF LOCKOUT
Lockout Is Defined as The Placement of a
Lockout Device on an Energy Isolating Device, in
Accordance With an Established Procedure,
Ensuring That the Energy Isolating Device and the
Equipment Being Controlled Cannot Be Operated
Until the Lockout Device Is Removed.
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DEFINITION OF ENERGY ISOLATING DEVICE

• Block
• Line Valve
• Disconnecting Switch
• Manually Operated Switch
• Any Other Device That Isolates Energy

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TYPES OF ENERGY SOURCES

• HYDRAULIC
• PNEUMATIC
• MECHANICAL
• RADIOACTIVE
• THERMAL
• ELECTRICAL
• CHEMICAL

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TYPES OF ENERGY STATES
STORED ENERGY
ACTIVE ENERGY
110 VOLTS AC
HOT SURFACE
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TYPES OF ENERGY STATES

• ACTIVE ENERGY
• VOLTAGES
• EXTERNAL PRESSURIZED LINE FEEDS
• TO THE MACHINE

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TYPES OF ENERGY STATES

• STORED ENERGY
• INTERNAL LINE PRESSURES
• CAPACITORS
• SURFACE TEMPERATURES
• MECHANICAL TENSION (SPRINGS, ETC.)
• COASTING OF PARTS
• CHEMICAL (OPPOSING pH)
• GRAVITY

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THE SCOPE OF LOCKOUT/TAGOUT
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ACTIVITIES COVERED

• NORMAL OPERATIONS

1. Covered If an Employee Must Remove or Bypass
Guards or Devices 2. Covered Where Employees
Are Required to Put A Body Part in a Machine
Process Area 3. Covered Where Employees Are
Required to Put A Body Part in a Machine Having a
Danger Zone
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TAGOUT REQUIREMENTS
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REQUIREMENTS IF TAGOUT IS USED

• SOME KEY POINTS ABOUT TAGS

• Tags Are Only Warning Devices!
• Tags Must Be Securely Attached!
• May Evoke False Sense of Security!
• Tags Do Not Provide Physical Restraint!
• Tags Must Never Be Defeated or Ignored!
• Must Withstand Environmental Conditions!
• Tags Must Be Legible and Understandable!
• Tags Are Only Removed by the Responsible
  Person.

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LOCK OUT SEQUENCE OF EVENTS
1. Preparation for Shutdown 2. Shutdown 3.
Machine or Equipment Isolation 4. Application of
Lockout/Tagout Devices 5. Testing of LO/TO 6.
Servicing or Maintenance 7. Removal of LO/TO
Devices 8. Reenergization 9. Equipment
Reactivation
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WRITTEN PROGRAM REQUIREMENTS
ALL EMPLOYERS MUST

• Maintain a Written Program.
• Review the Program on an Annual Basis.
• Develop Detailed Energy Control Procedures.
• Review Individual LO/TO Procedures Annually.
• Make the Written Program Available to All
  Affected Employees During Each Work Shift.

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ENERGY CONTROL PROCEDURES
29CFR 1910.147 REQUIRES THAT Procedures Be
Developed, Documented and Utilized for Control of
Potentially Hazardous Energy When Employees Are
Engaged in the Activities Covered by the Standard.
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ENERGY CONTROL PROCEDURES
PROCEDURES MUST CONTAIN
1. Statement of Intended Use. 2. Steps for
Shut-Down and Energy Control. 3. Steps for LO/TO
Device Placement, Transfer and Removal. 4.
Determination of Responsibility. 5. Steps for
Testing LO/TO.
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EXCEPTIONS TO THE REQUIREMENT TO HAVE WRITTEN
LOTO PROCEDURES
ALL OF THE FOLLOWING EIGHT CONDITIONS MUST EXIST
1. No Potential for Residual, Stored or
Reaccumulation of Energy.
2. Contains Only One Energy Source Which Is
Readily Identified and Isolated. 3. Isolating
Locking Out Results in Complete
De-Energization. 4. The Machine or Equipment Is
Isolated or Locked Out During Maintenance. 5.
One Lockout Device Will Achieve Complete Lockout.
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EXCEPTIONS TO THE REQUIREMENT TO HAVE WRITTEN
LOTO PROCEDURES
ALL OF THE FOLLOWING EIGHT CONDITIONS MUST EXIST
6. The Lockout Device Is Under Exclusive Control
Of An Authorized Employee 7. Servicing/Maintenan
ce Does Not Produce Hazards For Other
Employees 8. No Previous Energy Control
Accident History Exists for the Employer
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ENERGY CONTROL PROCEDURES

• PROCEDURES INSPECTED ANNUALLY
• INSPECTIONS PERFORMED BY -
• AUTHORIZED EMPLOYEES OTHER THAN PRIMARY
• LOCKOUT REVIEWED BETWEEN -
• INSPECTOR AND AUTHORIZED EMPLOYEES
• TAGOUT REVIEWED BETWEEN -
• INSPECTOR AND AUTHORIZED/AFFECTED EMPLOYEES

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ENERGY CONTROL PROCEDURES
ANNUAL INSPECTIONS MUST INCLUDE

• DATE OF INSPECTION
• IDENTIFICATION OF MACHINE OR EQUIPMENT
• EMPLOYEES INCLUDED IN INSPECTION
• PERSON PERFORMING INSPECTION

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RELEASE FROM LOCKOUT/TAGOUT
THE AUTHORIZED EMPLOYEE MUST
1. INSPECT WORK AREA FOR HAZARDS 2. CLEAR ALL
EMPLOYEES 3. NOTIFY ALL AFFECTED EMPLOYEES 4.
REMOVE ENERGY ISOLATING DEVICES
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IMPORTANT POINTS TO REMEMBER

• WHERE LOCKOUT CAN BE USED
• IT MUST BE

• WHERE LOCKOUT CANNOT BE USED
• TAGOUT PROCEDURES MUST BE INITIATED
• (Unless It Can Be Demonstrated That Full
  Protection Can Be Achieved by Other Means)

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GROUP LOCKOUT/TAGOUT

• FOUR SPECIFIC REQUIREMENTS

1. Responsibility Vested in a Single
Authorized Employee. 2. The Authorized Employee
Must Have the Authority To Determine Exposure
Status of Group Members. 3. With Multiple Crews
the Authorized Employee Must Be Assigned the
Responsibility of The Overall Job. 4. The
Authorized Employee Shall Affix an Individual
LO/TO Device at the Beginning of Work and Remove
It at Completion of the Work.
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GROUP LOCKOUT/TAGOUT

• WHEN THE AUTHORIZED EMPLOYEE IS UNAVAILABLE
• PROCEDURES MUST INCLUDE, AS A MINIMUM

1. Proof That the Employee Who Applied the Device
Is Unavailable. 2. A Valid Attempt to Inform
the Employee Who Applied the Device, That It Has
Been Removed. 3. Adequate Notice to the
Employee Who Applied The Device, of the Removal
of the Device Before That Employee Returns to
Work.
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CONTRACTOR SAFETY REQUIREMENTS
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TIPS FOR USING CONTRACTORS

• Remember, You Control Your Facility!
• Review Their Procedures With Them Before
  Starting the Job!
• Determine Their Safety Performance Record!
• Determine Who Is in Charge of Their People!
• Determine How They Will Affect Your Employees!
• Ensure Your Data on Your Facility Is Accurate!

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KEY ELEMENTS TO AN EFFECTIVE PROGRAM
1. Develop and Strictly Adhere to LO/TO
Procedures. 2. Establish and Enforce Safe Work
Practices. 3. Ensure Proper Training and
Supervision. 4. Strengthen and Modify Present
Policies. 5. Understand the Relationship Between
29 CFR 1910.147 And the Business or Industry
Involved.
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EQUIPMENT REQUIREMENTS
DEVICES AND TAGS MUST BE
1. Durable 2. Standardized 3. Identifiable 4.
Substantial
DEVICES AND TAGS ARE
1. Designed to Prevent Accidental
Energization. 2. Not Designed As a Substitution
for Security.
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CASE STUDY 1 WORKER KILLED BY MIXING MACHINE
NARRATIVE An employee was assigned the task of
cleaning the inside of a sand mixer. The task
was conducted during a break in the production
cycle, caused by routine maintenance work. He
did this without anyone elses knowledge. While
he was engaged in this, out of sight and hearing
of the others, an electrician started the
machine, killing the man inside. This plant had
a written lockout procedure, training had been
given, and all affected employees (including the
deceased), were issued keys and locks.
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QUESTIONS TO BE CONSIDERED

• What caused the death of the worker?
• Do you believe there are multiple causes?
• Are multiple OSHA Standard violations involved?
• What could upper management have done?
• What could the supervisor have done?
• What could the co-workers have done?
• To what extent was attitude responsible?
• To what extent is a lack of written policy
  responsible?
• To what extent is a lack of training responsible?
• Do you believe there is a single cause to this
  accident that, if removed would have prevented it?

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CASE STUDY 2 WORKER KILLED BY HIGH VOLTAGE
NARRATIVE A 13,800-volt main circuit breaker was
under routine inspection. A test instrument was
used to check for electrical energy. No
electrical energy was detected at the primary
power contacts in the circuit breaker. To verify
the operation of the tester, the sensitivity was
readjusted and checked against a known 120-volt
receptacle. The tester was found to be operable.
As the journeyman electrician approached one of
the contacts with a shop towel, an explosion,
engulfed him in flames. The power from the
public utility company to the main circuit
breaker had not been shut off.
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QUESTIONS TO BE CONSIDERED

• What caused the death of the worker?
• Do you believe there are multiple causes?
• Are multiple OSHA Standard violations involved?
• What could upper management have done?
• What could the supervisor have done?
• What could the co-workers have done?
• To what extent was attitude responsible?
• To what extent is a lack of written policy
  responsible?
• To what extent is a lack of training responsible?
• Do you believe there is a single cause to this
  accident that, if removed would have prevented it?

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CASE STUDY 3 WORKER KILLED BY STORAGE MECHANISM
NARRATIVE A stock handler entered a computer
controlled storage and retrieval area apparently
to perform stock inventory. While performing
this work he was crushed between the robot
retrieval vehicle and a third level post, when
the vehicle responded to an electronic command.
It was found that even though there were a number
of disconnect switches on the vehicle and main
console none had been used. The plant had no
written lockout procedure and workers had not
been trained or advised regarding entry into this
area.
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QUESTIONS TO BE CONSIDERED

• What caused the death of the worker?
• Do you believe there are multiple causes?
• Are multiple OSHA Standard violations involved?
• What could upper management have done?
• What could the supervisor have done?
• What could the co-workers have done?
• To what extent was attitude responsible?
• To what extent is a lack of written policy
  responsible?
• To what extent is a lack of training responsible?
• Do you believe there is a single cause to this
  accident that, if removed would have prevented it?

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CASE STUDY 4 WORKER KILLED BY PARTS UNLOADER
NARRATIVE The part presence switch to an
unloading fixture was sticking on an automatic
transfer line. The jobsetter removed a guard and
was standing at the side of the line to observe
the operation of the switch. He apparently
leaned forward just as the unloader actuated it
caught his right side and crushed him between the
moving unloader and the support post for the
guard. The company had a written lockout program
and the employee had attended operator awareness
training for control of hazardous energy.
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QUESTIONS TO BE CONSIDERED

• What caused the death of the worker?
• Do you believe there are multiple causes?
• Are multiple OSHA Standard violations involved?
• What could upper management have done?
• What could the supervisor have done?
• What could the co-workers have done?
• To what extent was attitude responsible?
• To what extent is a lack of written policy
  responsible?
• To what extent is a lack of training responsible?
• Do you believe there is a single cause to this
  accident that, if removed would have prevented it?

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CASE STUDY 5 DECAPITATED BY SHEARING MACHINE
NARRATIVE An employee was removing scrap from
beneath a large shear when a fellow employee hit
the control button activating The blade. The
blade cycled and decapitated the employee
cleaning scrap. The company had no written
lockout procedure and workers had not been
trained or advised regarding the hazards
associated with machinery.
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QUESTIONS TO BE CONSIDERED

• What caused the death of the worker?
• Do you believe there are multiple causes?
• Are multiple OSHA Standard violations involved?
• What could upper management have done?
• What could the supervisor have done?
• What could the co-workers have done?
• To what extent was attitude responsible?
• To what extent is a lack of written policy
  responsible?
• To what extent is a lack of training responsible?
• Do you believe there is a single cause to this
  accident that, if removed would have prevented it?

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ENERGY CONTROL PROGRAM REVIEW