OSHA's
Lockout/Tagout Standard |
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Dr. Thomas Bean and
Mr. Timothy Lawrence
Recently,
an employee was cleaning the unguarded side of an operating 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. This accident
was caused by the failure to shut down or turn off the equipment to perform
maintenance. If the employee utilized a lockout/tagout procedure, he would
still be alive today.
The Control of Hazardous
Energy Source Standard (29 CFR l9lO.l47), which is more commonly known
as the Lockout/Tagout Standard, is a Federal Occupational Safety and Health
Administration (OSHA) program, It is designed to prevent the unexpected
startup, or energizing, of machinery and equipment during service and
maintenance operations which could cause injury to employees. It is also
designed to prevent the release of stored energy which could cause injury
to employees. Industry has been obligated to comply with the Lockout/Tagout
Standard since January 3,l990.
The lockout standard
applies if:
- The employee
is required to remove or bypass a guard or other safety device during
service and maintenance.
- An associated
danger zone exists during a machine operating cycle.
- The employee
is required to place any body part into an area of the machinery or
equipment where work is actually being performed upon the material being
processed.
Minor tool changes,
adjustments, and other minor service activities, which take place during
normal production, are not included in the Lockout/Tagout Standard provided
they are 1) routine, repetitive, and integral to the use of the equipment,
and 2) that they are performed using alternative measures which provide
effective protection for the employee.
Energy Sources
Most people immediately
think of electricity as a potentially hazardous energy source. There are
other sources of energy, though, that can be just as hazardous. These
energy sources include thermal, chemical, pneumatic, hydraulic, mechanical,
and gravity, It is important to remember that all sources of energy that
have the potential to unexpectedly startup, energize, or release must
be identified and locked, blocked, or released before servicing or maintenance
is performed.
In order to comply,
a company must prepare a written Lockout/Tagout Program which includes the
scope, purpose, authorization, rules, and techniques to be utilized in the
control of hazardous energy. Training must also be provided to all employees
who are affected by the Lockout/Tagout procedures.
The written program
must have:
- A specific statement
as to the intended use of the program.
- Specific steps
for shutting down, isolating, and blocking machinery and equipment in
order to control hazardous energy.
- Specific procedures
for the placement and removal of lockout/tagout devices as well as the
method of identifying an individual's locks or tags.
- Requirements
for verifying the effectiveness of the lockout/ tagout device by testing
procedures for machinery and equipment.
- A detailed training
program for employees who perform the service and maintenance and for
employees who are indirectly affected by those operations.
- Descriptions
of company lockout/tagout policies regarding multiple lockout/tagouts,
outside personnel, shift changes, and training of employees.
The basic equipment
needed for a lockout/tagout procedure are locks and/or tags. Locks are to
be utilized whenever possible. Both locks and tags must clearly indicate
the identity of the employee who applied the device. This provides positive
identification as to who is servicing the machinery and equipment. The identification
will also indicate who may not have finished working in a multiple lockout/tagout
situation. The locks and tags must be durable enough to withstand the environment
in which they will be used. Information on the locks and tags must remain
legible, Locks must be substantial enough to prevent removal without the
use of excessive force. Tags must be substantial enough to prevent accidental
or inadvertent removal. Both locks and tags are to be standardized by either
color, shape, or size. Tags must have a standard print and format, If an
energy isolating device is not capable of being locked out, a tag is to
he used. An energy isolating device is simply a mechanical device that physically
prevents the transmission or release of energy. All machinery and equipment
must be designed to accept a lockout device when major replacements, repairs,renovations,modifications
of machinery or equipment are performed, or whenever new machinery is installed.
An audit should
be conducted on all machines and equipment to identify all potentially
dangerous energy sources and all energy isolating devices. By doing this,employers
will be able to establish all appropriate lockout/tagout procedures.
Two types of personnel
are directly affected by the Lockout/ Tagout Standard: Affected Employees
and Authorized Employees. OSHA defines an Affected Employee as an employee
whose job requires him/her to operate or use machinery or equipment on which
servicing or maintenance is being performed under a lockout/tagout procedure
or whose job requires him/her to work in an area in which servicing or maintenance
is being performed under a lockout/tagout procedure. OSHA defines an Authorized
Employee as an employee who implements a lockout/tagout procedure on machinery
or equipment in order that servicing or maintenance may be performed. Often,
an authorized employee and an affected employee may be the same person.
An actual lockout/tagout procedure is simple and straightforward.
There are two phases to the procedure.
Phase I - Locks,
Blocks or Releases Energy:
- The authorized
employee notifies all affected employees that a lockout/tagout procedure
is ready to begin.
- The machinery
or equipment is de-energized.
- The authorized
employee releases or restrains all stored energy.
- All locks and
tags are checked for defects. If any are found, the lock or tag is discarded
and replaced.
- The authorized
employee places a personalized lock or tag on the energy isolating device.
- The authorized
employee tries stating the machinery or equipment to ensure that it
has been isolated from its energy source. The machine is then de-energized
again after this test.
- The machinery
or equipment is now ready for service or maintenance.
Phase 2 - Returns
the Machinery or Equipment to Production:
- The authorized
employee checks the machinery or equipment to be certain no tools have
been left behind.
- All safety guards
are checked to be certain that they have been replaced properly.
- All affected
employees are notified that the machinery or equipment is about to go
back into production.
- The authorized
employee performs a secondary check of the area to ensure that no one
is exposed to danger.
- The authorized
employee removes the locks and/or tags from the energy isolating device
and restores energy to the machinery or equipment.
This basic example
of the lockout/tagout procedure is used when only one person is performing
service or maintenance on machinery or equipment and when no testing or
positioning of the equipment is required.
In a multiple lockout/tagout
procedure, each person working on the machinery or equipment must place
a lock or tag on the energy isolating device. If the energy isolating device
will not accept multiple locks or tags, a hasp (a multiple lockout device)
may be used. The locks or tags must be placed in such a way that energy
cannot be restored to the machinery or equipment until every lock or tag
is removed, As each employee involved no longer needs to maintain his/her
lockout/tagout protection, that employee removes his/her lock or tag. The
employee attaching the lock or tag is the only person authorized to remove
the lock or tag.
Before a machine can
be placed in service the positioning of pats is sometimes required.
The following procedure
should be followed when testing or positioning machinery or equipment
during service and maintenance:
- The authorized
employee makes certain that the work area is clear of tools and materials.
- The authorized
employee notifies all affected employees that the machinery or equipment
will be positioned or tested.
- All employees
leave the area
- Locks or tags
are removed.
- The machine is
started and tested or positioned.
- When testing
or positioning is complete, the machinery or equipment is de-energized
following the proper lockout/tagout procedure for servicing or the machine
is returned to production via the appropriate procedure.
This standard covers
the servicing and maintenance of machines and equipment where the unexpected
energizing,startup, or release of energy could cause injury to employees.
The standard establishes minimum performance requirements for the control
of such hazardous energy,and applies to the control of energy during normal
servicing /and or maintenance of machines and equipment However, this standard
does not apply to construction,agriculture and maritime employment; installation
under the exclusive control of electrical utilities; exposure to electrical
hazards from work on, near, or with conductors or equipment in electrical
utilization installation; and oil and gas well drilling and servicing. Although
there are exemptions to these standards this may not eliminate your personal
liability. If you have questions concerning liability obtain legal advice.
Inspections And Training
Each
energy control procedure must be inspected at least annually for the purpose
of ensuring that the requirements of the Lockout/Tagout Standard are being
met. Each inspection will be conducted by an authorized employee other than
the employee who normally uses the machinery or equipment or performs the
lockout/tagout procedure. After each inspection, the employer must certify
that the inspection has been completed.
All employees
working in an area requiring lockout/tagout procedures must be trained.
Training must include:
- The recognition
of lockout/tagout devices and the importance of not disturbing or removing
them unless authorized.
- The safe application,
use, and removal of energy controls,
- The limitations
of tags in a lockout/tagout procedure.
Training must occur
whenever there is a change in job assignment, a change in machinery or
equipment, an energy control procedure change, or a change in a process
that presents a new hazard. Retraining is to be conducted whenever the
employer believes that employees' knowledge of energy control procedures
is inadequate and as part of the annual inspection.
Outside Personnel
When outside personnel,
such as contractors, arc on site and engaged in activities that require
compliance with the Lockout/Tagout Standard, the on-site employer and the
outside employer must inform one another of their lockout/tagout procedures.
It is the responsibility of the on-site employer to ensure that his/her
employees understand and comply with the methods of the other's lockout/tagout
procedures.
Shift Changes
A high percentage of
accidents historically occur shortly after a shift change and are often
due to a lack of communication. During a shift change, exiting personnel
should meet oncoming personnel at the lockout/tagout device. The oncoming
authorized employee should place his/her lock or tag on the energy isolating
device before the exiting authorized employee removes his /her lock or tag.
If this is not possible, the oncoming authorized employee should place his/her
lock or tag on the energy isolating device immediately after the exiting
authorized employee removes his/her lock or tag. Exiting employees should
inform oncoming employees of any problems or concerns regarding the service
and maintenance of machinery or equipment.
Lockout/Tagout Checklist
The checklist below
has been developed to assist in complying with the Lockout/Tagout Standard:
- Audit all machinery
and equipment for types and magnitudes of energy and potential hazards,
- identify and
document all machinery and equipment for which a lockout/tagout procedure
must be developed.
- Identify and
document, by name and by job title, all affected employees.
- Identify and
document, by name and by job title, all employees authorized to perform
lockout/tagout procedures.
- Describe and
document types and locations of energy isolating devices for all machinery
and equipment identified in Step 2.
- Describe and
document the types of energy involved and the methods to be used to
dissipate or restrain the energy for all machinery and equipment identified
in Step 2.
- Describe and
document the method established to isolate the energy (lock or tag)
and any additional safety measures to be taken.
- Develop a written
Lockout/Tagout Program.
Summary
The Control
of Hazardous Energy Source Standard requires employers to isolate machinery
and equipment from its energy sources and to lock or tag them before service
or maintenance is performed The standard also requires that all employees
be trained in the company's lockout/tagout policies and procedures.
This document appears in the eLCOSH website with the permission of the
author and/or copyright holder and may not be reproduced without their
consent. eLCOSH is an information clearinghouse. eLCOSH and its sponsors
are not responsible for the accuracy of information provided on this web
site, nor for its use or misuse.
Acknowledgments: Dr. Thomas L. Bean and Mr. Timothy J. Lawrence wish to
acknowledge Dr. Curt C. Hassler and Mr. Herman C. Sims, et. al., , for
the initial development of this fact sheet material. 08/91- 2M-89272
Reviewed by Randall Wood and Mike Lichtensteiger, Department of Agricultural
Engineering.
Issued in furtherance of Cooperative Extension work, Acts of May 8 and
June 30, 1914, in cooperation with the U.S. department of Agriculture,
Bobby D. Moser, Director of the Ohio Cooperative Extension Service, The
Ohio State University.
All educational programs and activities conducted by the Ohio Cooperative
Extension Service are available to all potential clientele on a nondiscriminatory
basis without regard to race, color, creed, religion, sexual orientation,
national origin, sex, age, handicap or Vietnam-era veteran status.
Funded in whole or in part from Grant Number UO5/CCU506070-01,"Cooperative
Agreement Program for Agricultural Health Promotion Systems," National
Institute for Occupational Safety and Health.
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