Lockout/Tagout. What This Training Will Cover:. Who needs training? What is hazardous energy? What is lockout/tagout? What are the different types of lockout devices? What is the requirement for tags? What lockout/tagout procedures are required?. 1. Who Needs Training?.
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What This Training Will Cover:
Who needs training?
What is hazardous energy?
What is lockout/tagout?
What are the different types of lockout
What is the requirement for tags?
What lockout/tagout procedures are required?
Hazardous energy is any of the following:
Electricity – live or stored
Moving machinery parts
Stored mechanical movement in machinery
Stored heat (steam lines or hot liquids)
Hazardous chemicals in pipelines under pressure or force of gravity
Any other active or stored energy sources that could harm a worker
Live electrical lines
Engines that move machinery parts
Pneumatic (air pressure) lines
Pressurized water lines
Lockout/Tagout is important in confined spaces since it is easy to get trapped and hard to escape.
Pipelines leading into tanks must be blanked off before entering the space.
All electrical and mechanical hazardous energy must be addressed and locked out or tagged as needed.
The following hazardous energy sources require lockout/tag-out procedures:
Electrocution from live parts
Scalding from steam or hot liquids
Chemical burns or poisoning
- Deep cuts and gashes
- Crushing injuries
All of these can be fatal when severe
A man working inside a
supermarket cardboard compactor
was crushed when the unblocked
compactor suddenly came down on
top of him.
Three men were doing maintenance inside an asphalt pug mill mixer. One employee was still inside the mixer when the power was turned back on, thereby starting the mixer. He was killed instantly. Cause: failure to disconnect power source and lock out.
A cotton gin operator climbed into a jammed cotton cleaner/separator. The toggle switch controlling the operation of the gin was turned off but not locked out. For some reason, someone accidentally turned the machine back on, not knowing the gin operator was inside the gin. His leg was pulled through the feed rollers. Cause: failure to disconnect power source and lock out.
A warehouseman was repairing an air-operated valve which he had turned off but not disconnected and locked out. During the repair operation he slipped and inadvertently turned on the switch which let air into the valve. His hand was caught and crushed in the valve. Cause: failure to disconnect power source and lock out.
A maintenance employee was changing V-belts on an exhaust fan. He de-energized the fan before starting work. However, he did not block the blades of the fan. The suction in the duct work turned the fan blades, and his hand was caught in the V-belt drive. Cause: failure to block out potential energy sources.
One study on servicing equipment injuries found that 80 percent of the workers surveyed failed to even turn off the equipment before performing the service work.
There is a difference between turning off a machine and actually disengaging or de-energizing a piece of equipment. When you turn off a control switch, you are opening a circuit. There is still electrical energy at the switch, and a short in the switch or someone inadvertently turning on the machine may start the machine running again.
Of the 20 percent of the injured workers who did turn off the machinery, about half of them were injured when someone, generally a coworker who was unaware that the machine was being serviced, accidentally reactivated the machinery.
Of those workers who turned off the control switch, another 20% were injured by the energy still in the machine which should have been blocked. The moving parts of the machine either continued to coast, or the parts moved when a jam was cleared.
In an accident in California, a table saw was turned off, but the saw blade was still silently coasting and had not come to a complete stop. An employee began cleaning the machine, and his finger was amputated by the blade.
Other accidents have occurred when the control switch on a machine was turned off, but a short in the switch restarted the machine.
Accidents have also occurred even when workers did take the necessary steps of disconnecting the main power source. But they did not perform a crucial step for a complete lockout procedure: They did not test the equipment to make sure the machinery was, in fact, de-energized.
One case, the lockout had been done on the wrong power line. In another case, a second power line had been spliced into the wiring beyond the point of the lockout.
When someone will be servicing or repairing machinery or equipment
the unexpected machinery start-up or release of stored energy could cause injury
setup - preparing for normal function
These activities often require a worker to place all or part of their body into the machine’s hazard zone (“the line of fire”).
A device that physically prevents transmission or release of energy such as:
An electrical circuit breaker,
A pipeline valve,
A machine block,
Anything else that positively blocks or isolates energy.
A device that positively:
prevents a machine from being started up or turned on,
prevents a machinery part from moving,
prevents electrical energizing,
blocks a pipeline, steam line or air line
Locked out circuit breaker
Locked out electrical panel
Locked out electrical plug
Punch press blocks
Truck bed lockout
Used when more than one person doing maintenance or repair on same machine or equipment.
Machinery or equipment can’t be started up until all locks are removed.
Each person places and removes their own lock.
E-Z Panel LocTM snap-on breaker lockout device
Tags are warning devices only
They don’t provide the same level of protection as lockout devices. We only use for information, along with a locked device.
They can only be removed by an authorized person.
They must be legible (use a sharpie), securely attached (e.g., zip-tie not string) and resistant to degradation.
Six Steps to Follow:
4. Lock out energy-isolating devices with assigned locks.
5. Release or restrain stored or residual energy (capacitors, pressure, vacuum, blades, etc.)
6. Test machinery to make sure it can’t start up (use the normal start procedure)
Only Authorized employee can do startup
Warn everyone present to stay clear
Remove all tools, locks and tags
Remove, reverse, open or reactivate isolating devices
Visual check that all is clear
Start up machine, process or line flow