This packet is intended for use in an introductory mechanical engineering course. The material in this packet addresses control of hazardous energy by lockout and tagout, as well as a brief overview of OSHA. The lecture is based on a lockout/tagout handout, which is provided for the student's reference. Questions related to the handout are given as an assignment.
Time for presentation is approximately 20 minutes.
Objective:
To introduce mechanical engineering students to basic safety concerns, namely lockout/tagout procedures.
This packet includes the following items:
• Lecture material for instructor
• Lecture handouts for students
• Overheads for use during lecture
Download the Engergy Release Packet in a printable Adobe Acrobat Format (pdf). This includes overheads in a ready to use format.
Homework problem solutions, exam problems, and exam solutions are available to qualified recipients. Send an email with request information to Dr. Donald Bloswick.
I. OSHA and Lockout/Tagout
A. The Occupational Safety and Health Administration (OSHA) was created in 1971 by the United States Congress to reduce workplace fatalities and occupational injury and illness.
B. Federal and State OSHA exist to enforce workplace safety and health laws, improve rulemaking, and expand education and outreach.
C. Control of Hazardous Energy (lockout/tagout) 1910.1471. Title 29 of the Code of Federal Regulations (CFR).
2. Went into effect January 2, 1990.
3. 29 CFR is an OSHA regulation and standard.
4. OSHA definitions of lockout and tagout (http://www.osha.gov) (OVERHEAD 1)a. "Lockout." 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.
b. "Lockout device." A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds.
c. "Tagout." The placement of a tagout device on an energy isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.
d. "Tagout device." A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.D. Lockout/Tagout Standard (OVERHEAD 2)
1. Helps safeguard employees from:
a. Unexpected startup of machines or equipment
b. Release of hazardous energy
when service or maintenance is being performed.2. The standard: (OVERHEAD 3)
a. Identifies practices and procedures necessary to lockout and tagout machines.
b. Requires that employees receive training about lockout/tagout.
c. Mandates that periodic inspections be conducted.3. (OVERHEAD 4) The purpose of lockout/tagout is to prevent fatalities and injuries due to the accidental release of stored energy by locking all energy sources in the "OFF" or de-energized position.
II. Employee Injury Due to Energy Release (OVERHEAD 5)
A. Employees can be injured if energy is discharged during servicing or maintenance.
1. Machines and equipment use energy to perform work.
a. This energy may be:
(1) Electrical.
(2) Mechanical.
(3) Hydraulic.
(4) Pneumatic.
(5) Chemical.
(6) Thermal.b. Energy can also be stored, even after equipment has been shut off, in ways such as:
(1) Springs.
(2) Steam.
(3) Pressurized air.
(4) Pressurized liquid.B. Workers that service equipment face the greatest risk, but compliance with the standard will prevent fatalities and injuries.
III. Employer Responsibilities (OVERHEAD 6)
A. The employer shall establish a program consisting of:
1. Energy control procedures (written).
2. Employee training.
3. Periodic inspections.B. (OVERHEAD 7) The program should ensure that before an employee performs any servicing or maintenance on a machine where unexpected energizing, start-up or release of stored energy could occur and cause injury, the machine shall be isolated from the energy source and rendered inoperative.
1. If an energy-isolating device is capable of being locked out, the employer's energy control program shall utilize lockout.
2. If an energy-isolating device is not capable of being locked out, the employer's energy control program shall utilize a tagout system.
3. Whenever replacement, major repair, renovation, modification, or installation of new machines or equipment is performed, energy isolating devices for the machines and equipment shall be designed to accept a lockout device.
IV. Written Energy Control Procedures
A. Procedures shall be developed, documented and utilized for the control of potentially hazardous energy. The procedures shall clearly and specifically address: (OVERHEAD 8)
1. A specific statement of the intended use of the procedure.
2. Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy.
3. Specific procedural steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them.
4. Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures.
I. OSHA and Lockout/Tagout
A. The Occupational Safety and Health Administration (OSHA) was created in 1971 by the United States Congress to reduce workplace fatalities and occupational injury and illness.
B. Federal and State OSHA exist to enforce workplace safety and health laws, improve rulemaking, and expand education and outreach.
C. Control of Hazardous Energy (lockout/tagout) 1910.1471. Title 29 of the Code of Federal Regulations (CFR).
2. Went into effect January 2, 1990.
3. 29 CFR is an OSHA regulation and standard.
4. OSHA definitions of lockout and tagout (http://www.osha.gov)a. "Lockout." 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.
b. "Lockout device." A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds.
c. "Tagout." The placement of a tagout device on an energy isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.
d. "Tagout device." A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.D. Lockout/Tagout Standard
1. Helps safeguard employees from:
a. Unexpected startup of machines or equipment
b. Release of hazardous energy
when service or maintenance is being performed.2. The standard:
a. Identifies practices and procedures necessary to lockout and tagout machines.
b. Requires that employees receive training about lockout/tagout.
c. Mandates that periodic inspections be conducted.3. The purpose of lockout/tagout is to prevent fatalities and injuries due to the accidental release of stored energy by locking all energy sources in the "OFF" or de-energized position.
II. Employee Injury Due to Energy Release
A. Employees can be injured if energy is discharged during servicing or maintenance.
1. Machines and equipment use energy to perform work.
2. Energy can also be stored, even after equipment has been shut off, in ways such as:(1) Springs.
(2) Steam.
(3) Pressurized air.
(4) Pressurized liquid.B. Workers that service equipment face the greatest risk, but compliance with the standard will prevent fatalities and injuries.
III. Employer Responsibilities
A. The employer shall establish a program consisting of:
1. Energy control procedures (written).
2. Employee training.
3. Periodic inspections.B. The program should ensure that before an employee performs any servicing or maintenance on a machine where unexpected energizing, start-up or release of stored energy could occur and cause injury, the machine shall be isolated from the energy source and rendered inoperative.
1. If an energy-isolating device is capable of being locked out, the employer's energy control program shall utilize lockout.
2. If an energy-isolating device is not capable of being locked out, the employer's energy control program shall utilize a tagout system.
3. Whenever replacement, major repair, renovation, modification, or installation of new machines or equipment is performed, energy isolating devices for the machines and equipment shall be designed to accept a lockout device.
IV. Written Energy Control Procedures
A. Procedures shall be developed, documented and utilized for the control of potentially hazardous energy. The procedures shall clearly and specifically address:
1. A specific statement of the intended use of the procedure.
2. Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy.
3. Specific procedural steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them.
4. Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures.
Lockout/Tagout OSHA Definitions
• "Lockout." 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.
• "Lockout device." A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds.
• "Tagout." The placement of a tagout device on an energy isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.
• "Tagout device." A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.
Lockout/Tagout Standard
Helps safeguard employees from
• Unexpected startup of machines or equipment
• Release of hazardous energy
when service or maintenance is being performed.
The standard:
• Identifies practices and procedures necessary to lockout and tagout machines.
• Requires that employees receive training about lockout/tagout.
• Mandates that periodic inspections be conducted.
The purpose of lockout/tagout is to prevent fatalities and injuries due to
the accidental release of stored energy by locking all energy sources in the
"OFF" or
de-energized position.
Machines and equipment use energy to perform work. This energy may be:
• Electrical
• Mechanical
• Hydraulic
• Pneumatic
• Chemical
• Thermal
Energy can also be stored, even after equipment has been shut off, in ways such as:
• Springs
• Steam
• Pressurized air
• Pressurized liquid
The employer shall establish a program consisting of:
• Energy control procedures
• Employee training
• Periodic inspections
Before servicing or maintenance begins, the machine shall be isolated from the energy source and rendered inoperative.
• Lockout if possible
• Tagout if lockout is not possible
• If possible, adapt equipment to accept a lockout device.
Energy control procedures shall clearly and specifically address:
• A specific statement of the intended use of the procedure.
• Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy.
• Specific procedural steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them.
• Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures
(compiled from OSHA standards and fact sheets on http://www.osha.gov and http://www.osha-slc.gov/SLTC/controlhazardousenergy/index.html)
On September 1, 1989, OSHA issued a final rule on the Control of Hazardous Energy (Lockout/Tagout) of Title 29 of the Code of Federal Regulations (29 CFR) Part 1910.147. This standard, which went into effect on January 2, 1990, helps safeguard employees from the unexpected startup of machines or equipment or release of hazardous energy while they are performing servicing or maintenance. The standard identifies the practices and procedures necessary to shut down and lock out or tag out machines and equipment, requires that employees receive training in their role in the lockout/tagout program, and mandates that periodic inspections be conducted to maintain or enhance the energy control program.
All machines and equipment use or manipulate energy to perform work. This energy may be electrical, mechanical, hydraulic, pneumatic, chemical, or thermal. The energy may be stored (such as in springs, steam or pressurized air or liquids), even after the equipment has been shut off. An employee can be seriously injured if this energy is accidentally discharged during servicing or maintenance.
The standard for the control of hazardous energy sources (lockout-tagout) covers servicing and maintenance of machines and equipment in which the unexpected energization or start-up of the machines or equipment or release of stored energy could cause injury to employees.
About three million workers actually servicing equipment face the greatest risk. These include craft workers, machine operators, and laborers. Typical injuries include fractures, lacerations, contusions, amputations, and puncture wounds with the average lost time for injuries running twenty-four days. OSHA estimates compliance with the standard will prevent about 120 fatalities and approximately 28,000 serious and 32,000 minor injuries each year. About 39 million general industry workers are protected from accidents during maintenance and servicing of equipment under this ruling.
The purpose of lockout/tagout is to prevent the accidental release of stored energy by locking all energy sources in the "OFF" or de-energized position.
Scope
This standard covers the servicing and maintenance of machines and equipment in which the "unexpected" energization or start-up of machines and equipment or release of stored energy could cause injury to employees.
The employer shall establish a program consisting of energy control procedures (written), employee training, and periodic inspections. The program should ensure that before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing, start-up or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from the energy source and rendered inoperative.
If an energy-isolating device is not capable of being locked out, the employer's energy control program shall utilize a tagout system. If an energy-isolating device is capable of being locked out, the employees energy control program shall utilize lockout, unless the employer can demonstrate that the tagout program will provide a level of safety equivalent to that obtained by using a lockout program. Whenever replacement or major repair, renovation or modification of a machine or equipment is performed, and whenever new machines or equipment are installed, energy isolating devices for such machine or equipment shall be designed to accept a lockout device.
Written Energy Control Procedure
Procedures shall be developed, documented and utilized for the control of potentially
hazardous energy. The procedures shall clearly and specifically address:
A specific statement of the intended use of the procedure
Specific procedural steps for shutting down, isolating, blocking and securing
machines or equipment to control hazardous energy
Specific procedural steps for the placement, removal and transfer of lockout
devices or tagout devices and the responsibility for them
Specific requirements for testing a machine or equipment to determine and verify
the effectiveness of lockout devices, tagout devices, and other energy control
measures
Protective Materials and Hardware
Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware shall be provided for isolating, securing or blocking of machines or equipment from energy sources. Lockout devices and tagout devices shall be unique, are not to be used for other purposes, and shall meet the following requirements:
Durable
Standardized
Substantial
Identifiable
Tagout devices shall warn against hazardous conditions if the machine or equipment is energized and shall include a legend such as the following: "Do Not Start. Do Not Energize. Do Not Operate."
The employer's primary tool for providing protection under the standard is the energy-isolating device, which is the mechanism that prevents the transmission or release of energy and to which locks or tags are attached. This device guards against accidental startup or the unexpected reenergization in machines or equipment during servicing or maintenance. There are two types of energy-isolating devices: those capable of being locked and those that are not. The standard differentiates between the existence of these two conditions and the use of tagout when either condition exists. When the energy-isolating device cannot be locked out, the employer must use tagout. Of course, the employer may choose to modify or replace the device to make it capable of being locked-out. When using tagout, the employer must comply with all tagout-related provisions of the standard and, in addition to the normal training required for all employees, must train his or her employees in the following limitations of tags:
· Tags are essentially warning devices affixed to energy-isolating devices
and do not provide the physical restraint of a lock.
· When a tag is attached to an isolating means, it is not to be removed
except by the person who applied it, and it is never to be bypassed, ignored,
or otherwise defeated.
· Tags must be legible and understandable by all employees.
· Tags and their means of attachment must be made of materials that will
withstand the environmental conditions encountered in the workplace.
· Tags may evoke a false sense of security. They are only one part of
an overall energy control program.
· Tags must be securely attached to the energy-isolating devices so that
they cannot be detached accidentally during use.
If the energy-isolating device is lockable, the employer must use locks unless he or she can demonstrate that the use of tags would provide protection at least as effective as locks and would assure "full employee protection." Full employee protection includes complying with all tagout-related provisions plus implementing additional safety measures that can provide the level of safety equivalent to that obtained by using lockout. This might include removing and isolating a circuit element, blocking a controlling switch, opening an extra disconnecting device, or removing a valve handle to reduce the potential for any inadvertent energization while tags are attached. Although OSHA acknowledges the existence of energy-isolating devices that cannot be locked out, the standard clearly states that whenever major replacement, repair, renovation or modification of machines or equipment is performed and whenever new machines or equipment are installed, the employer must ensure that the energy-isolating devices for such machines or equipment are lockable. Such modifications and/or new purchases are most effectively and efficiently made as part of the normal equipment replacement cycle. All newly purchased equipment must be lockable.
Periodic Inspection
The employer shall conduct a periodic inspection of the energy control procedure
at least annually to ensure that the procedure and the requirements of this
standard are being followed.
The periodic inspection shall be performed by an authorized employee other than
the one(s) utilizing the energy control procedure being inspected.
The periodic inspection shall be conducted to correct any deviations or inadequacies
identified.
The inspection shall include a review of employee responsibilities under the
energy control procedure.
The employer shall document that the periodic inspections have been performed.
Training and Communication
The employer shall provide training to ensure that employees understand the purpose and function of the energy control program. The training shall include the following:
Each authorized employee shall receive training in the recognition of applicable
hazardous energy sources, the type and magnitude of the energy available in
the workplace, and the methods and means necessary for energy isolation and
control.
Each affected employee shall be instructed in the purpose and use of the energy
control procedure.
All other employees whose work operations are or may be in an area where energy
control procedures may be utilized, shall be instructed about the procedure,
and about the prohibition relating to attempts to restart or reenergize machines
or equipment which are locked out or tagged out.
Employee Retraining
Retraining shall be provided for all authorized and affected employees whenever:
there is a change in job assignments
a change in machines, equipment, or processes
a change in the energy control procedures
the employer has reason to believe that there are deviations from or inadequacies
in the employee's knowledge or use of the energy control procedures.
The retraining shall reestablish employee proficiency and introduce new or revised control methods and procedures, as necessary. Training must be documented.
Application of Control
The established procedures for the application of energy control (the lockout or tagout procedures) shall cover the following elements and actions and shall be done in the following sequence:
Preparation for shutdown, notification of affected employees.
Machine or equipment shutdown.
Machine or equipment isolation.
Lockout or tagout device application.
Relieve of stored energy.
Verification of isolation.
If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists.
Release from Lockout/Tagout.
Before lockout or tagout devices are removed and energy is restored to the machine or equipment, procedures shall be followed and actions taken by the authorized employee(s) to ensure the following:
Inspection of machine or equipment.
Employees notification.
Removal of lockout/tagout devices.
Removal of Another's Lock
The employee who applied the device shall remove each lockout or tagout device from each energy-isolating device. When the authorized employee who applied the lockout or tagout device is not available to remove it, that device may be removed provided that specific procedures and training for such removal have been developed. The specific procedure shall include:
Verification by the employer that the authorized employee who applied the
device is not at the facility
Making all reasonable efforts to contact the authorized employee to inform
him/her that his/her lockout or tagout device has been removed
Ensuring that the authorized employee has this knowledge before he/she resumes
work at that facility
Outside Personnel (contractors, etc.)
Whenever outside servicing personnel are to be engaged in activities covered by this standard, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures. The on-site employer shall ensure that his/her employees understand and comply with the restrictions and prohibitions of the outside employer's energy control program.
Group Lockout/Tagout
When servicing and/or maintenance is performed by a crew, craft, department or other group, they shall utilize a procedure which affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device. Each authorized employee shall affix a personal lockout or tagout device to the group lockout device, group lockbox, or comparable mechanism when he or she begins work, and shall remove those devices when he or she stops working on the machine or equipment being serviced or maintained.
Shift or Personnel Changes
Specific procedures shall be utilized during shift or personnel changes to ensure the continuity of lockout/tagout protection, including provision for the orderly transfer of lockout/tagout device protection between off-going and oncoming employees, to minimize exposure to hazards from the unexpected energization or start-up of the machine or equipment, or the release of stored energy.
Read the Lockout/Tagout handout and answer the following questions.
1. What is hazardous energy?
2. What is the purpose of lockout/tagout?
3. When is it acceptable to use only tagout?
4. What is the procedure when removing another individuals lock?
5. For what other purposes can a lockout device be used?