An Association of Service Providers Todd Culver Assistant Director
ACCESS SAFETY Occupational Safety & Health Training Project in partnership with MIOSHA CET Division
This material was prepared under a Consultation Education and Training (CET) Grant awarded by the Michigan Occupational Safety and Health Administration (MIOSHA). MIOSHA is part of the Michigan Department of Energy, Labor & Economic Growth (DELEG). Points of view or opinions stated in this document do not necessarily reflect the view or policies of DELEG.
LOCKOUT / TAGOUT Training Objectives The MIOSHA Standard When lockout is required Sources of Energy Lockout procedures Question & Answer
MIOSHA Standard Locking out equipment prior to service or maintenance is an essential element of protecting employees from the unexpected energization or motion, start up of the machine or equipment, or release of stored energy. Part 85: Control of Hazardous Energy Sources
EMPLOYER RESPONSIBILITY An employer is responsible for ensuring the safety of its employees and for complying with all related requirements of Part 85: The Control of Hazardous Energy Sources. It is important that all levels of management promote positive attitudes regarding safety, incorporate safety into their work practices, and cooperate fully in the implementation of safety-related programs.
EMPLOYER RESPONSIBILITY MIOSHA requires the employer to plan for the control of energy during servicing and/or maintenance of machines and equipment by: Establish an energy control program: Develop, document and utilize lockout/tagout procedures; Provide employees appropriate training; Provide, at no cost to employees, equipment required by the lockout/tagout procedures. Continuing competency through training.
LOCKOUT EXAMPLES OF MAINTENANCE OPERATIONS OR OTHER SERVICE PROJECTS DURING WHICH THE POTENTIAL RISK OF RELEASE AND/OR INJURY IS THE GREATEST: Removal or bypass of a guard or other safety device When you must place any part of your body where you could be caught by moving machinery
POTENTIAL INJURIES: Unexpected mechanical action can: CUT: If a saw suddenly starts up, it could sever a limb CRUSH: Moving parts in a rolling mill or calender can do severe damage ENTANGLE: Clothing can catch in a conveyor belt or pulley STRIKE: Flywheels or other moving machine parts can hit an employee unexpectedly PUSH: An unsecured machine part or piece of material can move suddenly, with harmful force CLAMP DOWN: A press ram or forge hammer that isn’t blocked could fall on a hand and cause injury
OSHA STATISTICS 10% of all serious industrial accidents 28,000 lost work days per year Approximately 120 deaths per year MIOSHA: #5 most frequently cited violation; #1 for highest penalties
DEFINITIONS: AUTHORIZED EMPLOYEE One who locks out machines or equipment in order to perform service or maintenance. AFFECTED EMPLOYEE One whose job requires him/her to operate or use a machine or equipment in an area where work is being done under lockout.
ENERGY ISOLATING DEVICE A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following: A manually operated electric circuit breaker; a disconnect switch; a line valve; any similar device to block/isolate energy. Push buttons, selector switches, and other control devices are not energy isolating devices.
POTENTIAL SOURCES OF HAZARDOUS ENERGY : ELECTRICAL PNEUMATIC HYDRAULIC FLUID GAS MECHANICAL GRAVITATIONAL
SPECIFIC MACHINE / EQUIPMENT PROCEDURES When a machine specific documented procedure is required, it must include the following actions and elements which must be done in the order listed below when locking or tagging out equipment:
1. Preparation for Shutdown All authorized employees need to know the type of energy, the hazards involved, and the method to control the energy before the employee turns off a machine or equipment. The Energy Control Procedure form (Appendix D in MIOSHA Compliance Guide) should be filled out in advance and used by the authorized employee.
2. Notify all affected employees The authorized employee turning off the power warns affected employees in the work area that power will be shut off, the reason for the shut-down, and that the equipment will be locked/tagged out.
3. Machine or equipment shutdown Turn off or shut down each piece of equipment. An orderly shutdown must be utilized to avoid additional or increased hazards to employees as a result of the equipment stoppage. When appropriate, a “DO NOT OPERATE” tag shall be affixed to the OFF switch.
4. Machine or equipment isolation Physically locate all energy isolating devices that are needed to control the energy of the machine or equipment. Isolate the machine or equipment from the energy sources.
5. Apply lockout device Authorized employee places locks or tags in the appropriate energy isolating location. A lockout device, such as a key lock, utilizes a positive means or holds an energy isolating device in a safe position and prevents the energizing of a machine or equipment.
NOTE ON “TAGOUT” A tagout device is a prominent warning, that can be securely fastened to an energy isolating device, to indicate that the device and equipment may not be operated until the tag is removed. Tags must contain warnings against energizing the equipment, such as DO NOT START, or DO NOT OPERATE Tags are only warning mechanisms placed on energy isolating devices, and do not provide physical restraint on those devices that is provided by a lock “Equivalent level of safety”
6. Release stored energy After lockout devices have been placed on the equipment, all stored electrical, gravitational, mechanical, and/or thermal energy must be disconnected and drained to a zero energy state or otherwise made safe by blocking or repositioning of equipment. This can be accomplished by: Release of pressurized lines such as hydraulic, air, steam, gas and water; Release of spring-loaded equipment; Blocking mechanical equipment with moving, rotating, or elevated parts.
7. Proof of isolation Before starting work on a machine or equipment that has been locked out, the authorized employee needs to show that machine or equipment has been isolated or de-energized. This is generally accomplished by first establishing that no personnel are exposed and then turning the machine switch to the ON position using the normal operating controls.
BEFORE RESTARTING EQUIPMENT, DOUBLE-CHECK EVERYTHING Make sure equipment is in proper operating condition, guards replaced, tools removed, and any braces or blocks taken away All pressure tubing or hoses reconnected, with valves in correct position Work area clear, and all workers safely positioned All employees wearing appropriate personal protective equipment Tags and locks removed by authorized employees
REMEMBER: After service or maintenance, be sure guards are replaced BEFORE machine is re-started NEVER share a lock or key BE SPECIFIC; written lockout procedures must be equipment- specific
Cord and Plug Connected Equipment Part 85 does not apply to work on electrical equipment for which exposure to the hazards of unexpected energization or start up is controlled by the unplugging of the equipment from the energy source. The unplugged cord must be under the exclusive control of the employee(s) conducting the service or maintenance activities.
EMPLOYEE TRAINING AUTHORIZED EMPLOYEES Recognition of locations, types and magnitudes of potential hazardous energy sources in the work area; Proper lockout/tagout procedures; Proper use of lockout/tagout devices (and any related equipment) used by the employer; Lockout or tagout device removal; Explanation of applicable MIOSHA standards.
EMPLOYEE TRAINING AFFECTED EMPLOYEES Purpose of the energy control procedures; Use of the lockout/tagout procedures; Prohibition on tampering with lockout/tagout equipment
PERIODIC INSPECTION Performed at least annually Lockout – include review with authorized employees Certification record kept: –Identify machine or equipment –Date of inspection –Employees performing and included in inspection
Re-training is Required When Change in job assignment Change in machine or process Change in lockout/tagout procedure Inadequacies revealed in periodic review
CONTACT INFO Todd Culver Assistant Director MARO An Association of Community Service Providers 517-484-5588 firstname.lastname@example.org
CONTACT INFO You can also visit the MIOSHA website at www.michigan.gov/mioshapublications where additional information may be available; or contact the Consultation, Education & Training Division at (517) 322-1809