LOCKOUTTAGOUT

POCKET GUIDE

Published and Distributed byGENIUM PUBLISHING CORPORATION

One Genium PlazaSchenectady, NY 12304-4690 USA

(518) 377-8854

AuthorJohn V. Conforti

EditorRobert A. Roy

Copyright 1993by Genium Publishing Corporation

All Rights ReservedISBN 0-931690-59-5

Printed in the United States of America

NOTICE: Every effort has been made t oensure the accuracy and completeness o fthe information in this publication. How-ever, Genium Publishing Corporation andthe editor assume no liability for any l o s sor damage resulting from inaccuracy or in -completeness.

The Lockout Tagout Pocket Guide isavailable with your organization's name

imprinted on the cover.

2/96

Table of Contents

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TABLE OF CONTENTS

I. Introduction ..................................... 5Review of the Law............................ 6Training.......................................... 7Periodic Inspection............................ 7

II. Hazardous Energy Sources................... 9A. Electrical Energy......................... 9B. Mechanical Energy...................... 10C. Thermal Energy.......................... 11D. Potential Energy......................... 13

III. Energy Control Program..................... 17A Lockout Versus Tagout................ 17B. Performance Requirements............ 19C. Major Messages on Tagout Devices23D. Review...................................... 24E. Lockout/Tagout Safety Tips.......... 24

IV. Energy Control Proceduresand Application Materials................... 27A. Purpose..................................... 27B. Shutdown/Isolation...................... 27C. Application of Lockout/Tagout...... 29D. Release of Stored Energy.............. 29

Securing/Isolating Energy Sources.. 30E. Examples of Isolating/Blocking..... 32F. Release from Lockout/Tagout........ 34

Sample Lockout Procedure............ 36

V. Energy Control Situations Not RequiringDocumented Procedures...................... 41A. Testing/Positioning During Lockout 43B. Outside Contractors..................... 44C. Shift Change.............................. 44D. Group Lockout........................... 46

VI. Training.......................................... 49A. Training Requirements................. 50B. Training Requirements when Using

Tagout Procedures....................... 52C. Periodic Inspection (Accountability) 53

VII. Summary......................................... 55

VIII. Glossary.......................................... 57

I. Introduction

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I. INTRODUCTION

Slick the Pick Wilson is what my friends call me.Theres not a lock I cant pick from Juniors schoollocker to the doors at the bank I've done em all.

Now, dont get me wrong, its all done on the square.I'm a master locksmith just like my father and hisfather before him. Ive got my college degree, and mybusiness now has 15 employees. My customers, whocall me Mr. Wilson, or just Freddy, range fromprivate individuals to major corporations. You see, Inot only reunite forgetful motorists with their carkeys, I help design systems that are used to secure orisolate energy sources on process equipment. Letssay you have a broken machine to fix in your plant.You turn off the power to it and you fix it. Right?But what happens if youve got your fingers in thething and somebody turns it back on. Ouch! Thatswhy its smart to tag out critical electrical switcheswith a sign that says to leave the switch OFF. To beeven more safe, you can put a lock on the switch.Thats called a lock out.

And thats why youre reading this now. Youremployer wants you to be aware of therequirements for locking-out or tagging-out(controlling) energy sources during servicing and/ormaintaining of machines and equipment. Whatrequirements? Why the requirements that are spelledout in the Occupational Safety and Health Standard1910.147, entitled The Control of Hazardous Energy(lockout/tagout). And who better to walk and talkyou through it than me, Slick the Pick Wilson?

Well look at the Standard and see how its designedto help keep you safe from the potential hazards posedby machines and equipment.

Well discuss the various types of energy sources andhow to keep them from harming you. And, we'll lookat a typical energy-control program, including lockoutvs. tagout along with lockout/tagout equipment. Andwe'll discuss the requirements for training andretraining to keep you sharp and safe.

Well see how to apply the program both tolockout/tagout procedures and finally, to proceduresfor restoring power.

II. Hazardous Energy Sources

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II. HAZARDOUS ENERGYSOURCES

The unexpected activation of machinery or processequipment during maintenance operations can havetragic results. Thats why the first point made underthe lockout/tagout program is to make sure you, theemployee, are aware of the type(s) of energy sourcesand the hazards associated with those energy sourcesthat need to be controlled.

How many kinds of energy sources are there? youask? Lets count em.

A. ELECTRICAL ENERGY

This is usually the first one everybody thinks of.Actually there are two types, generated and static.

Generated Electric Power

Found at the main source of electricity to the machineor equipment, generated electrical power could also befound in various circuitry within the machine orequipment. Think of electric power as the flow ofelectrons in a conductor because, well, thats whatit is.

And dont forget generated energy thats been stored,like in batteries or capacitors. I could show you anasty scar on my wrist I got off a car battery.Happened when I was a kid. Grounded the metal bandof my watch on it. But, I'm older and wiser now. Ifyou want to get older and wiser too, I suggest youread on.

Static Electricity, on the other hand, remains fixedon the surface of an object. Static electricity can befound in electrostatic precipitators that are commonlyused for dust collection by heavy industry to controlair pollution. Hey, Slick you ask, Is staticelectricity that dangerous? Well, lightning is actuallythe discharge of static electricity. And anything thatcan discharge that kind of juice demands respect, inmy opinion.

Anyway, whether its static or flowing, if you dontwant to get French fried, you better be aware of youremployers Energy Control Program and follow it.

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III. ENERGY CONTROL PROGRAM

The Energy Control Program consists of the energycontrol procedures, employee training on thoseprocedures, and periodic inspections relating to theprocedures.

Sounds like this law is a procedure thing, doesnt it?Well, youre right! And the Energy Control Programis the sum of all of these procedures. And one of themost important elements of the program to consideris whether to use locks or tags to control hazardousenergy.

A. LOCKOUT VERSUS TAGOUT

Youd hardly believe there could be an argument here,could you? As a general rule, lockout is the preferredmethod over tagout for the following reasons:

Locks are hard to bypass. It would require amajor effort and a pair of hefty bolt cutters tocompromise a lock. Tags can be pretty easilydefeated.

Tags only warn. They only serve as awarning and are not to be considered a safetydevice whereas locks are.

Tags may be easily lost or damaged. Tagscan be damaged by environmental or physicalhazards like chemicals or abrasives.

Locks speak everyones language. You'reassuming everyone can read. Of course you can,or you'd be using this book just to swat flies.Ah, but you are reading English. Lets say youwent to China to work on some made-in-the-USA machine, and you brought your big red andwhite Please-dont-turn-this-on-or-you will-electrocute-me warning tag. To your Chineseco-worker standing next to you, it probablywouldnt mean much, would it? Just like his warning tag in Chinese wouldnt mean much toyou.

Now I know youre thinking - Tag-schmag whoneeds them? Although the Standard agrees thatlockout is the preferred method when the energyisolation device is capable of being locked out, itrecognizes that there are situations where tagoutsystems are an acceptable choice. For example, when:

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IV. ENERGY CONTROLPROCEDURES AND APPLICATION

MATERIALS

The written Energy Control Procedures are kind oflike the game plan for lockout/tagout. And just likein sports, everyones playbook is a little different.

Your employer is responsible for issuing clear,specific instructions outlining the scope, purpose,authorization, rules, and techniques to be used for thecontrol of hazardous energy sources at your place ofwork.

While certain procedures will vary because of the widediversity of machines and processes found in industrytoday, there are certain basic rules and requirementsthat will be the same for everyone. Lets take a look.

A. PURPOSE

This is what I call the mission statement. It can beas brief or as long as your employer wants it whatever it takes to convey the message that there areimportant procedures covering the lockout of energyisolation devices wherever maintenance or servicing isdone on machines or equipment. It also has to beclear that compliance by everyone is a must andviolation of any part of the procedures or program isneither permissible nor acceptable. If you are theperson responsible for doing the actual servicing ormaintaining, you want to be sure that your fellowemployees will be just as anxious and willing as youare to comply with all procedures.

B. SHUTDOWN/ISOLATION

This is the orderly p