Lockout-Tagout System
Introduction
Workers servicing machinery and equipment are exposed to injuries from the unexpected energization, startup of the machinery or equipment, or release of stored energy in the equipment.
120 fatalities and 50,000 injuries each year
Workers injured from exposure to hazardous energy lose an average of 24 workdays for recovery.
Most injuries and fatalities are a result of improper hazardous energy control procedures.
A Bureau of Labor Statistics study on injuries suffered when servicing equipment showed :
- 80% failed to turn off equipment
- 10% of equipment activated by someone else
- 5% failed to control potential energy
- Remaining 5% failed to verify the effectiveness
What is Lockout-Tagout?
Lockout-Tagout is a hazard avoidance technique, used to prevent energy from being accidentally released during the servicing of equipment.
The Lockout-Tagout standard requires the adoption and implementation of written practices and procedures to:
- Shut down equipment
- Isolate it from its energy source or sources
- Prevent the release of potentially hazardous energy while maintenance and servicing activities are being performed
Main Causes of Lockout/Tagout Injuries
- Failure to stop equipment before servicing.
- Failure to disconnect the equipment from the power source.
- Failure to dissipate (bleed, neutralize) residual energy.
- Accidental restarting of equipment.
- Failure to clear work areas before restarting.
- All injuries resulting from inadequate hazardous energy control procedures can be prevented.
Types of Hazardous Energy
Mechanical – the potential energy and kinetic energy present in the components of a mechanical system
Kinetic – energy possessed by virtue of its motion
Common injuries: fracture, contusion, laceration, and amputation
Potential – energy stored by the mechanical system
Common injuries: fracture, contusion, laceration, and amputation
Electrical – energy as a result of a generated electrical power source or
a static source
Common injuries: shock, burns, and electrocution
Thermal – energy as a result of mechanical work, radiation, chemical
reaction or electrical resistance
Common injuries: burns
Chemical- energy released as a result of chemical Reactions
Common injuries: burns
Hydraulic – energy released as a result of liquids under Pressure
Common injuries: and contusions
Pneumatic – energy released as a result of compressed gasses under pressure
Common injuries: burns and contusions
Types of Lockout Devices
- Keyed and combination locks
- Ball valve locks
- Gate valve locks
- Group lockout hasp
- Circuit breaker locks
- Valve hand wheel cover
Lockout-Tagout Procedures are Required IF…
_A worker must remove or bypass machine guards or other safety devices, or
_A worker is required to place any part of their body into a point of operation or into the danger zone associated with the machine's operation
_Examples of activities where proper Lockout-Tagout procedures would be required include
- Installing
- Lubricating
- Cleaning and un-jamming machines or equipment, and
- Making adjustments or tool changes
Definition of Players
Authorized employee: An employee who locks or tags machines or equipment in order to perform servicing or maintenance
Affected employee: An employee who is required to use machines or equipment on which servicing is performed under the Lockout/Tagout standard or who performs other job responsibilities in an area where such servicing is performed
Other employees: All employees who are or maybe in an area where energy control procedures may be utilized
General Energy Control Procedures
Lockout Device Requirements
LOTO devices Must...
- Be capable of withstanding the environment to which they are exposed
- Be singularly identified
- Be the only devices used for controlling energy
- Not be used for other purposes
- Be standardized within the facility in terms of color, shape, or size.
- Indicate the identity of the employee applying the devices
- Prevent removal without the use of excessive force or unusual techniques
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