LOCKOUT TAGOUT POCKET - Genium.com

1 LOCKOUTTAGOUTPOCKET GUIDEP ublished and Distributed byGENIUM PUBLISHING CORPORATIONOne Genium PlazaSchenectady, NY 12304-4690 USA(518) 377-8854 AuthorJohn V. ConfortiEditorRobert A. RoyCopyright 1993by Genium Publishing CorporationAll Rights ReservedISBN 0-931690-59-5 Printed in the United States of AmericaNOTICE: 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 lossor damage resulting from inaccuracy or i n LOCKOUT TAGOUT POCKET Guide isavailable with your organization's nameimprinted on the of ContentsGenium Publishing3 TABLE OF CONTENTSI. Introduction ..5 Review of the Hazardous Energy Electrical Mechanical 10C . Thermal 11D. Potential Control 17 ALockout Versus 17B. Performance 19C . Major Messages on TAGOUT Devices23D.

2 24E. LOCKOUT / TAGOUT Safety 24IV. Energy Control Proceduresand Application 27A. 27B. 27C . Application of 29D. Release of Stored 29 Securing/Isolating Energy 30E. Examples of 32F . Release from 34 Sample LOCKOUT 36V. Energy Control Situations Not RequiringDocumented 41A. Testing/Positioning During LOCKOUT 43B. Outside 44C . Shift 44D. Group 46VI. 49A. Training 50B. Training Requirements when Using TAGOUT 52C . Periodic Inspection (Accountability) 55 VIII. 57I. IntroductionGenium Publishing5I. INTRODUCTION Slick the Pick Wilson is what my friends call s not a lock I can t pick from Junior s schoollocker to the doors at the bank I've done em , don t get me wrong, it s all done on the 'm a master locksmith just like my father and hisfather before him. I ve got my college degree, and mybusiness now has 15 employees. My customers, whocall me Mr.

3 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. Let ssay you have a broken machine to fix in your turn off the power to it and you fix it. Right?But what happens if you ve got your fingers in thething and somebody turns it back on. Ouch! That swhy it s 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 s called a lock out. And that s why you re 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 , entitled The Control of Hazardous Energy( LOCKOUT / TAGOUT ).

4 And who better to walk and talkyou through it than me, Slick the Pick Wilson?We ll look at the Standard and see how it s designedto help keep you safe from the potential hazards posedby machines and ll 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 ll see how to apply the program both tolockout/ TAGOUT procedures and finally, to proceduresfor restoring Hazardous Energy SourcesGenium Publishing9II. HAZARDOUS ENERGYSOURCESThe unexpected activation of machinery or processequipment during maintenance operations can havetragic results. That s 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.

5 How many kinds of energy sources are there? youask? Let s count ELECTRICAL ENERGYThis is usually the first one everybody thinks there are two types, generated and Electric PowerFound 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, that s whatit don t forget generated energy that s been stored,like in batteries or capacitors. I could show you anasty scar on my wrist I got off a car 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 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?

6 Well, lightning is actuallythe discharge of static electricity. And anything thatcan discharge that kind of juice demands respect, inmy , whether it s static or flowing, if you don twant to get French fried, you better be aware of youremployer s Energy Control Program and follow POCKET Guide16 Genium PublishingIII. ENERGY CONTROL PROGRAMThe Energy Control Program consists of the energycontrol procedures , employee training on thoseprocedures, and periodic inspections relating to like this law is a procedure thing, doesn t it?Well, you re 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 TAGOUTYou d 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.

7 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 everyone s language. You'reassuming everyone can read. Of course you can,or you'd be using this book just to swat , but you are reading English. Let s say youwent to China to work on some made-in-the-USA machine, and you brought your big red andwhite Please-don t-turn-this-on-or-you will-electrocute-me warning tag. To your Chineseco-worker standing next to you, it probablywouldn t mean much, would it? Just like his warning tag in Chinese wouldn t mean much I know you re 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.

8 For example, when: LOCKOUT / TAGOUT POCKET Guide26 Genium PublishingIV. ENERGY CONTROLPROCEDURES AND APPLICATIONMATERIALSThe written Energy Control procedures are kind oflike the game plan for LOCKOUT / TAGOUT . And just likein sports, everyone s playbook is a little 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 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. Let s take a PURPOSEThis 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.

9 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 SHUTDOWN/ISOLATIONThis is the orderly procedure for preparing themachine or equipment for the application of thelockout and/or TAGOUT devices. While the specificsmay change, based on your particular situation, hereare some basics: Notification First, notify all affectedpersonnel that servicing and maintenance onequipment and shutdown in preparation forlockout/ TAGOUT is about to occur. You can t justgo over and pull the switch on a piece ofequipment or process when it affects the actionsLockout/ TAGOUT POCKET Guide44 Genium PublishingV. ENERGY-CONTROLSITUATIONS NOT REQUIRINGDOCUMENTED PROCEDURESAnd that s the procedure Gee Whiz manufacturingCompany uses to control and LOCKOUT the energysource for the old Spin Deluxe 2200 Mixer.

10 Prettystraightforward wasn t it?But, you say, The shift I work on is even simpler all I gotta do is pull a plug. Well, now, you d thinkthat anyone would be able to figure out that methodof energy control. I know what you mean. But, youstill have to have a written Energy Control Program,no matter what. A documented procedure like the oneat Gee Whiz Manufacturing Company may not beneeded. But, and this is a big but, all the followingeight conditions must be met by the employer beforeany employees drop documenting a procedure for agiven machine or piece of equipment:1)No stored (potential) or residual energy Themachines or equipment must not have any hidden energy sources that are going to comeup and bite you. You remember things likesprings, capacitors, )Single energy source Like that plug youmentioned, you ve got to have a single, readilyidentifiable, easy-to-isolate, energy )Complete isolation That simple energysource, once locked up (like with one of theplug-type locks you saw earlier), mustcompletely deenergize and deactivate themachine or )Isolated LOCKOUT The machine or equipmentmust still be isolated and locked out duringservice or maintenance.