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Lock-Out Safety Maintaining Machines and Equipment Safety This document was printed by the "1990 Prinzing Enterprises - All rights reserved"
Your Employer wants to Protect You Your employer is concerned about the employees health and safety in the workplace. Safety training in the area of machine and equipment maintenance and servicing is only one aspect of a safe workplace. The Occupational Safety and Health Administration (OSHA) has issued regulations requiring the use of locks and/or tags prior to performing service or maintenance on equipment and machinery. Goal The goal of locking out machinery and equipment prior to maintenance or servicing is to avoid accidents that can occur from unexpected start-up or release of stored energy. It is estimated that almost 40 Million U.S. workers could be exposed to hazards from unsecured equipment. Implementation of OSHA lockout regulations and a supporting safety program could prevent 120 deaths and 60,000 injuries a year. Be Aware Some machinery and equipment is powered from multiple sources. For example, a machine might use electricity, gas, compressed air, coiled springs, raised load (which is residual energy), steam or pressurized liquids. Any single source, by itself...even if the others are turned off and locked out...presents a danger to maintenance workers. This is only one reason why its important to follow the lockout procedures established by your employer. Contact your Supervisor or Employer safety manager for specific lockout information on specific equipment. What is ENERGY LOCKOUT ? A lockout is a device which provides a positive means for rendering a switch, valve, raised load, coiled spring or any energy source inoperative. Lockout is a necessary step for ensuring worker safety prior to performing maintenance or service. The lockout device may be a padlock, blanking plate, restraining bar, chain and padlock or any device which prevents a machine from being energized or releasing stored energy. Most of the time a padlock is used to lockout the electrical box and a blocking bar is used to prevent the press weight from dropping (release of stored energy). A Multiple Lockout Device is used for accommodating padlocks when multiple locks are required. A Safety Donut is a device that can be used to lockout round valve handles of varying diameter. The device loosely encases the valve handle preventing access and turning. Or...depending on the type, some valve handles can be locked out with a chain and padlock. Equipment equipped with a hasp device, such as an electrical box, can be locked out with a padlock or multiple lockout device and padlocks. What is a TAGOUT ? A Tagout (or lockout tag) shows who locked out the mechanism, the time, date, and department. Other information such as phone or radio page number can also be shown. Tagouts should be durable and securely fastened to the locking mechanism so the don't fall off accidentally. The Tags should be legible in all weather conditions. Tagouts should only be applied and removed by the same authorized individual. A Tagout warns others that a particular switch, valve or energy source is "locked out" in the off or safe position and should not be operated. Secure locking devices such as padlocks should always be used with a Tagout whenever possible. Be sure your employer informs outside servicing personnel (contractors) of your company's lockout/tagout procedures. Eleven (11) Elements of a Lockout Program 1. Determine what energy sources will be locked out. 2. Can locks be Applied ? - Ensure that the equipment to be serviced can be locked out and de-energized...locks should be applied whenever possible. If locks or positive blocks can not be applied, your employer will tell you how to proceed. 3. Determine sequence to follow - Ex. (4) valve, (2) high voltage panel, (1) valve, (3) drop press 4. Determine who will apply locks/tags - This is the job of the Safety Manager responsible in assigning this types of jobs. 5. Multiple maintenance personnel - If there are multiple maintenance personnel, be sure each member applies their own lock/tag. At least one member should apply a lock/tag to all the lockout points (usually the Safety Manager). 6. Be sure all stored energy is safely released or blocked - Stored energy can be a raised blade or weight, residual line pressures from gases or liquids, capacitor stored electricity, reservoir tanks, coiled springs. It's NOT enough to ensure that only energy sources are blocked, stored energy is dangerous, too. 7. Follow company procedure for performing maintenance/service. 8. Before removing locks/tags and returning machinery to operation, be sure that : (1) all safety guards are back in place; (2) work is complete and tools are put away; (3) workers are positioned safely for start-up; (4) controls are positioned correctly for start-up and machine is operation ready. 9. Only person who applied lock/tag removes it - In accordance with company procedure, ONLY the person who applied the lock/tag should remove it. If there are multiple lockout points and members of the maintenance team, team leaders should remove their locks LAST...after all others have been removed. 10. Follow the predetermined company sequence of unlocking and untagging the lockout points to return the machine to service - Be sure no one is on, in or attempts to operate the machine during this step. 11. Continued employee training and education - Because safety is everyone's responsibility ALL employees ( and outside contractors) should have a basic understanding of lockout safety, tags and locks. Your employer will provide training and education specific to your workplace and machinery. Six (6) Lock Tips 1. One Lock-One Key - Each padlock used in equipment lockout should have only one key issued to the assigned person. 2. Identify Locks - Use a lock numbering, lettering or color code system to identify the locks to those authorized to apply and remove them. 3. Use multiple lockout devices if needed. 4. Never give your assigned key or lock to someone else...it's assigned to you...to protect you. 5. Always use a Tagout with your lock. 6. Can't apply a Lock ? - If the device requiring lockout cannot accommodate a lock, contact your supervisor for direction. A lock may be placed without a tag if and only if all three (3) of these conditions are met 1. Only one circuit or piece of equipment is de-energized. 2. The lockout period does not extend beyond the work shift. 3. Employees exposed to the hazards associated with re-energizing the circuit or equipment are familiar with this procedure. If using a lock without a tag, the tag must be supplemented by at least one additional safety measure, such as removing an isolating circuit element; blocking a controlling switch, or opening an extra disconnecting device. REMEMBER - LOCKS AND TAGS DON'T DE-ENERGIZE MACHINES OR EQUIPMENT, PEOPLE DO. For more information about lockout and tagging contact your local OSHA office, or visit the OSHA Website at www.osha.gov.
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