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Use proper Lock-Out / Tag-Out procedures
Please be careful when working on equipment
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Killed By The Moving Parts Of A Saw
Narrative: An Employee Was Cleaning the Unguarded Side of an
Operating Granite Saw. The Employee Was Caught in
the Moving Parts Of The Saw and Pulled Into a Nip
Point Between The Saw Blade and the Idler Wheel,
Resulting In Fatal Injuries.
Citation:
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Failure to Shutdown or Turn off Equipment To
Perform Maintenance.
How Most Injuries Occur In Order Of Occurrence
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Injured by Moving Machinery Part.
Made Contact With Energized Part.
Injured by Physical Hazard (Heat, Chemicals).
Injured by Falling Machine Part.
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Activity At Time Of Accident
Frequency Of Occurrence
1. Unjamming Object(S) From Equipment
2. Cleaning Equipment
3. Repairing Equipment
4. Performing Routine Maintenance
5. Installing Equipment
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Activity At Time Of Accident
Frequency Of Occurrence
6. Adjusting Equipment
7. Doing Set-up Work
8. Performing Electrical Work
9. Inspecting Equipment
10. Testing Materials
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Reasons For Equipment Not Being Turned Off
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Afraid of Slow Down in Production.
Afraid It Would Take Too Long.
Not Required by Company Procedure.
Worker Didn't Know Power Was on.
Worker Didn't Know How to Turn Off.
Did Not Think It Was Necessary.
Task Could Not Be Done With Power Off.
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ON
OFF
SYSTEM
CONTROL
SWITCH
Reasons For Equipment Being Turned On
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Accidentally Turned on by Injured Employee
Co-Worker Accidentally Turned Equipment On
Equipment Moved When Jam-up Cleared
Equipment Unexpectedly "Cycled"
ON
OFF
 Parts Still in Motion (Coasting)
SYSTEM
CONTROL
SWITCH
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 Authorized Employee
The Person Who Locks or Tags Out Machines To Perform
Servicing or Maintenance.
 Affected Employee
An Employee Whose Job Requires Him or Her To Operate or
Use a Machine or Piece of Equipment On Which Servicing or
Maintenance Is Being Performed.
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 Lock-Out / Tag-Out
The placement of a lock/tag on an energy isolating device,
in accordance with an established procedure, to ensure that
the energy isolating device and the equipment being
controlled cannot be operated until the lock and tag is
removed .
In addition to tag/lock out, the equipment must be blocked
against motion and any residual energy removed.
 Lock-Out Device
A device that utilizes a positive means such as a key lock to
hold an energy isolating device in the safe position and
prevents the energizing of equipment
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 De-Energized
Disconnected from all energy sources so no residual or
stored energy.
 Risk Assessment
Comprehensive evaluation of likelihood & extent of possible
injury or damage, undertaken to choose proper safety
precautions.
 Energy Isolating Device
A mechanical Device That Physically Prevents The
Transmission or Release of Energy. Examples include: circuit
breakers, disconnect switches, slide gates, valves, blocks,
and blind flanges. E-Stops-push button selector switches are
not included in isolation devices.
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 Authorized Employee
 Recognition of Hazardous Energy Sources.
 Type and Magnitude Energy Sources.
 Energy Isolation and Control Methods.
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 Affected Employee
Purpose and Use of The Energy Control Program.
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 All Other Employees
Procedures and Prohibitions Relating To Attempts to
Restart or Reenergize Machines or Equipment Which Are
Locked Out or Tagged Out..
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Authorized and Affected Employees
Retraining Provided When There Is a:
 Change in Job Assignment.
 Change in Machines, Equipment or Processes.
 Change in Energy Control Procedures.
 Close-Call Event.
 Failure in the Procedures.
 Reason to Doubt Employee Proficiency.
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 Three Elements To The Program:
1. Energy Control Procedures
2. Employee Training
3. Periodic Inspections
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Lockout Is Defined as:
The Placement of a Lockout Device on an Energy Isolating
Device, in Accordance With an Established Procedure,
Ensuring That the Energy Isolating Device and the
Equipment Being Controlled Cannot Be Operated Until the
Lockout Device Is Removed.
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Prevents release of hazardous energy
Lock placed on appropriate energy isolating device that is in
the off or closed position
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 Block
 Line Valve
 Disconnecting Switch
 Manually Operated Switch
 Any Other Device That Isolates Energy
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 HYDRAULIC
 PNEUMATIC
 MECHANICAL
 RADIOACTIVE
 THERMAL
 ELECTRICAL
 CHEMICAL
 WATER/GAS
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ACTIVE ENERGY
STORED ENERGY
110 VOLTS AC
HOT SURFACE
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ACTIVE ENERGY
 VOLTAGES
 EXTERNAL PRESSURIZED LINE FEEDS TO THE
MACHINE
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STORED ENERGY
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INTERNAL LINE PRESSURES
CAPACITORS
SURFACE TEMPERATURES
MECHANICAL TENSION (SPRINGS, ETC.)
COASTING OF PARTS
CHEMICAL (OPPOSING pH)
GRAVITY
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Kinetic - machinery in motion
Gears
Belts
Potential - stored energy
Weights (gravity) & springs
Pistons under pressure
Hydraulic controls
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 NORMAL OPERATIONS:
1. Covered If an Employee Must Remove or Bypass Guards
or Devices
2. Covered Where Employees Are Required to Put A Body
Part in a Machine Process Area
3. Covered Where Employees Are Required to Put A Body
Part in a Machine Having a Danger Zone
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Identifies problem
Identifies lockout date
Identifies person
Used by itself only when cannot
be locked out
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 SOME KEY POINTS ABOUT TAGS:
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Tags Are Only Warning Devices!
Tags Must Be Securely Attached!
May Evoke False Sense of Security!
Tags Do Not Provide Physical Restraint!
Tags Must Never Be Defeated or Ignored!
Must Withstand Environmental Conditions!
Tags Must Be Legible and Understandable!
Tags Are Only Removed by the Responsible
Person.
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Preparation for Shutdown
Shutdown
Machine or Equipment Isolation
Application of Lockout/Tagout Devices
Testing of LO/TO
Servicing or Maintenance
Removal of LO/TO Devices
Re-energization
Equipment Reactivation
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Plan your work & locate instructions
Understand equipment hazards
Notify others of shutdown
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Turn all switches to OFF
Normal shutdown procedure
Shut all control valves
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Disable all energy sources
Shut valves
Open breakers & disconnects
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Valves
Breaker & electrical
disconnects
Block or disconnect all
lines
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Plug locks
Ball valve
Gate valve
Hasp
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Electrical
Hydraulic
Pneumatic
Use only locks issued to you – lock all energy
isolation gear
Never use another workers lock or tag
Tell supervisor if you need more LOTO equipment
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Prior to servicing or maintenance, authorized
employee must verify that equipment is isolated by
turning it on
To Verify: The process of operating the start
controls, engaging levers, measuring voltage,
inspecting lockout devices valves,disconnect
switches, blades, piping systems in an area to make
sure that all energy sources have been isolated and
controlled.
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Block or release springs or other tension
Block elevated parts
Stop rotating flywheels
Relieve system pressure
Drain fluids
Vent gases
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Put all guards back
Remove tools
Inform others of startup
Restore system connections
Remove locks & tags
Restore equipment to normal
Conduct normal startup
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Only the employee who placed the lock and/or tag
A supervisor, after obtaining permission from the
worker who placed the tag
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All Employers Must:
 Maintain a Written Program.
 Review the Program on an Annual Basis.
 Develop Detailed Energy Control Procedures.
 Review Individual LO/TO Procedures Annually.
 Make the Written Program Available to all
Affected Employees During Each Work Shift.
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Procedures Must Contain:
1. Statement of Intended Use.
2. Steps for Shut-Down and Energy Control.
3. Steps for LO/TO Device Placement, Transfer and Removal.
4. Determination of Responsibility.
5. Steps for Testing LO/TO.
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Exceptions to the Requirement to have
written LOTO Procedures
All Of The Following Eight Conditions Must Exist:
1. No Potential for Residual, Stored or Reaccumulation of Energy.
2. Contains Only One Energy Source Which Is Readily Identified
and Isolated.
3. Isolating & Locking Out Results in Complete De-Energization.
4. The Machine or Equipment Is Isolated or Locked Out During
Maintenance.
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6. The Lockout Device Is Under Exclusive Control Of An
Authorized Employee
7. Servicing/Maintenance Does Not Produce Hazards For Other
Employees
8. No Previous Energy Control Accident History Exists for the
Employer
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ID hazardous energy covered by program
ID types of energy isolating/de-energizing devices
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Annual Inspections Must Include:
 DATE OF INSPECTION
 IDENTIFICATION OF MACHINE OR EQUIPMENT
 EMPLOYEES INCLUDED IN INSPECTION
 PERSON PERFORMING INSPECTION
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The Authorized Employee Must:
1. INSPECT WORK AREA FOR HAZARDS
2. CLEAR ALL EMPLOYEES
3. NOTIFY ALL AFFECTED EMPLOYEES
4. REMOVE ENERGY ISOLATING DEVICES
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 WHERE LOCKOUT CAN BE USED:
IT MUST BE*
 WHERE LOCKOUT CANNOT BE USED:
TAGOUT PROCEDURES MUST BE INITIATED
* (Unless It Can Be Demonstrated That Full Protection Can Be
Achieved by Other Means)
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 FOUR SPECIFIC REQUIREMENTS
1. Responsibility Vested in a Single Authorized Employee.
2. The Authorized Employee Must Have the Authority To
Determine Exposure Status of Group Members.
3. With Multiple Crews the Authorized Employee Must Be
Assigned the Responsibility of The Overall Job.
4.
The Authorized Employee Shall Affix an Individual LO/TO
Device at the Beginning of Work and Remove It at
Completion of the Work.
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When The Authorized Employee Is Unavailable
 PROCEDURES MUST INCLUDE, AS A MINIMUM:
1. Proof That the Employee Who Applied the Device Is
Unavailable.
2. A Valid Attempt to Inform the Employee Who Applied
the Device, That It Has Been Removed.
3. Adequate Notice to the Employee Who Applied The
Device, of the Removal of the Device Before That
Employee Returns to Work.
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OUTSIDE CONTRACTORS MUST:
 Inform Representatives of the Facility Of Their LO/TO
Procedures and Devices.
COMPANY REPRESENTATIVES MUST:
 Inform the Contractor of Internal LO/TO Procedures and
Devices.
 Ensure That the Contractor(S) Are Following LOTO
Procedures.
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 Remember, You Control Your Facility!
 Review Their Procedures With Them Before Starting the Job!
 Determine Their Safety Performance Record!
 Determine Who Is in Charge of Their People!
 Determine How They Will Affect Your Employees!
 Ensure Your Data on Your Facility Is Accurate!
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1. Develop and Strictly Adhere to LO/TO Procedures.
2. Establish and Enforce Safe Work Practices.
3. Ensure Proper Training and Supervision.
4. Strengthen and Modify Present Policies.
5. Understand the Relationship Between 29 CFR 1910.147
And the Business or Industry Involved.
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DEVICES AND TAGS MUST BE:
1.
2.
3.
4.
Durable
Standardized
Identifiable
Substantial
DEVICES AND TAGS ARE:
1. Designed to Prevent Accidental Energization.
2. Not Designed As a Substitution for Security.
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Worker Killed By Mixing Machine
NARRATIVE: An employee was assigned the task of cleaning
the inside of a sand mixer. The task was
conducted during a break in the production
cycle, caused by routine maintenance work. He
did this without anyone else’s knowledge. While
he was engaged in this, out of sight and hearing
of the others, an electrician started the machine,
killing the man inside. This plant had a written
lockout procedure, training had been given, and
all affected employees (including the deceased),
were issued keys and locks.
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What caused the death of the worker?
Do you believe there are multiple causes?
Are multiple OSHA Standard violations involved?
What could upper management have done?
What could the supervisor have done?
What could the co-workers have done?
To what extent was attitude responsible?
To what extent is a lack of written policy responsible?
To what extent is a lack of training responsible?
Do you believe there is a single cause to this accident
that, if removed would have prevented it?
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Worker Killed By High Voltage
NARRATIVE: A 13,800-volt main circuit breaker was under
routine inspection. A test instrument was used to
check for electrical energy. No electrical energy
was detected at the primary power contacts in the
circuit breaker. To verify the operation of the
tester, the sensitivity was readjusted and checked
against a known 120-volt receptacle. The tester
was found to be operable. As the journeyman
electrician approached one of the contacts with a
shop towel, an explosion, engulfed him in flames.
The power from the public utility company to the
main circuit breaker had not been shut off.
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What caused the death of the worker?
Do you believe there are multiple causes?
Are multiple OSHA Standard violations involved?
What could upper management have done?
What could the supervisor have done?
What could the co-workers have done?
To what extent was attitude responsible?
To what extent is a lack of written policy responsible?
To what extent is a lack of training responsible?
Do you believe there is a single cause to this accident
that, if removed would have prevented it?
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 THREE ELEMENTS TO THE PROGRAM:
1. ENERGY CONTROL PROCEDURES
2. EMPLOYEE TRAINING
3. PERIODIC INSPECTIONS
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What a typical Lock-Out / Tag-Out looks like
with an equipment lock.
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What a typical Lock-Out / Tag-Out looks like
with a personal protection lock.
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What a Lock-Out / Tag-Out looks like with a
contractor & personal protection lock.
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Occasionally you may see a yellow tag without a lock on
equipment that is out of service.
 This machine is Tagged Out
because it will not run
The tag will tell you what is
wrong with the equipment
 Never attempt to operate
equipment that has been
tagged
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In order to properly block or secure any piece of
mobile equipment, you must block or pin all
articulation joints. Failure to properly secure
articulation could result in vehicle movement
when it is blocked in the raised position.
Adequate Blocking?
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Equipment already has a lock and tag on it.
Do I have to place my own locks & tags?
YES!
everyone working on equipment
must place their own locks and tags
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The following examples illustrate tampered lockout
hasps. These hasps are easily pried open with minimal
effort. The construction and design does not provide
adequate protection based on policies we have set or
industry standards.
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This picture illustrates the new lockout hasp.
4 lock (stock code 2060184)
8 lock (stock code 2060192)
The heavy-duty hinge-style
hasp offers added pry
resistance. Steel construction
with 9/32" diameter shackles.
This new hasp will restore
lockout security.
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Properly plan the job.
Notify all affected employees in the area of work.
Shut down the equipment at the operating
controls.
Isolate all energy sources to equipment.
Lock and tag all isolating devices
Dissipate all stored or residual energy sources.
Verify the isolation.
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Stay clear of the area as much as possible.
Never attempt to assist .
Never interfere or tamper with a lock or tag.
Report all unusual situation to your supervisor or
foreman.
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Portable cord and plug connected equipment and
flexible cord sets (extension cords) shall be visually
inspected before use on any shift for external defects:
Loose parts
Deformed or missing pins
Damage to outer jacket or insulation
Evidence of possible internal damage
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Portable equipment must be handled in a manner which will
not cause damage.
Flexible electric cords connected to equipment may not be
used for raising or lowering the equipment.
Flexible cords may not be fastened with staples or
otherwise hung in such a fashion as could damage the outer
jacket or insulation.
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A GFCI is device intended for the protection of persons that
functions to de-energize a circuit.
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GFCIs constantly monitor electricity flowing in a circuit.
If the electricity flowing into the circuit differs by even a
slight amount from that returning, the GFCI will quickly
shut off the current flowing through that circuit.
GFCIs work• quickly, so they can help protect persons
from severe electric shocks and electrocution.
GFCI do not require a ground.
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Bathrooms over your sink or tub
Kitchens (sink area)
Basements unfinished.
Garages
Cord and Plug Deicing and Snow Melting Equipment.
On any portable electric equipment
Pools and hot tubs
Fountains
Boat houses
Wet Bar
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Electrical outlet
breaker trips
Yes
Was something NEW plugged
in?
Unplug Device
& Reset Breaker
Does it Trip Again?
Reset Breaker ONCE
Yes
Yes
Contact
Maintenance
Supervisor
Try Device in
New Circuit
Does it Trip Again?
No
Yes
Have device
inspected by
qualified
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No
Complete
Does it Trip Again?
No
When In Doubt
“Lock And Tag It Out”
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