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Guidelines for Controlling
Hazardous Energy
During Maintenance and Servicing
GUIDELINES FOR CONTROLLING HAZARDOUS ENERGY
DURING MAINTENANCE AND SERVICING
U.S. DEPARTMENT OF HEALTH AND HUMAN SERVICES
Public Health Service
Centers for Disease Control
tio n a l I n s t it u t e for Occupational Safety and Health
D iv isio n of Safety Research
Morgantown, West V irginia 26505
Sep tem b er
1983
D IS C L A IM E R
Mention of company names or products does not c o n s t it u t e
endorsement by the N ation al I n s t i t u t e fo r Occupational
Safety and Health.
DHHS (NIOSH) Publication No. 83-125
PREFACE
The Occupational Safety and Health Act o f 1970 emphasized the need fo r
standards to p ro tect the h ealth and s a fe ty of workers exposed to an
ever increasin g number o f p o t e n tia l hazards in the workplace. Section
2 2(d )(2 ) of the Act authorizes the D irector o f the National I n s t i t u t e
fo r Occupational Safety and Health (NIOSH) to make recommendations to
the Occupational Safety and Health Adm inistration (OSHA) concerning
improved occupational s a fe ty and h ealth standards.
The purpose o f
t h i s document i s to provide recommendations for preventing in j u r ie s
and d is e a s e caused by hazardous energy.
The document was developed through the use o f "systems a n a ly sis" so as
to provide a l o g i c a l means of performing maintenance and se r v ic in g
a c t i v i t i e s s a f e ly , with energy present, with energy removed, and
during the process o f r een erg izin g .
We g r a t e f u lly acknowledge the co n trib u tio n s to t h is document made by
r e p re sen ta tiv e s of other Federal agencies or departments,
labor
unions, trade and p r o fe s sio n a l a s s o c ia t io n s , c o n su lta n ts, and the
s t a f f o f the I n s t i t u t e .
Whatever the co n trib u tion s
made byoth ers, conclusions expressed in
th is document are those
o f the I n s t i t u t e ,
and we are s o l e l y
resp o n sib le for them.
However, a l l comments made by those o u tsid e
NIOSH, whether or not incorporated, were considered carjêïully and were
sent with the document to the
Occupational Sa^e(ty\ and Health
Adm inistration.
.A Dona kid M illa r, M.D.
A ss is ta n t Surgeon General
D irector, National I n s t i t u t e fo r
Occupational Safety and Health
The D iv isio n o f Safety Research, NIOSH, had primary r e s p o n s i b i l i t y for d e v e l­
opment of the recommended g u id e lin e s for c o n t r o llin g hazardous energy during
maintenance and s e r v ic in g .
Ted A. P e t t i t served as p ro ject o f f i c e r and docu­
ment manager. Boeing Aerospace developed the b asic information for co n sid era ­
tio n by NIOSH s t a f f and c o n su lta n ts under contract No. 210-79-0024.
The NIOSH d iv is io n review o f th is document was provided by David L. West,
Ph.D., Robert G. McDonald (D iv is io n o f Standards Development and Technology
T ran sfer), David J. Huebener (D iv is io n o f P h ysical Sciences and E ngineering),
John R. Etherton, Murray L. Cohen, Ph.D., and James A. Oppold, Ph.D. (D iv is io n
o f Safety Research).
Technical e d itin g for the document was provided by
Herbert Linn (D iv isio n o f Safety Research).
iv
ABSTRACT
This document has been developed to provide g u id e lin e s for c o n t r o llin g hazard­
ous energy during maintenance and s e r v ic in g o p e r a tio n s.
The g u id e lin e s were
developed by a s s o c ia tin g work p r a c tic e s with attendant r i s k s .
Methods of
obtaining information which contributed to the development o f the g u id e lin e s
included s i t e v i s i t s to various in d u s tr ia l f a c i l i t i e s , the c o l l e c t i o n and
a n a ly s is of data r ela ted to maintenance techniques and p r o c e s s e s , ev a lu a tio n
of accident case s tu d ies and in cid en t report inform ation, e x te n siv e searches
of l i t e r a t u r e , and review of other pertin en t data.
The g u id e lin e s emphasize
rec o g n itio n of hazards and safe work procedures.
This document provides a l o g i c a l system for performing maintenance and
se r v ic in g a c t i v i t i e s s a f e l y , and recognizes that such a c t i v i t i e s can be per­
formed s a f e ly with energy p resen t, with energy removed, and w hile reen er­
g iz in g .
The recommended g u id e lin e s were developed through a systems a n a ly s is
approach. The lo g ic tr e e (Figure I) provides a ste p -b y -ste p diagram for con­
t r o l l i n g hazardous energy that should be u t i l i z e d
in the formulation of
s p e c i f i c maintenance and s e r v ic in g procedures.
v
REVIEW CONSULTANTS
Frederick D. Broussard, P.E.
Safety and Training S e r v ic e s , Inc.
5615 Corporate Boulevard
Baton Rouge, Louisiana 70808
Leonard S. Corey
Engineering Supervisor
Eastman Kodak Company
1669 Lake Avenue
Rochester, New York 14650
Burleigh J. F u se lie r
O il, Chemical, and Atomic Workers Union
913 Bradley
Sulphur, Louisiana 70663
Kenneth L. Lauch
I n d u stria l R elations S ta ff - Safety
General Motors Corporation
D e tr o it, Michigan 48202
J. F. Naber
D irector of Health and Safety
Sun Petroleum Products Company
1608 Walnut S tre e t
P h ila d elp h ia , Pennsylvania 19103
Frank J. Rapp, P.E.
Chief, Health and Safety S ta ff
UAW S ocial Security Department
8000 East Jefferson Avenue
D e tr o it, Michigan 48214
William L. Wachs
Manager, Quality Assurance
C incinnati Milacron, Inc.
47C1 Marburg Avenue
C in cin n a ti, Ohio 45209
Ray E. Witter
D irecto r, Safety and Property Protection
Monsanto Company
800 North Lindbergh Boulevard
St. Louis, Missouri 63166
CONTENTS
PAGE
P refa ce
m -
Abstract
Review Consultants
I.
II.
III.
v
vi
Introduction
1
A. Management Commitment
1
B. D e fin it io n s
1
C. Working With or Without Energy Present
5
D. Energy Sources
6
I n v e s tig a tio n of the Problem
7
A. The Accident Scenarios
7
B. S t a t i s t i c a l I n v e s tig a tio n
9
Guidelines for C ontrolling Hazardous Energy During Maintenance
and Servicing
11
A. C ontrolling Hazardous Energy Sources
11
B. C ontrolling Hazards with Energy Present
15
IV.
Conclusions
16
V.
Research Needs
18
A. Study Continuation
18
B. Guidelines for Other Maintenance Hazards
18
C. P o te n tia l Hazards in New Technological A p p lication s
19
VI.
References
20
VII.
Appendix A - Examples of A lternate Methods of I s o la t in g or
Blocking Energy and Securing the P o in t(s ) o f Control
26
Appendix B - Examples o f Accidents Preventable by Good Energy
Control Techniques
32
VIII.
IX.
X.
XI.
Appendix C - Evaluation of E xistin g Standards - I n te r n a tio n a l,
N ation al, S ta te , and Consensus
43
Appendix D - E x istin g OSHA Standards Related to Lockout, Tagout, or
the Control o f Energy During Maintenance
55
Appendix E - References Supporting Guidelines for C ontrolling
Hazardous Energy During Maintenance and S ervicing
70
FIGURE
I
Diagram for C ontrolling Hazardous Energy During Maintenance and
Servicing
2
TABLES
I
Accident Cause Summary
8
C-l
Comparison
Summary of Types of Energy
45
C-2
Comparison
Summary of Indu stries A ffected
46
C-3
Comparison
Summary o f C riteria Requirements
47
C-4
Lockout and Tagout National Standards
49
C-5
State Standards
50
C-6
In tern a tio n a l Standards
53
C-7
Consensus Standards
54
v iii
I .
INTRODUCTION
This document i s prim arily intended to o u t lin e methods o f p r o te c tin g workers
engaged in maintenance and s e r v ic in g o f machines, p r o c e s s e s , or systems from
injury by the unexpected and u n r e s tr ic te d r e le a s e o f hazardous energy.
Maintenance a c t i v i t i e s can be performed with or without energy p r e se n t.
A
probable, underlying cause o f many ac cid en ts r e s u lt in g in injury during main­
tenance i s that work i s
performed without the knowledge that the system,
whether energized or n o t , can produce hazardous energy.
Unexpected and
u n r e s tr ic te d r e le a s e o f hazardous energy can occur i f :
1) a l l energy sources
are not id e n t if ie d ; 2) p r o v isio n s are not made for s a fe work p r a c tic e s with
energy present; or 3) d e a c tiv a te d energy sources are r e a c t iv a t e d , m istak en ly,
in t e n t io n a l ly , or a c c id e n t a lly , without the maintenance worker's knowledge.
Problems inv olvin g co n tro l o f hazardous energy require procedural s o lu t io n s .
The lo g ic o f the g u id e lin e s proposed in t h is document for c o n t r o llin g hazard­
ous energy i s g r a p h ic a lly represented in Figure I , Diagram for C o n tro llin g
Hazardous Energy During Maintenance and S e r v icin g .
This diagram should be
u t i l i z e d by those personnel r esp o n sib le for the design o f s a fe work procedures
s p e c i f i c to ind iv id u al employer requirements.
Employers must adopt such procedural s o lu tio n s for c o n t r o llin g hazards to
ensure worker s a fe ty during maintenance. However, such procedures are e f f e c ­
t i v e only i f s t r i c t l y enforced.
Employers must, t h e r e fo r e , be committed to
s t r i c t implementation o f such procedures.
A.
MANAGEMENT COMMITMENT
During v i s i t s to se v e r a l pla n ts conducted as part o f t h is study, employers
str e s se d that cooperation between management personnel and employees i s essen­
t i a l to the implementation o f s a f e t y programs, in clu d in g energy control
measures. Many employers b e lie v e that f i r s t li n e su p erviso rs and employees
comprise weak lin k s in s a f e t y programs.
Presumably, th ese employees remain
unconvinced that employers r e a l l y want to implement s t r i c t s a f e t y r u le s .
Employee perception o f management a t t it u d e s toward s a fe ty procedures, tr a in ­
in g , or m otivation campaigns forms a b a s ic , though in t a n g ib le , in flu e n c e upon
the r e l a t i v e success or f a il u r e o f any s a f e t y program. Safety programs are
more l i k e l y to be e f f e c t i v e i f management demonstrates to employees a firm
commitment to achieve s a fe working c o n d itio n s .
B.
DEFINITIONS
Certain terms used throughout these g u id e lin e s may have d i f f e r e n t meaning to
d if f e r e n t people and may be to p ic s o f disagreement.
A term may be s e l f explanatory for some in d u s tr ia l a p p lic a tio n s , but c o n tr o v e r s ia l in other
a p p lic a tio n s . The terms below have the fo llo w in g d e f i n i t i o n s for the purpose
o f t h is document.
Maintenance and S e r v ic in g . The tasks necessary to keep a machine, p r o c ess, or
system in a s t a t e o f rep air or e f f i c i e n c y . This a c t i v i t y inclu des in s p e c tio n ,
s e r v ic in g , r e p a ir , tr o u b lesh o o tin g , setu p , c le a r in g jams, and other r e la te d
a c t i v i t i e s . These a c t i v i t i e s are not considered to commence on a new system
F i g u r e I. D I A G R A M
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IM P L E M E N T A T IO N O F S A F E G U A R D S T O C O N T R O L H A Z A R D S WITH
E N E R G Y P R E S E N T M A Y BE C H O S E N IN S T E A D O F H A Z A R D O U S
E N E R G Y E L IM IN A T IO N B Y D E V IC E S O R T E C H N IQ U E S^ W H E N IT
CAN BE D E M O N STR A T ED T H A T H A Z A R D S A R E C O N TRO LLED
W ITH E N E R G Y P R E S E N T B Y :
1 . I D E N T IF Y IN G A L L H A Z A R D O U S E N E R G Y S O U R C E S A N D
H A Z A R D O U S R E S ID U A L E N E R G Y , A N D
2 . D O C U M E N T IN G A P R O C E D U R E F O R A N D D E M O N S T R A T IN G
T H A T T H E P R O C E D U R E W ILL C O N T R O L H A Z A R D S R E S U L T IN G
F R O M E A C H H A Z A R D O U S E N E R G Y ID E N T IF IE D .
T H E D E C IS IO N A T T H IS P O IN T IS P R E D E T E R M IN E D B Y T H E O R IG IN A L
O P T IO N C H O S E N IN
.
I
I
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Legend
R E C T A N G L E S Y M B O L - I D E N T IF IE S A N E V E N T T H A T R E S U L T S F R O M T H E C O M B IN A T IO N
O R E X C L U S IO N O F A C T IV IT IE S O R E V E N T S .
A N D G A T E - D E S C R IB E S A N O P E R A T IO N W H E R E B Y C O -E X IS T E N C E O F A L L IN P U T S A R E
R E Q U IR E D TO P R O D U C E A N O U T P U T E V E N T S .
O R G A T E - D E F I N E S S IT U A T IO N W H E R E B Y A N O U T P U T E V E N T W ILL O C C U R IF O N E O F
T H E IN P U T S E X IS T .
D E C ISIO N G A T E -
E X C L U S IV E O R G A T E W H IC H F U N C T IO N S A S A N O R G A T E B U T
P R O V ID E S A F O O T N O T E D ( t > ) L IS T O F D E C IS IO N C R IT E R IA
A R E N O T S E L F E V ID E N T .
D IA M O N D - D E S C R IB E S A N E V E N T T H A T
IS -C O N S ID E R E D B A S IC IN A
G IV E N L O G IC S E Q U E N C E .
E V E N T IS N O T D E V E L O P E D
FURTH ER BEC A U SE
D E V E L O P M E N T IS O B V IO U S .
u n t i l i t becomes o p e r a tio n a l. For s i m p li f ic a t io n , "maintenance and servicin g"
are referred to as "maintenance" throughout much o f the document.
"Inspection" i s defined as checking or t e s t in g machinery, equipment, system,
e t c . , ag a in st e s ta b lis h e d standards. The d e f i n i t i o n su gg ests that the o b ject
being inspected has a function and should comply with a standard. From t h i s ,
i t i s deduced that (1) a standard must e x i s t that: e s t a b lis h e s the good or bad
c h a r a c t e r is t ic s o f the o b ject being inspected and (2) the o b ject must be com­
p le t e so that i t can perform i t s function; i . e . , c o n s tr u c tio n , assembly, or
manufacture should be complete before the o b ject can be maintained.
I f the
o b ject has more than one fu n c tio n , i t may be necessary to change or add parts
to the ob ject so th at i t may perform the d if f e r e n t fu n c tio n s.
The a c t i v i t y
required to make the changes or a d d itio n s i s considered maintenance. In some
se c to r s o f industry the term "set-up" i s used to denote the a c t i v i t i e s needed
to change the fu nctions o f the equipment.
"Service" i s defined as rep air or maintenance.
The d e f i n i t i o n of s e r v ic e i s
synonymous with maintenance; however, s e r v ic e (as used in th is rep ort) r e fe r s
to the a c t i v i t i e s needed to keep a machine, p rocess, or system in a s t a t e of
e f f i c i e n c y ; e . g . , changing crank case o i l , g reasing, c le a n in g , p a in tin g ,
a d ju s tin g , c a lib r a t in g , e t c .
Energy. For th is document, "energy" means mechanical motion; p o t e n tia l energy
due to pressure, g r a v ity , or springs; e l e c t r i c a l energy; or thermal energy
r e s u lt in g from higfr or low temperature.
As suggested by one o f the approaches taken by in d u stry , maintenance may be
performed with power o f f or power on.
Maintenance a c t i v i t i e s , however, are
always performed with some form o f energy on and some form o f energy o f f .
Thus, the concept o f "power o ff" or "power on" im plies that power, the time
ra te at which work is done or energy em itted or tr a n sfe rr e d , can be turned
o f f . This concept i s too r e s t r i c t i v e because i t does not consider gra v ity or
temperature. The term "energy," as opposed to "power," i s th erefo re suggested
as an a lt e r n a t iv e , because current consensus standards and other l i t e r a t u r e on
t h i s su b ject use t h is term.
The concept o f energy (any qu antity with
dimensions mass times length squared divided by time squared), however, i s too
in c lu s iv e .
The concept o f energy, for the purpose o f t h i s document, i s
lim ite d to:
1.
K in etic energy - energy possessed by a body by v ir t u e o f i t s motion.
2.
P o te n tia l energy - energy possessed by a body by v ir tu e
a g r a v ity f i e l d .
3.
E l e c t r i c a l energy - energy as a r e s u lt
source or a s t a t i c source.
4.
Thermal energy - energy as a r e s u lt o f mechanical work, r a d ia tio n , chemi­
c a l r e a c tio n , or e l e c t r i c a l r e s is t a n c e .
o f i t s p o s it io n in
o f a generated e l e c t r i c a l
power
Radiation, the process by which electrom agnetic energy i s propagated, i s not
included because th is type o f energy a f f e c t s in t e r n a l organ to le r a n c e , which
i s a health e f f e c t .
-3 -
Personnel Hazard. A co n d itio n which could lead to injury or death. This con­
d i t i o n should be recognized by a person fa m ilia r with the p a r tic u la r circum­
stances and fa c ts unique to a p a r tic u la r in d u str y .
The fo llo w in g concept o f
personnel hazard was used to o b j e c t iv e ly id e n t if y hazards to humans: A per­
sonnel hazard e x i s t s when the environment, c o n d it io n s , natural phenomena, or
equipment c h a r a c t e r is t ic s may r e le a s e l e v e l s o f energy that exceed human
to le r a n c e .
This concept encompasses the human p h y sio lo g ic a l tolera n ce to
trauma as w e ll as in te r n a l organ to lera n ce to environment.
Iso la te d or Blocked Energy. Energy i s considered is o la t e d or blocked
flow would not be r e a c tiv a te d by a foreseea b le unplanned e v en t.
" is o la te " means to s e t apart from o th e r s .
The term "block" (noun)
o b s ta c le or o b stru ctio n ; or, (verb) to make u n su ita b le for passage or
by o b s tr u c tio n , to prevent normal fu n ctio n in g .
when i t s
The term
means an
progress
These terms are s im ila r in meaning, but they cannot be used synonymously in
a l l in s ta n c e s . Although they may describe the same fu n ction ( i . e . , prevention
o f the normal flow o f en erg y), the way in which the function is performed i s
d iffe re n t.
For in s ta n c e , to co n tro l g r a v ita tio n a l energy, the energy should
be blocked in the sense that an o b s ta c le or o b str u c tio n i s placed.
I t would
be in correct to use the term " is o la te " when r e fe r r in g to the con trol o f g r a v i­
t a t io n a l energy. E l e c t r i c a l energy should be c o n tr o lle d by i s o l a t i n g i t in
the sense that i t i s s e t apart, or d isconnected. It would be in c o r re c t to use
the terra "blocked" when r e fe r r in g to the c o n tr o l of e l e c t r i c a l energy.
The terms may be used synonymously in some c a s e s , such as when r e fe r r in g to
blocking the passage o f f lu id or is o l a t i n g the pressure in a p ip e.
Sometimes
the d if fe r e n c e in meaning becomes evident only by the method used to implement
the fu nction.
P o in t(s )
o f C ontrol.
The point or poin ts from
- i s o l a t i n g , or - d i s s i p a t i n g d ev ices are c o n tr o lle d .
which
energy-blockin g,
Securing the P o in t(s ) o f C ontrol. The p o in t(s ) o f co n tro l are secured to pre­
vent unauthorized persons from r e a c tiv a t in g the flow o f energy. Securing i s a
separate and d i s t i n c t a c tio n from i s o l a t i n g or blocking the energy sources.
The use o f lo c k s , t a g s , or postin g a q u a lif ie d person or a combination th ereo f
are methods o f accomplishing th ese c r i t e r i a .
D issip a te Energy.
To cause energy to be spread out or reduced to l e v e l s
t o le r a b le by humans.
When the word " d issip a te" i s applied to the word
"energy," the term may be in terp reted d i f f e r e n t l y .
The fo llow in g concepts
should be used to determine the d is s ip a t i o n a c t i v i t i e s :
1. D issip a te Mechanical Motion - Motion tends to continue because o f i n e r t i a
a f t e r removal o f energy; th e r e fo r e , mechanical motion should be d is s ip a t e d .
For example, a flyw heel should be allowed to come to r e s t before s t a r t in g work.
2.
D issip a te P o t e n tia l Energy - P o t e n tia l energy can be manifested in the
form o f pressure (above or below atm ospheric), sp r in g s, and g r a v ity . Gravity
-4 -
can never be elim in ated or d is s ip a te d ; i t can only be c o n t r o lle d .
Springs
under tension or compression can be r e le a se d ( t o d i s s i p a t e stored energy) or
the stored energy can be c o n t r o lle d .
Pressure may be blocked, i s o l a t e d , or
d is s ip a t e d .
The term " d is s ip a t e pressure" im p lies reducing pressure to a
l e v e l that would not harm humans.
Normally, t h is pressure va lu e i s atmos­
pheric .
3.
D is sip a te E l e c t r i c a l Energy - D is s ip a tio n o f e l e c t r i c i t y may be accom­
p lish ed by "grounding" the d e e l e c t r i f i e d portion o f the c i r c u i t a f t e r i t has
been i s o l a t e d .
Grounding l i v e c i r c u i t s may be c a ta s tr o p h ic .
D is s ip a tio n o f
e l e c t r i c a l energy inclu des the a c tio n s n ecessary to prevent the buildup of
e l e c t r i c a l p o t e n tia l ( s t a t i c e l e c t r i c i t y ) .
4.
D is sip a te Chemicals - Chemical r e a c tio n s are exothermic or endothermie.
Exothermic r ea c tio n s r a is e temperatures, which may cause a v a r ie t y o f e f f e c t s
such as f i r e s , e x p lo s io n s , burns, e t c .
Endothermie r e a c tio n s lower tempera­
tures and cause the need for a d d itio n a l h e a t.
Some elements manufactured by
endothermie r e a c tio n are used as e x p lo s iv e s or have e x p lo s iv e c h a r a c t e r i s t i c s
because o f th e ir i n s t a b i l i t y and rapid r e le a s e of energy. For the purpose of
t h i s document, emphasis i s placed on the e f f o r t necessary for the prevention
or control o f chemical r e a c t io n s .
Thus, the term " d is s ip a t io n o f chemicals"
im plies those a c tio n s needed to prevent chemical r e a c tio n s that would (1)
r a is e or lower temperatures or (2 ) cause e f f e c t s which humans cannot t o l e r a t e .
5.
D is sip a te Thermal Energy - Human to le r a n c e to temperature i s very
lim it e d . Human t i s s u e i s harmed when i t i s exposed to temperatures above 45°C
(113°F) or below 4°C (3 9 °F ). Since temperature cannot be is o la t e d or blocked,
the only way to c o n tr o l i t s e f f e c t s on humans i s through d i s s i p a t i o n or
employee p r o te c tio n .
Mechanical motion, e l e c t r i c a l r e s i s t a n c e , chemical
r e a c t io n s , and r a d ia tio n w i l l r a is e the temperature o f m a ter ia ls which, in
turn, can burn or damage human t i s s u e .
Therefore, when energy sources that
a f f e c t temperature
are i d e n t i f i e d in equipment, p r o c e s s e s , or system s,
co n tro ls of the energy source should be e f f e c t e d to allow the temperature to
d is s ip a t e to a to le r a b le l e v e l .
C.
WORKING WITH OR WITHOUT ENERGY PRESENT
The b a sic d e c isio n
that must be made before maintenance begins i s : Can the
task be accomplished s a f e l y with or without energy present or is i t necessary
to deenergize before i n i t i a t i n g maintenance?
Concepts which should be considered in t h i s d e c is io n include:
1) Energy i s
always present; 2)
energy i s not n e c e s s a r ily dangerous; and3) danger is
present only when energy i s r ele a sed in q u a n t it ie s which exceed human t o l e r ­
ances. Further, prior to the development o f s p e c i f i c energy c o n tr o l measures,
a l l energy sources should be:
1) i d e n t i f i e d ; 2) analyzed independently; and
3) analyzed in combination with any other energy sources p r e se n t.
The follow ing paragraphs present c r i t e r i a which should be considered during
a n a ly s is of s p e c i f i c energy so u rces.
-5 -
D.
ENERGY SOURCES
Mechanical motion can be lin e a r t r a n s la t io n or r o ta tio n , or i t can produce
work which, in turn, produces changes in temperature. This type of energy can
be turned o f f or l e f t on.
P o t e n t ia l energy can be due to pressure (above or below atm ospheric), sp rin g s,
or g r a v ity .
Maintenance i s always conducted with grav ity on.
P o te n tia l
energy manifested as pressures or in springs can be d is s ip a te d or c o n tr o lle d ;
i t cannot be turned o f f or on.
E le c t r ic a l energy r e fe r s to generated e l e c t r i c a l power or s t a t i c e l e c t r i c i t y .
In the case o f generated e l e c t r i c i t y , the e l e c t r i c a l power can be turned on or
turned o f f .
S t a tic e l e c t r i c i t y may not be turned o f f ; i t can only be d i s s i ­
pated .
Thermal energy i s m anifested by high or low temperature. This type o f energy
i s the r e s u lt o f mechanical work, r a d ia tio n , chemical r e a c tio n , or e l e c t r i c a l
r e s is t a n c e .
It cannot be turned o f f or elim in ated; however, i t can be d i s s i ­
pated or c o n tr o lle d .
Chemical r ea c tio n i s manifested by exothermic or endothermic e f f e c t s .
In
e it h e r c a s e , the e n e rg y -o n /e n e rg y -o ff approach does not apply.
Any m aterial
which could chem ically react should be e lim in a te d , d is s ip a t e d , or c o n tr o lle d .
That i s , some p o s i t i v e measures must be taken to (1) e lim in a te the chemical so
th a t no chemical r ea c tio n can take p la c e , or (2) co n tro l the r ea c tio n so that
the energy r ele a sed by the chemical r ea c tio n w i l l not harm humans. Methods o f
c o n tr o llin g hazards due to chemicals or chemical r ea c tio n s as energy sources
have not been addressed in t h i s document because o f th e ir co m p lex ity .
These c r i t e r i a in d ic a te that some energy sources can be turned o f f , some can
be d is s ip a t e d , other sources o f energy can be e lim in a te d , and some can only be
c o n tr o lle d . The fo llo w in g examples i l l u s t r a t e how t h i s concept i s a p p lie d .
Example 1:
The task i s the removal and replacement o f a spring in a car.
P o t e n tia l
energy i s present due to the force o f g ra vity and o f the te n sio n or compres­
sio n o f the sp rin g . The force o f g r a v ity can be c o n tr o lle d only by blocking
the c a r. The energy stored in the spring can be d is s ip a te d or c o n t r o lle d . I t
i s u s u a lly c o n tr o lle d by blocking the r e le a s e o f the sp rin g .
Therefore, the
d e c is io n lo g ic in d ic a te s that maintenance must be done with energy p resen t.
Example 2:
A large mixing drum with in te r n a l r o ta tin g blades is in need of r e p a ir .
One
o f the mixing blades i s out o f alignment.
The e s ta b lis h e d maintenance pro­
cedure requires the entry o f two mento r e a lig n the blade.
The e l e c t r i c a l
energy source can be switched o f f and locked out and/or the mechanical li n k ­
ages can be disco n n ected . The lockout at the switch w i l l provide a p h y sic a l
b a r r ier and a tag w i l l i d e n t if y the task being performed. In a d d itio n , i f the
mechanical linkages are d isconnected, a l l energy sources, except g r a v ity , w i l l
be removed from the system.
-6-
II.
IN V E S T IG A T IO N OF THE PROBLEM
Much o f the data examined during t h is study did not include enough s p e c i f i c
information to id e n t if y the fa c to r s causing or co n tr ib u tin g to accid en ts which
occur during maintenance as a r e s u lt o f inadequate energy con tro l measures.
However, an e x te n s iv e search o f world l i t e r a t u r e r e la te d to maintenance haz­
ards and maintenance hazard c o n tr o ls , revealed a number o f accid en t scen arios
which could be evaluated in the attempt to id e n t if y gen eric causes o f
m aintenance-related a c c id e n ts .
Accidents which could be a ttr ib u te d to the
presence o f un controlled energy during maintenance a c t i v i t i e s were s e le c t e d
for c lo s e r study. Although the lim ited nature o f the information precluded
exact cause determ ination, the scen a rio s did provide a general in d ic a tio n o f
causes or contribu ting causes as w e ll as i l l u s t r a t i o n s o f the types o f a c c i ­
dents that can occur when hazardous l e v e l s o f energy are not c o n tr o lle d .
A.
THE ACCIDENT SCENARIOS
Out o f 300 accident scen ario s found in 14 d if f e r e n t so u rces, 59 a ccid en ts were
s e le c t e d to i l l u s t r a t e that adequate energy co n tro l methods may have prevented
the a c c id e n ts .
(A b r i e f d e s c r ip tio n o f each accident is included in Appendix
B.) Causes o f these a c cid en ts have been c a teg o rized as fo llo w s:
1.
Maintenance a c t i v i t i e s were i n i t i a t e d without attempting to deenergize
the equipment or system, or con trol the hazards with energy present.
Twenty-seven a c cid en ts f e l l in to t h i s c a te g o ry .
Typical o f th ese
a ccid en ts was accid en t No. 10 (Appendix B), in which an experienced
repairman saw a p iece o f wire stuck in a f i l t e r wheel. He attempted
to remove the wire w hile the wheel was in motion. Losing h is balan ce,
he f e l l in to the wheel. His le g was crushed and had to be amputated.
2.
Energy blockage or i s o l a t i o n was attempted, but was inadequate.
Six in c id e n ts were the r e s u lt o f i n e f f e c t i v e energy i s o l a t i o n or
blockage.
An example was accident No. 30 (Appendix B), in which a
worker attempted to prevent an e le v a to r from moving by jamming the
doors open with a plank while the e le v a to r was on the second f l o o r ,
and then turning o f f the o u tsid e panel switch on the main f l o o r .
He
was k i l l e d w hile working on the main flo o r when the e le v a to r returned
to i t s home base rather than remaining on the second f lo o r .
3.
Residual ( p o t e n t ia l) energy was not d is s ip a t e d .
Accident No. 34 (Appendix B) r e s u lte d in injury due to fa ilu r e to
d is s ip a t e r e sid u a l energy.
The worker turned o f f the power to a
packaging machine and attempted to remove a jam. Residual hydraulic
pressure a c tiv a te d the holding device causing the in ju r y .
4.
A ccidental a c t iv a t io n o f energy.
Twenty-five o f the a ccid en ts were caused by a c c id e n ta l a c t iv a t io n .
These a c cid en ts were caused by e it h e r (1) persons u n in te n tio n a lly
-7 -
a ctu atin g c o n tr o ls , or (2) by other persons a c tiv a tin g the c o n tr o ls ,
not r e a li z in g that maintenance was in progress. The r e s u l t , in e it h e r
c a s e , can be d is a s tr o u s .
An accident t y p ic a l o f t h is category was accident No. 36 (Appendix B)
in which a mechanic was rep airing an e l e c t r i c a l l y operated c a u s tic
pump.
A co-worker dragged a cable across the to g g le switch that
operated the pump, and the mechanic was sprayed with c a u s t i c . Another
i n c id e n t , accid en t No. 38 (Appendix B), occurred when an employee was
c u ttin g a pipe with a torch and d i e s e l fu e l was m istakenly discharged
in to the l i n e . The ensuing i g n i t io n o f the d i e s e l fu el r e su lte d in a
fa ta lity .
These types o f a ccid en ts are preventable i f e f f e c t i v e energy c o n tr o l tech ­
niques or procedures are a v a ila b le , workers are trained to use them, and
management provides the m otivation to ensure th e ir u se.
Table I summarizes
the accident causes and in d ic a te s the a p p lic a b le g u id e lin e s from Chapter I I I
which, i f fo llow ed , would have elim inated the hazard and prevented the a c c i ­
d ent. In Appendix B, an energy control method th at would have been e f f e c t i v e
i s i d e n t i f i e d for each e n tr y . The methods shown are only examples. For many
c a s e s , s ev e r a l energy co n tro l techniques could have been used to prevent the
a c c id e n t.
In a d d itio n , Appendix B i d e n t i f i e s the hazard typ es, energy
so u r ce s, and accid en t causes as w e ll as consequences o f each a c c id e n t.
TABLE I
ACCIDENT CAUSE SUMMARY*
ACCIDENT CAUSE
INITIATED ACTIVITY
WITHOUT ATTEMPTING
TO CONTROL HAZARDOUS
ENERGY
*
NUMBER OF
ACCIDENTS
APPLICABLE
GUIDELINES
27
A . I . , A .2 . , A .3 . ,
AND
B . I . , B .2 ., B.3.
ENERGY ISOLATION
WAS ATTEMPTED
BUT WAS INADEQUATE
6
A. 2. a . and A. 2 . d .
RESIDUAL ENERGY WAS
NOT DISSIPATED
1
A .2 .b . and A .2 .d .
ACCIDENTAL ACTIVATION
OF ENERGY
25
A .2 . a . , A .2 .C .,
A. 2 . d . and A .2 . e .
ALL CAUSES
59
See Appendix B for Accident D escription s
B.
S T A T IS T IC A L
IN V E S T IG A T IO N
Besides the li t e r a t u r e search, a s t a t i s t i c a l in v e s t ig a t i o n was undertaken in
the attempt to obtain data that would help to i d e n t if y fa c to r s causing or
c o n trib u tin g to the type o f a ccid en t under co n sid e ra tio n .
I t was planned that s t a t i s t i c a l accid en t data would be obtained that r e la te d
to inadequate energy c o n tr o ls during maintenance.
The data would help to
id e n t if y i n e f f e c t i v e c o n tr o l methods and p a r tic u la r problems that should be
avoided. Manual and automated searches were conducted to lo c a te the informa­
t io n .
Most o f the data found, however, did not include enough s p e c i f i c
information to i d e n t if y the fa c to r s causing or co n trib u tin g to the a c c id e n ts .
This fin din g c o in c id e s with the r e s u lt s o f a study conducted by the National
S afety Council and reported on June 30, 1978 to the members of the National
Safety Council P r e sid e n t's Advisory Committee and Technical Work Session
P a r tic ip a n ts o f the National Program to Improve Occupational Injury Informa­
t io n . The report s t a t e s :
"Problems with the te c h n ic a l q u a lity o f current d a ta . These include the
lack o f d e t a i l , c o n s is t e n c y , and relevance for the development o f counter­
measures in current occupational injury data.
E x istin g data are very
lim it e d .
Occupational injury data are o ften gathered prim arily for the purpose o f
processing worker's compensation claims rather than for developing
countermeasures.
Most current information systems emphasize data about
the in ju r y , not the a c c id e n t, and about the end r e s u lt s o f the a ccid en t
sequence, rather than the p r e c ip ita tin g events and co n d itio n s leading to
the in ju r in g e v en t. Data o f the l a t t e r type are o fte n much more important
for the development o f countermeasures.
Ihe ANSI Z16.2 American National Standard Method o f Recording Basic Facts
R elating to the Nature and Occurrence o f Work I n j u r ie s , or an adaptation
o f th is coding method, i s used almost e x c lu s i v e ly among both the Federal
and State Government agencies and p riv a te s e c to r information systems. The
ANSI Z16.2 method i s extremely lim ite d and i s designed prim arily as a
monitoring to o l for grouping a ccid en ts by major types and for fla g g in g a
lim ite d number o f i s o la t e d fa c to r s about a c cid en ts so that the cases can
be r e c a lle d when data a n a ly s is b e g in s.
The ANSI Z16.2 method i s not
designed as an a n a ly t ic a l t o o l for id e n t if y in g the p a tte r n s, the p r e c ip i­
ta t in g events and con d itio n s in an accid en t sequence, or the r e la t io n s h ip s
among con tr ib u tin g causal fa c to r s in an a ccid en t that are normally needed
for countermeasure development."
Attempts to obtain more s p e c i f i c data from such sources as a s s o c ia t io n s ,
insurance companies, labor unions, and industry proved u n su ccessfu l because o f
one or more o f the fo llo w in g reasons:
1.
Trade a s s o c ia tio n s did not c o l l e c t the data, or the data were not
c o lle c t e d in a u s e fu l format or for s p e c i f i c enough in s ta n c e s .
2.
Data from insurance companies, p r iv a te companies, and unions
considered proprietary and/or involve l i a b i l i t y c o n s id e r a tio n s .
-9 -
are
3.
Changing format and e d it i n g the data would be too time consuming or
c o s t l y (the data are considered proprietary without changing format
and e d i t i n g , and insurance companies are not in t e r e s t e d in reworking
the d a t a ) .
-1 0 -
III.
GUIDELINES FOR CONTROLLING HAZARDOUS ENERGY DURING
MAINTENANCE AND SERVICING
(The fo llo tr in g g u id e lin e s f o r c o n t r o l l in g h a za rd o u s energy d u rin g m a in te ­
nance and s e r v ic in g o f m a c h in ery , p r o c e s s e s , o r sy ste m s a re shown g r a p h ic a lly
in F igure I . R e fe re n c e s which su p p o rt th e u se o f each s p e c i f i c g u id e lin e may
b e fo u n d , c r o s s - r e fe r e n c e d t o th e t e x t o f t h i s s e c t i o n , in A ppendix E .)
In o rd er to p r o te c t th e w orker from e n e r g y -r e la te d h a za rd s d u rin g m aintenance
o r s e r v ic in g o f a m achine, p r o c e s s o r s y s te m , m ethod A o r B o f h a za rd c o n tr o l
m ust be ch o sen .
Several fa c to r s must be considered in decidin g i f energy should be elim in ated
and determining what method o f hazard c o n tr o l should be implemented for a
p a r tic u la r a p p lic a tio n .
Factors that should be considered inclu de (1) the
energy l e v e l , (2) the a ccess or proximity to the energy source necessary to
accomplish the work, and (3) whether proven methods e x i s t for performing the
task s a f e l y with hazardous energy present.
A.
CONTROLLING HAZARDOUS ENERGY SOURCES
1 . I f d e e n e r g iz in g i s c h o se n , a thorough in s p e c tio n sh o u ld be p erfo rm ed
t o i d e n t i f y a l l p o t e n t i a l l y ha za rd o u s en erg y s o u r c e s , in c lu d in g a d ja c e n t
equipm ent o r energy so u rc e s th a t r e p r e s e n t h a za rd s t o p e r s o n n e l.
2 . When a l l p o t e n t i a l l y hazardous so u rc e s o f energy have been i d e n t i f i e d ,
each so u rc e m ust be c o n tr o lle d and th e d e v ic e c o n t r o l l i n g th e energy so u rc e
m ust be sec u red and v e r i f i e d . The fo llo tr in g a re s te p s to a cco m p lish th e con­
t r o l o f hazardous energy s o u rc e s:
a.
A l l energy s o u rc e s i d e n t i f i e d a s h azardous s h a l l be i s o l a t e d , b lo c k e d ,
o r d is s ip a t e d a t p o in ts o f c o n tr o l th a t c a n n o t, w ith rea so n a b le
e f f o r t , be o v e r r id d e n o r b y -p a s s e d .
These is o la t e d p oin ts o f con­
t r o l must be secured in accordance with paragraph A .2 .c . o f these
g u id e lin e s to ensure complete blockage for the duration o f the mainte­
nance operation to preclude any p o s s i b i l i t y o f r e a c t iv a t in g the flow
o f energy.
Energy i s c o n sid e r e d a d e q u a te ly i s o l a t e d , b lo c k e d , o r d is s ip a t e d
when an unplanned e v e n t would n o t r e a c t i v a t e th e flo w o f e n e r g y .
Adequate i s o l a t i o n can be achieved by many methods or combinations o f
methods so long as the c o n tr o ls are not l i k e l y to be a c c id e n ta lly
turned on.
Appendix A i d e n t i f i e s s e v e r a l examples o f methods o f
e f f e c t i v e l y i s o l a t i n g or blocking energy.
b.
S to r e d o r r e s id u a l energy th a t c o n s t i t u t e s a p e rso n n e l h azard s h a ll be
i s o l a t e d , b lo c k e d , o r d is s ip a t e d .
Another necessary s te p i s to block or d i s s i p a t e any hazardous r e s id u a l
energy once the d e c is io n i s made to d e en erg ize.
Residual energy i s
not always as obvious a hazard as the incoming energy s u p p lie s .
For
t h i s reason, s p e c ia l e f f o r t must be made to id e n t if y any stored energy
that could r e s u lt in personnel hazards.
For example, i f i t i s
-11-
n e c e s s a r y f o r a w o r k e r t o c l i m b o r move a b o u t m e c h a n i c a l l i n k a g e s , t h e
p o t e n t i a l e n e r g y d u e t o t h e w o r k e r ' s w e i g h t may b e s u f f i c i e n t t o c a u s e
d a n g e r o u s movements o f t h e l i n k a g e s .
I f t h i s hazard is p re s e n t, a
m e c h a n ic a l b l o c k o r p i n can u s u a l l y be u sed t o b l o c k o u t th e e n e rg y
and p o t e n t i a l l y d a n g e ro u s movement.
Forms o f p o t e n t i a l e n e r g y w h i c h may b e s t o r e d
to re p re se n t hazards include:
in s u f f i c ie n t q u a n titie s
o
H y d ra u lic or pneumatic p r e s s u r e
o
P r e s s u r e below a tm o sp h e ric
o
Compressed o r e x te n d e d s p r i n g s
o
P o t e n t i a l e n e rg y due t o g r a v i t y
o
Stored m echanical energy
o
S tatic e le c tric ity
o
Stored e l e c t r i c a l energy
o
Stored e l e c t r i c a l energy (as in c a p a c ito r s )
o
Therm al e n e r g y due t o r e s i d u a l h e a t o r low
tem perature
o
R e s i d u a l c h e m i c a l s i n p i p e w h i c h may c a u s e
buildups.
therm al or p re ssu re
( a s i n vacuum s y s t e m s )
(as i n fly w h e e ls )
(as in b a t t e r i e s )
I f s t o r e d h a z a rd o u s e n e rg y i s p r e s e n t i n any form, c a r e must be ta k e n
to ensure th at
the r e s id u a l energy is
reduced to a nonhazardous
level.
E xtra
c a r e must be e x e r c i s e d t o a v o id r e a c c u m u l a ti o n o f e n e rg y
to hazardous
levels.
S p ecial measures
to continuously bleed
off
e n e rg y should be used
i f energy b u ild u p is p o s s ib le .
In a d d i t i o n ,
m o n i t o r i n g t o be s u r e e n e rg y h a s n o t a c c u m u la te d to d a n g e ro u s l e v e l s
may b e n e c e s s a r y .
c.
The p o i n t ( s ) o f c o n t r o l s h a l l h e s e c u r e d s o t h a t u n a u t h o r iz e d p e r s o n s
a r e p re v e n t e d from r e e n e r g i z i n g th e m a c h in e , p r o c e s s , o r s y s t e m .
A m eans o f s e c u r i t y m ust b e im plem ented t o e n s u r e t h a t th e equipm ent
b e in g m a in t a in e d o r s e r v i c e d i s n o t somehow r e e n e r g iz e d .
The g u id e ­
l i n e s a llo t r a c h o ic e o f t h r e e m eth o d s.
The s e l e c t i o n s h o u l d b e
b a s e d on t h e p a r t i c u l a r c i r c u m s t a n c e s
and c h a r a c t e r i s t i c s
o f each
re sp ectiv e f a c i l i t y or a p p lica tio n .
A farm employee w o rk in g w ith
p o t e n t i a l l y h a z a r d o u s powered eq u ip m en t in a rem o te f i e l d would n o t be
expected to use a padlock fo r s e c u r i t y .
A padlock (or e q u i v a l e n t) ,
how ever, would be a l o g i c a l s e l e c t i o n f o r a s w i tc h o r v a l v e a c c e s s i b l e
t o a l a r g e number o f p e o p l e .
The u s e o f t a g s , when o n l y t r a i n e d p e r ­
s o n n e l h a v e a c c e s s t o th e p o i n t ( s ) o f c o n t r o l i s an a c c e p t e d i n d u s t r y
practice.
Any o n e o f t h e f o l l o w i n g m e t h o d s w i l l p r e v e n t u n w a n t e d
r e e n e r g iz a tio n o f equipm ent.
- 1 2 -
(1 )
s e c u r e b y p h y s ic e il m eans ( " L o c k o u t " ) su c h t h a t r e e n e r g i z i n g
th e sy ste m r e q u i r e s th e u s e o f s p e c i a l equipm ent r o u t i n e l y a v a i l ­
a b l e o n l y t o th e p e r s o n who a p p li e d th e c o n t r o l .
A w a rn in g c o n ­
t a i n i n g a p p r o p r ia t e in f o r m a t io n s h a l l be d i s p l a y e d a t th e p o i n t ( s )
o f c o n t ro l.
The m e t h o d o f s e c u r i n g t h e p o i n t s o f
c o n t r o l by
p h y s i c a l means t h a t p r e v e n t u n a u t h o r i s e d p e r s o n s from r e e n e r g i z i n g
th e machine, p ro c e s s , or system is w id ely u se d .
The m o s t common
d e v ic e used f o r s e c u r i t y i s the p ad lo ck . O ften
each worker is
p r o v i d e d w i t h h i s own p a d l o c k a n d t h e o n l y k e y .
(2 )
P o s t a w a rn in g
( "T a g o u t m) a t
th e p o i n t ( s )
o f co n tro l
p r o v i d i n g in f o r m a t io n a s t o why th e e n e r g y s o u r c e s h a v e b een i s o ­
l a t e d , b l o c k e d , o r d i s s i p a t e d , th e d a t e , th e p e r s o n ( s ) r e s p o n s i b l e
f o r th e c o n t r o l m e a su re , and th e p e r s o n ( s ) r e s p o n s i b l e f o r th e
w ork t o b e a c c o m p lis h e d .
i n a d d i t i o n , a c c e s s t o th e c o n t r o l
p o i n t ( s ) o u s t be l i m i t e d t o p e r s o n s who a r e t r a in e d t o u n d e r s ta n d
and o b s e r v e
th e p o s t e d w a r n in g .
Access
may b e
lim ited
by
p h y s i c a l l o c a t i o n ( s u c h a s e l e v a t i o n ) o r by p r o c e d u r a l m e a n s s u c h
as c o lo r-co d ed badges.
When
t h i s method o f
s e c u r i t y i s u s e d , each
new e m p l o y e e s h o u l d r e c e i v e
tr a in in g to observe the
guidelines
b e fo re having ac cess to th e p o i n t ( s ) used fo r c o n t r o l l i n g energy.
The t r a i n i n g s h o u l d i n c l u d e t h e p u r p o s e o f t h e w a r n i n g , t h e f o r m a t
and c o l o r o f t h e w a r n in g , and sh o u ld s t r e s s th e r e s p o n s i b i l i t y o f
each person fo r h i s co -w o rk ers'
safety.
R e t r a i n i n g s h o u ld be
g i v e n as n e c e s s a r y so t h a t th e im p o rta n c e o f o b s e r v i n g t h e p o s te d
w arning i s n o t f o r g o tte n .
(3 )
P o s t q u a l i f i e d p e r s o n n e l , w ith th e s p e c i f i c r e s p o n s i b i l i t y
o f p r o t e c t i n g a g a i n s t u n a u t h o r iz e d a c t u a t i o n , a t th e p o i n t ( s ) o f
c o n t r o l t h ro u g h o u t th e m a in te n a n ce a c t i v i t y .
T h is a p p l i e s m a in ly
t o s h o r t d u r a t io n w ork i n th e im m ediate v i c i n i t y o f th e c o n t r o l
p o in t (s ).
d.
B e f o r e s t a r t i n g m a in te n a n c e , v e r i f y t h a t s t e p s a . th ro u g h c . h a v e been
e f f e c t i v e i n i s o l a t i n g , b l o c k i n g o r d i s s i p a t i n g h a z a r d o u s e n e r g y , and
s e c u r i n g th e p o i n t ( s ) o f c o n t r o l .
In a p p ly in g any method o r t e c h n i q u e to i s o l a t e , b l o c k , or d i s s i p a t e
e n e r g y from s p e c i f i e d a r e a s , d e v i c e s , m a c h i n e s , s y s t e m s , o r p r o c e s s e s ,
i t s h o u ld be v e r i f i e d t h a t d e e n e r g i z a t i o n h a s b ee n e f f e c t e d p r i o r t o
the s t a r t of m aintenance.
V e r i f i c a t i o n sh o u ld be ac co m p lish e d each
t i m e e n e r g y i s e l i m i n a t e d and r e a p p l i e d , r e g a r d l e s s o f t h e t i m e i n t e r ­
v a l b etw een rem oval and r e a p p l i c a t i o n .
P r o v e n m e t h o d s s h o u l d be u s e d
to e f f e c t i v e l y d em o n strate t h a t a l l hazard o u s energy has been i s o l a ­
t e d , b l o c k e d , o r d i s s i p a t e d i n t h e a r e a s where p e r s o n n e l w i l l p e r fo rm
the re q u ired ta s k s .
I f th e re is the p o s s i b i l i t y of reaccum ulation of
e n e r g y t o h a z a r d o u s l e v e l s , v e r i f i c a t i o n s h o u l d be c o n t i n u e d u n t i l t h e
m aintenance a c t i v i t y i s com pleted.
I f s e n s i n g d e v i c e s a r e used f o r v e r i f i c a t i o n , t h e s e d e v i c e s s h a l l be
used acco rd in g to e s t a b l i s h e d procedures t h a t have been determ ined to
safely
and c o n s i s t e n t l y
indicate
the
presence
of energy.
These
s e n s i n g d e v i c e s s h o u l d be p r i m a r y ; i . e . , t h e y s h o u l d n o t d ep e n d upon
sec o n d ary o r d e r i v e d i n d i c a t i o n s which c o u ld in d u c e g r e a t e r p r o b a b i l i t y
-1 3 -
of error.
The d e v i c e s s h o u l d b e r e g u l a r l y a n d f r e q u e n t l y i n s p e c t e d
a n d / o r c a l i b r a t e d t o e n s u r e t h a t th e y a r e f u n c t i o n a l and a c c u r a t e and
to d e t e c t any p o t e n t i a l d ev ice f a i l u r e s .
Good i n t e n t i o n s t o e l i m i n a t e e n e r g y h a v e f a i l e d a n d i n j u r i e s h a v e
r e s u l t e d when t h e w r o n g s o u r c e s o f e n e r g y w e r e c o n t r o l l e d .
To a v o i d
t h i s p o s s i b i l i t y , th e en e rg y sh o u ld be v e r i f i e d to be below h a z a rd o u s
le v e ls before proceeding.
e.
V e r i f y that, a l l p e r s o n n e l a r e c l e a r o f th e p o i n t ( s )
r e e n e r g i z i n g t h e m a ch in e , p r o c e s s , o r sy ste m .
o f danger b e fo re
T h i s a c t i o n i s s o o b v i o u s t h a t many r e f e r e n c e s f a i l t o i d e n t i f y
y e t i t i s v i t a l l y im p o rta n t t h a t i t be in c lu d e d in each p ro c e d u re .
it;
3.
F o r t h e f i v e s t e p s l i s t e d a b o ve t o c o m p r is e a v a l i d t e c h n iq u e f o r
c o n t r o l l i n g h a z a r d o u s e n e r g y s o u r c e s , th e f o l l o w i n g two p r e c o n d i t i o n s m ust
b e m et:
a.
The p r o c e d u r e s
docum ented.
to
be
u se d
to
a c c o m p lis h
th e
above
ste p s
s h a ll
be
P r o c e d u r e s f o r e n e r g y c o n t r o l a p p l i c a t i o n s s h o u l d be d o cu m en te d t o t h e
d e t a i l r e q u i r e d t o p r o v i d e a c l e a r u n d e r s t a n d i n g o f t h e d e v i c e s and
m ethods o f a p p l i c a t i o n and re m o v a l, so t h a t t h e c o n t r o l s a r e u n i f o r m l y
an d s a f e l y a p p l i e d and removed e a c h t i m e .
The p r o c e d u r e s s h o u l d
c l e a r l y a s s i g n r e s p o n s i b i l i t y f o r each s t e p o f th e c r i t e r i a as w e l l as
i n d i c a t e where i s o l a t i o n , b l o c k i n g , o r d i s s i p a t i o n o f en e rg y i s t o be
a c c o m p l i s h e d , how d e e n e r g i z a t i o n i s t o b e v e r i f i e d , w h a t m e t h o d i s t o
b e u s e d f o r s e c u r i t y , a n d how r e s p o n s i b i l i t y i s t o b e t r a n s f e r r e d
during s h i f t changes.
The p r o c e d u r e s n e e d n o t b e u n i q u e f o r a s i n g l e
m a c h i n e o r t a s k ; p r o c e d u r e s may b e u s e d w h i c h a p p l y t o a g r o u p o f
s i m i l a r machines o r t a s k s .
Depending upon t h e c o m p le x ity o f th e
e q u i p m e n t a n d i t s a p p l i c a t i o n , g o o d p r o c e d u r e s may v a r y f r o m o n e t o
many p a g e s .
No m a t t e r how s i m p l e a n d s t r a i g h t f o r w a r d t h e p r o c e d u r e s
may s e e m , t h e y s h o u l d b e d o c u m e n t e d s o t h a t a l l l e v e l s o f p e r s o n n e l
u n d e r s t a n d company p o l i c y , a s w e l l a s t h e r e q u i r e d s a f e t y p r o c e d u r e s .
b.
The p e r s o n n e l who im plem ent th e a b o ve s t e p s s h a l l be q u a l i f i e d .
E a ch
w o rk e r m ust t h o r o u g h ly u n d e r sta n d a l l docum ented p r o c e d u r e s .
T ra in in g
s h a l l b e a c c o m p lis h e d a s n e c e s s a r y t o e s t a b l i s h and m a in t a in p r o f i ­
c i e n c y , and t o e n com p a ss p r o c e d u r a l o r eq u ip m ent c h a n g e s w h ich a f f e c t
e n e r g y c o n t r o l d u r i n g m a in te n a n ce .
A f t e r th e e n e rg y c o n t r o l need h as been i d e n t i f i e d , th e methods o f
im plem entation s e l e c t e d ,
and t h e p r o c e d u r e s
finalized,
a training
program sh o u ld
be
in stitu ted
to
ensure
that
the
procedures
are
f o l l o w e d and t h e p u r p o s e and f u n c t i o n s a r e u n d e r s t o o d .
The t r a i n i n g
s h o u l d i n v o l v e e l e m e n t s o f management and t h e w o r k f o r c e c o n c e r n e d w i t h
m a in te n a n c e a c t i v i t i e s so t h a t th e c r i t e r i a a r e e x p e d i t i o u s l y and u n i ­
formly a p p l i e d .
The t r a i n i n g s h o u l d e n s u r e t h a t t h e u n d e r s t a n d i n g a n d
s k i l l s r e q u i r e d f o r t h e s a f e a p p l i c a t i o n and r e m o v a l o f e n e r g y c o n ­
tr o ls are a v a ila b le as re q u ired .
R e t r a i n i n g sh o u ld be s c h e d u le d as
-1 4 -
C liX U
L i 11 J .
o f te n as n e c e ssa ry
devices, p ra c tic e s ,
to m aintain
and m ethods.
proficiency
and
to
introduce
revised
I f energy i s o l a t i o n , b lo ck in g , or d i s s ip a t io n are secured acco rd in g to
c r i t e r i o n 2 . c . ( 2 ) , th en every p erson h av in g job r e l a t e d ac c e ss to the
p o i n t ( s ) o f c o n t r o l sh o uld be t r a i n e d .
This t r a i n i n g i s in a d d i t i o n
to th a t re q u ire d fo r personnel involved in applying energy c o n tr o ls .
The t r a i n i n g s h o u l d i n c l u d e t h e p u r p o s e o f t h e w a r n i n g , t h e f o r m a t a n d
c o l o r o f t h e w a r n i n g , and sh o u ld em p h asiz e th e e x tre m e im p o r ta n c e f o r
a l l p e r s o n n e l to obey th e w arnings in o r d e r to p r o t e c t t h e i r co­
w orkers.
The p e r s o n n e l who i m p l e m e n t t h e p r o c e d u r e s s h o u l d b e t r a i n e d
n o t o n l y t o know how t o a c c o m p l i s h t h e s t e p s r e q u i r e d t o c o n t r o l
energy so u rc es, b u t a ls o to u nderstand the hazard s a s s o c ia te d w ith
energy so u rc e s.
All l e v e l s o f s u p e r v is io n concerned w ith m aintenance
and s e r v i c i n g , w i t h s p e c i a l e m p h a s is on f i r s t - l i n e s u p e r v i s i o n , m u st
be t r a i n e d i n o r d e r t o e n s u r e t h a t p ro c e d u re s a r e fo llo w e d .
B.
CONTROLLING HAZARDS WITH ENERGY PRESENT
C o n t r o l l i n g m a in te n a n ce h a z a r d s w ith e n e rg y p r e s e n t i s th e o n l y a l t e r n a t i v e t o
d e e n e r g i z in g t o p e rfo rm m a in te n a n ce t a s k s s a f e l y .
F o r some t y p e s o f m a c h in e s
o r p r o c e s s e s , th e c o n d i t i o n s o r c o m b in a t io n o f c o n d i t i o n s t h a t m ust be e v a l u ­
a t e d a n d c o n t r o l l e d i n e n e r g iz e d s y s t e m s ca n be much more com p lex th a n d e e n e r­
g iz e d sy ste m s.
The f o l l o w i n g p a r a g r a p h s d e s c r i b e g u i d e l i n e s f o r m a in t a in i n g
"e n e r g iz e d " syste m s.
1.
H a z a rd o u s e n e r g y s o u r c e s , i n c l u d i n g r e s i d u a l
id e n t if ie d .
e n e rg y
so u rce s, s h a ll
I d e n t i f i c a t i o n o f t h e h a z a r d s n e e d s no j u s t i f i c a t i o n ,
c a n n o t be c o n t r o l l e d u n l e s s i t i s i d e n t i f i e d .
2.
for
a
be
hazard
Docum ented p r o c e d u r e s , w h ich h a v e b een d e te rm in e d t o c o n t r o l each
h a za rd o u s en e rgy s o u r c e , s h a l l be u se d .
Pro ce d ure s s h a ll a s s ig n
r e s p o n s i b i l i t y and a c c o u n t a b i l i t y f o r c o n t r o l l i n g p e r s o n n e l h a z a r d s .
Before a w orker i s exposed to a h a z a r d , th e h a z a rd c o n t r o l s must be
kn own t o b e e f f e c t i v e .
D eterm ination of hazard c o n tro l e f fe c tiv e n e s s
c a n b e b a s e d on p h y s i c a l d e m o n s t r a t i o n p r i o r t o i m p l e m e n t a t i o n on a
day-to-day b a s is .
This
can be by s i m i l a r i t y
to
a dem onstrably
e f f e c t i v e h a z a r d c o n t r o l , o r by a n a l y s i s .
3.
P e r s o n n e l who p e rfo rm t h e m a in te n a n ce s h a l l be q u a l i f i e d t o u se th e
p ro ce d u re s.
Q u a l i f i c a t i o n t o u se th e p r o c e d u r e s may b e o b t a in e d b y
e d u c a t io n , e x p e r ie n c e a n d / o r t r a i n i n g .
The p e r s o n n e l who p e r f o r m
th e m a in te n a n c e and s e r v i c i n g a c t i v i t i e s m ust be t r a i n e d t o u n d e r s t a n d
the p a r ti c u la r h azard s,
the c o n tro ls
f o r t h e h a z a r d s , a n d how t o
implem ent t h e c o n t r o l s e f f e c t i v e l y .
-1 5 -
IV.
CONCLUSIONS
This s tu d y co n firm s t h a t the need
to c o n tr o l hazardous energy d u rin g m a in te ­
n a n c e a c t i v i t i e s i s r e c o g n i z e d by
i n d u s t r y , l a b o r , and t h e G overnment.
This
n e e d i s m a n i f e s t e d by t h e d i f f e r e n t a p p r o a c h e s i m p l e m e n t e d b y i n d u s t r y t o
r e d u c e i n j u r i e s , t h e e v i d e n c e s u b m i t t e d t o t h e O c c u p a t i o n a l S a f e t y and H e a l t h
A d m i n i s t r a t i o n a t p u b l i c h e a r i n g s on t h e s u b j e c t o f l o c k o u t s and t a g o u t s , and
r e s u l t s o f t h e l i t e r a t u r e s e a r c h i n which a g r e a t number
of a rtic le s
were
f o u n d w h i c h e m p h a s i z e t h e n e e d f o r some t y p e o f c o n t r o l .
The l i t e r a t u r e r e v i e w d i d n o t p r o d u c e s t a t i s t i c a l e v i d e n c e o f t h e e f f e c t i v e ­
n e s s o f any one s p e c i f i c t y p e o f e n e r g y c o n t r o l m ethod o v e r a n o t h e r , n o r d i d
i t id e n tify accid en t ca u sativ e fa c to rs leading to i n j u r ie s .
No v a l u e s c o u l d
b e d e v e l o p e d w h ic h d i f f e r e n t i a t e a c c i d e n t s and i n j u r i e s o c c u r r i n g d u r i n g m a i n ­
t e n a n c e from a g g r e g a t e U .S . i n j u r y s t a t i s t i c s ; i . e . , d a t a t o p r o v i d e i n d i c e s
on t h e p r o b a b i l i t y o f i n j u r y o c c u r r e n c e , t h e m a g n i t u d e o f t h e i n j u r i e s , and
th e exposure to th e hazard (p o p u la tio n o f workers a t r i s k ) t h a t c o r r e l a t e with
the i d e n t i f i e d prim ary h az ard c a u se s.
I n d u s t r i a l a c c i d e n t and i n j u r y d a t a a v a i l a b l e i n t h e U .S . d e s c r i b e t h e i n j u ­
r i e s s u s t a i n e d by t h e w o r k e r s i n g r e a t e r d e t a i l t h a n t h e c a u s e s o f t h e a c c i ­
dents th a t in f l i c t e d the i n j u r ie s .
The h a z a r d c a u s e s f o u n d i n t h e a n a l y z e d
a c c i d e n t r e p o r t s a r e c a t e g o r i z e d by f i r e , e x p l o s i o n , i m p a c t , f a l l , c a u g h t i n
o r b e t w e e n , and o t h e r s .
The h a z a r d c a u s e s i d e n t i f i e d b y t h i s s t u d y a r e d i f ­
ferent.
Consequently, the p u b lish ed s t a t i s t i c s (ag g reg ates of a c c i d e n t / in j u r y
r e p o r t s ) c a n n o t b e b r o k e n down i n t o a c c i d e n t c a u s e s i d e n t i f i e d a s s p e c i f i c t o
m a i n t e n a n c e and s e r v i c i n g a c t i v i t i e s .
The s t u d y i d e n t i f i e d
th e follow ing hazard causes:
1.
M aintenance a c t i v i t i e s were i n i t i a t e d w ith o u t a t t e m p t i n g to d e e n e r g i z e
th e equipment o r system or c o n t r o l th e h azard w ith energ y p r e s e n t .
2.
E n e r g y b l o c k a g e o r i s o l a t i o n wa s a t t e m p t e d , b u t wa s i n a d e q u a t e .
3.
R e s i d u a l e n e r g y was n o t d i s s i p a t e d .
4.
Energy was a c c i d e n t a l l y a c t i v a t e d .
Th e w o r k e r p o p u l a t i o n a t r i s k c o u l d n o t b e d e f i n e d b e c a u s e e m p l o y e r s who
i m p l e m e n t p r o c e d u r a l c o n t r o l s may c h o o s e t o ma ke t h e p r o c e d u r e s a p p l i c a b l e t o
(1) a l l p e r s o n n e l ;
( 2 ) p e r s o n n e l e n g a g e d i n a ny o n e o r a n y c o m b i n a t i o n o f
a c t i v i t i e s such as c o n s t r u c t i o n , o p e r a t i o n s , m a n u fa c tu rin g , t e s t i n g , e t c . ; or
(3) m aintenance p e rs o n n e l o n ly .
T hus, t h e e f f e c t i v e n e s s o f any one m ethod o f
c o n t r o l w i t h r e s p e c t t o a n o t h e r c a n n o t be d e t e r m i n e d .
However, t h e im p lem en ­
t a t i o n o f any m ethod which i n c r e a s e s w o r k e r a w a r e n e s s o f p o t e n t i a l l y h a z a r d o u s
e n e rg y s o u r c e s i s b e t t e r th a n no method a t a l l .
E x i s t i n g F e d e r a l and
S tate
Government s a f e t y
regulations
(C alifornia
and
M ichigan e x c e p te d ) o f e n e rg y c o n t r o l d u r in g m ain ten an ce a r e i n c o n s i s t e n t ,
f r a g m e n t e d , and o n l y a p p l i c a b l e t o c e r t a i n e q u i p m e n t , p r o c e s s e s , and i n d u s ­
tries
(e .g .,
t e l e c o m m u n i c a ti o n and c o n s t r u c t i o n ) .
Most o f t h e s e e x i s t i n g
r e g u l a t i o n s u s e t h e c o n c e p t o f " p o w e r o f f " t o p r e v e n t i n j u r i e s , a n d do n o t
-1 6 -
p r o v i d e g u i d a n c e o n how t o d i s c e r n when t o a p p l y l o c k s , t a g s , o r a c o m b i n a t i o n
o f lo c k s and t a g s .
They a l s o d o n o t a l l o w f o r t h e p e r f o r m a n c e o f m a i n t e n a n c e
w i t h p o w e r o n , e v e n u n d e r n o r m a l , e v e r y d a y c o n d i t i o n s , o r when s u c h m a i n t e ­
n an ce c a n n o t be p e rfo rm ed w i t h power o f f .
-1 7 -
V.
W hile d e v e lo p in g th e g u i d e l i n e s ,
r e s e a r c h w ould prove v a l u a b l e .
A.
RESEARCH NEEDS
a re a s
w ere
id e n tifie d
in
w hich
a d d itio n a l
STUDY CONTINUATION
T he r e s u l t o f t h i s s t u d y , " G u i d e l i n e s f o r C o n t r o l l i n g H a z a r d o u s E n e r g y D u r i n g
M aintenance and S e r v i c i n g , " i s a c o n s o l i d a t i o n o f d i f f e r e n t a p p ro a c h e s a l r e a d y
in use.
These g u i d e l i n e s i n c r e a s e th e l a t i t u d e o f im p le m e n tatio n methods
av ailab le.
The g r e a t e r l a t i t u d e , i n t u r n , may c r e a t e p r o b l e m s w h i c h h a v e n o t
been a n tic ip a te d .
I t i s t h e r e f o r e recommended t h a t s t u d i e s be c o n d u c t e d t o :
B.
1.
D e velop u n i v e r s a l p r o c e d u r e s f o r t h e recommended g u i d e l i n e s
2.
I d e n t i f y p ro b lem s c r e a t e d by t h e g u i d e l i n e s ,
3.
Identify effectiv en ess
ing i n j u r i e s
4.
I d e n t i f y c o s t s o f im plem enting th e g u i d e l i n e s .
of d if f e r e n t hazard
i f any
c o n t r o l methods
in
prevent­
GUIDELINES FOR OTHER MAINTENANCE HAZARDS
T h is t e c h n i c a l r e p o r t a d d r e s s e s one o f s e v e r a l m a i n t e n a n c e a c t i v i t i e s which
require d ecision c r ite r ia .
These a c t i v i t i e s a r e :
s e l e c t i o n and u s e o f t o o l s ;
s e l e c t i o n and u s e o f a n c i l l a r y e q u i p m e n t ; s e l e c t i o n o f a c c e s s r o u t e s t o and
from t h e m a i n t e n a n c e a r e a ; e v a l u a t i o n o f t h e m a i n t e n a n c e e n v i r o n m e n t ; s e l e c ­
tio n o f s k ille d personnel;
and i d e n t i f i c a t i o n and v e r i f i c a t i o n
o f energy
sources.
The g u i d e l i n e s h e r e i n s u g g e s t a c t i o n s t h a t s h o u l d b e t a k e n a f t e r t h e
energy so u rces have been i d e n t i f i e d .
G u i d e l i n e s which a d d r e s s th e s e l e c t i o n
and u s e o f t o o l s , as w e l l as th e s e l e c t i o n o f p e r s o n n e l , sh o u ld be d e v e lo p e d .
F u r t h e r , g u i d e l i n e s a d d r e s s i n g s e l e c t i o n o f a c c e s s m ethods t o and from t h e
m a i n t e n a n c e a r e a , and e v a l u a t i o n o f m a i n t e n a n c e e n v i r o n m e n t s s h o u l d be d e v e l ­
oped .
M a t e r i a l s h av in g t o x i c , c a u s t i c , o r a s p h y x ia n t p r o p e r t i e s can p r e s e n t s e r i o u s
h azard s to m aintenance p e r s o n n e l.
S u ita b le c o n tro l measures for m a te r ia ls
h a v i n g t h e s e d a n g e r o u s p r o p e r t i e s do n o t n e c e s s a r i l y m a t c h t h e c r i t e r i a f o r
c o n t r o l o f h a z a r d o u s e n e r g y recommended w i t h i n t h i s d o c u m e n t .
In f a c t , p e r ­
s o n n e l ca n be harmed by t o x i c , c a u s t i c , o r a s p h y x i a n t m a t e r i a l s w i t h no c o n ­
c u rre n t r e le a s e of energy.
It is
t h e r e f o r e recommended t h a t c r i t e r i a b e
d e v e l o p e d s p e c i f i c a l l y t o p r o t e c t m a i n t e n a n c e p e r s o n n e l from such h a z a r d o u s
m aterials.
-1 8 -
C.
POTENTIAL HAZARDS IN NEW TECHNOLOGICAL APPLICATIONS
C u r r e n t l y , U . S . i n d u s t r i e s u t i l i z e many o l d m a c h i n e s a n d p r o c e s s e s .
To com­
p e t e more e f f e c t i v e l y i n t h e w o r l d m a r k e t p l a c e , U .S . i n d u s t r y w i l l h a v e t o
r e p l a c e a g i n g m a c h i n e s a n d p r o c e s s e s w i t h new,
more e f f i c i e n t
equipm ent
i n c l u d i n g r o b o t i c and f u l l y a u to m a tic m a c h in e s .
I n some c a s e s , t h e i n f l u x o f
new m a c h i n e s a n d t e c h n o l o g y i n t o U . S . i n d u s t r y may me an g r e a t e r s a f e t y f o r t h e
w o r k e r ; i n o t h e r c a s e s , i t may p o s e new o r u nk no wn h a z a r d s .
A research e f fo rt
i s n e e d e d t o a s s e s s t h e s a f e t y o f t h e s e n ew t e c h n o l o g i e s a n d m a t e r i a l s .
Some e x a m p l e s o f r e c e n t a d v a n c e s i n m a n u f a c t u r i n g t e c h n i q u e s a n d m a t e r i a l s
t h a t could pose unique h az ard s to workers in c lu d e :
num erical c o n tro l; ro b o tic
m a c h i n e s ; l a s e r a p p l i c a t i o n s ; new m a t e r i a l s f o r t o o l s , w o r k p i e c e s , f i n i s h e s ,
l u b r i c a n t s , m o l d s , b o n d i n g , and w e l d i n g ; u l t r a s o n i c a p p l i c a t i o n s ; and e x p l o ­
s iv e form ing.
The r e s e a r c h e f f o r t s h o u l d f o c u s on i d e n t i f y i n g p o t e n t i a l h a z ­
a r d s and d e t e r m i n i n g c o r r e c t i v e a c t i o n which e i t h e r r e d u c e s h a z a r d o u s e n e r g y
l e v e l s o r c h a n g e s t h e w o r k e r ’s p r o x i m i t y t o h a z a r d o u s e n e r g y .
-1 9 -
V I.
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- 2 0 -
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3 r d Q u a r t e r , No. 1 0 5 , 1 9 7 4 .
pp. 35-39
50.
Ano ny mou s.
How t o E s t a b l i s h a n
C a s t i n g (December 1977) p p . 66 -67
51.
W e s t e r n Wood P r o d u c t s A s s o c i a t i o n .
Federal R egister
OSHA L o c k o u t ANPR.
P o r t l a n d , OR:
S eptem b er 12, 1980.
F e d e r a l R e g i s t e r N o tice Response
New Y o r k , NY:
J u n e 1980.
20pp.
N otice
23pp.
Response
F ed eral R e g is te r N otice
S ep tem b er 5, 1980.
4pp.
An INC0 Company.
H u n t i n g t o n , WV:
of
to
Texas.
Response
to
to
OSHA L o c k o u t
OSHA L o c k o u t
F e d e r a l R e g i s t e r N o tic e Response
S ep tem b er 10, 1980.
13pp.
to
F e d e r a l R e g i s t e r N o tice Response
September 15, 1980.
3pp.
to
S a fe ty and T e c h n ic a l
OSHA L o c k o u t ANPR.
I n s t i t u te , Inc.
W a s h i n g t o n , DC:
Employment.
Federal
S a l t L a ke C i t y , UT:
to
OSHA L o c k o u t
S pecifications,
D raft
"Power-D riven
Equipment"
S t a t u s , De c e m b er 1 9 7 8 .
Incom plete C i t a t i o n .
P o w e r Company.
M i l w a u k e e , WI:
- 2 2 -
F ed eral R e g is te r N otice
September 12, 1980.
8pp.
E ffective
Lockout
Response
Procedure.
Notice
8pp.
to
M od er n
Response
to
52.
K u e p e r , C. J .
c i l , Chicago,
53.
L a r s e n , R.
P & WA S a y s I t F a v o r s Tag S y s t e m O v e r L o c k s F o r M a c h i n e r y
S a f e t y ( T a g o u t Over L o c k o u t ) .
A m e r i c a n M e t a l M a r k e t (May 1 6 , 1 9 7 7 ) l p .
54.
Corey, L .S .; F a r r e l ,
W.H.
R ep o rt o f Committee on E l e c t r i c a l
Safety
R e q u ir e m e n ts f o r Employee W o r k p la c e s .
NFPA 70E, P a r t I I .
pp. 68-72.
55.
N a tio n a l I n s t i t u t e f o r O c c u p a tio n a l S a fe ty and H e a l th .
Employee H e a l t h
and S a f e ty i n t h e L i t h o g r a p h i c P r i n t i n g I n d u s t r y .
C i n c i n n a t i , OH:
NTIS
PB-276 6 7 3 ; A u g u s t , 1977.
pp. 12-13.
56.
Lockouts P revent S erio u s A c c id e n ts .
N ational
IL.
I n d u s t r i a l S u p e r v i s o r ( M a r c h , 1 9 7 8 ) p . 13
N atio n al S afety C ouncil.
M u lle r s and O ther
5 2 6 , R e v i s i o n B, ( E x t e n s i v e ) .
C h icag o , IL:
S a f e t y Coun­
Pan-Type M ix ers.
1977.
2pp.
Guide.
Englewood
D ata S h eet
57.
Cotz, V .J.
P l a n t E n g i n e e r s Manual and
P r e n t i c e - H a l 1, I n c . ; 1 9 7 3 .
p p . 124-126
58.
E . I . D u P o n t DeNemours & C ompany .
OSHA L o c k o u t ANPR.
W i l m i n g t o n , DE:
59.
The I d a h o B r a n c h , I n c . o f t h e A s s o c i a t e d G e n e r a l C o n t r a c t o r s
Federal R egister
N otice
R e s p o n s e t o OSHA L o c k o u t ANPR.
A u g u s t 29, 1980.
3pp.
60.
B e c h t e l Power
L o c k o u t ANPR.
61.
H y t r o l C o n v e y o r C ompany , I n c .
L o c k o u t ANPR.
J o n e s b o r o , AR:
62.
A l t a n t i c R i c h f i e l d C ompany .
F e d e r a l R e g i s t e r N o tic e Response
L o c k o u t ANPR.
Los A n g e l e s , CA:
September 3, 1980.
8pp.
63.
Texas Chemical C o u n c il.
F e d e r a l R e g i s t e r N o t i c e R e s p o n s e t o OSHA L o c k o u t
ANPR.
A u s t i n , TX:
S e p te m b e r 11, 1980.
3pp.
64.
New W a l e s C h e m i c a l , I n c . , I n t e r n a t i o n a l M i n e r a l s & C h e m i c a l C o r p o r a t i o n ,
F e d e r a l R e g i s t e r N o t i c e R e s p o n s e t o OSHA L o c k o u t ANPR.
M u l b e r r y , FL:
Septem ber 8, 1980.
5pp.
65.
Far-Mar C o ., I n c .
F e d e r a l R e g i s t e r N o tic e Response
ANPR.
H u t c h i n s o n , KS:
September 12, 1980.
6pp.
66.
PPG I n d u s t r i e s , I n c .
ANPR ( D o c k e t S - 0 1 2 ) .
67.
The A m e r i c a n Gas A s s o c i a t i o n .
L o c k o u t ANPR.
A r l i n g t o n , VA:
68.
M ille r s ' N ational F e d e ra tio n .
L o c k o u t ANPR.
W a s h i n g t o n , DC:
F ederal R e g is te r N otice
J u n e 17, 1980.
25pp.
C orporation.
Federal R egister
San F r a n c i s c o , CA:
September 8,
C liffs,
Response
F e d e r a l R e g i s t e r N o tic e Response
P i t t s b u r g h , PA:
Septem ber 9, 1980.
F ed eral R e g is te r N otice
J u n e 17, 1980.
10pp.
Response
to
to
o f A m erica.
Boise,
ID:
N o tic e Response
1980.
18pp.
F ederal R e g iste r N otice
Septem ber 3, 1980.
lp.
NJ:
OSHA
to
OSHA
to
OSHA
to
OSHA
Lockout
t o OSHA L o c k o u t
10pp.
Response
to
OSHA
F e d e r a l R e g i s t e r N o tic e Response
S eptem b er 18, 1980.
3pp.
to
OSHA
-2 3 -
69.
International
Brotherhood
of
Team sters,
C hauffeurs,
H e lp e r s o f A m erica.
F e d e r a l R e g i s t e r N o tice Response
ANPR.
W a s h i n g t o n , DC:
S ep tem b er 16, 1980.
4pp.
70.
Trus J o i s t C o rp o ra tio n .
F ed eral R e g is te r N otice
ANPR.
E u g e n e , OR:
J u l y 2 9 , 1980.
4pp.
71.
B ritish
Standards I n s t i t u t i o n .
London, E n g la n d :
1975.
77pp.
72.
H ercules In c o rp o ra te d .
Federal
ANPR.
September 5, 1980.
6pp.
73.
N ational S afety C ouncil.
C h icag o , IL:
1979.
3pp.
74.
The B i s c u i t a n d C r a c k e r
N o t i c e R e s p o n s e t o OSHA
1980.
6pp.
75.
S t a t e o f M ichigan, Department o f L abor.
F ed eral R e g iste r N otice
t o OSHA L o c k o u t ANPR.
L a n s i n g , MI:
Septem ber 15, 1980.
4pp.
76.
W e s t e r n A re a Power
OSHA L o c k o u t ANPR.
A dm inistration.
Federal R egister
G o l d e n , CO:
June 17, 1980.
6pp.
N otice
Response
to
77.
A . E . S t a l e y M a n u f a c t u r i n g C omp an y.
Federal R egister
OSHA L o c k o u t ANPR.
D e c a tu r , IL:
September 12, 1980.
N otice
9pp.
Response
to
78.
PPG I n d u s t r i e s , I n c .
ANPR ( D o c k e t S - 2 0 3 ) .
79.
C e n t r a l Soya.
Federal R egister
(Docket S -0 1 2 ).
F o r t Wayne, IN:
80.
D a v e n p o rt M achine T o o l D i v i s i o n ,
Dover C o r p o r a t i o n .
Federal R egister
N o t i c e R e s p o n s e t o OSHA
L o c k o u t ANPR. R o c h e s t e r , NY:
September
24,
1980.
2pp.
81.
The P r i n t i n g I n d u s t r i e s o f A m e r i c a , I n c . , J o h n F . G r a n t ,
Government A f f a i r s .
F e d e r a l R e g i s t e r N otice Response to
ANPR. W a s h i n g t o n , DC:
A ugust 17, 1980.
lp.
82.
I n t e r n a t i o n a l C o u n cil f o r Sheet Metal D evelopm ent/A m erican M etal Stam ping
A ssociation.
19 7 9 / E x p o - C e n t e r C h i c a g o P r o c e e d i n g s ,
C ongress Overview,
Including
S tate
of
Industry
Report:
From
the
S ixth
International
C o n g r e s s on S h e e t M e t a l Work.
Ri ch mo n d H e i g h t s , OH.
83.
L a w r i e , W.B.
Development o f S a f e t y and H e a l th F e a t u r e s i n t h e D e sig n and
C o n s t r u c t i o n o f M a c h in e ry and E q u i p m e n t .
7 t h W o r l d C o n g r e s s on t h e P r e ­
vention
of
O ccupational
A ccidents
and
D i s e a s e s . May
20-25,
1974.
D ublin, I r e l a n d .
15pp.
Safeguarding
R egister
T extile
Looms.
Warehousemen
&
t o OSHA L o c k o u t
R e s p o n s e t o OSHA L o c k o u t
of
N otice
Data
M achinery.
Response
Sheet
to
279,
BS
5304.
OSHA L o c k o u t
R evision
A.
M anufacturers' A sso cia tio n .
Federal R egister
L o c k o u t ANPR. W a s h i n g t o n , DC:
September
12,
Response
F e d e r a l R e g i s t e r N o t i c e R e s p o n s e t o OSHA L o c k o u t
P i t t s b u r g h , PA:
Septem ber 9, 1980.
10pp.
N o t i c e R e s p o n s e t o OSHA
September 8, 1980.
5pp.
-2 4 -
Lockout
ANPR
D irector of
OSHA L o c k o u t
84.
N ational E lev a to r In d u s try , In c .
OSHA L o c k o u t ANPR.
New Y o r k , NY:
85.
E lias,
J.
Latch
C ircuits
E l e c t r o n i c s . 4 8 ( 1 ) : 1 1 1 ; 1975.
86.
C e n t r a l Soya.
Federal R egister
(Docket S -203).
F o r t Wayne, IN:
87.
Thomas J . L i p t o n , I n c .
F e d e r a l R e g i s t e r N o tic e Response
ANPR.
E n g l e w o o d C l i f f s , NJ:
September 12, 1980.
3pp.
88.
C l o e , W.W.; V i r a , C.M.
O c c u p a t i o n a l F a t a l i t i e s R e l a t e d t o F i x e d Ma­
c h i n e r y a s F oun d i n R e p o r t s o f OSHA F a t a l i t y / C a t a s t r o p h e I n v e s t i g a t i o n s .
W a s h i n g t o n , DC:
OSHA, U . S . D e p a r t m e n t o f L a b o r ; May, 1 9 7 8 .
pp. 8-10,
15-20, 23-26, 2 8 -4 2 , 4 4 -5 1 , 5 3-54, 69.
89.
B erkovitch, I.
6 1 : 5 ; 1971.
(Case
S tudies).
90.
F r a s e r , D.A.
Foundry F a t a l i t y P r e v e n t i o n .
D ep artm en t; September 1977.
16pp.
D etro it,
91.
S cully, J.L .
P r e l i m i n a r y N o t e s f o r ANPR o n L o c k o u t / T a g o u t
11, 1979.
W a s h i n g t o n , DC:
7pp.
92.
A l b e r t a W o r k e r s ' H e a l t h , S a f e t y and C o m p e n s a t i o n , O c c u p a t i o n a l H e a l t h and
S a f e t y D i v i s i o n , R e s e a r c h and E d u c a t i o n B ra n c h .
O ccupational H ealth &
S afety R egulations.
A l b e r t a , Canada:
1976.
256pp.
Why
Conveyors
F ed eral R e g is te r N otice
September 9 , 1980.
2pp.
Interlock
Remo te
Sw itches
- 2 5 -
to
E lectrically .
N o t i c e R e s p o n s e t o OSHA
September 8 , 1980.
7pp.
K ill
Response
to
Mech.
MI:
Lockout
ANPR
OSHA L o c k o u t
H andl.
Social
(GB)
S ecurity
Issues.
July
V II.
APPENDIX A
EXAMPLES OF ALTERNATE METHODS OF ISOLATING OR BLOCKING ENERGY
AND SECURING THE POI NT( S) OF CONTROL
-2 6 -
APPENDIX A
EXAMPLES OF ALTERNATE METHODS OF ISOLATING OR BLOCKING ENERGY
AND SECURING THE P OINT( S) OF CONTROL
ENERGY TYPE
METHOD OF ISOLATING
OR BLOCKING ENERGY
METHOD OF SECURING
THE POINT OF CONTROL
M ec h an ical M otion
R otation
T ranslation
Linear
O scillation
1.
( 1 ) Ta g t h e l i n k a g e s
and p l a c e them i n
a locked c a b in e t
away f r o m t h e
m achine.
or
(2) A ttach w arning ta g s
where th e lin k a g e s
w ere removed and
r e s tr ic t access to
train ed personnel.
or
(3) Post a p erso n t o
protect ag ain st
unauthorized
rein stallatio n of
the lin k a g e s .
Remove s e g m e n t s
of operating
m echanical linkages
such as d ism a n tlin g
push r o d s , removing
b e l t s , and removing
flyw heels.
2 . Use b l o c k i n g
d e v ic e s such as
wood o r m e t a l
blocks.
(1) Chain and lo c k
in p o in t of
c o n tro l or use
m etal pins
d r i v e n o r w elded
in place.
or
(2) A ttach w arning
t a g s on t h e
blocking devices
and r e s t r i c t
access in to the
area to train ed
personnel.
or
(3) P ost a p e rs o n t o
protect ag ain st
unauthorized
removal o f th e
blocking d ev ices.
-2 7 -
REMARKS
ENERGY TYPE
METHOD OF ISOLATING
OR BLOCKING ENERGY
METHOD OF SECURING
THE POINT OF CONTROL
REMARKS
3 . Remove p o w e r o r
e n e r g y from t h e
d r i v i n g mechanism,
such as:
(l)a.
Padlock in the
"off" p o sitio n .
b.
D isconnect
p n e u m a t i c and
hydraulic lin es
and t a g .
or
Check f o r
alternate
sources of
power.
M ec h an ical Motion
(continued)
E lectrical
a.
D is c o n n e c t main
electrical
source.
b.
Close h y d r a u lic
or pneum atic
v alves, bleed.
1. P l a c e t h e m ain
e le c tric a l dis­
connect sw itch in
the "o ff" p o s itio n .
(2)
A ttach w arning
tags a t c o n tro l
p o i n t s and
r e s t r i c t access
to trained
personnel.
or
(3)
Post a person
to p ro te c t
against
unauthorized
re co n n ec t ion
o f the energy
sources.
(1)
S e c u r e by a p a d ­
lo c k , a c l i p and
padlock, or a
b a r and p a d lo c k .
or
A ttach a w arning
t a g and r e s t r i c t
access in to the
area to train ed
personnel.
or
Post a person to
protect against
unauthorized
a c tu a tio n of the
sw itch.
(2)
(3)
-2 8 -
C h ec k f o r
resid u al
pneumatic
and
h ydraulic
energy.
Check f o r
alternate
sources
o f power.
ENERGY TYPE
METHOD OF ISOLATING
OR BLOCKING ENERGY
METHOD OF SECURING
THE POINT OF CONTROL
REMARKS
2 . Remove s e g m e n t s o f
electrical circu it,
such as p r i n t e d c i r ­
c u i t m odules.
( 1 ) Tag t h e m o d u l e a n d
p la c e in a locked
c a b i n e t a wa y f r o m t h e
c o n t r o l c e n t e r and
tag the c o n tro l c e n te r
door.
or
(2) A ttach a w arn in g ta g
a t th e module l o c a t i o n
and r e s t r i c t a c c e ss t o
train ed personnel.
or
( 3 ) Have a p e r s o n r e m a i n
a t the c o n tro l c e n te r
t o p r o t e c t from
unauthorized i n s t a l l a ­
tio n of a spare or
re p la cem e n t module.
1. C lo se v a l v e s and
m a i n t a i n an open
bleed.
(1) Chain and p a d lo c k
valve or use b lin d
flanges or s l i p
blinds.
or
(2) A ttach w arning
tags to the
v a l v e s and
r e s t r i c t access
to the area to
trained
p e r s o n n e 1.
or
(3) S ta t io n a person
a t the valve lo ca­
tio n s to p ro tect
a g a in st unauthorized
or inadvertent
opening o f v a lv e s .
E lectrical
(continued)
Thermal (Steam)
-2 9 -
Allow tim e
for
resid u al
h ea t to
d issip ate.
ENERGY TYPE
P o ten tial
Pressure
P otential
G ravity
METHOD OF ISOLATING
OR BLOCKING ENERGY
METHOD OF SECURING
THE POINT OF CONTROL
1. C lo se v a l v e s and
m a in ta in open v en t
to re lie v e .
(1)
B l o c k i n p l a c e by
u s i n g m e t a l o r wood
blocks under the
mechanism o r p i n
the lin k ag es in a
p o s i t i o n where
grav ity w ill not
c a u s e t h e mechanism
to in ad v erten tly
fa ll.
-3 0 -
REMARKS
Secure, block,
blind flange, s lip
b lin d , or valve
w ith locking
device.
or
(2) A tta c h w arning
ta g s and r e s t r i c t
access to train ed
personnel.
or
(3) S t a t i o n a p e rs o n
a t the v alves to
protect against
unauthorized a c tu a tio n .
(1)
Secure, block, or
pin w ith a lock­
ing d e v ic e .
or
(2) A t t a c h w a rn in g
tags to blocks,
l i n k a g e s , and p i n s
and r e s t r i c t a c c e s s
to train e d
personnel.
or
(3)
S ta tio n a person
a t th e mechanism
to prevent u n au th o r­
iz e d removal o f
b l o c k s and p i n s and
re in stallatio n of
linkages.
Energy
could be
dissip ated
by lo w e r­
ing t o a
point
where
g ravity
c o u l d no
longer
cause
inadvertent
fa llin g .
ENERGY TYPE
P otential
(continued)
Springs
METHOD OF ISOLATING
OR BLOCKING ENERGY
METHOD OF SECURING
THE POINT OF CONTROL
REMARKS
3.
(1)
Spring
energy
c o u ld be
d issip ated
by r e l e a s e
or d i s ­
m antling
o f the
mechanism.
Block i n a s a f e
p o s i t i o n by p i n ­
nin g or clam ping
the device elim ­
in a tin g the
p o te n tia l of
unrestricted
and u n d e s i r e d
travel.
-3 1 -
Secure p in or
clamp i n p l a c e
w ith a locking
device.
or
(2) A tta c h w arning
tags to the pins
and clam ps and
r e s tr ic t release
or access to
train ed personnel.
or
(3) S ta t io n a p erso n
a t the c o n tro l
p o in t to p ro te c t
ag a in st pin or
clamp rem oval and
unauthorized
a c tiv a tio n o f the
s p r in g m echanisms.
V III.
APPENDIX B
EXAMPLES OF ACCIDENTS PREVENTABLE BY
GOOD ENERGY CONTROL TECHNIQUES
-3 2 -
APPENDIX B
DESCRIPTION
OF ACCIDENT
REFERENCE
[NO. IN BRACKETS]
1.
[4]
WITHOUT DISCONNECTING THE
ELECTRICAL SOURCE, AN EMPLOY­
EE ATTEMPTED TO BREAK A CON­
NECTION IN A 2300-VOLT CIRCUIT
(WITHOUT ALSO TESTING THE
C I R CU I T ) , RESULTING IN FATAL
ELECTROCUTION.
2.
[1]
WHILE MAKING ADJUSTMENTS TO
A DUMB WAITER, THE BACK OF A
MECHANIC'S HEAD MADE CONTACT
WITH AN OPEN ELECTRICAL RESET
SWITCH RESULTING IN CONVULSIVE
SHOCK AND A SEPARATED AND
FRACTURED SHOULDER.
3.
[2]
AN ELECTRICIAN WAS ELECTROCUTED
WHILE REPAIRING A 480-VOLT ELEC­
TRICAL CABLE IN AN AUTOMOBILE
MANUFACTURING PLANT.
4.
[2]
AN EMPLOYEE WAS DISMANTLING A
DRILLING RIG.
AFTER REMOVING
THE MAIN P I N ON THE BOOM, HE
WAS MOVING TO THE CONTROL STATION
WHEN THE BOOM FELL AND STRUCK
HIM. HE HAD FAILED TO INSTALL
THE SAFETY P I N .
5.
[88]
THE CONVEYOR STARTED UP AS THE
MAN WAS STANDING ON I T TO WORK
ON AN OVERHEAD CHUTE.
6.
[89]
A MAN WAS CAUGHT BETWEEN A
VERTICAL CONVEYOR AND A BARRIER
GUARD.
HAZARD
TYPE
ACCIDENT
CAUSES
SHOCK
ENERGY
SOURCE
ENERGY
CONTROL
METHOD
1
ELECTRICAL
ELECTRICAL
DISCONNECT
1
ELECTRICAL
ELECTRICAL
DISCONNECT
1
ELECTRICAL
ELECTRICAL
DISCONNECT
1
GRAVITY
BLOCKING
DEVICE
1
TRANSLATION
ELECTRICAL
DISCONNECT
1
TRANSLATION
ELECTRICAL
DISCONNECT
FATALITY
SHOCK
FRACTURE
SHOCK
FATALITY
IMPACT
FATALITY
IMPACT
FATALITY
CRUSHED
FATALITY
-3 3 -
7.
[4]
A REPAIRMAN WAS CRUSHED BETWEEN
TWO PATTERNS OF COPE MACHINE
UNDER AIR PRESSURE.
8.
[13]
A HOPPER GATE CLOSED ON THE
TORSO OF A WELDER WHO WAS
REPAIRING THE HOPPER LINING.
CRUSHED
CRUSHED
10.
AMPUTATION
11.
[89]
A JOB SETTER WAS HAVING PROBLEMS
WITH A SWITCH ON AN UNLOADING
FIXTURE OF AN AUTOMATIC TRANS­
FER LINE.
THE GUARD WAS RE­
MOVED TO OBSERVE THE OPERATION
OF THE SWITCH.
AS THE UNLOADER
ACTUATED, I T CAUGHT THE MAN AND
SQUEEZED HIM BETWEEN THE MOVING
UNLOADER AND THE SUPPORT POST
FOR THE GUARD.
12.
[2]
AN EMPLOYEE WAS LUBRICATING THE
CHAIN DRIVE LINKS IN A CONVEYOR
BELT SYSTEM THROUGH A 1 0 " X 1 2"
OPENING BETWEEN THE BINS AND THE
METAL GUIDE POST OF THE UNSTACKER
WHILE THE MACHINERY WAS RUNNING.
AS THE BINS MOVED FORWARD, HI S
HEAD WAS CAUGHT BETWEEN THE BIN
AND THE GUIDE POST.
TRANSLATION
ELECTRICAL
DISCONNECT
ROTATION
ELECTRICAL
DISCONNECT
ROTATION
ELECTRICAL
DISCONNECT
TRANSLATION
ELECTRICAL
DISCONNECT
TRANSLATION
ELECTRICAL
DISCONNECT
FATALITY
LACERATIONS
[1]
BLOCKING
DEVICE
FATALITY
9.
[2]
AN EMPLOYEE WAS CLEANING ON THE
UNGUARDED SIDE OF A GRANITE WIRE
SAW WHEN HE SLIPPED AND FELL.
HE WAS CAUGHT BY THE WIRE CLOSEST
TO THE OUTSIDE OF THE IDLER
WHEEL AND PULLED INTO THE NIP
POINT AREA, RESULTING IN FATAL
I NJ URI ES.
A REPAIRMAN ATTEMPTED TO CLEAN
A FILTER WHEEL WHILE I T WAS IN
OPERATION.
LOSING HI S BALANCE,
HE FELL ON THE WHEEL; HIS LEG
WAS CAUGHT BETWEEN THE MOVING
WHEEL AND THE ROLLER RESULTING
IN A CRUSHED LEG THAT HAD TO BE
AMPUTATED.
TRANSLATION
FATALITY
INJURED
CRUSHED
FATALITY
CRUSHED
FATALITY
-3 4 -
13.
[ 1]
CONTUSION
AN EMPLOYEE WAS WORKING ON FOUR
DIVERTER VALVES INSIDE A CABINET
INJURED
WHEN A VALVE WAS ACTIVATED BY COM­
PUTER CONTROL. THE EMPLOYEE WAS
STRUCK ON THE SIDE OF HEAD BY THE
VALVE ARM.
TRANSLATION
ELECTRICAL
DISCONNECT
ROTATION
ELECTRICAL
DISCONNECT
ROTATION
ELECTRICAL
DISCONNECT
ROTATION
PNEUMATIC
DISCONNECT
17.
[1]
AMPUTATION
AN OPERATOR REMOVED THE SLEEVE
FROM A BAGGING MACHINE TO CLEAR
INJURED
AN OBSTRUCTION FROM THE FEED SCREW.
THE MACHINE WAS STILL RUNNING,
AND HI S FINGER WAS CAUGHT.
ROTATION
ELECTRICAL
DISCONNECT
18.
[1]
A MACHINE OPERATOR WAS ATTEMPTING
TO UNJAM VINYL MATERIAL IN THE
AIR LOCK PORTION OF A RECLAIM
SYSTEM. A HATCH ABOVE THE AIR
LOCK WAS OPENED, AND HE REACHED
INTO THE THROAT WITH HIS HAND TO
PUSH THE MATERIAL FREE. HI S HAND
WENT DOWN INTO THE ROTATING VANES
AND H I S FINGER WAS AMPUTATED.
ROTATION
ELECTRICAL
DISCONNECT
14.
[2]
AN EMPLOYEE HAD BEEN FEEDING
WASTE PAPER INTO AN INTAKE DUCT
FAN ASSEMBLY OF A PAPER SHREDDER
AFTER REMOVING THE FAN COVER.
WITH THE FAN STILL OPERATING,
HE ATTEMPTED TO REPLACE THE COVER
WHEN HE WAS PULLED INTO THE FAN
RESULTING IN A FATALITY.
15.
[2]
AN EMPLOYEE WAS STANDING ON A
STRUCTURAL BEAM OF A SHAKER
ATTEMPTING TO UNJAM SAWDUST IN
AN AUGER WITH A STICK WHEN HE
WAS PULLED INTO THE AUGER AND
CRUSHED TO DEATH.
16.
[2]
WHILE AN EMPLOYEE WAS CLEANING
A BRICK CUTTER MACHINE WITHOUT
TURNING OFF AIR PRESSURE, THE
MACHINE WAS ACCIDENTALLY
ACTIVATED, AND HE WAS DRAGGED
INTO THE CUTTER.
LACERATIONS
FATALITY
CRUSHED
FATALITY
LACERATIONS
FATALITY
AMPUTATION
INJURED
-3 5 -
19.
[1]
LACERATIONS
AN OPERATOR ATTEMPTED TO CLEAN OUT
THE DOOR TRACK OF A DRYER WITHOUT INJURED
TURNING THE MACHINE OFF WHEN THE
AGITATOR STRUCK HIS FINGER.
1
ROTATION
ELECTRICAL
DISCONNECT
20.
[1]
AMPUTATION
AN EMPLOYEE REMOVED A COVER FROM A
SCREW CONVEYOR TO CHECK IF IT WAS INJURED
RUNNING. HE LOST HIS BALANCE AND
STUCK HIS FOOT INTO THE CONVEYOR.
1
ROTATION
ELECTRICAL
DISCONNECT
CHOKED
21.
[2]
AN EMPLOYEE ATTEMPTED TO REMOVE
FATALITY
SOME CLOGGED COMPOST MATERIAL
THAT HAD JAMMED AN OPERATING KILN
DISCHARGE CONVEYOR. HIS CLOTHING
BECAME ENTANGLED IN THE UNGUARDED
REVOLVING ROLLERS. HIS ARM WAS
CAUGHT IN THE MACHINE. HE WAS
PULLED AGAINST THE MACHINE AND
WAS CHOKED TO DEATH.
1
ROTATION
ELECTRICAL
DISCONNECT
1
ROTATION
ELECTRICAL
DISCONNECT
22 ^
nn
AN EMPLOYEE WAS ATTEMPTING TO
CLEAR A JAM ON A GARNETT MA­
CHINE WHILE IT WAS IN OPERATION.
HE CRAWLED INSIDE THE MACHINE
THROUGH AN UNGUARDED HOLE WHERE
HE BECAME ENTANGLED IN MOVING
PARTS, WAS DRAWN INTO THE ROLLER
AND WAS CRUSHED.
CRUSHED
FATALITY
TT.
[Ti
LACERATIONS
AN EMPLOYEE WAS CLEANING AN EDGER
SAW IN A SAWMILL. PROTECTIVE
FATALITY
PANELS WERE REMOVED. HE REQUESTED
ANOTHER EMPLOYEE TO START THE SAW.
HIS CLOTHES BECAME ENTANGLED AND
HE WAS PULLED INTOTHE SAW.
1
ROTATION
ELECTRICAL
DISCONNECT
24^
[T]
CRUSHED
AN EMPLOYEE WAS EMPTYING DOUGH
FROM A MIXER WHILE IT WAS STILL
FATALITY
RUNNING. WHEN HE REACHED INTO THE
MACHINE HIS ARM WAS CAUGHT AND HE
WAS PULLED INTO THE MACHINE.
I
ROTATION
ELECTRICAL
DISCONNECT
-3 6 -
25.
[ 2]
CRUSHED
AN EMPLOYEE REACHED TO FREE A
CLOTH THAT HAD WRAPPED AROUND THE FATALITY
WHIPROLL OF AN OPERATING TEXTILE
DOLLEY WASHER. HI S HAND WAS CAUGHT
IN THE CLOTH AND HE WAS DRAGGED
INTO THE WHIPROLL.
1
ROTATION
ELECTRICAL
DISCONNECT
26.
[2]
AN EMPLOYEE WAS USING A HOOK TO
CLEAN THE WOOL FROM THE BRUSH
ROLLER OF A YARN CARDING MACHINE
WHILE I T WAS RUNNING.
HE WAS
PULLED INTO THE MACHINE.
1
ROTATION
ELECTRICAL
DISCONNECT
1
ROTATION
ELECTRICAL
DISCONNECT
28.
[1]
BURNS
AN ELECTRICIAN WAS REPAIRING A
BURNED FEEDER TO A FURNACE.
HE
INJURED
GRASPED A AND B PHASE FEEDERS, A
CURRENT PASSED THROUGH BOTH ARMS
AND CHEST CAUSING BURNS TO BOTH
HANDS AND A FALL.
AUXILIARY POWER
WAS STILL ON.
2
ELECTRICAL
ELECTRICAL
DISCONNECT
29.
[5]
SHOCK
A PLANT ELECTRICIAN WAS REPAIRING
SOME DAMAGED ELECTRICAL CABLES.
FATALITY
CIRCUIT BREAKERS HAD BEEN OPENED
IN A SUBSTATION.
AS HE CUT ONE OF
THE CABLES, HE WAS ELECTROCUTED.
PROPER VOLTAGE TESTS WERE NOT MADE
PRIOR TO BEGINNING WORK.
2
ELECTRICAL
ELECTRICAL
DISCONNECT
27.
[2]
AN EMPLOYEE WAS WIPING THE MIXER
SHAFT WITH A LARGE RAG WHILE
THE MIXER WAS RUNNING. THE CLOTH
BECAME ENTANGLED AND PULLED HIM
AGAINST THE STEEL ARM THAT HELD
THE SHAFT.
CRUSHED
FATALITY
CRUSHED
FATALITY
- 3 7 -
30.
[ 2]
CRUSHED
AN EMPLOYEE WAS PERFORMING DRYWALL
REPAIRS FROM THE INSIDE OF AN
FATALITY
ELEVATOR SHAFT RATHER THAN FROM
THE OUTSIDE AS INSTRUCTED.
A
WOODEN BEAM WAS USED TO JAM THE
ELEVATOR DOOR ON THE SECOND FLOOR
AND THE OUTSIDE PANEL SWITCH ON
THE MAIN FLOOR HAD BEEN TURNED OFF.
THE EMPLOYEE WAS CRUSHED TO DEATH BY
THE ELEVATOR WHEN WORKING ON THE
MAIN FLOOR BECAUSE THE ELEVATOR
RETURNED TO I T S HOME BASE RATHER
THAN REMAINING ON THE SECOND FLOOR.
TRANSLATION
ELECTRICAL
DISCONNECT
31.
[2]
CRUSHED
THE WASTE HOGGER OPERATOR CLEANING
THE MACHINE FELL INTO A CONVEYOR
FATALITY
AND WAS PULLED INTO A 14-INCH
OPENING AND CRUSHED.
THE HOGGER
HAD BEEN TURNED OFF BUT NOT THE
CONVEYOR.
TRANSLATION
ELECTRICAL
DISCONNECT
32.
[2]
IMPACT
AN EMPLOYEE WAS PARTIALLY INSIDE
AN ASPHALT MIXING MACHINE CHANG­
FATALITY
ING PADDLES. ANOTHER EMPLOYEE
ACCIDENTALLY HIT A TOGGLE SWITCH
WHICH CLOSED THE DOOR OF THE MIXER,
STRIKING THE MAN.
TRANSLATION
ELECTRICAL
DISCONNECT
OR
BLOCKING
DEVICE
33.
[1]
FRACTURE
A WORKER WAS REPLACING A V-BELT ON
A DUST COLLECTOR BLOWER.
HE HAD
INJURED
SHUT DOWN THE UNIT BY A LOCAL
SWITCH ONLY.
AN OPERATOR IN THE
CONTROL ROOM RESTARTED THE UNIT,
USING A REMOTE SWITCH CENTER.
THE WORKER'S HAND WAS CAUGHT
BETWEEN THE PULLEY AND BELTS
RESULTING IN CUTS AND A
FRACTURED FINGER.
ROTATION
ELECTRICAL
DISCONNECT
34.
[91]
AN EMPLOYEE REMOVED A JAM FROM A
PACKAGING MACHINE WITH THE POWER
TURNED OFF.
RESIDUAL HYDRAULIC
PRESSURE ACTIVATED THE HOLDING
DEVICE.
TRANSLATION
BLOCKING
DEVICE
CRUSHED
INJURED
-3 8 -
35.
[1]
TWO EMPLOYEES HAD OPENED A P I P E ­
LINE FOR REPAIRS WHEN A THIRD
EMPLOYEE STARTED A FEED PUMP.
TWO EMPLOYEES WERE SPRAYED WITH
ACID.
ACID
BURNS
36.
[1]
A MECHANIC WAS REPAIRING A
CAUSTIC PUMP WHEN A COWORKER
ACCIDENTALLY ENERGIZED THE PUMP
AND SPRAYED THE MECHANIC WITH
CAUSTIC.
CAUSTIC
BLIND
37.
[1]
AN EMPLOYEE RECEIVED CHEMICAL
BURNS WHEN A COWORKER IN THE
CONTROL ROOM OPENED A VALVE TO
A DISCONNECTED LINE THAT WAS IN
THE PROCESS OF BEING TESTED.
CHEMICAL
38.
[4]
AN EMPLOYEE WAS IN THE PROCESS OF
CUTTING A P IPE WHEN DIESEL FUEL
WAS MISTAKENLY DISCHARGED INTO
LINE AND WAS IGNITED BY THE
TORCH.
BURNS
ELECTRICAL
ELECTRICAL
DISCONNECT
AND/OR
S LIP BLIND
4
ELECTRICAL
ELECTRICAL
DISCONNECT
4
PRESSURE
S LIP BLIND
OR VALVE
CHAINED IN
CLOSED
POSITION
4
THERMAL
S L IP BLIND
OR VALVE
CHAINED IN
CLOSED
POSITION
4
TRANSLATION
ELECTRICAL
DISCONNECT
4
TRANSLATION
ELECTRICAL
DISCONNECT
4
TRANSLATION
ELECTRICAL
AND/OR
PNEUMATIC
DISCONNECT
INJURED
INJURED
INJURED
FATALITY
39.
[ 9 1]
A REPAIRMAN WAS CRUSHED WHEN
ANOTHER EMPLOYEE ACTIVATED A
CONVEYOR IN A COKE FURNACE.
CRUSHED
40.
[2]
AN EMPLOYEE WAS GREASING BEARINGS
ON THE ROLLERS OF A LOG CART
MACHINE. HE ACCIDENTALLY TRIPPED
A LEVER CAUSING A ROLLER TO MOVE
WHICH CRUSHED HIM.
CRUSHED
41.
[2]
WHILE SETTING UP A VACUUM FORMING
PRESS, AN EMPLOYEE LEANED OVER
THE PRESS AND ACCIDENTALLY
ACTIVATED THE START SWITCH AND
WAS CRUSHED.
4
INJURED
FATALITY
CRUSHED
FATALITY
- 3 9 -
4
TRANSLATION
ELECTRICAL
DISCONNECT
AMPUTATION
43.
[1]
AN EMPLOYEE WAS WORKING AT TOP OF
A KILN LARK? WHEN ANOTHER EMPLOYEE INJURED
CAUSED THE COUNTERWEIGHT TO DROP.
4
TRANSLATION
ELECTRICAL
DISCONNECT
44.
[2]
LACERATIONS
AN EMPLOYEE ACCIDENTALLY ACTIVATED
FATALITY
THE CARRIAGE CONTROL LEVER IN
THE BOOTH.
THE BOOTH MOVED,
THROWING HIM INTO THE 3 6 - INCH
SAW BLADE.
4
ROTATION
ELECTRICAL
DISCONNECT
IMPACT
45.
[1]
A MAINTENANCE MAN INSIDE A LARGE
FATALITY
MIXING DRUM MAKING REPAIRS WAS
STRUCK BY THE BEATER BLADES WHEN
THEY WERE INADVERTENTLY ACTIVATED.
4
ROTATION
ELECTRICAL
DISCONNECT
IMPACT
46.
[1]
A UTILITY MAN WAS USING A TOOL TO
INJURED
TURN THE FEED ROLL MOTOR OF A
STAPLE MACHINE FOR CLEANING.
THE
MOTOR WAS TURNED ON ACCIDENTALLY
AFTER HE GAVE VERBAL INSTRUCTIONS,
"DON'T START MOTOR." HE WAS
STRUCK ON THE ARM BY THE TOOL.
4
ROTATION
ELECTRICAL
DISCONNECT
47.
[1]
LACERATIONS
AN EMPLOYEE WAS WORKING ON AN AGI­
TATOR IN A P I T WHEN SOMEONE ELSE
INJURED
STARTED THE AGITATOR AND ALSO COM­
MENCED FILLING THE P I T WITH WATER
AND STOCK. HE RECEIVED MULTIPLE
CONTUSIONS, ABRASIONS, AND LACERA­
TIONS TO LEGS, H I P , AND SCALP.
4
ROTATION
DISCONNECT
ALL ENERGY
48.
[91]
AN EMPLOYEE WAS INJURED WHEN THE
PLASTIC PELLETIZER HE OPERATED
ACCIDENTALLY ACTIVATED WHILE HE
WAS REACHING THROUGH AN UN­
GUARDED PORTHOLE TO CLEAN I T .
4
TRANSLATION
ELECTRICAL
DISCONNECT
42.
[2]
AN EMPLOYEE WAS REPAIRING A CON­
VEYOR INSIDE A COKE FURNACE WHEN
ANOTHER EMPLOYEE ACTIVATED THE
CONVEYOR.
CRUSHED
FATALITY
CRUSHED
INJURED
-4 0 -
CRUSHED
49.
[2]
AN EMPLOYEE WAS WORKING ON A MOLD­
FATALITY
ING MACHINE TURNTABLE. HE WAS
STANDING BETWEEN THE TRANSFER ARM
AND THE WEIGHT CHANGER WHEN HE
ACCIDENTALLY ACTIVATED THE CON­
TROLS OF THE TRANSFER ARM. THE
TRANSFER ARM CRUSHED HIM AGAINST
THE WEIGHT CHANGER.
50.
[2]
AN EMPLOYEE WAS INSIDE A T I E BORING MACHINE ADJUSTING THE
SWITCHES TO RELIEVE A JAM WHEN
THE CONVEYOR SYSTEM STARTED
MOVING CAUSING HIM TO BE
CAUGHT BETWEEN A TIE AND THE
BORING MILL.
CRUSHED
51.
[2]
TWO EMPLOYEES WERE OPERATING A
PRESS BRAKE.
THE WORK PIECE WAS
BEING REPOSITIONED FOR THE NEXT
OPERATION.
ONE EMPLOYEE HAD HIS
HEAD IN THE POINT OF OPERATION
WHEN THE PRESS WAS ACTIVATED
ACCIDENTALLY BY THE OTHER
EMPLOYEE.
CRUSHED
TRANSLATION
ELECTRICAL
DISCONNECT
4
TRANSLATION
ELECTRICAL
DISCONNECT
4
TRANSLATION
ELECTRICAL
CONNECT OR
BLOCKING
DEVICE
4
ROTATION
ELECTRICAL
DISCONNECT
4
ROTATION
ELECTRICAL
DISCONNECT
4
ROTATION
ELECTRICAL
DISCONNECT
FATALITY
FATALITY
CRUSHED
52.
[18]
AN EMPLOYEE WAS CLEANING A FLOUR
BATCH MIXER WHEN THE START SWITCH FATALITY
WAS INADVERTENTLY ACTIVATED CRUSH­
ING HIS NECK.
53.
[2]
AN EMPLOYEE WAS CLEANING THE
INSIDE OF A PUG MILL MIXER SILO
WHEN ANOTHER EMPLOYEE STARTED
THE MACHINE.
4
CRUSHED
FATALITY
54.
[1]
AMPUTATION
AN EMPLOYEE WAS REPLACING A ROLLER
CHAIN KEY AND SPROCKET FOR A SET
INJURED
OF ROLLS ON METAL SCRUBBER WHEN
SOMEONE ELSE JOGGED THE MACHINE AND
CAUGHT H I S FINGERS.
-41-
55.
[1]
AN EMPLOYEE WAS CLEANING A PELLET
MACHINE WHILE THE GUARD OVER THE
FEED ROLLS WAS REMOVED.
HE
ACCIDENTLY STARTED THE MACHINE
AND HIS HAND BECAME CAUGHT
IN THE ROLLS.
CRUSHED
4
ROTATION
ELECTRICAL
DISCONNECT
56.
AN EMPLOYEE
THE BLENDER
DOOR HE WAS
THE BLENDER
ENERGIZED.
CRUSHED
4
ROTATION
ELECTRICAL
DISCONNECT
4
ROTATION
ELECTRICAL
DISCONNECT
58.
[1]
AMPUTATION
AN EMPLOYEE REMOVED THE HOSE FROM
THE CLEANOUT OPENING OF A PUMP
INJURED
AND COMMENCED CLEANING OUT THE PUMP
WITH HIS HAND. A COWORKER STARTED
THE PUMP RESULTING IN AMPUTATION
OF A FINGER.
4
ROTATION
ELECTRICAL
DISCONNECT
59.
[1]
FRACTURE
AN EMPLOYEE WAS CLEANING THE DRIVE
PULLEY OF A CENTRIFUGE CONVEYOR.
INJURED
THE CONVEYOR SUDDENLY BEGAN MOVING
DRAWING HIS ARM IN BETWEEN THE
PULLEY AND THE BELT RESULTING IN
FRACTURES OF HIS ARM. A COWORKER HAD
ENERGIZED THE CONVEYOR.
4
ROTATION
ELECTRICAL
DISCONNECT
[1]
WAS TRAPPED BETWEEN
SHELL AND THE OPENED
WORKING THROUGH WHEN
WAS ACCIDENTALLY
5 7.
[1]
AN EMPLOYEE WAS TRAPPED INSIDE
A MIXER WHEN I T WAS ACCIDENTALLY
ENERGIZED BY ANOTHER EMPLOYEE.
INJURED
INJURED
LACERATIONS
INJURED
-4 2 -
IX .
APPENDIX C
EVALUATION OF EXISTING STANDARDS
INTERNATIONAL, NATIONAL,
-4 3 -
STATE, AND CONSENSUS
Appendix C
EVALUATION OF EXISTING STANDARDS - INTERNATIONAL, NATIONAL, STATE, CONSENSUS
Th e f o l l o w i n g p a r a g r a p h s c o m p a r e a n d e v a l u a t e t h e c u r r e n t n a t i o n a l , s t a t e ,
i n t e r n a t i o n a l , and c o n s e n s u s s t a n d a r d s r e l a t e d t o e n e rg y c o n t r o l s
(lockout/
tagouts)
for
accom plishing
m aintenance
and
servicing
activ ities
safely.
S pecifically,
t h e g u i d e l i n e s recommended a r e com pared w i t h :
OSHA G e n e r a l
I n d u s t r y S t a n d a r d s ( 2 9 CFR 1 9 1 0 ) a n d OSHA C o n s t r u c t i o n S t a n d a r d s
( 2 9 CFR
1926); S ta t e S tan d ard s
( w i t h a p p r o v e d OSHA p l a n s ) ;
criteria
developed in
Canada
(A lberta),
Germany,
and
B ritain;
and
consensus
standards
ANSI
Z 2 4 4 . 1 - 1 9 8 2 a n d NFPA 70E p a r t I I .
Summary
A p p e n d i x T a b l e s C - l , C - 2 , a n d C -3 p r e s e n t a n o v e r a l l c o m p a r i s o n o f t h e r e c o m ­
mended g u i d e l i n e s w i t h t h e r e s p e c t i v e n a t i o n a l ,
state,
i n t e r n a t i o n a l , and
consensus stan d ard s.
Even though t h e t y p e s o f e n e r g y a p p l i c a b l e and t h e
i n d u s t r i e s a f f e c t e d v a r y , a c o n s i d e r a b l e c o n s i s t e n c y is found in th e g u id e ­
l i n e s r e q u i r e d f o r a l l e x c e p t t h e OSHA n a t i o n a l s t a n d a r d s a n d t h e s t a t e OSHA
standards
( w i t h th e e x c e p t i o n s o f C a l i f o r n i a and M i c h i g a n ) .
The p r i m a r y
c r i t e r i a e l e m e n t s e l i m i n a t i n g e n e r g y , s e c u r i n g t h e m e a n s by w h i c h t h e e n e r g y
is e lim in a te d , v e r if y in g th a t energy has d is s ip a te d to s a fe l e v e l s , docu­
m enting
the
procedures,
and
training
the
personnel
involved,
are
found
c o n s is te n tly in the o th e r sta n d a rd s .
T he e x i s t i n g n a t i o n a l OSHA s t a n d a r d s a r e i n a d e q u a t e b e c a u s e o f i n c o m p l e t e
i n d u s t r y c o v e r a g e and i n c o m p l e t e and i n c o n s i s t e n t c r i t e r i a w here s t a n d a r d s
ex ist.
The e x i s t i n g
state
standards,
w ith
the
exception
of
those
for
C alifornia
and
M ichigan,
are
reprints
of
the
national
standards.
The
C a l i f o r n i a and M i c h ig a n s t a n d a r d s c l o s e l y p a r a l l e l t h e recommended g u i d e l i n e s ;
however,
t h e y do n o t
p r o v i d e t h e t h r e e a l t e r n a t e means o f s e c u r i n g
the
p o i n t ( s ) o f c o n t r o l a s p r o v i d e d by t h e recommended g u i d e l i n e s .
The C a l i f o r n i a
s t a n d a r d s a r e a l s o l i m i t e d t o e l e c t r i c a l e n e rg y and m e c h a n ic a l m o tio n o f
e q u i p m e n t ; w h e r e a s , t h e recommended c r i t e r i a c o v e r e l e c t r i c a l , m e c h a n i c a l , and
therm al energy.
The e x i s t i n g A l b e r t a , C a n a d a , r e g u l a t i o n s l a c k e f f e c t i v e n e s s s i n c e t h e y d o n o t
i n c l u d e m e c h a n i c a l m o tio n o r th e r m a l e n e r g y as a p p l i c a b l e forms o f e n e r g y t h a t
p e r s o n n e l must be s a f e g u a r d e d a g a i n s t .
A l s o , t h e A l b e r t a r e g u l a t i o n s do n o t
s p e c i f y t h e d o c u m e n t i n g o f p r o c e d u r e s and t r a i n i n g o f p e r s o n n e l a s n e c e s s a r y
re q u ir e m e n ts f o r an e f f e c t i v e program fo r c o n t r o l l i n g h a z a r d s d u rin g m a in te ­
nance.
T he d r a f t Ge rman A c c i d e n t P r e v e n t i o n S p e c i f i c a t i o n s do n o t i n c l u d e e l e c t r i c a l ,
c h e m ic a l, o r th e rm a l as a p p l i c a b l e forms o f e n e r g y t o be c o n t r o l l e d d u r i n g
m a in te n a n c e and s e r v i c i n g .
I n d u s t r i e s a f f e c t e d by t h e s p e c i f i c a t i o n s a r e
l i m i t e d t o " p o w e r d r i v e n e q u i p m e n t " w h i c h e x c l u d e s many i n d u s t r i e s t h a t e x p o s e
w orkers to hazardous le v e ls o f energy during m aintenance.
The Ge rman s p e c i f i ­
c a t i o n s do n o t r e q u i r e v e r i f i c a t i o n t h a t h a z a r d s h a v e b e e n c o n t r o l l e d , d o c u ­
m e n tin g o f p r o c e d u r e s , o r t r a i n i n g o f p e r s o n n e l i n s a f e work p r a c t i c e s .
-4 4 -
TABLE C - l
COMPARISON SUMMARY OF
TYPES OF ENERGY
RECOMMENDED GUIDELINES:
NATIONAL
M e c h a n i c a l m o t i o n ; p o t e n t i a l e n e r g y due t o p r e s s u r e , g r a v i t y , o r s p r i n g s ;
e n e r g y ; t h e r m a l e n e r g y r e s u l t i n g from h i g h o r low t e m p e r a t u r e .
STATES*
INTERNATIONAL
ALBERTA
CANADA
[92]
i
-pn>
l_
I
E l e c t r i c a l energy;
hydraulic p ressure;
therm al energy.
M echanical m otion
i s im plied b u t n o t
stated.
* S ta te s rev ie w e d :
E ssentially
i d e n t i c a l to the
n a t i o n a l OSHA
standard except
for C alifo rn ia.
C alifo rn ia stand­
ards apply to
e l e c t r i c a l energy
and m e c h a n i c a l
m otion.
P o ten tial
energy,
power,
chemical
energy.
GERMANY
[46]
BRITAIN
[71]
M echanical
m otion,
potential
energy.
M echanical
m otion.
electrical
CONSENSUS
NFPA 70E
ANSI
Z 2 4 4 .1-1982
Part II
[54]
[ 5]
E lectrical,
m echanical,
h y d rau lic,
chem ical,
n u c l e a r , and
therm al energy.
AL, AZ, CA, H I, IN, IA, KY, MD, MI, MN, NC, NV, OR, SC, TN, VT, WA, and WY.
E lectrical
energy.
TABLE C -2
COMPARISON SUMMARY OF
INDUSTRIES AFFECTED
RECOMMENDED GUIDELINES:
Those i n d u s t r i e s
m aintenance.
t h a t expose w orkers to hazardous
INTERNATIONAL
STATES*
NATIONAL
ALBERTA
CANADA
[92]
I
■p-
ON
I
Overhead and g a n tr y
c r a n e s ; woodworking;
m e c h a n i c a l p o we r
presses; forging
m achines; p u lp ,
p a p e r , and p a p e r ­
board m i l l s ;
te x tile s ; bakeries;
saw m ills; t e l e ­
communications;
and c o n s t r u c t i o n .
* S ta te s re v ie w e d :
Same a s t h e
n a t i o n a l OSHA
standard except
for C alifornia.
C a lifo rn ia lock­
out standards
are applicable
to e le c tr ic a l
and g e n e r a l
indus t r y .
Machinery
and e q u i p ­
ment ,
powered
m obile
equipment
and h o i s t s .
GERMANY
[46]
BRITAIN
[71]
Power
driven
equipm ent.
M achinery
and
processes
applicable
to a l l
sectors of
industry.
levels
of energy during
CONSENSUS
ANSI
NFPA 7 OE
Part II
Z 2 44 .1-1982
[54]
[5]
Not s p e c i f i e d ,
AL, AZ, CA, H I, IN, IA, KY, MD, MI, MN, NC, NV, OR, SC, TN, VT, WA, and WY.
Not s p e c i f i e d .
A pplies to
a n y o n e who
works on, n e a r
or with
electric
c i r c u i t s and
equipm ent.
TABLE C -3
COMPARISON SUMMARY OF
CRITERIA REQUIREMENTS
RECOMMENDED GUIDELINES:
NATIONAL
Energy s h a l l be i s o l a t e d , b lo c k e d , d i s s i p a t e d ,
be documented and p e r s o n n e l s h a l l be t r a i n e d .
STATES*
INTERNATIONAL
ALBERTA
CANADA
[92]
In c o m p le te and
inconsistent.
Some
sections require
provisions fo r lock­
out only w hile
o ther sections
require physical
lockout or tagout
b u t do n o t r e q u i r e
v erificatio n ,
procedures, or
training.
* S ta te s review ed:
E ssentially
i d e n t i c a l to the
n a t i o n a l OSHA
standard except
in C a lifo rn ia .
C alifornia
requires th at
e n e rg y be
iso lated ,
blocked, d i s s i ­
pated, secured,
a w arn in g be
p o s t e d , and
verified .
Procedures
s h a l l be docu­
m ented and
personnel sh all
be t r a i n e d .
AL, AZ, CA, H I ,
secured, v e r if ie d .
I N,
Energy
s h a l l be
isolated,
blocked,
d issipated,
secured
against
accidental
mov em en t
or use a
physical
means on
t h e power
control, a
w arning
t a g , and
v erified .
GERMANY
[46]
BRITAIN
[71]
Energy
s h a l l be
iso lated ,
blocked,
and d i s ­
sipated .
U nauthorized
erroneous or
unexpected
in itiatio n
o f hazardous
movements
s h a l l be
avoided.
Do cume nt a
w ritten
"perm it to
work"
system
procedure
and t r a i n
personnel
in safe
p ractices.
Procedures s h a ll
CONSENSUS
ANSI
Z 2 4 4 .1-1982
[5]
Energy so u rces
s h a l l be
blocked, d i s s i ­
p ated , secured
by l o c k o u t
devices or ta g ­
out devices,
and v e r i f i e d .
Procedures
s h a l l be d o c u ­
m en ted and
personnel
s h a l l be
train ed .
IA,, KY, MD, MI , MN, NC, NV, OR , SC, TN, VT, WA, a n d WY.
NFPA 70E
Part II
[54]
Energy
sources
s h a l l be
blocked,
d issip ated ,
s e c u r e d by
t a g only, o
lock o n ly ,
o r no l o c k s
or tags.
= n
v erified .
Procedures
s h a l l be
documented
and p e r s o n ­
n e l shall
train ed .
T h e e x i s t i n g B r i t i s h Code o f P r a c t i c e r e l i e s o n t h e hu man e l e m e n t t o f o l l o w a
documented " p e rm it t o work" sy stem f o r p e r fo rm in g m a in te n a n c e .
It closely
p a r a l l e l s t h e r e c o m m e n d e d g u i d e l i n e s , a n d r e l i e s on t h e d o c u m e n t e d s y s t e m t o
s e r v e as a r e c o r d o f a l l th e f o r e s e e a b l e h a z a rd s which h ave been c o n s id e r e d i n
advance.
I t a l s o r e l i e s h e a v i l y on s u p e r v i s i o n t o s e e t h a t t h e s y s t e m o p e r ­
ate s properly.
The C o n s e n s u s S t a n d a r d s a r e s i m i l a r t o t h e r e c o m m e n d e d g u i d e l i n e s .
They p r o ­
v i d e t h e o p t i o n s o f ( 1 ) s e c u r i n g t h e p o i n t ( s ) o f c o n t r o l by l o c k o u t o r t a g o u t
d e v i c e s o r (2) h a v in g no l o c k s o r t a g s , p r o v i d e d o t h e r r e q u i r e m e n t s a r e m e t.
Th ese s t a n d a r d s , h o w e v e r , do n o t a l l o w t h e o p t i o n o f h a v i n g a p e r s o n r e m a i n a t
t h e p o i n t ( s ) o f c o n t r o l t o p r o t e c t a g a i n s t u n a u t h o r i z e d a c t u a t i o n o f t h e ma­
c h in e o r p ro c e s s d u r i n g m a in te n a n c e and s e r v i c i n g .
A l s o , t h e s t a n d a r d s do n o t
c o v e r t h e b r o a d s p e c t r u m o f h a z a r d s a s do t h e recommended g u i d e l i n e s .
N atio n al Standards
Th e e x i s t i n g n a t i o n a l s t a n d a r d s a s s hown i n T a b l e C - 4 a r e n o t u n i f o r m i n t h e i r
coverage.
I n c o n s i s t e n c i e s i n th e re q u ir e m e n t s e x i s t b etw een i n d u s t r i e s and
b e t w e e n e q u i p m e n t w i t h i n t h e same i n d u s t r y .
Some s e c t i o n s o f t h e G e n e r a l
I n d u s t r y S ta n d a rd s im ply lo c k in g o u t o r t a g g in g o u t e n e rg y r a t h e r th a n s p e c i ­
fy in g t h a t lo c k o u ts or t a g o u ts be p erfo rm ed .
S ections of the standard cover­
in g i n d u s t r i e s or equipm ent r e q u i r in g p r o v is io n s f o r o nly lo c k in g out or t a g ­
ging out energy are:
o v erh ead and g a n tr y
c r a n e s ; woodworking m a c h i n e r y ;
m e c h a n i c a l power p r e s s e s ; c e r t a i n f o r g i n g m a c h i n e s ; c e r t a i n p u l p , p a p e r , and
paperboard m ills ;
tex tiles;
c e r t a i n bakery equipm ent;
and c e r t a i n s a w m i l l
equipm ent.
O th e r s e c t i o n s o f t h e G e n e r a l I n d u s t r y S t a n d a r d a r e more p o s i t i v e
and e x p l i c i t i n t h e i r c o v e ra g e i n t h a t th e y s p e c i f y t h a t l o c k o u t s o r t a g o u t s
s h a l l be u t i l i z e d .
I n d u s t r i e s or equipment in t h i s c a te g o ry a r e :
certain
f o r g i n g m a c h in e s; c e r t a i n p u l p , p a p e r , and p a p e rb o a r d m i l l e q u ip m e n t; c e r t a i n
b a k e ry eq u ip m en t; c e r t a i n saw m ill eq u ip m en t; and te le c o m m u n ic a tio n s s y s te m s .
Th e C o n s t r u c t i o n S t a n d a r d i s a l s o i n c o n s i s t e n t i n i t s r e q u i r e m e n t s .
S ections
o f the s ta n d a rd c o v e rin g i n d u s t r i e s or equipm ent w herein p ro v is io n s fo r only
locking out or tagging out energy are s p e c if ie d c o n s is t of:
woodworking
t o o l s , b a s e - m o u n t e d drum h o i s t s , m o t o r v e h i c l e s , a n d p i l e - d r i v i n g e q u i p m e n t .
S e c t i o n s o f t h e C o n s t r u c t i o n S ta n d ard c o v e r i n g i n d u s t r i e s o r equipm ent which
specify
that
lockouts
or
tagouts
be perform ed
are:
general
contractor
m achinery, e l e c t r i c a l c i r c u i t s ,
conveyors,
co n stru ctio n
equipm ent
such as
b u l l d o z e r s and e n d - l o a d e r s , e l e c t r i c b l a s t i n g e q u i p m e n t , power t r a n s m i s s i o n
an d d i s t r i b u t i o n l i n e s and e q u i p m e n t , and e l e c t r i c a l s u b s t a t i o n s .
The e x i s t ­
ing n a t io n a l sta n d a rd s have only lim ite d e f f e c ti v e n e s s because of the lack o f
u n i f o r m i t y ( l o c k o u t s f o r some i n d u s t r i e s a n d o n l y p r o v i s i o n s f o r l o c k o u t s f o r
o t h e r s ) and b e c a u s e th e y a r e w r i t t e n o n ly f o r s p e c i f i c i n d u s t r i e s .
The e x i s t ­
ing G e n eral I n d u s t r y and C o n s t r u c t i o n S ta n d a rd s r e l a t e d t o t h i s s u b j e c t , as
c o m p i l e d b y OSHA, a r e c o n t a i n e d i n A p p e n d i x D.
S ta te Standards
The e x i s t i n g s t a t e s t a n d a r d s ( T a b l e C - 5 ) , w i t h t h e e x c e p t i o n o f t h o s e f o r
C a l i f o r n i a and M i c h i g a n , a r e e s s e n t i a l l y i d e n t i c a l t o t h e n a t i o n a l s t a n d a r d s .
C a l i f o r n i a h a s h o r i z o n t a l s t a n d a r d s w h i c h r e c o mm en d i s o l a t i n g
or blocking
energy so u rc es; d i s s ip a t in g or blo ck in g s to re d energy th a t c o n s t i t u te s a p e r ­
s o n n e l h a z a r d ; u s i n g p h y s i c a l m e an s o r d e v i c e s t o s e c u r e t h e p o i n t o f c o n t r o l
-4 8 -
TABLE C-4
LOCKOUT AND TAGOUT NATIONAL STANDARDS
i.
1
'
<
<
'
i
t
E
I
c
c
3
3
3
3
3
i
5
i
>
i
£
'
GENERAL INDUSTRY, OSHA SAFETY AND HEALTH STANDARDS
(29 CFR 1 9 1 0 )
29 CFR PART 1 9 2 6 , OSHA SAFETY AND HEALTH REGULATIONS
CONSTRUCTION, FEDERAL REGISTER
These s t a n d a r d s a r e w r i t t e n f o r s p e c i f i c i n d u s t r i e s
only.
I h e f o l l o w i n g s e c t i o n s o f t h e s t a n d a r d s make
p ro v isio n s fo r locking out or tagging out energy.
These r e g u l a t i o n s a re w r i t t e n f o r g e n e r a l use equipment
s p e c i f i c p u r p o s e e q u i p m e n t , and s p e c i a l s y s t e m s w i t h
lim ited a p p lic a b ility .
The f o l l o w i n g s e c t i o n s o f t h e
r e g u l a t i o n s make p r o v i s i o n s f o r l o c k i n g o u t o r t a g g i r n
out energy.
1910.145( f ) ( 1 ) ( i )
145(f)(3 )( iii)
179(g)( 5 ) (i)
17 9 ( g ) ( 5 ) ( i i )
179(g)(5)(iii)
1 7 9 ( 1 ) ( 2 ) Ci) ( c )
181(f)(2 )(i)(c )
2 1 3 ( a ) (10)
213(b)(5)
217(b)(8 )(i)
217(d ) ( 9 ) (iv)
218( a ) ( 3 ) ( i i i )
218(a)( 3 ) (iv)
2 18 (d) (2)
218(e)(1) ( i i )
218(f)(1)
218(f)(2)
218(g)(1)
218(h)(2)
218(h)(5)
2 1 8 ( i ) (1)
2 1 8 ( i ) (2)
218(j )(1 )
252(c)(1 )(i)
261(b)(4)
261(b)(5)
261(e)(2)
2 6 1 ( e ) (10)
26 1 ( e
261 ( e
26 1 ( f
261 (g
2 61 (g
261 (g
26 1 (g
261 (g
261 ( j
261 ( j
26 1 ( j
261 ( j
26 1 ( k
262(c
2 62 ( n
262(p
262 (q
263(k
263(1
263(1
26 5 (c
265(c
2 65 (c
265(c
2 65 ( e
268(1
2 6 8 (m
(12)( iii)
(13)
( 6 )(i)
(4) ( i i )
(1 5 )(i)
(16)(i)
(19)(iii)
(21)
(1)(iii)
(4)(iii)
(5)(iii)
(6) ( i )
(2)(ii)
(1)
(2)
(1)
(2)
(12)(i)
(3)(iii)(b )
(8)(iii)
( 1 2 ) (v)
(13)
(26) ( i i i )
(26) (v)
(l)(iv )
(2 )
(7 )(i)
1926.20(b)(3)
200(h)(1)
200(h)(2)
304(a)
400(a)
555(a)(7)
6 0 1 ( b ) (10)
906 ( j )
906(1)
950(d)(1)(ii)(b)
950(d)(2)
TABLE C-5
STATE STANDARDS
STATE OF CALIFORNIA STANDARDS
STANDARDS FROM OTHER STATES
AND THE TERRITORY OF PUERTO RICO
These s t a n d a r d s p a r a l l e l
recommended g u i d e l i n e s .
These s t a n d a r d s a r e w r i t t e n f o r
s p e c i f i c i n d u s t r i e s o n l y and
are not h o rizo n tal standards.
They a r e e s s e n t i a l l y i d e n t i c a l
t o a n d p a r a l l e l t o t h e 29 CFR
1910 n a t i o n a l s t a n d a r d s .
the
The s t a n d a r d s a r e w r i t t e n f o r
e l e c t r i c a l equipm ent or
s y s te m s , prime m overs,
m ach in e ry , and equipm ent in
general.
The M i c h i g a n s t a n d a r d s c l o s e l y
p a r a l l e l t h e recommended
g u i d e l i n e s e x c e p t t h e y do n o t
include v e r if ic a t i o n p rio r to
s t a r t i n g m aintenance.
-5 0 -
to prevent unauthorized persons from r een er gi zin g the system; using warning
tags to caution personnel that energy has been i s o l a t e d and the reason for
i s o l a t i o n ; v e r i f y i n g that i s o l a t i o n of energy has been e f f e c t i v e ; v e r i f y i n g
that personnel have cleared the area prior to ree ne r gizin g the machine or
system; documenting procedures; and ensuring that personnel who implement the
c r i t e r i a have been adequately trained to thoroughly understand the procedures.
The Michigan standards c l o s e l y p a r a l l e l the recommended g u i d e l i n e s except
Michigan does not include v e r i f i c a t i o n that bl o c k i n g , i s o l a t i n g , and d i s s i p a ­
ti n g hazardous energy have been e f f e c t e d before s t a r t i n g maintenance.
I nt er nat ion al Standards
I n te r n a ti o n a l standards from Canada, Germany, and B r i ta in (summarized in Table
C-6) p a r a l l e l portions o f the recommended c r i t e r i a .
The Alberta, Canada,
r e g u la ti o n s for machinery and equipment s t a t e that no maintenance or repairs
s h a l l be carried out u n t i l the machinery or equipment has been shut down and
secured again st a c c id e n t a l movement or the power contro l d ev ic es have been
locked out in an in op era ti ve mode by the i n s t a l l a t i o n o f lockout d ev ic es and
warning tags .
D i s s i p a t i o n o f stored energy, v e r i f i c a t i o n that i s o l a t i o n and
d i s s i p a t i o n have been e f f e c t e d prior to s t a r t i n g maintenance, and v e r i f i c a t i o n
that upon completion of maintenance, personnel are c le a r o f the danger points
before the machine or equipment i s reenergized are a l s o included as r equ ir e­
ments.
The German s p e c i f i c a t i o n s for setup, t r o ub les ho ot in g, and maintenance o f
power-driven equipment s t a t e that these tasks must only be performed when:
(1) The hazardous movements are brought to a h a l t ; (2) the i n i t i a t i o n o f haz­
ardous movements as a consequence o f stored power or energy i s prevented; and
(3) unauthorized, erroneous, or unexpected i n i t i a t i o n o f hazardous movements
i s avoided by some adequate means.
The B r i t i s h Code o f P r ac ti c e for Safeguarding of Machinery s t a t e s that e f f e c ­
t i v e c ont ro l o f hazards during maintenance can be achieved by having a w r it t e n
"permit to work" system. Such a system must c l e a r l y i d e n t i f y the hazards and
document the pr a c ti c e s to be foll owed, precautions to be taken, and r es p on si ­
b i l i t i e s of the workers and o f management. The code of p r a c t ic e a l s o c a l l s
for adequate tr ai ni ng o f workers and s up e r vi si on in s a f e systems of work and
lockout systems for maintenance operation.
Consensus Standards
The ANSI and NFPA standards (Table C-7) e s t a b l i s h requirements and procedures
for loc ko ut /ta gout o f energy sources for s t a t i o n a r y machines and equipment and
for e l e c t r i c a l c i r c u i t s and e l e c t r i c a l equipment, r e s p e c t i v e l y .
These st an­
dards require (1) that energy sources be i s o l a t e d or blocked for maintenance,
(2) that stored energy be d i s s i p a t e d prior to beginning maintenance, (3) that
physical means or de v ic e s be used to secure the energy s ou rce s, (4) v e r i f i c a ­
t i o n that the energy sources have been i s o l a t e d prior to s t a r t i n g work, (5)
v e r i f i c a t i o n that a l l personnel are c l e a r of hazards before r een er giz in g the
machines or systems, (6) assurance that the procedures for lo ckout /ta gou t have
been documented, and (7) that personnel have been adequately trained to under­
stand and implement the recommended g u i d e l i n e s .
-5 1 -
A p p l i c a b i l i t y o f the ANSI standard i s l im it e d to unexpected e n e r g iz a t io n ,
s ta r tu p, or r e le a s e o f stored energy o f equipment or process.
The NFPA
standard does not have such a l i m i t a t i o n but covers only e l e c t r i c a l energy.
The recommended g u i d e l i n e s are app lic abl e for a l l phases o f maintenance and
servicing.
-5 2 -
TABLE C-6
INTERNATIONAL STANDARDS
OCCUPATIONAL HEALTH AND SAFETY
REGULATIONS, ALBERTA, CANADA [92]
These r eg u la ti on s contain both
h or iz on ta l and v e r t i c a l standards
for s p e c i f i c equipment and a
limited number o f s p e c i f i c
industries.
This r e gu la ti on p a r a l l e l s the
recommended g u i d e l i n e s . *
I
U!
u>
I
*"When machinery or equipment i s
shut down for maintenance or
r e p a ir s , no work s h a l l be ca rried
out u n t i l a l l parts, ex tens ion s
and attachments thereto have been
secured a gain s t a c ci d en ta l move­
ment o£ the power contro l d e vi c es
have been locked out in an
inoperative p o s i t i o n with a
supplemental tag which describes
the work to be performed and the
name o f the worker r esp on sib le
for the i n s t a l l a t i o n o f the
lockout dev ic e."
ACCIDENT PREVENTION SPECIFICATION
(DRAFT) "POWER-DRIVEN EQUIPMENT,"
GERMANY [46]
This s p e c i f i c a t i o n p a r a l l e l s c e r t a i n
s e c t i o n s o f the recommended guide­
lines. *
*"Setup, troubleshooting or mainte­
nance tasks must be performed only
in the area provided for t h i s
purpose when unauthorized, erroneous,
or unexpected i n i t i a t i o n o f hazard­
ous movements i s avoided." The
s p e c i f i c a t i o n does not de scr ibe how
hazardous movements s h a l l be avoided.
SAFEGUARDING OF MACHINERY, BSI
CODE OF PRACTICE, BRITAIN [71]
This standard s t a t e s that mainte­
nance hazards can be e f f e c t i v e l y
c o n tr o ll e d by documenting a
"permit to work" system i d e n t i ­
fying hazards and precautions to
be taken, d e fi n in g p r a c ti c es to be
followed and d e fi n in g worker and
management r e s p o n s i b i l i t i e s for
maintenance. Adequate tra in i n g of
workers and su pe rv ision in the
a p p l i c a t i o n o f s a f e work pr a c ti c e s
during maintenance i s a l s o a
requirement.
TABLE C-7
CONSENSUS STANDARDS
ANSI Z244.1-1982 SAFETY STANDARD FOR
THE LOCKOUT/TAGOUT OF ENERGY SOURCES
[5]
NFPA 70E PART I I LOCKOUT SAFETY
RELATED WORK PRACTICES
[54]
This standard p a r a l l e l s the recommended
guidelines.
This standard allows that e i t h e r lockout
d ev ic es s h a l l be attached to hold the
energy i s o l a t i n g d ev ic es in a s a fe
p o s i t i o n or tagout d e vic es s h a l l be
attached to forbid the operation o f the
energy i s o l a t i n g d e v ic e s .
-5 4 -
These s a f e t y r e l a t e d work prac­
t i c e s cover procedures for employ­
ees who work with e l e c t r i c c i r ­
c u i t s and equipment. These pro­
cedures are e s s e n t i a l l y i d e n t i c a l
to the recommended g u i d e l i n e s .
This standard allows the use o f
tags only when i t i s not f e a s i b l e
to apply locks to e f f e c t loc ko ut .
Where c i r c u i t s or equipment are
deenergized for minor maintenance,
s e r v i c i n g , a d j u s t i n g , e t c . , the
work s h a l l be permitted to be
performed without the placement o f
locks or tags on the disc onn ec tin g
device.
X.
APPENDIX D
EXISTING OSHA STANDARDS RELATED TO LOCKOUT, TAGOUT,
OR THE CONTROL OF ENERGY DURING MAINTENANCE
NOTE:
THE INFORMATION IN THIS APPENDIX WAS ADAPTED FROM
INFORMATION SUPPLIED BY OSHA.
-5 5 -
General Industry Lockout Related
Standard Provisions
SPECIFICATIONS FOR ACCIDENT PREVENTIONSIGNS AND TAGS
No.
STANDARD
1 9 1 0 .1 4 5 ( f ) ( 1 )
( i ) The tags are a temporary means of warning a l l con­
cerned of a hazardous c o n d it io n , d e f e c t i v e equipment,
r a d ia ti o n hazards, e t c .
The tags are not to be con­
sidered as a complete warning method, but should be
used u n t i l a p o s i t i v e means can be employed to e l i m i ­
nate the hazard; for example, a "Do not Start" tag on
power equipment s h a l l be used for a few moments or a
very short time u n t i l the switch in the system can be
locked out; a "Defective Equipment" tag s h a l l be placed
on a damaged ladder and immediate arrangements made for
the ladder to be taken out of s e r v i c e and sent to the
repa ir shop.
1 9 1 0 .1 4 5 ( f ) ( 3 )
( i i i ) Do Not Start tags s h a l l be placed in a conspicu­
ous l o c a t i o n or s h a l l be placed in such a manner that
they e f f e c t i v e l y block the s t a r t i n g mechanism which
would cause hazardous c o nd it io ns should the equipment
be e n e r g i z e d .
1910.145(f)(4)
( i ) Danger tags should be used only where an immediate
hazard e x i s t s .
There should be no v a r i a t i o n in the
type of design o f tags posted or hung to warn of spe­
c i f i c dangers.
1 9 1 0 .1 4 5 ( f ) ( 5 )
( i ) Caution tags should be used only to warn aga in st
potential
hazards
or
to
caution
a ga in s t
unsafe
practices.
1910.145(f )
(6) Out o f order tags .
Out o f Order tags should be
used only for the s p e c i f i c purpose of in d i c a t i n g that a
pie c e o f equipment, machinery, e t c . , i s out o f order
and to attempt to use i t might present a hazard.
POWERED INDUSTRIAL TRUCKS
1910.178(q)
(4) Trucks in need of r e p a ir s to the e l e c t r i c a l system
s h a l l have the b a t te r y disconnected prior to such
repairs.
OVERHEAD AND GANTRY CRANES
1910.1 79(g )( 5)
( i ) The power supply to the runway conductors s h a l l be
c o n t r o l l e d by a switch or c i r c u i t breaker loca ted on a
fix e d
structure,
accessible
from the
floor,
and
arranged to be locked in the open p o s i t i o n .
-5 6 -
( i i ) On cab-operated cranes a switch or c i r c u i t breaker
o f the enclosed type, with provision for locking in the
open p o s i t i o n , s h a l l be provided in the leads from the
runway conductors.
A means of opening t h i s switch or
c i r c u i t breaker s h a l l be located wit hi n easy reach o f
the operator.
( i i i ) On floor- op era ted cranes, a switch or c i r c u i t
breaker o f the enclosed type, with provision for lo c k ­
ing in the open p o s i t i o n , s h a l l be provided in the
leads from runway conductors. This disconnect s h a l l be
mounted on the bridge or footwalk near the runway c o l ­
lectors.
One o f the fol lo wi ng types o f floor-o pera ted
disco nnects s h a l l be provided:
1910.179(1X 2)
( i ) Before adjustments and repairs are s t a r t e d
crane the following precautions s h a l l be taken:
on
a
(b) All c o n t r o l l e r s s h a l l be at the o f f p o s i t i o n .
(c) The main or emergency
locked in the open p o s i t i o n .
switch
shall
be
open
and
(d) Warning or "out o f order" si gn s s h a l l be placed on
the crane, a l s o on the f l o o r beneath or on the hook
where v i s i b l e from the f l o o r .
DERRICKS
1910.1 8 1 ( f ) ( 2 ) (i)
(c) The main or emergency switch s h a l l be locked in the
open p o s i t i o n , i f an e l e c t r i c h o i s t i s used.
(d) Warning or out o f order signs
the derric k and h o i s t .
s h a l l be placed on
WOODWORKING MACHINERY REQUIREMENTS
1910.213(a)
(10) It i s recommended that each power-driven wood
working machine be provided with a disconnect switch
that can be locked in the o f f p o s i t i o n .
1910.213(b)
(3) On a p p li c a ti o n s where injury to the operator might
r e s u l t i f motors were to r e s t a r t a f t e r power f a i l u r e s ,
provision s h a l l be made to prevent machines from auto­
m a t i c a l l y r e s t a r t i n g upon r e s t o r a t i o n of power.
1910.213(b)
(5) On each machine operated by e l e c t r i c motors, p o s i ­
t i v e means s h a l l be provided for rendering such con­
t r o l s or devices in op era ti ve while r ep air s or a d j u s t ­
ments are being made to the machines they c on tr ol .
-5 7 -
„ 4 ,^ ,
u iH t u
i.u c a
l i
1
v
r n n
t t * a
i
MECHANICAL POWER PRESSES
1910.217(b)(8)
( i ) A main power disconnect switch capable o f being
locked only in the Off p o s i t i o n s h a l l be provided with
every power press control system.
1910.217(d)(9)
( i v ) The employer s h a l l provide and enforce the use of
s a f e t y blocks for use whenever di es are being adjusted
or repaired in the press.
FORGING MACHINES
19 10.218(a) (3)
( i i i ) Means s h a l l be provided for dis connecting the
power to the machine and for locking out or rendering
c y c l i n g co nt r ols inoperable.
( i v ) The ram s h a l l be blocked when die s are being
changed or other work i s being done on the hammer.
Blocks or wedges s h a l l be made of material the strength
and const ruct ion of which should meet or exceed the
s p e c i f i c a t i o n s and dimensions shown in Table 0-11.
1910.218(d)
(2) Shutoff va lv e .
Steam hammers s h a l l be provided
with a quick c l o s i n g emergency valve in the admission
pipe l i n e at a convenient l o c a t i o n .
This valve s h a l l
be c los ed and locked in the o f f p o s i t i o n while the
hammer i s being adj usted, repa ired, or s e r v ic e d , or
when the d i e s are being changed.
1 9 1 0 . 2 1 8 ( e ) (1)
( i i ) A i r - l i f t hammers s h a l l have an air s h u t o ff v alv e
as required in paragraph ( d ) ( 2 ) o f th i s s e c t i o n and
should be conveniently loca ted and d i s t i n c t l y marked
for ease o f i d e n t i f i c a t i o n .
( i i i ) A i r - l i f t hammers s h a l l be provided with two drain
cocks: one on main head c y l i n d e r , and one on clamp
cylinder.
1910.21 8(f )
(1) Mechanical forging p r e s s e s .
When d ie s are being
changed or maintenance
i s being performed on the p re ss,
the foll owing s h a l l be accomplished:
(1) The power to the press s h a l l be locked ou t.
( i i ) The flywheel s h a l l be at r e s t .
( i i i ) The ram s h a l l be blocked with a material the
strength of which s h a l l meet or exceed the s p e c i f i c a ­
t i o n s or dimensions shown in Table 0-11.
1 9 1 0 .2 1 8 (f)
(2) Hydraulic forging
p r e s s e s . When d ie s are being
changed or maintenance
i s being performed on the pre ss,
the foll owi ng s h a l l be accomplished.
-5 8 -
( i ) The hydraulic
locked o u t .
pumps and power apparatus
shall
be
( i i ) The ram s h a l l
be blocked with a material the
s trength o f which s h a l l meet or exceed the s p e c i f i c a ­
t io n s or dimensions shown in Table 0-11.
1 9 1 0 .2 1 8 (g )
(1) Hot trimming p r e s s e s .
The requirements o f para­
graph ( f ) ( 1 )
o f t h i s s e c t i o n s h a l l a l s o apply to hot
trimming p r e ss e s.
1910.218(h)
(2) Lockout. Upsetters s h a l l be provided
with a means
for locking
out the power at i t s entry point to the
machine and rendering i t s c y c l i n g c o n t r o ls inoperable.
(5) Changing d i e s .
When d i e s are being changed, main­
tenance performed, or any work done on the machine, the
power to the u p s e t t e r s h a l l be locked o u t , and the f l y ­
wheel s h a l l be at r e s t .
1910.21 8U)
(1) Boltheading.
The pr ovis io ns of paragraph
t h i s s e c t i o n s h a l l apply to bolt headin g.
(h)
of
(2) Rivet making.
The pr ov is io ns o f paragraph (h) o f
t h i s s e c t i o n s h a l l apply to r i v e t making.
1910.218(j)
(1) B i l l e t shears.
A p o s i t i v e - t y p e lockout device for
dis c o nn e c tin g the power to the shear s h a l l be provided.
WELDING, CUTTING, AND BRAZING
1 9 1 0 . 2 5 2 ( c ) (1)
(i) Installation.
All equipment s h a l l be i n s t a l l e d by
a q u a l i f i e d e l e c t r i c i a n in conformance with subpart S
o f t h i s part. There s h a l l be a s a f e t y - t y p e dis co nne ct ­
ing switch or a c i r c u i t breaker or c i r c u i t in te rr upt er
to open each power c i r c u i t to the machine, co nve niently
lo ca te d at or near the machine, so that the power can
be shut o f f when the machine or i t s co n tr o ls are to be
serviced.
1 9 1 0 . 2 5 2 ( c ) (2)
( i i ) Capacitor welding.
Stored energy or capac itor
discharge type o f r e s i s t a n c e welding equipment and
c on tro l panels involving high v o lt a g e (over 550 v o l t s )
s h a l l be s u i t a b l y in s u l a te d and protected by complete
e n c lo su re s , a l l doors o f which s h a l l be provided with
s u i t a b l e i n t e r l o c k s and c on tac ts wired in t o the c on tr ol
c i r c u i t ( s i m i l a r to e l e v a t o r i n t e r l o c k s ) .
Such i n t e r ­
locks or conta cts s h a l l be so designed as to e f f e c t i v e ­
l y interr upt power and short c i r c u i t a l l capac itors
when the door or panel i s open.
A manually operated
switch or s u i t a b l e p o s i t i v e device s h a l l be i n s t a l l e d ,
in ad d iti on to the mechanical i n t e r l o c k s or c o n t a c t s ,
as an added s a f e t y measure assuring absolute discharge
o f a l l capacitors.
-5 9 -
PULP, PAPER AND PAPERBOARD MILLS
1910.261(b)
(4) Lockouts.
Devices such as padlocks s h a l l be pro­
vided for locking out the source of power at the main
disconnect switch. Before any maintenance, in s p e c t i o n ,
c le a n in g , a d j u s t i n g , or s e r v i c i n g o f equipment ( e l e c ­
t r i c a l , mechanical, or other) that requires entrance
i n t o or c l o s e contact with the machinery or equipment,
the main power disconnect switch or v a l v e , or both,
c o n t r o l l i n g i t s source o f power or flow of m a t e r ia l,
s h a l l be locked out or blocked o f f with padlock, blank
f l a n g e , or s im il a r d e v ic e .
(5) Vess el e n te r in g .
L i f e l i n e s and s a f e t y harness
s h a l l be worn by anyone en te r in g c los ed v e s s e l s , tanks,
ship bi n s, and s im il a r equipment, and a person s h a l l be
s t a t i o n e d ou ts id e in a p o s i t i o n to handle the l i n e and
to summon a s s i s t a n c e in case of emergency. The a i r in
the v e s s e l s s h a l l be t e s t e d for oxygen d e f i c i e n c y and
the presence of both t o x i c and e x p lo s iv e gases and
vapors, before entry in t o c lo se d v e s s e l s , tanks, e t c . ,
i s permitted.
S e lf - c o n ta in e d a i r - or oxygen-supply
masks s h a l l be r e a d i l y a v a i l a b l e in case of emergency.
Work s h a l l not be done on equipment under co nd it io ns
where an injury would r e s u l t i f a valve were unexpect­
edl y opened or c los ed un les s the v alv e has been locked
in a s a f e p o s i t i o n .
1910.261(e)
(2) Slasher t a b l e s .
Saws s h a l l be stopped and power
switches s h a l l be locked out and tagged whenever i t i s
necessary for any person to be on the s l a s h e r t a b l e .
(10) Stops.
All contr ol d ev ices s h a l l be locked out
and tagged when knives are being changed.
1 9 1 0 .2 6 1 ( e ) (12)
( i i i ) Whenever i t becomes necessary for a workman to go
wit hi n a drum, the driv in g mechanism s h a l l be locked
and tagged, at the main disconnect swi tch, in accor­
dance with paragraph ( b ) ( 4 ) of t h i s s e c t i o n .
1910.261(e)
(13) Intermittent barking drums.
In ad d it io n to motor
switch, c lu tc h , b e l t s h i f t e r , or other power disc on­
n e c ti n g d e v i c e , i n t e r m it te n t barking drums s h a l l be
equipped with a device which may be locked to prevent
the drum from moving while i t i s being emptied or
filled .
1910.261(f)(6)
( i ) When c le a n in g , in s p e c t i o n , or other work requires
that persons enter rag cookers, a l l steam and water
v a l v e s , or other c on tr ol d e v i c e s , s h a l l be locked and
tagged in the c los ed or "off" p o s i t i o n .
Blank flan gin g
o f p i p e l i n e s i s acceptable in place o f c lo se d and
locked v a l v e s .
-6 0 -
1 9 1 0 .2 6 1 (g )(4 )
( i i ) A man s h a l l be s ta ti o n e d o ut sid e to summon a s s i s ­
tance i f neces sa ry. All intake v a lv e s to a tank s h a l l
be blanked o f f or disconnected.
1 9 1 0. 26 1( g) (15)
( i ) Valves c o n t r o l l i n g l i n e s leading i n t o a d i g e s t e r
s h a l l be locked out and tagged. The keys to the locks
s h a l l be in the po s s es si on of a person or persons doing
the in s pe c tin g or making r e p a ir s .
1910.261( g ) (16)
(i)
Safety r egu lat ion s
governing
i n s p e c ti o n
and
r epair in g o f pressure tanks-accumulators (acid) s h a l l
be the same as those s p e c i f i e d in subparagraph (15) of
t h i s paragraph.
1 9 1 0 .2 6 1 (g )(19)
( i i i ) When blow l i n e s from
i n t o one pip e, the cock or
the tank being inspected or
tagged out, or the l i n e
blocked o f f .
1910.261( g )(21)
Ins pection and repair of tanks.
All piping leading to
tanks s h a l l be blanked o f f or valved and locked or
tagged.
Any l i n e s to sewers s h a l l be blanked o f f to
protect workers from a i r contaminants.
1910.261( j ) (1)
( i i i ) Repairs for cleaning o f blockage s h a l l be done
only when the shredder i s shutdown and c ont ro l devices
locked.
1910.261(j ) ( 4 )
(iii)
When
requires that
devic es s h a l l
with paragraph
1910.261(j ) (6)
( i ) All contr ol d ev ic es s h a l l be locked or tagged out
when persons enter st ock c h e s t s , in accordance with
paragraph ( b ) ( 4 ) o f t h i s s e c t i o n .
1 9 1 0 . 2 6 1 ( j ) (5)
( i i i ) When c le a n in g , in s p e c t i n g , or other work requires
that persons enter pulpers, a l l steam, water, or other
c on tro l devic es s h a l l be locked or tagged ou t.
Blank
flan ging and tagging o f pipe l i n e s are acceptable in
place o f c lo se d and locked or tagged v a l v e s .
Blank
flanging of steam and water l i n e s s h a l l be acceptable
in place o f va lv e lo c k s .
1 9 1 0 .2 6 1 (k ) (2)
( i i ) All drives s h a l l be provided with lockout d ev ices
at the power switch which interr upt s the flow o f cur­
rent to the u n i t .
more than one d i g e s t e r lead
v alv e o f the blow l i n e from
repaired s h a l l be locked or
s h a l l be disconnected and
c le a n in g ,
in s p e c t i n g ,
or
other work
persons enter the b e a t e r s , a l l con trol
be locked or tagged out, in accordance
( b )( 4 ) o f t h i s s e c t i o n .
-6 1 -
T e x t il e s
1910.262(c)
(1) Means of stopping machines.
Every t e x t i l e machine
s h a l l be provided with in d iv id u al mechanical or e l e c ­
t r i c a l means for stopping such machines.
On machines
driven by b e l t s and s h a f t i n g , a lo c ki n g-ty pe s h i f t e r or
an equiv al ent p o s i t i v e device s h a l l be used. On opera­
t io n s where injury to the operator might r e s u l t i f
motors were to r e s t a r t a f t e r f a i l u r e s , pr ovi si on s h a l l
be made to prevent machines from aut om ati ca lly r e s t a r t ­
ing upon r e s t o r a t i o n o f power.
1910.262(n)
(2) Pr otection for loom f i x e r .
Provisions s h a l l be
made so that every loom f i x e r can prevent the loom from
being s ta r te d while he i s at work on the loom.
This
may be accomplished by means o f a lock, the key to
which i s retained in the p o s s e s s i o n of the loom f i x e r ,
or by some other e f f e c t i v e means to prevent s t a r t i n g
the loom.
1910.262(p)
(1) J-box pr o te c ti o n .
Each valv e c o n t r o l l i n g the flow
o f steam, injur ious g a s e s , or l i q u i d s i n t o a J-box
s h a l l be equipped with a chain, lock, and key, so that
any worker who enters the J-box can lock the valv e and
r e t a i n the
key in h i s p o s s e s s i o n . Any other
method
which w i l l
prevent steam, in ju ri ous g a s e s , or l i q u i d s
from ente ring the J-box while the worker is in i t w i l l
be a c ce pt ab le .
1910.262(q)
(2) Kier valve p r o te c ti o n .
Each valve c o n t r o l l i n g the
flow o f steam, in ju ri ous
g a s e s , or l i q u i d s i n t o a k ie r
s h a l l be equipped with a chain, lock, and key, so that
any worker who enters the k i e r can lock the valv e and
r e t a i n the
key in h i s p o s s e s s i o n . Any other
method
which w i l l
prevent steam, inj ur iou s g a s e s , or l i q u i d s
from ent er ing the k ie r while the worker i s in i t w i l l
be a c ce p t a b le .
BAKERY EQUIPMENT
1 9 1 0 .2 6 3 (k )(12)
( i ) Where pan c o ol in g towers extend to two or more
f l o o r s , a lockout switch s h a l l be provided on each
f l o o r in order that mechanics working on the tower may
p o s i t i v e l y lock the mechanism a ga in s t s t a r t i n g .
Only
one s t a r t switch s h a l l be used in the motor c on trol
c ircu it.
1910.263(1)(3)( i i i )
(b) Main s h u t o f f va lv e s s h a l l be locked in the c los ed
p o s i t i o n when men must enter the oven or when the oven
i s not in s e r v i c e .
191 0.2 63 (1 )( 8)
( i i i ) A main disconnect switch or c i r c u i t breaker s h a l l
be provided.
This switch or c i r c u i t breaker s h a l l be
so located that i t can be reached quickly and s a f e l y .
-6 2 -
The main switch or c i r c u i t breaker s h a l l have provi­
s io n s for locking i t in the open p o s i t i o n i f any work
on the e l e c t r i c a l equipment or i n s i d e the oven must be
performed.
SAWMILLS
1 9 1 0 . 2 6 5 ( c ) (12)
(v) Open switches. Before working on e l e c t r i c a l equip­
ment, switches s h a l l be open and s h a l l be tagged,
blocked, or locked out .
1910.265(c)
(13) Hydraulic systems.
Means s h a l l be provided to
block, chain, or otherwise secure equipment normally
supported by hydraulic pressure so as to provide for
s a f e maintenance.
1 9 1 0 . 2 6 5 ( c ) (26)
( i i i ) Blocking h o i s t i n g platform. Means s h a l l be pro­
vided to p o s i t i v e l y block the h o i s t i n g platform when
employees must go beneath the stacker or unstacker
hoist.
(v)
Locking main c on tr ol sw it c he s.
Main contr ol
switches s h a l l be so designed that they can be locked
in the open p o s i t i o n .
19 10 .2 6 5 (e )( 1 )
( i v ) Carriage c o n tr o l.
A p o s i t i v e means s h a l l be pro­
vided to prevent unintended movement o f the c a r r ia g e .
This may in volve a c ont ro l locking d e v i c e , a ca rriage
tie-down, or both.
1910.268(1)
(2) Before the v o lt a g e i s a pp lie d, cable conductors
s h a l l be i s o l a t e d to the ex ten t p r a c t i c a b l e . Employees
s h a l l be warned, by such techniques as b r i e f i n g and
tagging at a l l a f f e c t e d l o c a t i o n s , to stay c le a r while
the v o l t a g e i s a p p li e d .
1910.268(m)(7)
( i ) Pr i o r to grounding a radio transmitting s t a t i o n
antenna, the employer s h a l l insure that the ri gger in
charge:
(A) Prepares a danger tag signed with h i s
s ig n a t u r e , (B) Requests the tr ansmitting te c h n ic ia n to
shutdown the transmitter and to ground the antenna with
i t s grounding switch, (C.) Is n o t i f i e d by the transmit­
ti n g te c h n ic ia n that the transmitter has been shutdown,
and (D) Tags the antenna ground switch perso na lly in
the presence o f the trans mit ting te c h n ic ia n a f t e r the
antenna
has
been
grounded
by
the
tr ansmitting
t e c h n ic ia n .
NATIONAL ELECTRICAL CODE
1910.309
NEC A r t i c l e 430-86(a)
430-86.
Motor Not in Sight from Co nt r olle r .
Where a
motor and the driven machinery are not in s i g h t from
the c o n t r o l l e r l o c a t i o n , the i n s t a l l a t i o n s h a l l comply
with one o f the foll owi ng c on di ti on s :
-6 3 -
(a) The c o n t r o l l e r disconn ec ting means
being locked in the open p o s i t i o n .
is
capable
of
GENERAL SAFETY AND HEALTH PROVISIONS
1926.20(b)
(3) The use o f any machinery, t o o l , material or equip­
ment which i s not in compliance with any a p p lic abl e
requirement of t h i s part i s pr ohi b ite d.
Such machine,
t o o l , m a t e r i a l , or equipment s h a l l e i t h e r be i d e n t i f i e d
as unsafe by tagging or locking the c ont ro ls to render
them inoperable or s h a l l be p h y s ic a ll y removed from i t s
place o f ope ra tio n.
NONIONIZING RADIATION
1926.54
(e) Beam s h u t te r s or caps s h a l l be u t i l i z e d , or the
la s e r turned o f f , when l a s e r transmission i s not
a c t u a l l y required.
When the la s e r i s l e f t unattended
for a s u b s t a n t i a l period of time, such as during lunch
hour, ov ern igh t, or at change o f s h i f t s , the l a s e r
s h a l l be turned o f f .
FIRE PROTECTION AND PREVENTION
1926.150(d)(1)
( i i ) During demolition or a l t e r a t i o n s , e x i s t i n g auto­
matic sp rinkler i n s t a l l a t i o n s s h a l l be retaine d in
s e r v i c e as long as reasonable.
The operation of
sprinkler c ont r ol va lv e s s h a l l be permitted only by
properly authorized persons. Modification of spr ink le r
systems to permit a l t e r a t i o n s or a d d it io n a l demolition
should be expedited so that the automatic pr o te c ti o n
may be returned to s e r v i c e as quickly as p o s s i b l e .
Sprinkler c on trol va lv e s s h a l l be checked d a i l y at
c l o s e o f work to a s c e r t a i n that the pr o te c tio n i s in
service.
1926.200(h)
(1) Accident prevention tags s h a l l be used as a
temporary means of warning employees o f an e x i s t i n g
hazard, such as d e f e c t i v e t o o l s , equipment, e t c .
They
s h a l l not be used in place o f , or as a s u b s t i t u t e for,
accid ent prevention s ig n s .
(2) S p e c i f i c a t i o n s for accident prevention tags s im il a r
to those in Table G-l s h a l l apply.
1926.304
(a) All fixed power driven woodworking t o o l s s h a l l be
provided with a disconnect switch that can e i t h e r be
locked or tagged in the o f f p o s i t i o n .
WELDING AND CUTTING
1926.352
(g) For the el im in a ti o n o f p o s s i b l e f i r e in enclosed
spaces as a r e s u l t of gas escaping through leaking or
-6 4 -
improperly cl osed torch v a l v e s , the gas supply to the
torch s h a l l be p o s i t i v e l y shut o f f at some point out­
s i d e the enclosed space whenever the torch i s not to be
used or whenever the torch i s l e f t unattended for a
s u b s t a n t i a l period o f time, such as during the lunch
period.
Overnight and at the change o f s h i f t s , the
torch and hose s h a l l be
removed fromthe confined
space.
Open end fu el gas and oxygen hoses s h a l l be
immediately removed from enclosed spaces when they are
disconnected from the torch or other gas-consuming
device.
ELECTRICAL-GENERAL REQUIREMENTS
1926.400(g)
(1) Equipment or c i r c u i t s that are deenergized s h a l l be
rendered in op era ti ve
and have tags
attached at a l l
poi nt s
where such equipment or
circuits
can be
energized.
(2) Controls that are to be de ac tiv ate d during the
course o f work on energized or deenergized equipment or
c i r c u i t s s h a l l be tagged.
(3) Tags s h a l l be placed to
i d e n t i f y p l a i n l y the equip­
ment or c i r c u i t s being worked on.
BASE-MOUNTED DRUM HOISTS
1926.553(a )( 3)
( i ) A device to disconnect a l l motors from the l i n e
upon power f a i l u r e and not permit any motor to be
r e s t a r t e d u n t i l the c o n t r o l l e r handle i s brought to the
"off" p o s i t i o n .
( i i i ) A means whereby remotely
when any control i s i n e f f e c t i v e .
operated
hoists
stop
CONVEYORS
1926.555(a)
(7) Conveyors s h a l l be locked out or otherwise rendered
inop erable, and tagged out with a "Do Not Operate" tag
during repa irs and when operation i s hazardous to
employees performing maintenance work.
MOTOR VEHICLES, MECHANIZED EQUIPMENT, AND MARINE OPERATIONS
1926.600(a)(3)
( i ) Heavy machinery, equipment, or parts t h e r e o f , which
are suspended or held a l o f t by use o f s l i n g s , h o i s t s ,
or jacks s h a l l be s u b s t a n t i a l l y blocked or cribbed to
prevent f a l l i n g or s h i f t i n g before
employees
are
permitted to work under or between them. Bulldozer and
scraper blades, end-loader buckets, dump bodies, and
s i m i l a r equipment, s h a l l be e i t h e r f u l l y lowered or
blocked when being repaired or when not in use.
All
-6 5 -
U f“ i h fK H n
K ill
1
c o n t r o l s s h a l l be in a neu tral
motors stopped and brakes s e t ,
performed requires otherwise.
p o s i t i o n , with the
un le s s work being
1926.60 0(a )( 3)
( i i ) Whenever the equipment i s parked, the parking
brake s h a l l be s e t . Equipment parked on i n c l i n e s s h a l l
have the wheels chocked and the parking brake s e t .
1926.601(b)
(10) Trucks with dump bodies s h a l l be equipped with
p o s i t i v e means o f support, permanently att ached, and
capable of being locked in p o s i t i o n to prevent acciden­
t a l lowering o f the body while maintenance or in s p e c ­
t i o n work i s being done.
(11) Operating le v e r s c o n t r o l l i n g h o i s t i n g or dumping
d ev ic es on haulage bodies s h a l l be equipped with a
latch or other device which w i l l prevent a c c id e n t a l
s t a r t i n g or tripping o f the mechanism.
1926.603(a)
(5) A blocking d e v i c e , capable of s a f e l y supporting the
weight of the hammer, s h a l l be provided for placement
in the leads under the hammer at a l l times while
employees are working under the hammer.
INITIATION OF EXPLOSIVE CHARGES-ELECTRICAL BLASTING
1926.906
( j ) In underground operations when f i r i n g from a power
c i r c u i t , a s a f e t y switch s h a l l be placed in the perma­
nent f i r i n g l i n e at i n t e r v a l s .
This switch s h a l l be
made so i t can be locked only in the "Off" p o s i t i o n and
s h a l l be provided with a s h o r t - c i r c u i t arrangement o f
the f i r i n g l i n e s to the cap c i r c u i t .
(1) When f i r i n g from a power c i r c u i t , the f i r i n g switch
s h a l l be locked in the open or "Off" p o s i t i o n at a l l
tim es, except when f i r i n g .
I t s h a l l be so designed
tha t the f i r i n g l i n e s to the cap c i r c u i t are automati­
c a l l y s h o r t - c i r c u i t e d when the switch i s in the "Off"
position.
Keys to t h i s switch s h a l l be entrusted only
to the b l a s t e r .
POWER TRANSMISSION AND DISTRIBUTION
1926.950
(d) Deenergizing l i n e s and equipment
(1) When deenergizing l i n e s and equipment operated in
e xc e s s o f 600 v o l t s , and the means o f disc onn ec tin g
from e l e c t r i c energy i s not v i s i b l y open or v i s i b l y
locked out, the provis io ns of su bd ivi si on s ( i ) through
( v i i ) o f t h i s subparagraph s h a l l be complied with:
( i ) The p a r ti c u l a r s e c t i o n of l i n e or equipment to be
deenergized s h a l l be c l e a r l y i d e n t i f i e d , and i t s h a l l
be i s o l a t e d from a l l sources o f v o l t a g e .
-6 6 -
( i i ) N o t i f i c a t i o n and assurances
employee s h a l l be obtained that:
from the
designated
(a) All switches and disconnectors through which
energy may be supplied to the p a r t ic u l a r s e c t i o n
o f l i n e or equipment to be worked have been
deenergized;
(b) All switches and disconnectors are
tagged i n d i c a t i n g that men are at work;
(c) And that
disconnectors
in o p e r a b l e .
plainly
where design o f such switches and
permits, they have been rendered
( i i i ) After a l l designated switches and disconnectors
have been opened, rendered inoperable, and tagged,
v i s u a l in s p e c ti o n or t e s t s s h a l l be conducted to insure
that equipment or l i n e s have been deenergized.
( i v ) P r o t e c t iv e grounds s h a l l be applied on the disc on­
nected l i n e s or equipment to be worked on.
(v) Guards or b ar ri ers s h a l l be erected as necessary to
adjacent energized l i n e s .
( v i ) When more than one independent crew requires the
same l i n e or equipment to be deenergized, a prominent
tag for each such independent crew s h a l l be placed on
the l i n e or equipment by the designated employee in
charge.
( v i i ) Upon completion o f work on deenergized l i n e s or
equipment, each designated employee in charge s h a l l
determine that a l l employees in h i s crew are c l e a r ,
that p r ot e c ti ve grounds i n s t a l l e d by h is crew have been
removed, and he s h a l l report to the designated au th or i­
ty that a l l tags p r ot e c ti n g h i s crew may be removed.
(2) When a crew working on a l i n e or equipment can
c l e a r l y see that the means o f disco nne cting from e l e c ­
t r i c energy are v i s i b l y open or v i s i b l y lo cked-ou t, the
provisions of s ub d iv is io ns ( i ) and ( i i ) of t h is subparagraph s h a l l apply:
( i ) Guards or b ar riers s h a l l be erected as neces ­
sary to adjacent energized l i n e s .
( i i ) Upon completion o f work on deenergized l i n e s
or equipment, each designated employee in charge
s h a l l determine that a l l employees in h i s crew are
c l e a r , that pr o te c ti v e grounds i n s t a l l e d by h i s
-6 7-
crew have been removed, and he s h a l l report to the
designated a ut ho r ity that a l l tags p r ot e c ti ng h i s
crew may be removed.
1926.957
(b) Deenergized equipment or l i n e s
When i t i s necessary to deenergize equipment or l i n e s
for p r o te c ti on o f employees, the requirements of para­
graph 1926.950(d) s h a l l be complied with.
-6 8 -
X I.
APPENDIX E
REFERENCES SUPPORTING GUIDELINES FOR CONTROLLING HAZARDOUS
ENERGY DURING MAINTENANCE AND SERVICING
- 6 9 -
APPENDIX E
REFERENCES SUPPORTING GUIDELINES FOR CONTROLLING HAZARDOUS
ENERGY DURING MAINTENANCE AND SERVICING
A .2 . a. - Among the organizations concurring in t h i s requirement are the United
Automobile, Aerospace, and A gr icu ltu ra l Implementation Workers of America [ 2 ] ,
the American National Standards I n s t i t u t e [ 5 ] , the
National Safety Council
[6 ] , the Rubber Manufacturing A ss oc ia tio n [7 ] , the I n te r na tio n al Brotherhood
of E l e c t r i c a l Workers [ 8 ] , the American Iron and S t e e l I n s t i t u t e [ 9 ] , and the
Conveyor Equipment Manufacturers A ss oc ia tio n [ 1 0 ] .
Other supporting r e f e r ­
ences for t h i s f i r s t e s s e n t i a l g u id e l in e are as fo ll ow s : [ 7 - 4 5 ] .
A. 2 . b . - Public ati on s supporting t h i s requirement include the German Accident
Prevention S p e c i f i c a t i o n s (d ra f t) [46] which in d i c a t e that the i n i t i a t i o n of
hazardous movements may r e s u l t from stored energy and that t h i s stored energy
may be in the form o f p o t e n t i a l or k i n e t i c energy.
The ANSI Safety Standard
for the Lockout/Tagout o f Energy Sources [5] in d i c a t e s in Section 5 . 2 . 5 that
a l l equipment and processes "shall be c a r e f u l l y examined to d e t e c t and
r e l i e v e , d is co nn ec t, or r e s t r a i n any r e s id u a l energy."
The Edison E l e c t r i c
I n s t i t u t e in des crib ing procedures for de energizing [47]
states:
"Reliance
a l s o should be placed on work procedures which assure
the removal of r e s id u a l
energy from l i n e s and equipment before work i s begun."
Other supporting
r efe ren ces are:
[3, 15, 17, 19, 22, 23, 25, 26, 31, 35, 37, 39-43, 4 6 - 5 1 ] .
A . 2 . c . ( l ) - Physical means o f s e c u r i t y are u t i l i z e d in many a p p l i c a t i o n s and
i n d u s t r i e s as ind icated by the ANSI Safety Standard for the Lockout/Tagout o f
Energy Sources [5] presentation o f a generic lockout procedure.
The UAW
s tr o n g ly advocates the use o f physical lockouts in t h e i r Machinery Lockout
Procedures [ 4 ] .
The National Safety
Council d e scr ib es physical
lockout
provis ion s in t h e ir Accident Prevention Manual for I n d u s t r ia l Operations [ 6 ] .
An a r t i c l e e n t i t l e d "Lockouts Prevent Serious Accidents" in the I n d u st r ia l
Supervisor magazine recommends the use of p h ys ic al locks [5 2 ] .
Other r e f e r ­
ences supporting the use of physical means to secure p o i n t ( s ) o f c on tro l
include:
[4 -6 , 8, 9, 11-13, 17, 19, 22-25, 27-30, 34, 37, 38, 45, 47, 5 1 -7 0] .
A.2.C. ( 2 ) - The summary o f a Panel Presentation on Lockout and Tagout Safety
Procedures [11] c l e a r l y in d i c a t e s the current use and a c c e p t a b i l i t y o f tagout
p r ac ti c es in industry by d e t a i l i n g sample tagout procedures which have proven
to be e f f e c t i v e . The American Iron and S t ee l I n s t i t u t e [9] s t a t e s that tagout
procedures have long been acceptable as an a l t e r n a t e to locking procedures in
the United S t a te s.
The Pratt and Whitney A ir c r a ft Group of United Technolo­
g i e s , East Hartford, Connecticut, s t a t e s that "a tagout system i s more r e l i ­
able than a lock system" for t h e i r f a c i l i t y [5 3 ] . Other supporting r efe ren ces
for using t h i s method of s e c u r i t y include:
[3, 6, 9, 11-13, 15, 38-41, 43,
44, 47, 48, 53, 54, 58-61, 63, 66, 68 -7 0].
A .2 . c . ( 3 ) - The Square D Company in d i c a t e s that minor maintenance, in s p e c t i o n ,
adjustment, and cleaning tasks can be performed s a f e l y with the power o f f , but
not locked or tagged out as long as the operator maintains v i s u a l c on trol of
the energy c on trol point [1 2 ] . A s i m i l a r instance i s adopted by the Wisconsin
E l e c t r i c a l Power Company in a l e t t e r to the U.S. Department o f Labor [ 4 8 ] .
-7 0-
an nisi TTinni . « r»ci n p ^ n i n v i kk k i: « ri 11*-* u e n ormeii s h i p i v wiiri in*-» ■nni*7#-»T~ n r r . nil r
The "Report o f the Committee on E l e c t r i c a l Safety Requirements for Employee
Workplaces"
[54] makes s p e c i f i c
pr ovis io ns
for
performing maintenance
functions without b e n e f i t o f lockout or tagout procedures.
Other supporting
r eferences are:
[9, 12, 35, 40, 45, 48, 51, 54, 58] .
A . 2 . d . - An a r t i c l e in the Plant Engineering magazine [13] de scr ibi ng poin ts
to consider when d r a f t in g an e l e c t r i c a l clearance ( l o c k o u t/ ta g o u t) system
s t a t e s : "The system should in d ic a t e that no clearance s h a l l be considered
complete u n t i l the c i r c u i t has been t e s t e d with a v o l t a g e t e s t e r . . . ." An
a r t i c l e from the Czechoslovakian Occupational Safety Ins pection Of fi ce Publ i­
c ati on e n t i t l e d Power Switching - E f f e c t i v e Accident Prevention [14] s t a t e s
( a f t e r s h u t o f f o f the e l e c t r i c a l e n e r g y ) : " B e f o r e s t a r t i n g such work, however,
the parts of the machine involved must be t r i a l s ta r te d to assure that they
are not en erg iz ed ." Monsanto, in i t s response to the OSHAAdvance Notice o f
Proposed Rulemaking [1 5 ] , s t a t e s : " V e r i f i c a t i o n that the
system has been
deenergized should be e s t a b l i s h e d , but the method may vary depending on the
energy source."
Other ref er en ce s supporting the need for v e r i f i c a t i o n
include: [3, 6, 9, 13-15, 17, 24-27, 30, 31, 33, 39, 40, 43, 47, 48, 50-52,
54, 57, 58, 64, 71, 72].
A .2 . e . - Many procedures were found to s t a t e t h i s requirement in one way or
another, but three o f the b e s t were the UAW "Machinery Lockout Procedures"
[4 ] , the ANSI "Safety Standard for the Lockout/ Tagout o f Energy Sources" [ 5 ] ,
and the "Report o f the Committee on E l e c t r i c a l Safety Requirements for
Employee Workplaces" [ 54 ] .
Other supporting r ef eren ces are:
[3, 5, 12, 26,
37, 48, 51, 54, 65, 73-7 5] .
A.3 . a. - Though not per tain ing d i r e c t l y to w r it te n procedures, the UAW "Ma­
chinery Lockout Procedures" [4] makes the f o ll ow in g statement: "Risk o f a c c i ­
dent w i l l be reduced i f workers are not required to r e l y on memory. . . ."
The BSI Code o f P r a c t i c e , "Safeguarding o f Machinery" [ 7 1 ] , addresses the need
for such a c r i t e r i o n as follo ws:
"Oral i n s t r u c t i o n s , r eq u e st s, or promises
are l i a b l e to be misheard, m is in t er p r e te d , or fo r go tt e n and ar e, th e r e f o r e ,
not a s a t i s f a c t o r y b a s i s for a c ti o n on which men's l i v e s may depend." The
u n s a t i s f a c t o r y working o f such procedures has been proven time and again. The
American National Standards I n s t i t u t e [ 5 ] , the Committee on E l e c t r i c a l Safety
Requirements for Employee Workplaces [ 5 4 ] , and the Manufacturing Chemists
A ss o c ia ti o n [16] agree that documented procedures are e s s e n t i a l . During emer­
gencies i t should be assured that energy is i s o l a t e d ,
blocked, d i s s i p a t e d ,
and secured.
Also, pr ov is io ns for c l o s e s up e r vi si on and v a l i d a t i o n should be
made, because emergency a c t i v i t i e s can pose s e r io u s and unexpected hazards.
Actions taken during emergencies should be documented in the event reuse i s
required.
Other r eferences supporting documented procedures are:
[3, 5,
8-10, 13, 16, 21, 27, 33, 37, 39-41, 48, 54, 56, 58, 64, 65, 7 1 ].
A .3.b. - The UAW "Machinery Lockout Procedures" [4] encourage tr ai ni ng for
workers in a l l asp ect s o f s a f e t y , including the r e c o g n it io n of hazards as w e ll
as s a f e t y procedures.
The National Safety Council in the Accident Prevention
Manual for I n d u s t r ia l Operations [6] emphasizes that ". . . contr ol can be
maintained only by constant su pe rv isi on and by t r a in i n g maintenance men in the
s a fe r out in e." Both the ANSI Safety Standard for the Lockout/Tagout o f Energy
Sources [5] and the Report o f the Committee on E l e c t r i c a l Safety Requirements
for Employee Workplaces [54] emphasize t r a in i n g not only for personnel
-7 1 -
a c t u a l l y involved in u t i l i z i n g the hazard c on tr ol techniques but a l s o for
those su pe rv isi n g and those working in the a f f e c t e d ar ea s .
Training i s
s t r o n g ly supported by the foll owi ng r ef eren ces :
[5, 6, 9, 12, 21, 26, 27, 32,
37, 39, 41, 45, 48, 54, 56, 58, 62, 69, 71, 73, 74, 76, 77 ].
B.1. - The requirement i s su b s ta n ti a te d by noting that ANSI [5] requires that
e f f e c t i v e pr ote ction s h a l l be provided when work i s done on energized equip­
ment or systems.
Hazardous energy sources must be i d e n t i f i e d before t h i s
requirement can be met.
The report of the Committee on E l e c t r i c a l Safety
Requirements for Employee Workplaces [54] requires that when work i s to be
accomplished near energized c i r c u i t s , employees s h a l l consider a l l exposed
conductors and c i r c u i t paths that are dangerous.
Other supporting ref er en ce s
for energized work include PPG Indu st rie s [78] , which contains a requirement
to "analyze work (i n ) each s p e c i f i c case for s p e c i f i c p o t e n t i a l hazards . . ."
Central Soya [79] s t a t e s ". . . an awareness o f p o t e n t i a l hazards" i s n e c e s ­
sary when performing energized work.
B.2. - A l e t t e r to OSHA fromthe Davenport Machine Tool D iv is io n [80] s t a t e s
the need for s a f e ope r atin g, s e t u p , and maintenance procedures performed with
equipment ene rgiz ed.
In a l e t t e r to OSHA from the Pr in ti n g In du st rie s o f
America, Inc. [ 8 1 ] , the statement that "much o f the equipment c urr en tl y used
in the print ing process i s designed to be cl eaned, and to a l e s s e r degree
repaired, while energized" h i ^ i l i g h t s the need to protect workers from ener­
giz ed equipment. The only way to protec t the worker under thes e co nd it io ns is
to be sure the procedures used are s a f e . A d d it io n a l ly , the ANSI Safety Stan­
dard for
the Lockout/Tagout of Energy Sources [5] s t a t e s that "where energized
work
i s required, acceptable
procedures and equipment s h a l l be employed to
provide e f f e c t i v e p r o te c ti o n to personnel."
The terms "acceptable" and
" e f f e c t i v e protection" in d i c a t e a d e f i n i t e need to determine that the proce­
dures used are s a f e .
B.3. - The documents re fe r re d to in the foregoing ( [ 5 ] , [5 4 ] , and [80] ) d e t a i l
the need for s a f e procedures and the implied need to demonstrate that these
procedures are s a f e .
They a l s o c i t e the need for tr a in i n g the maintenance
workers and th e ir supe rv iso rs in the hazards and procedures required to ensure
s a f e t y . J u s t i f i c a t i o n for tr a in i n g workers in how to c on tr ol hazards to which
they would otherwise be exposed should be e v i d e n t . References supporting s a f e
performance of maintenance on energized systems are:
[5, 7, 9, 15, 26, 27,
32, 38, 39, 47, 48, 51, 54, 58, 62, 65, 66, 68, 71, 73, 75, 76, 77, 7 9 - 8 7 ] .
-7 2-
*U. S. GOVERNMENTPRINTINGOFFICE:1S83--659-096/1024
DEPARTMENT OF HEALTH AND HUMAN SERVICES
PUBLICHEALTHSERVICE
CENTERS FORDISEASECONTROL
N A T IO N A L IN S T IT U T E FO R O C C U P A T IO N A L S A F E T Y A N D H E A L T H
R O B E R T A. T A F T L A B O R A T O R IE S
4676 C O L U M B IA P A R K W A Y , C IN C IN N A T I, O H IO 45226
OFFICIALBUSINESS
P E N A L T Y F O R P R IV A T E USE. $300
Redistribution using indicia is illegal.
Special Fourth Class-Book
P O ST A G E A N D F E E S P A ID
U.S. D E P A R T M E N T O F H H S
H H S 396
DH H S (N IO S H ) Publication No. 83-125