CONTROL OF

HAZARDOUS ENERGY
(LOCK-OUT/TAG-OUT)
Electrical
Hydraulic
Steam
Spring
Loaded
Chemical
Gravity
Developed by
Garold L. Russell
Joseph P. Flick
Mark C. Radomsky
Raja V. Ramani

Department of Energy & Geo-Engineering
The Pennsylvania State University
126 Hosler Building
University Park, PA 16802
(814) 865-7472

June, 2001

Energy
Weve harnessed it, tamed it and put it to
work for us.
But, energy is always ready to escape.
And if it is not kept under control, it can hurt
you----even kill you
The objectives of this program is to assist
miner(s) to become more aware of;

Electrical hazards

Types of electrical hazards

MSHA regulations

Prudent safe work procedures

Consequences of Lock-Out/Tag-Out Incidents

Unexpectedly getting caught in machinery

Unplanned startup of machinery

Unexpected movement of machine parts

Unexpected release of stored energy

Consequences of Lock-Out/Tag-Out Incidents

Loss of life

Personal injury

Property damage

Loss of production

Loss of jobs

Types of Hazardous
Energy
Live energy




Stored energy

Live Energy

Electrical energy






Moving machine parts

Stored Energy

Hydraulic or pneumatic pressure that could be
released




Electric energy stored in electric components


Steam pressure that could be released





Spring loaded mechanisms that could be released




Chemicals





Gravitational force that pulls on equipment, parts,
or objects

Common Factors in Lock-Out/Tag-Out Incidents

Accidental start up

Release of stored energy

Working on energized equipment

Removal of guards


Accidental Start Up

Equipment being accidentally started by someone
who did not know that work was being performed

Electrical energy from an alternative source
providing power for a machine or equipment to
start

Release of Stored Energy

Hydraulic or pneumatic pressure being released
and allowing a raised component to fall or drift
onto a worker



Electric energy stored in electric components
causing electrical shock or even allowing a machine
to start up

Steam pressure being released when a pipeline is
disconnected
Release of Stored Energy

Spring loaded mechanisms that fly or are projected
and hit a worker

Chemicals in pipelines that flow onto workers




Gravitational pulling force on equipment, parts, or
objects that allows parts or components to roll,
drift, or turn onto a worker

Working on Energized Equipment

Failing to deenergize and secure equipment against
start up or movement






Failing to deenergize and secure all energy sources-
one energy source was locked out, but the
equipment moved or started from another energy
source


Removal of Guards

Removing a guard from active machinery for
cleanup or repair and being caught in or by the
unguarded, active machinery

MSHA Regulations, Part 56 (highlights and overview
only--not complete for all regulations)

Electrically powered equipment shall be deenergized
before work is done on such equipment--power switches
shall be locked out or other measures taken which shall
prevent the equipment from being energized without the
knowledge of the individuals working on it--Suitable
warning notices shall be posted at the power switch and
signed by the individuals who are to do the work--such
locks or preventive devices shall be removed only by the
persons who installed them or by authorized personnel
MSHA Regulations, Part 56 (highlights and overview
only--not complete for all regulations)

Power circuits shall be deenergized before work is done on
such circuits unless hot-line tools are used--suitable
warning signs shall be posted by the individuals who are to
do the work--switches shall be locked out or other
measures taken which shall prevent the power circuits
from being energized without the knowledge of the
individuals working on them--such locks, signs, or
preventative devices shall be removed only by the persons
who installed them or by authorized
MSHA Regulations, Part 56 (highlights and overview
only--not complete for all regulations)

Repairs or maintenance of machinery or equipment shall
be performed only after the power is off, and the
machinery or equipment is blocked against hazardous
motion

Persons shall not work on top of, under, or work from
mobile equipment in a raised position until the equipment
has been blocked or mechanically secured to prevent it
from rolling, falling, or being accidentally lowered

Factors Affecting Hazardous Energy
Control

Lock-Out
Program

Employee
Training
Types of
Equipment

Types of Work
Performed

Multiple Energy
Sources

Lock-Out Program

An organized program must be in effect to identify
and control all energy sources

The plan must be consistently used during all types
of work involving the control of
hazardous energy

Employee Training

MSHA-required task training should address all
parts of hazardous energy control

If you do not know how to perform lock-out/tag-
out--dont attempt to do so until you have been
trained

Employee Training

If you are asked to participate in the lock out of
any machinery or equipment and do not know the
correct and proper procedures--stop--advise the
supervisor immediately

If you are going to be part of the work, you must be
part of the lock-out--if you dont know, arent sure,
or have any doubts or questions--stop--advise the
supervisor immediately


Types of Equipment
Electrically powered equipment needs to be properly
deenergized, and locked out prior to work being done

Some electrically powered equipment may have more
than one energy source, if so, all energy sources have to
be identified, deenergized, and locked out

Bucket elevators, crusher counter-weights, truck beds,
and other such parts and components need to be secured
against movement as part of the lock-out procedure


All feed belts, lines, bins, etc. need to be isolated, locked
out, and secured to prevent any process material from
feeding or falling into the work area

All parts that may be under load, force, or pressure that
could spring out, or fly, need to be secured as part of the
lock out process


Hydraulic and pneumatically supported
components need to be secured against
movement as part of the lock-out procedure

Pipelines need to be bled off and blanked or
disconnected as part of the lock out process


Types of Work Performed

All forms of construction, maintenance, repair, clean up,
adjustment or modification work require control of
hazardous energy

Any type of work that places you in any location or
position where you may be exposed to live or stored energy
requires control of hazardous energy

Many jobs require more than one person--if you
are part of the work, you must be part of the lock-
out

Energy control is vitally important in any type of
confined space work, and should also be part of the
confined space entry procedures


Multiple Energy Sources

There may be more than one form of hazardous
energy in any type of machine

Do not assume that electricity is the only form of
hazardous energy

Evaluate each work task to identify and control all
forms of hazardous energy
Control of Hazardous Energy

Hazard identification and correction
Notification of impending work
Identification/isolation of all energy sources
Lock-out/tag-out/block-out of all energy sources
Verification/testing of all energy sources
Replacement of all guards and safety devices
Accounting of all personnel following work
Sounding of all appropriate alarms/warning devices prior
to restart
Company-specific procedures

Hazard Identification and Correction

The lock-out process begins before the actual work
starts

All sources of energy and all potential hazards
must be identified and controlled before any work
begins


The lock-out process includes a visual inspection, mental
inspection, and physical inspection of the work area

The electrician will be helpful in identifying all electrical
energy sources--you cant see whats going through a wire-
-dont take chances--have all energy sources verified and
confirmed

You cant lock-out an accident after it starts--the time to
take all precautions is before the work begins

Notification of Impending Work

Notify any and all employees who may be affected
by the impending shut down of equipment of what
is about to occur--you do not need to cause any
upstream or downstream surprises (or accidents)

Have a team meeting with all other employees
who will be part of the work to standardize and
confirm what is to be done and why

Identification/Isolation of
All Energy Sources

All energy sources (both live and stored energy)
must be identified, located, and targeted for lock-
out

Lock-Out/Tag-Out
All Energy Sources

All energy sources must be deenergized and
locked out

Lock electrical energy sources at main sources

If there is more than one energy source, it needs
to be locked-out

All persons participating in the work must attach their
own personal lock to all energy sources--that may mean
each person needs more than one lock

Lock-out hasps are a practical and convenient way for
more than one person to attach his/her lock to an energy
source

Each persons lock should have a unique and individual
key--no common keys

Each energy source that is locked out, must be
tagged, advising of the work, and the dangers of
trying to start the machine--the tag must be signed
by all persons who have a lock attached

The key(s) to the lock should be kept in the
personal possession and under the personal control
of the person who attached the lock

Verification/Testing of
All Energy Sources

Verify that all electrical energy is controlled by
attempting to start the machine


Control Stored Energy
Stored energy sources must be bled off,
supported, blocked, or otherwise
neutralized to prevent any and all
movement, motion, or other hazard

Replacement of All Guards
and Safety Devices

Replace all guards after work is completed and
before the equipment is reenergized

Accounting of All Personnel
Following Work
Physically account for all persons who were part of
the work before reenergizing

Advise co-workers that the equipment is about to
be restarted

Only the person who attached the lock may remove
his/her lock

Sounding of All Appropriate Alarms/Warning
Devices Prior to Restart

After all guards have been replaced, all persons
have been accounted for, and all upstream and
downstream workers advised of the impending
restart, sound all warning or start-up alarms
before actually restarting the equipment

Company-Specific Procedures

The way you obtain your own personal lock is:

Lock-out hasps are located:


The procedure to follow at this facility to prepare
for a lock-out is:

The types of equipment at this facility that require
energy control are:

Equipment at this facility that has more than one
electrical energy source is:

The actual lock-out procedure at this facility is:

The procedure to follow at this facility if you are
relieving someone and that person has a lock
attached is:

The procedure to follow at this facility if/when
using a box-system lock-out is:

Analysis of Lock-Out Incidents




Causes
Prudent Safe
Work Practices
Corrections/
Lessons Learned
Causes

Review of MSHA fatalgram or fatal accident
report involving energy control

Review of company incident reports

Corrections/Lessons Learned

Analysis of MSHA fatalgram or fatal accident
reports involving energy control

Review of company incident reports

Prudent Safe Work Practices

If you have the slightest doubt, concern, or confusion
about any part of the lock-out process--STOP--do not
continue--ASK the supervisor--have your issues addressed
to YOUR satisfaction before continuing

Once a piece of machinery has you in its grasp, its very
difficult to start the lock-out process--that is why all
energy must be controlled before starting work

Hazardous energy control is not a gray-area subject--it
is not debatable--it must, and it will, be part of regular
work procedures at this facility because it is literally a
matter of life and death

If you will be part of the work, you must be part of
the lock-out process

You must have your own personal lock(s) and
key(s)

Never pass your lock or key off to somebody else,
or accept theirs

You and you alone must put on and take off your
own lock

Keep your key(s) in your own personal control and
possession

Never remove any lock that belongs to anyone
else--you are in control of your lock--they are in
control of their lock

Remember that there may be numerous types of
energy to control on one piece of equipment

Consult the electrician to identify all electrical
energy sources

Lock-out and tag-out all electrical energy sources-
-this may mean that you need more than one
personal lock

Have a team meeting with coworkers to review the
lock-out procedure before starting the job

Block and support any and all parts and
components that could fall, slide, or roll onto you

Test all energy sources to verify that they are
deenergized

Do not remove guards for any reason without
locking out

Replace all guards and sound all warning alarms
before reenergizing

Regularly review your company energy control
procedures--always be alert for ways to improve
the program--lives are on the line

Ask questions--get answers--know, understand
and follow energy control procedures at all times

Instead of thinking about the time you may save
by not locking out, think about the time you may
lose--forever is a long, long time

Several possible last words regarding hazardous
energy control

I thought someone else locked it out

I never thought it would start

Weve done it before without locking out

Lock out takes too much time

I was only going in there for a few seconds

They should have known I was working on it

Why didnt the start-up alarm sound

I locked out but forgot the hydraulic pressure

The odds were a million to one that Id get
hurt



References
Florida Department of Environmental Protection, U.S.
Department of Labor. Mine Safety and Health
Administration. Lock out and Tag Out for Safety.
Videotape. Cat. No. VC-852. Beckley, WV: National Mine
Health and Safety Academy, 1994.
Title 30 Code of Federal Regulations. Part 56, Subpart C,
Fire Prevention and Control. Washington: U.S.
Government Printing Office.
U. S. Department of Health and Human Services. Center
for Disease Control and Prevention. National Institute for
Occupational Safety and Health. Preventing Worker
Deaths From Uncontrolled Release of Electrical,
Mechanical and Other Types of Hazardous Energy.
NIOSH Publications: 99-110. Cincinnati: NIOSH, 1999.
References
U.S. Department of Labor. Mine Safety and Health Administration.
Electrical Hazards Awareness Program. Cat. No.: IG-65. Beckley,
WV: National Mine Health and Safety Academy, 1988.
U.S. Department of Labor.Occupational Safety and Health
Administration. Control of Hazardous Energy Sources
(Lockout/Tagout). OSHA Factsheet. Washington: OSHA.
U.S. Department of Labor.Occupational Safety and Health
Administration. Control of Hazardous Energy Sources
(Lockout/Tagout). OSHA Publication: Unnumbered. Washington:
OSHA Rev.1997.
Graphics
Safety Services of Texas, Safety Clipart. Austin, TX 2000.

U. S. Department of Labor. Mine Safety and Health Administration.