Do you know everything you need to know about the 10 most frequently cited Occupational Safety and Health Administration standards? In this series, we’re exploring the most common OSHA violations, one by one. Keep reading to learn about OSHA’s Control of Hazardous Energy (or Lockout Tagout).
What is Lockout Tagout?
OSHA definition:
“The OSHA standard for The Control of Hazardous Energy (Lockout/Tagout), Title 29 Code of Federal Regulations (CFR) Part 1910.147, addresses the practices and procedures necessary to disable machinery or equipment, thereby preventing the release of hazardous energy while employees perform servicing and maintenance activities. The standard outlines measures for controlling hazardous energies—electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources.” (Source [PDF])
Simple definition:
Some machines can seriously injure or kill workers. These machines are dangerous because they are hazardous energy sources—in the form of electricity, steam, chemicals, or another kind of power.
Hazardous energy sources can release whether the machine or equipment is being used or not. This is why it’s important for dangerous machines to be completely shut off before servicing and maintenance. For example:
- A capacitor that hasn’t been properly disconnected could electrocute someone trying to repair it.
- A hydraulic press that hasn’t been de-energized could crush someone.
- A steam valve that hasn’t been bled out could scald someone.
OSHA’s Control of Hazardous Energy control programs, usually called the “Lockout/Tagout” standard (or LOTO for short), outlines what workers should do to safely depower dangerous machines. One of the main steps of a LOTO program is literally locking the machine or equipment in the “off” position and adding a tag with the name of the person who carries the key to the lock.
Do you know everything you need to know about the 10 most frequently cited Occupational Safety and Health Administration standards? In this series, we’re exploring the most common OSHA violations, one by one.
Why Lockout/Tagout Violations Happen
As with so many OSHA standards, lockout/tagout violations frequently come down to poor documentation. Authorized employees should have detailed, written procedures for every machine they have in use. Some organizations neglect to document certain pieces of equipment; other organizations lack written procedures entirely.
Inadequate employee protection and training is another critical risk area. Training isn’t just for workers who operate, service, or apply locks and tags to the machines. Any affected employee who works around dangerous equipment needs to undergo some level of lockout/tagout training.
Some employers violate the standard by simply failing to identify every source of hazardous energy in their facilities.
Others use the wrong lockout/tagout devices.
Still other employers don’t recognize their lockout/tagout risks because they don’t perform regular audits. OSHA requires organizations with dangerous machines to perform periodic inspection and test those machines, as well as to evaluate their LOTO procedures.
Finally, organizations sometimes fall short because they don’t follow all lockout/tagout procedures in the correct order.
What You Stand to Lose When Lockout/Tagout Violations Happen
Direct costs: OSHA penalties can exceed $15,000 per violation—and as much per day for every day the issue hasn’t been fixed by OSHA’s deadline. The fine for a willful or repeated violation can be 10 times as much.
- workers’ compensation claims from workers injured by improperly locked machinery
- lost productivity during and after an incident
- costs of replacing any equipment damaged by improper lockout/tagout procedures
- legal and compliance fees
- decreased morale
- negative publicity and reputational damage
Signs You’re at Risk of a Lockout/Tagout Violation
The more dangerous equipment you have in use, the higher your risk for a lockout/tagout violation.
If you’re constantly servicing or fixing your machines, you’ll need to ensure continuous lockout/tagout program compliance.
Workers involved in a lockout/tagout program need specific training. The same goes for workers who perform servicing and maintenance. On top of that, everyone who works around dangerous machines should be aware of basic lockout/tagout procedures.
If it’s been over a year since you evaluated your equipment and procedures, you could be in trouble.
How to Avoid a Lockout/Tagout Violation: Your Prevention Checklist
Procedures should include maintenance tasks or activities to machinery, including setup, installation, removal, maintenance, operation, adjusting, cleaning, troubleshooting, and programming. Procedures should also cover equipment connected to the hazardous machinery
Employees should never remove or bypass machine guards or other safety devices, place any part of their bodies in or near a machine’s point of operation, or place any part of their bodies in a danger zone associated with machine operations. Employees should check the safety of a lockout without exposing anyone else to potential hazards.
Employee protecton entails a complete maintenance tasks or activities on machinery, be sure there are no potential stored energy hazards associated with the task, such as electrical, gravitational, mechanical, chemical, thermal, pneumatic, hydraulic, or radiation. Be sure to eliminate all potential hazards due to human error as well.
Have you eliminated all potential for injury (burns, laceration, contusions, punctures, electrocution, crushing, etc.) or death from the hazards while completing the maintenance tasks?
Designated employees should have individually keyed personal safety locks, and should be required to keep personal control of their key(s) while they have safety locks in use. Only the employee exposed to a given hazard should place or remove their safety lock. Any and all employees working on locked-out equipment should be able to be identified by their locks and/or tags. Additionally, OSHA recommends a “sufficient number of accident prevention signs or tags and safety padlocks” be “provided for any reasonably foreseeable repair emergency.”
What is the Difference Between Lock Out and Tag Out?
Lockout involves physically blocking the energy-isolating device with a lockout device, while tagout refers to attaching a warning tag.
During a lockout procedure, workers use a device to prevent equipment from being energized. This process ensures that machinery cannot be operated until the lockout is removed.
In contrast, when you tag out a piece of equipment, you attach a warning tag without physically blocking the energy source. Group lockout may be necessary when multiple workers are involved.
Both procedures are essential for workplace safety. Outlining the steps clearly is crucial, as procedures may vary depending on the equipment. The final rule is that all workers must receive proper training in these procedures for using energy-isolating devices to prevent accidents and injuries.
What are the 4 Most Common Types of LOTO Devices?
According to the lockout tagout standard, four primary types of LOTO devices are commonly used in various industries.
- The first type is the padlock, which is the most frequently used device to secure an energy-isolating device in the off or safe position.
- Second, we have lockout hasps, which allow multiple workers to apply their individual locks to a single energy source.
- Third, valve lockouts are designed specifically for different types of valves to prevent them from being operated during maintenance.
- Lastly, electrical plug lockouts are used to secure plugs and prevent accidental reconnection to power sources.
These devices and proper procedures used in LOTO programs help ensure worker safety during equipment maintenance and repair tasks.
7 Steps of Lockout Tagout Procedure
Implementing a robust lockout tagout program is crucial for ensuring loto safety and preventing exposure to hazardous energy. The steps of a lockout tagout procedure must be followed diligently to protect workers during maintenance or servicing activities.
- First, develop a comprehensive plan and communicate it to all affected employees.
- Next, identify and locate all energy-isolating devices for the machines and equipment involved.
- Third, notify all impacted personnel about the impending shutdown.
- Fourth, shut down the equipment following established energy control procedures.
- Fifth, isolate the equipment from its power source by applying appropriate lockout tagout devices, such as a valve lockout or battery disconnect.
- Sixth, release any stored energy and verify that the equipment is fully de-energized.
- Finally, apply a lock out tag to each isolating device in a safe manner.
Remember, according to OSHA, the equipment should not be operated if proper lockout and tagout procedures are not followed. Always adhere to lockout tagout best practices and ensure only authorized personnel can remove the lock before startup. This safety measure is vital in preventing accidents and injuries during maintenance or repair work.
You Don’t Have to Manage Your OSHA Requirements Alone
Have questions? Looking for more detailed OSHA compliance guidance?
KPA is here to help.
To truly protect your workforce and bottom line, you’ll need in-depth information—and not just about OSHA’s top 10, but every potential hazard that exists in your organization. You’ll also need to conduct a thorough evaluation of your facilities to identify current gaps and risk areas.
KPA’s unique combination of software, training, and consulting services can provide the coverage your people and your organization need. For more information and guidance about preventing a hazard communication violation, please contact us.
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