Fundamental Principles
Many injuries are sustained when a piece of equipment suddenly activates or moves unexpectedly when you are servicing, adjusting, or setting up a piece of equipment. While the foundations of this topic are found in Occupational Safety and Health Administration, OSHA, regulations, the fundamental principles apply everywhere. Since the OSHA standard is regulatory in nature and therefore not an easy read. Let us focus on the fundamental principles of controlling hazardous energy.
Two Elements
There are two parts to this process – Tagout and Lockout
Tagout is the first level of control. You must alert people that you are working on the item in question and that it should not be handled, changed, or used by anyone else. Your tagout should identify who is in control of the process and the date of the tag application. This will allow others to know who to see and when the work commenced. This first level of the process is a warning, not a control point. A tagout alone is not an acceptable level of control.
Lockout is the positive control of hazardous energy sources. This is a positive action that prevents the energy from being released or used by the equipment. This is the point of hazard control that provides protection to you.
Energy Sources - Identification
To control hazardous energy, you must recognize the source of that energy. You need to look carefully at the equipment you are working with to identify the energy source(s) that require control.
Electrical Energy — is more than throwing a switch. Do you have exclusive control over the switch? If the answer is no, then you have not controlled the electrical energy. Anyone can turn on the switch, plug the cord in or reset the breaker while you are working on the equipment. You also need to consider if the equipment has alternate power feeds. This can be solar, wind, battery, or backup generator power.
Water, Hydraulic, and Air Pressure — are generally controlled by some type of valve. Having control over that valve or valves offers control over these energy sources.
Stored Energy — batteries and capacitors are sources of electrical energy. There can also be stored energy in any pressurized system.
Heat Energy — can be found in a variety of equipment. Steam, hot water, thermal oils and cooking oils are all common types of heat transfer mechanisms.
Mechanical Energy — found in wheels, springs, gears, and elevated parts. Preventing these parts from moving may require actions beyond controlling the primary power source.
Chemical Energy – energy from a chemical reaction may require isolating the process and any number of feed mechanisms or sources.
Gravity — a commonly neglected energy source that cannot be discounted. Blocking up a vehicle with solid cribbing or jack stands prevents the release of gravity from a failed lift or jack. Support any part that could fall or drop.
Lockout control methods
The best controls allow you to apply a personal lock to a device that prevents the energy source from changing state. There are a number of commercially available kits and tools for this purpose. The part that many people neglect is the concept of a personal lock that you have control over. This is not a zip tie, piece of tape or an opened disconnect. If you cannot assert 100% control over the energy source, you are at risk.
For cord and plug equipment placing the plug in your pocket can be an effective control. It is low tech and requires no purchase. It does require personal effort to take action to protect yourself.
Testing the controls
After you have applied a tag and locked out the power source, attempt to operate the equipment to verify that it is in a safe state. This is when you may discover stored energy sources or alternate power sources. It is better to make these discoveries in a test environment than when your body parts are at risk.
Removing the controls
Test the equipment to be sure your repairs and adjustments are working, and that normal power and operation is restored. If hands in the hazard area adjustments are needed, keep the tagout and lockout process in place until repairs are completed. When you are satisfied that the equipment is ready to return to service, alert affected staff that work is completed.
Workplace documentation
The OSHA standard calls for an inventory of your equipment and specifically identifying power sources and control points. This will also guide your purchase of control devices and materials. This step is often left incomplete, and the failure is noted when an injury occurs.
In addition to the documented procedures, you should document the training of your staff. There are staff who will be applying the tags and locks and a second audience of people who work in and around the affected equipment. Both groups need training on the program and to recognize and honor the tags and locks.
The Driehaus Difference
We can help you identify resources to get your lockout tagout program in place. We advocate that you extend these principles to home exposures. Many of the same hazards at work are present at home is different packages. We want to be your risk management and insurance provider. Call us at 513-977-6860 or reach out via our website www.driehausins.com
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