FREE ESSAY ON LOCKOUT/TAGOUT

LOCKOUT/TAGOUT

It is a hot day in the middle of July, and there is a brother and sister impatiently
waiting while their mother finishes packing for their trip to Disneyworld. This is their
father's last day to work before his vacation starts. Their father is an air conditioning
technician, and this morning he was called out to a movie theater to work on an air
conditioning unit. This particular unit is located on the roof of the theater. It had
been raining the day before; on the roof around the unit water is standing where he is
going to have to work. In checking the unit out, he finds electrical problems that
require him to shut the power off to the unit. He looks for the disconnect at the unit.
Not finding one, he discovers that the only way to shut the power off is a breaker
located downstairs inside the projection booth. He turns the breaker off and goes back on
the roof to repair the unit. He does not know that someone has also connected one of the
projectors to the same breaker. While he is working on the unit, the projectionist comes
in and finds out that one of the projectors will not work, so he checks the breaker and
finds it in the off position. He does not know that the air conditioning unit is also on
that breaker. The projectionist turns the breaker on and at the same time, the technician
working on the unit is standing in the water with his hands on the wiring. The
electricity flows and electrocutes the technician, killing him. If this unit had been
properly Lockedout/Taggedout, the brother and sister would be enjoying Disneyworld with
their father. Instead, they are attending his funeral. Lockout/Tagout is essential in the
workplace because it prevents unneeded shutdowns, saves money, and prevents loss of limb
and life.
Lockout/Tagout is essential in the workplace because it prevents unneeded shutdowns.
These shutdowns are primarily the result of improper Lockout/Tagout procedures. In
Lockout/Tagout: A Matter of Control, Susannah Zak Figura explains that in 1996 OSHA
(Occupational Safety and Health Administration) reported that Lockout/Tagout was the
third most frequently cited standard and that the average number of days lost from work
was twenty-four per incident (27-9). In some cases, a portion of the building or factory
could be destroyed by fire and cause the business to shutdown longer than was originally
anticipated. According to Tommy Gilbreath, Associate Professor at The University of Texas
at Tyler, There is nothing more unproductive than an injured worker (Personal interview).
Often these companies wait until an accident occurs to implement the proper
Lockout/Tagout procedures. Companies that have proper Lockout/Tagout programs in place
have fewer accidents, lost work time, and fewer shutdowns than companies that do not.
Safety is no accident explains Frank C. De Felice, author of Electrical Construction and
Maintenance (48). According to Occupational Hazards, AK Steel, a company with a bad
safety record, hired a former OSHA compliance officer as vice president of safety and
health to help the company comply with OSHA's rules. Since 1993, AK Steel, the nation's
seventh largest steelmaker, has had a flash fire that killed one and injured two and an
explosion that injured fourteen (Federal OSHA targets AK Steel for Fines and Further
Inspections 25). OSHA issued more than 6,000 citations in 1996 alone for the violation of
the Lockout/Tagout standard. Lockout/Tagout is a common sense approach to safety. Yet,
many companies do not implement it until an accident injures or kills someone. Then it is
a little late. Some companies have had Lockout/Tagout procedures in place long before the
OSHA standard went into effect in 1990; because the policies were not written down,
sometimes crucial steps were left undone (Figura 27-9). Performing Lockout/Tagout
properly prevents losses arising from failure to control hazardous energy. Figura notes
that in 1994 a 3,700-pound table broke loose from temporary slings and crushed a worker
killing him. Because of this accident, OSHA cited the company for failure to control
hazardous energy, i.e. gravity, and fined it $2.1 million. Under the Lockout/Tagout rule,
hazardous energy must be isolated and rendered inoperative before work can begin. Not
having the proper procedures in place accounted for seventy-five percent of the
Lockout/Tagout standard violations in 1996 (27-9). The Lockout/Tagout standard is a
common sense practice, which, when properly administered, will hopefully prevent unneeded
shutdowns and be economically beneficial to all parties involved.
Lockout/Tagout is also essential in the workplace because it saves time and money. Proper
Lockout/Tagout programs will prevent or reduce fines and citations from OSHA.
Occupational Hazards reports that in 1995, the Middletown, Ohio, plant of AK Steel was
cited for fourteen willful violations and five serious violations of the Lockout/Tagout
standard. The proposed fines were $70,000 per willful violations and $7,000 per serious
violation (Federal OSHA Targets A.K. Steel for Fines and Further Inspections 25). In
fiscal year 1996, there were more than 6,000 citations issued for non-Lockout/Tagout and
it was the third most frequently cited OSHA standard. Noncompliance is a serious and
expensive mistake (Figura 27-9). In addition, Lockout/Tagout saves money because it
prevents unnecessary damage to equipment resulting from improper startup during repairs.
Figura reports that the general industry standard 29 CFR1910.147, published in September
1989, was designed to prevent the accidental start-up of machines undergoing repairs
(27-9). Machines can suddenly startup if the proper lockout procedures are not followed.
Arnot Ogden Medical Center emphasizes that to prevent these accidental startups from
happening, the worker must identify all power sources and lock or tag them out
(Lockout/Tagout 1). Gilbreath concedes that a secondary benefit of Lockout/Tagout is that
it prevents further damage to equipment being serviced or repaired, saving the company
money. It also saves time because the equipment will not be shut down for as long
(Personal interview). In addition, Lockout/Tagout prevents lost workdays because of
litigation arising from improper Lockout/Tagout procedures that result in death or
injury. According to Gilbreath, If a company does not utilize Lockout/Tagout, then not
only will it be open to fines and citations from OSHA if an accident occurs but also will
open the company up for lawsuits from family members (Personal interview). Stephen M.
Kelly, author of Lockout/Tagout: A Reminder, says,
Injuries associated with improper Lockout are often serious or fatal. Thus, personnel
must be held accountable and understand the consequences for violating Lockout/Tagout
procedures. Discipline should be initiated when Lockout/Tagout violations occur to
bolster enforcement. Many companies have disciplinary policies in which progressive
discipline steps are skipped and actions up to and including discharge are imposed, and
when safety violations such as failing to follow Lockout/Tagout occur. This is because
the risks associated with non-adherence to lockout procedures are simply too high to
tolerate (40).
Not only does Lockout/Tagout benefit the company economically; it also helps to prevent
fatalities and lost work time from injuries.
Importantly, because it prevents loss of limb and life, Lockout/Tagout is essential in
the workplace. The Lockout/Tagout standard saves at least 120 lives per year. According
to (National Institute of Occupational Safety and Health) NIOSH they have investigated
1,281 fatal incidents during the years 1982-1997 of these at least 152 were caused by
non-Lockout/Tagout (Preventing Worker Deaths from Uncontrolled Release of Electrical,
Mechanical, and Other Types of Hazardous Energy 99-110). According to OSHA Fact Sheets,
Lockout/Tagout compliance will save at least 120 lives per year (01/01/1989 - Control of
Hazardous Energy Sources (Lockout/Tagout)). Secondly, Lockout/Tagout prevents at least
28,000 lost workday injuries per year. According to OSHA Fact Sheets, About three million
workers actually servicing equipment face the greatest risk. In addition, OSHA Fact
Sheets states that approximately 28,000 serious and 32,000 minor injuries are prevented
each year (01/01/1989). Some of the injuries prevented include fractures, contusions,
amputations, and puncture wounds. All of these have an average of 24 lost workdays each.
Injuries attributed to improper Lockout/Tagout are often serious or fatal. According to
Occupational Hazards, in Oct. 1995 a flash fire injured two workers and killed one. In
addition, in Dec. 1995 an Explosion injured 14 workers (27-9). These incidents happened
at the same company. According to NIOSH Alert, out of the 152 fatalities investigated in
20 states during the years 1982-1997, the factors that contributed to these deaths were:
Failure to completely de-energize the power source was 82% of the 152 deaths, failure to
Lockout/Tagout was 11% of the 152, and failure to check to make sure all power sources
were locked out/ tagged out were 7% of the 152 fatalities (Preventing Worker Deaths
99-110). Before the Lockout/Tagout standard went into effect, numerous injuries and
fatalities occurred in the workplace that could have been prevented.
After reviewing why Lockout/Tagout is essential in the workplace, one understands that
for a minimal cost to implement a Lockout/Tagout program, the benefits that a company
will reap are reduced downtime for machinery, reduced injuries and fatalities, and less
monetary outflow caused from litigation. 
Bibliography
Works Cited
DeFelice Jr., Frank C. Maintaining Medium-Voltage Substations and Switchgear Safely.
Electrical Construction and Maintenance May 1997: 48+. Applied Science and Technology.
H.W. Wilson. Randolph C. Watson Lib., Kilgore, TX, 16 Sept. 2000 http://hwwilsonweb.com/.

Federal OSHA Targets AK Steel for Fines and Further Inspections. Occupational Hazards May
1996: 25. Periodical Abstracts. Ovid Technologies. Randolph C. Watson Lib., Kilgore, TX,
11 Sept. 2000 http://texshare.edu/ovidweb/ovidweb.cgi. 
Figura, Susannah Zak. Lockout/Tagout: A Matter of Control. Occupational Hazard Dec. 1996:
27-29. Periodical Abstracts. Ovid Technologies. Randolph C. Watson Lib., Kilgore, TX, 11
Sept. 2000 http://texshare.edu/ovidweb/ovidweb.cgi. 
Finnigan, Lisa. A Downside to Lockout/Tagout Rules. Occupational Hazards Aug. 1997:
15-16. Periodical Abstracts. Ovid Technologies. Randolph C. Watson Lib., Kilgore, TX, 11
Sept. 2000 http://texshare.edu/ovidweb/ovidweb.cgi. 
Gilbreath, Tommy Dr. Personal interview. 28 Sept. 2000.
How to Lockout/Tagout as per the Procedure Laid Out in 1910.147. 9 Sept. 2000
http://www.fred.net/ogdenc/howloto.html. 
Kelley, Stephen M. Lockout/Tagout: A Reminder. Material Handling Management Mar. 2000:
40. Applied Science and Technology Fulltext. H.W. Wilson. Randolph C. Watson Lib.,
Kilgore, TX, 16 Sept. 2000 http://hwwilsonweb.com/. 
Lockout/Tagout. Arnot Ogden Medical Center. 9 Sept. 2000
http://www.aomc.org/HOD2/general/Accinjpr-LOCKOUT_.html. 
No Exemption from Lockout Tagout. Occupational Hazards Jan. 1994:12-13. Periodical
Abstracts. Ovid Technologies. Randolph C. Watson Lib., Kilgore, TX, 11 Sept. 2000
http://www.texshare.edu/ovidweb/ovidweb.cgi.
Preventing Worker Deaths from Uncontrolled Release of Electrical, Mechanical, and Other
Types of Hazardous Energy. NIOSH Alert. Aug. 1999. 17 Oct. 2000
http://www.cdc.gov/niosh/99-110.html 
01/01/1989 - Control of Hazardous Energy Sources (Lockout/Tagout). OSHA Fact Sheets. 1
Jan. 1989, 17 Oct. 2000 http://www.osha-slc.gov/OshDoc/Fact_data/FSNO89-32.html 
Annotated Bibliography
DeFelice Jr., Frank C. Maintaining Medium-Voltage Substations and Switchgear Safely.
Electrical Construction and Maintenance May 1997: 48+. Applied Science and Technology.
H.W. Wilson. Randolph C. Watson Lib., Kilgore, TX, 16 Sept. 2000 http://hwwilsonweb.com/.
Safety is no accident. Many companies that were built with safety steps in place from the
beginning have much better safety records than those who did not use this strategy. The
safety steps include training and inspection, pre-outage preparation, system shut down,
and Lockout/Tagout, which include personal and department, and insuring de-energization.

Federal OSHA Targets AK Steel for Fines and Further Inspections. Occupational Hazards May
1996: 25. Periodical Abstracts. Ovid Technologies. Randolph C. Watson Lib., Kilgore, TX,
11 Sept. 2000 http://texshare.edu/ovidweb/ovidweb.cgi. In Oct., 1995, there was a flash
fire at AK Steel Corp. killing one production and injured to maintenance workers. OSHA
fined steel mill with a $1 million proposed penalty and hinted that more enforcement
action may be forthcoming. The company was cited for fourteen alleged willful violations
and five alleged serious violations of the Lockout/Tagout standard. 
Figura, Susannah Zak. Lockout/Tagout: A Matter of Control. Occupational Hazards Dec.
1996: 27-29. Periodical Abstracts. Ovid Technologies. Randolph C. Watson Lib., Kilgore,
TX, 11 Sept. 2000 http://texshare.edu/ovidweb/ovidweb.cgi. In 1996, OSHA issued over 6000
violations of the lockout tagout standard. Why do so many companies violate the lockout
tagout standard? According to many safety professionals, this standard is the easiest and
most effective to follow. OSHA estimates that the lockout tagout standard saves 122 lives
and prevents 28,000 lost workday injuries annually. According to OSHA, a lockout tagout
program must include three basic elements: (1). Written procedures, (2). Training, and
(3). Periodic audits at least once a year. 
Finnigan, Lisa. A Downside to Lockout/Tagout Rules. Occupational Hazards Aug. 1997:
15-16. Periodical Abstracts. Ovid Technologies. Randolph C. Watson Lib., Kilgore, TX, 11
Sept. 2000 http://texshare.edu/ovidweb/ovidweb.cgi. Does OSHA's Lockout/Tagout
requirements create hazards for process systems and piping networks, workers? According
to Jerry Walker, a representative of the American Petroleum Institute, it does. Walker
says that special provisions can be incorporated into this rule. American Petroleum
Institute will like a separate, general industry rule addressing the isolation of process
systems and piping networks. 
How to Lockout/Tagout as per the Procedure Laid Out in 1910.147. 9 Sept. 2000
http://www.fred.net/ogdenc/howloto.html. In utilizing Lockout/Tagout, one must follow
certain procedures. These procedures involve preparing equipment for shutdown, actually
shutting down the equipment then isolating a power source. After the technician has
performed these steps, the technician must apply the lock and/or tag. Once the lock
and/or tag is applied the technician must release residual energy then try to power up
the equipment. Do not remove the lock or tag until the equipment is safe to operate. 
Kelley, Stephen M. Lockout/Tagout: A Reminder. Material Handling Management Mar. 2000:
40. Applied Science and Technology Fulltext. H.W. Wilson. Randolph C. Watson Lib.,
Kilgore, TX, 16 Sept. 2000 http://hwwilsonweb.com/. OSHA's Lockout/Tagout standard has
been in effect since September 1, 1989; yet, there are still hazardous energy release
incidents occurring. There are elements to success in preventing these incidents. These
include visible management leadership, employer participation, enforcement and
accountability, design and installation, and review and revision. Vital to program
success these procedures must be understandable and easy for employees to implement. 
Lockout/Tagout. Arnot Ogden Medical Center. 9 Sept. 2000
http://www.aomc.org/HOD2/general/Accinjpr-LOCKOUT_.html. When it comes time to setup
equipment, repair or maintain equipment, unplugging the equipment is simply not enough.
Accidents can happen when people think that the machine is safely off. Lockout/Tagout is
the best way to protect oneself. Using Lockout/Tagout ensures that the machine is safely
turned off. Without the Lockout/Tagout procedure, the machine can possibly start up. To
prevent these start-ups the technician needs to be sure that all the machines electrical
systems and /or power sources are off. (Power sources such as: electrical current, stored
electricity (such as in a capacitor), stored pressure (such as compressed air), stored
mechanical energy (such as in a coiled spring), or gravity needs to be identified and
shut down.) 
No Exemption from Lockout Tagout. Occupational Hazards Jan. 1994:12-13. Periodical
Abstracts. Ovid Technologies. Randolph C. Watson Lib., Kilgore, TX, 11 Sept. 2000
http://www.texshare.edu/ovidweb/ovidweb.cgi.
According to a rule set by the Occupational Safety and Health Review Commission,
servicing repairs on printer/slotter machines between operational runs are not exempt
from Lockout/Tagout coverage. A printer/slotter machine prints, scores, and slots sheets
of paperboard. According To Westvaco Corp., each order of cartons is different. According
to the company officials, the adjustments to the machine take between fifteen and
forty-five minutes. The Commission cited Westvaco Corp. for not developing an Energy
Control Program to protect employees from the energizing of this machine and the company
was fined $560.