On a hot day in July, a brother and sister eagerly await their mother’s completion of packing for their upcoming trip to Disneyworld. At the same time, their father, an air conditioning technician, is finishing his last day of work before his long-awaited vacation. Unfortunately, he receives a call to fix an issue with an air conditioning unit at a movie theater. The unit on the roof has standing water from previous day’s rain, causing electrical problems that require cutting off the power supply. Unable to find a disconnect at the unit itself, he realizes he needs to turn off a breaker downstairs in the projection booth instead.
After deactivating the breaker, he returns to repairing the rooftop unit. Unbeknownst to him, another person has connected one of the projectors to this same breaker. Meanwhile, while diligently working on the AC unit, the projectionist notices that one of the projectors isn’t functioning properly and investigates further only to discover that someone had turned off the breaker. Unaware that it also controls her father’s air conditioning service upstairs on the roof,
she flips th e breaker back on. Tragically, while standing in water with his hands on wiring due to this surge of electric current caused by turning on the breaker again;the technician experiences an untimely death.The importance of Lockout/Tagout in the workplace is that it can prevent unnecessary shutdowns,
save money,and eliminate
the risk of bodily harm and fatalitiesIf appropriate precautions had been taken, the brother and sister would be currently experiencing Disneyworld alongside their father instead of having to attend his funeral.
Lockout/Tagout procedures are essential in the workplace to prevent unnecessary shutdowns caused by improper procedures. According to OSHA in 1996, Lockout/Tagout was the third most frequently cited standard, resulting in an average of twenty-four days lost from work per incident. Improper Lockout/Tagout can even lead to building or factory damage due to fire, causing longer than anticipated shutdowns.
Tommy Gilbreath, Associate Professor at The University of Texas at Tyler, emphasizes the importance of safety and states that an injured worker is highly unproductive. However, many companies only implement proper Lockout/Tagout procedures after accidents occur. On the other hand, companies with well-established Lockout/Tagout programs experience fewer accidents, reduced work time loss, and fewer shutdowns compared to those without.
In line with the mindset that “Safety is no accident,” AK Steel hired a former OSHA compliance officer as their vice president of safety and health. This move aims to ensure compliance with OSHA’s rules as AK Steel has had a poor safety record since 1993. These incidents include a fatal flash fire resulting in one death and two injuries, as well as an explosion that injured fourteen people.The Federal OSHA has targeted AK Steel for fines and further inspections due to the incidents that occurred. In 1996, OSHA issued over 6,000 citations for violations of the Lockout/Tagout standard, which is a common sense approach to safety. It is surprising that many companies only implement this standard after an accident occurs and someone gets injured or killed, which is often too late. Some companies had already established Lockout/Tagout procedures before the OSHA standard was introduced in 1990 but neglected important steps because these policies were not written down. Properly following Lockout/Tagout procedures is crucial in preventing losses caused by the failure to control hazardous energy. An example of the consequences of not adhering to these procedures occurred in 1994 when a worker was killed by a 3,700-pound table breaking loose from temporary slings. This incident led to OSHA citing the company for not properly controlling hazardous energy (gravity) and imposing a fine of $2.1 million. In 1996, seventy-five percent of Lockout/Tagout standard violations were due to not having appropriate procedures in place. Therefore, it is important to adopt and enforce the Lockout/Tagout standard as it is a common sense practice that can prevent unnecessary shutdowns and prove economically advantageous for all parties involved (Federal OSHA targets AK Steel for Fines and Further Inspections 25; Figura 27-9).
Lockout/Tagout is crucial in the workplace as it saves time and money. Implementation of proper Lockout/Tagout programs can prevent or reduce fines and citations from OSHA. The AK Steel plant in Middletown, Ohio, was cited in 1995 for multiple violations of the Lockout/Tagout standard, with proposed fines ranging from $7,000 to $70,000 (Federal OSHA Targets A.K. Steel for Fines and Further Inspections 25). In the fiscal year 1996 alone, there were over 6,000 citations issued for non-compliance with Lockout/Tagout, making it one of the most frequently cited OSHA standards (Figura 27-9). Noncompliance with Lockout/Tagout is a serious and costly mistake (Figura 27-9).
Furthermore, Lockout/Tagout helps save money by preventing unnecessary damage to equipment caused by improper startup during repairs. The general industry standard 29 CFR1910.147, introduced in September 1989, was specifically designed to prevent accidental machine start-ups during repairs (Figura 27-9). Failure to follow proper lockout procedures can result in sudden machine startups. To prevent these accidental startups, workers must identify all power sources and lock or tag them out (Lockout/Tagout 1) as emphasized by Arnot Ogden Medical Center.
Additionally, Lockout/Tagout also prevents further damage to equipment being serviced or repaired, ultimately saving the company money (Gilbreath).Lockout/Tagout procedures can save both time and prevent lost workdays due to accidents resulting in death or injury. According to a personal interview with Gilbreath, failure to implement Lockout/Tagout measures not only exposes a company to fines and citations from OSHA, but also makes the company vulnerable to lawsuits from family members. In his book Lockout/Tagout: A Reminder, Stephen M. Kelly emphasizes the importance of these procedures.
It is essential to stress the severity of injuries caused by improper Lockout and hold personnel responsible for their actions. Informing employees about the consequences of not following Lockout/Tagout procedures is crucial. Implementing disciplinary measures for violations helps ensure compliance. Certain companies have policies that skip progressive discipline and may lead to termination for safety violations, especially those related to Lockout/Tagout protocols. This strict approach is necessary because disregarding lockout procedures poses significant risks (40).
Implementing Lockout/Tagout measures can provide companies with financial benefits while also reducing the risk of fatalities and work-related injuries, ultimately preventing lost work time.
According to the Lockout/Tagout standard (source: OSHA Fact Sheets), Lockout/Tagout is essential in the workplace as it prevents loss of limb and life, saving at least 120 lives per year. The National Institute of Occupational Safety and Health (NIOSH) has investigated 1,281 fatal incidents from 1982-1997. At least 152 of these incidents were caused by non-Lockout/Tagout measures, as stated in a report titled “Preventing Worker Deaths from Uncontrolled Release of Electrical, Mechanical, and Other Types of Hazardous Energy” (source: CDC NIOSH). Compliance with Lockout/Tagout is emphasized in OSHA Fact Sheets due to its effectiveness in preventing injuries. It is particularly important for approximately three million workers who service equipment. OSHA Fact Sheets highlight that an estimated 28,000 serious injuries and 32,000 minor injuries are prevented annually through proper implementation of Lockout/Tagout. This includes various types of injuries such as fractures, contusions’, amputations’, and puncture wounds’. These injuries typically result in an average of 24 lost workdays each. Failure to follow Lockout/Tagout procedures has often resulted in serious or fatal consequences.The significance of Lockout/Tagout procedures is highlighted by a real-life example that occurred in October 1995 at the same company. This incident resulted in two workers being injured and one worker losing their life. Furthermore, another explosion took place in December 1995, causing fourteen workers to be injured. These occurrences were documented in Occupational Hazards magazine. The NIOSH Alert report states that from 1982-1997, a total of 152 fatalities were investigated across twenty states. The primary factors responsible for these deaths were failure to fully de-energize the power source (accounting for 82% of deaths), failure to implement Lockout/Tagout measures (contributing to 11% of deaths), and failure to verify if all power sources were locked out or tagged out (being responsible for 7% of deaths) (Preventing Worker Deaths 99-110). Prior to the implementation of the Lockout/Tagout standard, there were numerous avoidable injuries and fatalities occurring in the workplace.
It is essential to implement a Lockout/Tagout program in the workplace due to its various advantages for a company. These include minimizing machinery downtime, reducing injuries and fatalities, and alleviating financial burdens related to litigation. Additionally, this program can be implemented at a low cost.
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.PeriodicalAbstracts.OvidTechnologies.RandolphC.WatsonLib.,
Kilgore,
TX,
11Sept.
2000http://texshare.edu/
ovidweb/
ovidweb.cgi.
Gilbreath,TommyDr.Personalinterview28Sept.
2000.
The following information outlines how to implement the lockout/tagout procedure as stated in 1910.147. The source for this information is a website called “How to Lockout/Tagout” by Fred.net, which can be found at http://www.fred.net/ogdenc/howloto.html. Another resource on this topic is an article titled “Lockout/Tagout: A Reminder” by Stephen M. Kelley, published in Material Handling Management in March 2000 (volume 40). This article can be accessed through Applied Science and Technology Fulltext database available at H.W. Wilson, specifically from Randolph C. Watson Library in Kilgore, TX. For more information about lockout/tagout, visit the website of Arnot Ogden Medical Center at http://www.aomc.org/HOD2/general/Accinjpr-LOCKOUT_.html. Lastly, there is an article called “No Exemption from Lockout Tagout,” published in Occupational Hazards in January 1994 (pages 12-13), accessible through Periodical Abstracts database provided by Ovid Technologies via Randolph C. Watson Library in Kilgore, TX. To access this database, go to 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 two maintenance workers. OSHA fined the 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.
In a 1996 article by Susannah Zak titled “Lockout/Tagout: A Matter of Control,” it is stated that OSHA issued over 6000 violations of the lockout tagout standard. Many companies violate this standard, despite it being considered the easiest and most effective to follow according to safety professionals. OSHA estimates that the lockout tagout standard saves 122 lives and prevents 28,000 lost workday injuries annually. To comply with the lockout tagout program, OSHA requires written procedures, training, and periodic audits at least once a year.
In a different article by Lisa Finnigan called “A Downside to Lockout/Tagout Rules,” concerns are raised about OSHA’s requirements for lockout tagout and how they may create hazards for process systems and piping networks, as well as workers. According to Jerry Walker of the American Petroleum Institute, special provisions should be incorporated into this rule. The American Petroleum Institute is advocating for a separate general industry rule that addresses the isolation of process systems and piping networks.
To understand how to implement lockout tagout procedures as laid out in 1910.147, more information can be found at http://www.fred.net/ogdenc/howloto.html.To effectively implement Lockout/Tagout protocols, specific procedures must be followed. These procedures entail preparing the equipment for shutdown, executing the shutdown process, and isolating the power source. Once these steps have been completed, the technician must affix the appropriate lock and/or tag. After applying the lock and/or tag, the technician needs to release any residual energy and attempt to power up the equipment. It is vital to keep the lock or tag in place until the equipment is deemed safe for operation.
According to Stephen M. Kelley in his article “Lockout/Tagout: A Reminder” from Material Handling Management (Mar. 2000), OSHA’s Lockout/Tagout standard has been in effect since September 1, 1989. Despite this, there are still instances where hazardous energy releases occur. To prevent such incidents, certain elements contribute to success: visible management leadership, employer participation, enforcement and accountability, design and installation, and review and revision. These procedures are essential for program success and must be easily understandable and implementable for employees.
According to Arnot Ogden Medical Center’s Lockout/Tagout information page (9 Sept. 2000), when setting up, repairing, or maintaining equipment, simply unplugging it is insufficient. Accidents can still occur if individuals mistakenly believe that the machine is safely turned off. Therefore, Lockout/Tagout is the most effective method of self-protection.Lockout/Tagout is a procedure used to ensure the safe shutdown of machines. Failure to follow this procedure may result in the machine starting up unexpectedly. It is important for technicians to confirm that all electrical systems and power sources of the machine are switched off, including electrical current, stored electricity, stored pressure, stored mechanical energy, or gravity. This information is sourced from “No Exemption from Lockout Tagout” in Occupational Hazards Journal. 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 the Occupational Safety and Health Review Commission, repairs on printer/slotter machines during operational runs are not exempt from Lockout/Tagout coverage. These machines are used for printing, scoring, and slotting sheets of paperboard. Westvaco Corp. stated that each order of cartons is unique and the adjustments to the machine typically take between fifteen and forty-five minutes. However, the company was cited by the Commission for not implementing an Energy Control Program to prevent employee exposure to the energized machine. As a result, Westvaco Corp. was fined $560.
