Shear Machine Lockout/Tagout Procedure

Document Number: [SWP-NUMBER]

Revision Date: [DATE]

Next Review Date: [NEXT REVIEW DATE]

Department: [DEPARTMENT NAME]

1. Scope

This safe work procedure (SWP) outlines the steps for the safe lockout/tagout of the Shear Machine during maintenance and servicing activities. It applies to all employees, contractors, and visitors who may be exposed to hazardous energy during these activities. The purpose of this procedure is to prevent accidental startup or release of stored energy, which could result in serious injury or death. This procedure is designed to comply with OSHA standard 29 CFR 1910.147, "The Control of Hazardous Energy (Lockout/Tagout)".

2. Definitions

Authorized Employee A person who locks out or tags out machines/equipment in order to perform service or maintenance on that piece of equipment; an affected employee becomes an authorized employee when that employee's duties include performing service or maintenance. [3]

Affected Employee An employee whose job requires him/her to operate or use a machine or equipment on which service or maintenance is being performed under lockout or tagout or whose job requires him/her to work in an area in which service or maintenance is being performed. [3]

Energy-Isolating Device A mechanical device that physically prevents the transmission or release of energy. Examples include circuit breakers, disconnect switches, and valves. [1]

Lockout Device A device that locks an energy-isolating device in the safe position. [5]

Tagout Device A prominent warning sign, such as a tag, that can be securely fastened to an energy-isolating device to indicate that the energy-isolating device and the equipment it controls cannot be operated until the tagout device is removed. [5]

3. Responsibilities

3.1 Supervisors

Ensure that all employees are trained and competent in the lockout/tagout procedures.
Provide the necessary lockout/tagout devices and equipment.
Enforce the lockout/tagout procedures and ensure compliance.
Conduct periodic inspections of the lockout/tagout procedures to ensure effectiveness.

3.2 Workers

Follow the lockout/tagout procedures as outlined in this SWP.
Attend required training and demonstrate competency in lockout/tagout procedures.
Report any hazards or unsafe conditions to the supervisor.
Never attempt to operate equipment that is locked out or tagged out.

3.3 Health and Safety Representative

Assist in the development and implementation of the lockout/tagout program.
Participate in periodic inspections of the lockout/tagout procedures.
Provide guidance and support to employees on lockout/tagout procedures.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Unexpected startup of the Shear Machine	Serious injury or death to workers performing maintenance or servicing.	Implement a comprehensive lockout/tagout procedure to isolate the machine from all energy sources before maintenance or servicing begins.
Release of stored mechanical energy (e.g., spring tension)	Pinch points, crushing injuries.	Relieve or restrain all stored mechanical energy before starting work. Use appropriate tools and techniques to safely release tension.
Electrical shock	Electrocution, burns.	De-energize and lockout electrical circuits. Verify de-energization with a voltage tester before starting work. Use insulated tools.
Hydraulic fluid injection	Serious tissue damage, infection.	Relieve hydraulic pressure before disconnecting lines. Wear appropriate PPE, including eye protection and gloves. Seek immediate medical attention for any injection injury.
Failure to verify isolation	Exposure to hazardous energy, potential for injury.	Always verify that the machine is de-energized and isolated before starting work. Use the "Lock, Tag, Try" method to ensure isolation.
Inadequate training	Incorrect lockout/tagout procedures, leading to exposure to hazardous energy.	Provide comprehensive training to all authorized and affected employees. Retrain employees when procedures change or if deficiencies are observed.
Use of incorrect lockout/tagout devices	Failure of the device, allowing the machine to be energized.	Use only approved and standardized lockout/tagout devices. Ensure devices are durable, substantial, and identifiable.
Long-term shutdowns	Equipment malfunctions or unexpected startup after prolonged inactivity.	Develop a specific energy control procedure for restarting equipment after long-term shutdowns, including inspection and verification steps.

5. Personal Protective Equipment (PPE)

All PPE must be inspected before each use to ensure that it is in good condition and provides adequate protection.

Safety Glasses: ANSI Z87.1-approved safety glasses with side shields to protect against flying debris and hydraulic fluid splashes.
Gloves: Appropriate work gloves (e.g., leather or nitrile) to protect against cuts, abrasions, and contact with hydraulic fluids.
Steel-Toed Boots: Steel-toed boots meeting ASTM F2413 standards to protect against foot injuries from falling objects.
Hearing Protection: Earplugs or earmuffs with a suitable noise reduction rating (NRR) if noise levels exceed 85 dBA.

1. Inspect safety glasses for cracks or scratches before each use. 2. Inspect gloves for tears or punctures before each use. 3. Ensure that steel-toed boots are in good condition with no damage to the steel toe. 4. Clean and maintain hearing protection regularly.

6. Equipment and Tools

All equipment and tools used for lockout/tagout must be in good working condition and inspected before each use.

Lockout/Tagout Kit: A comprehensive kit containing locks, tags, hasps, and other necessary devices for effective lockout/tagout.
Voltage Tester: A calibrated voltage tester to verify the absence of voltage in electrical circuits.
Hydraulic Pressure Gauge: A gauge to verify that hydraulic pressure has been relieved.
Hand Tools: A variety of hand tools, such as wrenches, screwdrivers, and pliers, for performing maintenance and servicing tasks.

1. Inspect all lockout/tagout devices for damage or wear before each use. 2. Replace any damaged or worn devices immediately. 3. Ensure that voltage testers are calibrated regularly. 4. Maintain hand tools in good working condition.

7. Pre-Job Requirements

7.1 Training and Competency

Training and Competency: All authorized employees must receive comprehensive training on lockout/tagout procedures. Training must include the recognition of hazardous energy sources, the methods for energy isolation, and the requirements of this SWP. Affected employees must be instructed on the purpose and use of the energy control procedure. [6]

7.2 Pre-Job Briefing

Pre-Job Briefing: Conduct a pre-job briefing with all involved employees to discuss the scope of the work, the hazards involved, and the control measures to be implemented. Review the lockout/tagout procedure and ensure that all employees understand their roles and responsibilities.

7.3 Work Area Preparation

Work Area Preparation: Ensure that the work area is clean, dry, and free of obstructions. Provide adequate lighting. Identify all potential hazards in the work area.

8. Safe Work Procedure Steps

1. Notify Affected Employees: Inform all affected employees that the Shear Machine will be shut down for maintenance or servicing.
2. Shut Down the Shear Machine: Turn off the Shear Machine using the normal shutdown procedure. Ensure an orderly shutdown to avoid additional hazards. [7]
3. Isolate Energy Sources: Identify and isolate all energy sources to the Shear Machine, including electrical, mechanical, and hydraulic. This may involve disconnecting electrical power, closing valves, and blocking moving parts. [7]
4. Apply Lockout/Tagout Devices: Affix lockout devices to all energy-isolating devices in a manner that prevents them from being re-energized. If lockout is not possible, use tagout devices along with additional safety measures. [7]
5. Relieve Stored Energy: Relieve or restrain any stored energy, such as spring tension or hydraulic pressure. Ensure that all moving parts have come to a complete stop. [2]
6. Verify Isolation: Verify that the Shear Machine is completely de-energized and isolated by attempting to restart it. Use a voltage tester to confirm the absence of voltage in electrical circuits. This is the "Lock, Tag, Try" method. [2]
7. Perform Maintenance or Servicing: Perform the necessary maintenance or servicing tasks on the Shear Machine.
8. Remove Lockout/Tagout Devices: Once the maintenance or servicing is complete, inspect the work area to ensure that all tools and materials have been removed and that all components are operationally intact. Inform co-workers that the lockout/tagout devices will be removed. [4]
- Ensure all workers are clear of the area.
- Verify that the equipment power controls are in a neutral or "off" position.
9. Re-energize the Equipment: Remove the lockout/tagout devices and re-energize the Shear Machine. Verify that the controls are in neutral or off position. [4]
10. Notify Affected Employees: Notify all affected employees that the Shear Machine has been re-energized and is ready for operation.

9. Precautions and Safety Measures

Never remove a lock or tag without authorization. [3]
Never attempt to operate a machine that is locked out or tagged out. [3]
Always verify isolation before starting work.
Use only approved and standardized lockout/tagout devices.
Ensure that all employees are properly trained in lockout/tagout procedures.

10. Emergency Procedures

10.1 General Emergency Response

1. Immediately stop work and assess the situation. 2. If someone is injured, provide first aid and call for medical assistance. 3. Evacuate the area if necessary. 4. Report the incident to the supervisor.

10.2 Specific Emergency Scenarios

Accidental Startup: 1. Immediately press the emergency stop button. 2. Evacuate the area. 3. Investigate the cause of the startup before attempting to re-energize the machine.
Electrical Shock: 1. Do not touch the person if they are still in contact with the electrical source. 2. Use a non-conductive object to separate the person from the electrical source. 3. Call for medical assistance immediately. 4. Administer first aid, if trained.
Hydraulic Fluid Injection: 1. Seek immediate medical attention. 2. Inform the medical personnel that the injury was caused by hydraulic fluid injection.

10.3 Emergency Contact Information

In case of emergency, contact the following:

11. Incident Reporting and Investigation

All incidents, including near misses, must be reported to the supervisor immediately. A written report must be submitted within 24 hours.

A thorough investigation will be conducted to determine the root cause of the incident and to implement corrective actions to prevent recurrence.

Approved by: [NAME AND POSITION]

Date: [APPROVAL DATE]