Lockout / Tagout - Carboard Baler
Many companies throughout the country use cardboard compacting machines to reduce the volume of cardboard stored on site (companies typically store the bundled cardboard until picked up for recycling). The unintended activation of a baling machine can have catastrophic results. Proper training and precautions are necessary to protect workers from potential injuries and fatalities.
This baler is intended for use in an indoor-protected environment and not designed for outdoor-unprotected use. Drastic temperature changes and high moisture levels can affect the performance of this machine.
Hazards and Precautions
Collection
Forklifts
Crushing Hazards
Machinery - Moving Parts
Unexpected Machine Startup
Operating Hazards of Baler Discharge-Door Locks
Operator Safety
It is the employer’s responsibility to take appropriate action to insure all employees and operating personnel understand and adhere to all safe operating procedures. In the event that the operator of this baler is unable to read in English, it is the employer’s responsibility to translate these instructions either verbally or in writing so that the operator fully understands the operation of this baler.
All employees and qualified operating personnel must completely understand the following procedures for safe operation of the baler.
Never enter the chamber. Do not put hands or feet in or near the chamber when the machine is in operation. Always disconnect power before servicing machine and place a sign on baler stating “UNDER REPAIR DO NOT USE”.
No one under the age of 18 may operate this equipment. No one under 16 may load material into this unit. Failure to abide may violate federal law.
Install equipment to meet all OSHA and ANSI safety requirements. *Do not bale any volatile or combustible materials in your equipment.
Any attempts to process unauthorized materials such as glass, concrete, steel, wood, tanks, or containers could cause serious injury and damage to the baler or compactor.
Stand clear of the equipment while in operation and when ejecting bales from vertical balers. Keep working area clean and dry with no obstructions. Do not stack things on equipment.
Safety shields, access panels, and all safety switches and devices shall be maintained to function at all times to protect personnel and meet safety standards.
Avoid all contact with hydraulic fluid. If injury results from contact with fluid consult a doctor immediately. Do not operate baler if hydraulic fluid is leaking in any area.
Inspect hydraulic hoses, fittings and electrical connections before cycling equipment. Do not use if repairs are needed.
Repair work should be done by trained service personnel. Contact distributor or manufacturer for instructions on how to proceed when repairs are needed.
Maintenance Safety
Whenever service or work is preformed on your equipment please follow the Lock-Out/Tag-Out procedure. Make sure that each of the following steps are taken.
Disconnect all electrical power to the baler or compactor.
Place a lock on the power source and place a warning tag that reads, “UNDER REPAIR DO NOT USE” on the power source and on the baler or compactor.
Always double check to confirm that the unit has no power by testing for voltage on the control panel with a voltmeter.
Remove all hydraulic stored energy in the hydraulic circuit by manually shifting the solenoid valve. Press in on the center ends of valve.
When the job is complete, be sure everyone is out of danger before removing the lock and tags.
Reconnect all electrical power to the baler or compactor.
The actions listed below must be performed in the following sequence before servicing and maintenance work may be performed on equipment:
Step 1
Prepare for shutdown – authorized employees must know the type and magnitude of the energy, the hazards involved, and the means to control the energy.
Step 2
Shut down the equipment in an orderly and safe manner.
Step 3
Operate all isolating devices (valves or switches) to deenergize the equipment.
Step 4
Attach all LOTO devices to the energy isolating devices (and, if appropriate, personal LOTO devices to group LOTO mechanisms).
Step 5
Release all stored energy (electric charge, pressure, charged springs, etc.).
Step 6
Verify that equipment energy isolation has been accomplished.
Notify affected employees of the application of LOTO devices before applying controls. (Notification of workers as the second step, before shutdown of equipment, is a best practice.)
Release from Lockout/Tagout When the work is completed, each worker must take another personal action to indicate that he or she is no longer working under the clearance conditions. This action, along with checking the workplace area and making sure that workers are clear of the potential danger areas, includes removing the personal lockout or tag device and notifying affected employees that the LOTO devices have been removed. All individuals must complete these actions before a lead person can authorize re-energizing the equipment. The following are additional highlights of the 1910.269(d) standard. Lockout versus Tagout Lockout (LO) is a surer method of assuring deenergization and control of hazardous energy sources than tagout (TO) because a LO device physically restrains energy isolating devices, whereas a TO device is merely a prominent warning device. Employers may choose to use TO devices instead of LO devices when isolating devices cannot accept a LO device. Additionally, LO is preferred, but an employer may use TO on a lockable energy isolating device if the facility's comprehensive TO program provides employee protection equivalent to a LO program. [See 1910.269(d)(2)(ii)]. Lockable Energy Isolating Devices Any energy isolating device (valve, switch, etc.) installed after November 1, 1994, must be designed to accept a lockout device that holds it in the off or safe position and prevents operation. Any energy isolating device that has been replaced, renovated, overhauled, or modified since November 1, 1994, must also be able to accept a lockout device. An energy isolating device is considered capable of being locked out if it: 1) is designed with a part to which a lock can be attached; 2) has a locking mechanism built-in; or 3) can be externally locked, such as using a chain/lock assembly, a lockable valve cover, a circuit breaker LO, or fuse block-out devices. Tags Plus – Full Employee Protection If an employer chooses to design and implement a TO program, all of the TO-related provisions of 1910.269(d) must be addressed together with the Full employee protection measures, also known as Tags plus. For example, a TO device may be applied to a lockable disconnect switch if another independent control measure, such as opening a second disconnect switch or removing a valve handle, is implemented. This redundant control measure is designed to protect a worker from injury or death through the inadvertent activation of the primary control switch due to human error, inadvertent contact, or the loss or detachment of a tag. These additional control measures must be an integral part of the energy control program. Group LOTO Methods Group LOTO is required when more than one worker is engaged in the performance of servicing and/or maintenance activities. The hazardous energy control procedures used in group LOTO situations must provide each authorized employee with the same level of control that he or she would be afforded in an individual LOTO scenario. Each worker in a group needs to affix his or her personal LOTO device as part of the group LOTO process because the core concept of LOTO is personal control of the equipment energy sources through the application and removal of LOTO devices. Verbal accountability methods are not acceptable because they do not afford protection equivalent to that provided by the implementation of a personal LOTO device. (See 1910.269(d)(8)(ii).)
The employer may designate a primary authorized employee with the primary responsibility for a set number of workers working under the group LOTO device(s). The primary authorized employee must implement and coordinate activities related to the control of hazardous energy sources and verify that the steps taken, in accordance with the specific energy control procedure, have in fact isolated the machine or equipment effectively from the hazardous energy sources.
This must be accomplished before authorized employees participating in the group LOTO affix their personal lockout or tagout device to the group LOTO box and before they perform servicing/maintenance activities. As in all situations, all authorized employees must be given an opportunity to verify energy isolation.
Lockout-tagout annual auditing is required by OSHA. At a minimum, OSHA requires that each procedure in the facility be reviewed annually to confirm it accurately reflects the equipment’s energy sources, as well as a sampling audit of authorized employees to confirm they fully understand their responsibilities and proper usage of the lockout-tagout procedures. Annual program auditing confirms program deficiencies are identified and corrected.
