What is a Circuit Breaker Lockout?

A circuit breaker lockout is a device that is used to secure a circuit breaker in the OFF position, preventing it from being accidentally turned ON while maintenance or repair work is being performed on electrical equipment. Circuit breaker lockouts typically consist of a lockout device that is applied to the circuit breaker handle, along with a lock or tag that indicates the circuit breaker is locked out and should not be operated.

When to Use a Circuit Breaker Lockout?

1. During Maintenance or Repair Work: Circuit breaker lockouts should be used whenever maintenance or repair work is being performed on electrical equipment that requires de-energizing the circuit. This can include tasks such as replacing or repairing electrical components, conducting inspections or testing, or performing any work that requires accessing the inside of electrical panels or cabinets. Using circuit breaker lockouts during these tasks helps to prevent accidental energization of the circuit and protects workers from electrical hazards.
2. When Performing Electrical Installations or Modifications: Circuit breaker lockouts should also be used when performing electrical installations or modifications, such as adding or modifying electrical circuits, connecting or disconnecting electrical equipment, or making changes to electrical systems. Locking out the appropriate circuit breaker ensures that the circuit remains de-energized during these activities, preventing potential electrical accidents.
3. When Performing Troubleshooting or Diagnostics: Troubleshooting or diagnostics work on electrical equipment may involve working on live circuits, but circuit breaker lockouts should be used whenever possible to ensure safety. If it is not feasible to lock out a circuit breaker due to operational requirements, alternative safety measures such as personal protective equipment (PPE) and safe work practices should be implemented in addition to regular risk assessments.
4. When Working on Shared Electrical Systems: In workplaces where multiple workers or contractors may be working on shared electrical systems, circuit breaker lockouts should be used to prevent unauthorized or accidental operation of circuit breakers. Each worker or contractor should apply their own lockout device, and the keys or tags should be kept securely in the possession of the authorized personnel to ensure that only authorized personnel can remove the lockout devices.
5. When Following Lockout/Tagout Procedures: Circuit breaker lockouts are an essential component of lockout/tagout (LOTO) procedures, which are industry-standard practices for ensuring the safety of workers performing maintenance or repair work on electrical equipment. LOTO procedures involve de-energizing and locking out energy sources to prevent the accidental release of hazardous energy, and circuit breaker lockouts are commonly used as part of these procedures to secure electrical circuits.

In conclusion, circuit breaker lockouts are critical tools for ensuring electrical safety in the workplace. They should be used during maintenance or repair work, electrical installations or modifications, troubleshooting or diagnostics, when working on shared electrical systems, and when following lockout/tagout procedures. Proper training, implementation of lockout/tagout procedures, and regular risk assessments are crucial for ensuring the safe use of circuit breaker lockouts and protecting workers from electrical hazards. Remember, electrical safety is paramount, and using circuit breaker lockouts is a key practice in preventing electrical accidents in the workplace.

According the National Safety Council, forklifts cause nearly 40,000 injuries per year and 100 fatalities. In addition, millions of dollars are spent on property damage resulting from improper use of lift trucks. Potential hazards include tipping, falling, crushing or striking, falling loads, and driving off loading docks. Most fatalities occur when forklifts tip.

TYPES OF LIFT TRUCKS

Lift trucks are categorized by their power source: gasoline (G), diesel (D), propane (LP) or electric (E). Some lift trucks may have more than one power source. Not all power sources are appropriate for every work environment, so it is important consider your workplace. For instance, a gasoline-powered lift truck is a hazard in an environment with a potentially flammable atmosphere.

COMPONENTS OF A LIFT TRUCK

A lift truck is comprised of two main parts: the body and the hydraulic lift. 

The Body

• Wheels

• Counterweight

The counterweight is metal casing on the back of the body that provides stability and a more even distribution of weight.

• Seating area

• Control panel

The control panel is located in the front of the lift truck, much like a typical car or truck. The control panel displays information related to the lift truck’s fuel and performance. Typical indicators on the control panel include the charge or fuel amounts, engine hour meter, oil pressure, and the engine temperature.

• Controls

The steering wheel, brakes, and accelerator work much like a car or truck. Lift trucks however, have unique features. Lift trucks have a directional control which allows the vehicle to be driven forward or backward. Controls for operating the hydraulic lift are also present. In most lift trucks the hydraulic lift can be moved up and down and tilted backward. Also present are controls that move forks in or out. Lift trucks also have horns and lights, important safety features which increase awareness and visibility.

• Overhead guard

The overhead guard encloses the seating area and prevents falling objects from striking the driver. If there are openings in the overhead guard, you may be required to wear a hard hat.

• Data plate

The data plate contains information about the truck’s fuel category and weight limit. The data plate is permanently attached to the body of the truck and must be completely legible.

The Hydraulic Lift

• Lift and chains

Forklift chains are attached to the mast and routed up and over a chain wheel. This allows the mast carriage to be moved.

• Mast

The mast is the vertical assembly that lifts, tilts, and lowers loads.

• Forks

The forks are prongs used for lifting pallets and other objects. Forks can generally be moved inwards or outwards by the controls.

OPERATING A LIFT TRUCK

The most common danger associated with driving lift trucks is instability. To avoid instability, workers must be familiar with the points of a suspension and proper load placement.

The Stability Triangle

A lift truck has three points of suspension: the two front wheels and the center of the rear axle. Understanding the three points of suspension is essential to operating the lift truck safely. If theoretical lines were drawn between the three points of suspension, it would form a triangle. This is known as the stability triangle; to keep the lift truck stable, the center of gravity must remain inside this triangle.

Weight added to the forks will cause the center of gravity to move forward. Tilting the load backwards moves the center of gravity backwards. Improperly placed loads and fast turns can cause the center of gravity to move outside of the stability triangle, which will cause the lift truck to tip. This graphic from OSHA shows how the stability triangle works:

Load Capacity and Placement

The load capacity is indicated on the lift truck’s data plate. You must make sure the load does not exceed the load capacity. If the data plate is damaged, illegible, or in any way unclear, do not use the lift truck. Instead, notify your supervisor that the data plate needs to be replaced. The placement of the load can also affect the overall weight. The further away the load is from the fulcrum point (the front wheels act as a fulcrum between the body of the lift truck and the hydraulic lift), the less stability the load has.

The load should be placed as close to the front of the lift truck as possible. The forks should be tilted slightly backwards and the load should always be lowered before driving. This keeps the load close to the fulcrum point and prevents the truck from tipping. If you must move an unbalanced load, make sure that the heaviest part of the load is closest to the fulcrum point.

Taking care while driving any motor vehicle is common sense, but lift trucks pose unique hazards. Fork trucks have a much higher center of gravity than cars. For this reason, it is important to drive at reasonable speeds and to take turns slowly. Driving too fast can cause loads to spill or the lift truck to tip. In either of these situations, drivers and nearby employees face serious injuries. Costly damage to equipment and goods is also likely to occur in the event of a spill or tip.

MAINTENANCE AND INSPECTION

It is important to keep your lift truck clean of oil, dirt, or grease, which can prevent moving parts from working correctly. It is recommended to wipe down your lift truck daily to prevent buildup of dirt or grease.

Before each use, an inspection must be conducted to ensure that the lift truck is in good working order. An inspection tag that verifies that the inspection has taken place must be signed, dated, and filed. Inspection tags generally have checklists to help guide the inspection. The inspection should cover the following aspects of the lift truck:

• Tires

Because one of the dangers of lift trucks is tipping, it is important to make sure all tires have good tire pressure and are free from any punctures and splits, which may cause the truck to operate unevenly or poorly.

• Overhead Guard

The overhead guard will protect you from falling materials and even protect your head from impact with the ground if the truck tips.

• Hydraulic Lift and Forks

Check to see that the lift is in good working condition and is not leaking any fluids. Make sure that the forks are not bent or deteriorating. If there are problems with the hydraulic lift, loads can quickly become fall hazards.

• Power Source

If your lift truck is powered by a propane tank, check to make sure the tank is safely secured and that there are no leaks in the connections. If you smell propane, report the problem immediately to your supervisor; do not start the truck and make sure all valves are turned off. If your truck is battery-powered, make sure that the battery is not showing any signs of corrosion, leaks, or damaged connections in the wires.

• Operating Controls

You must make sure that your brakes, steering, horn, lights, seatbelts are in good working order.

DRIVING HAZARDS

Warehouses and industrial environments pose many potential hazards to the lift truck driver. These include pedestrians, low ceilings, sharp corners, slippery surfaces, loading docks, and electrical lines. Many of these hazards can be minimized by awareness of your environment and slow, careful driving. Pedestrians should always be given the right of way. The forklift driver must always be ready to stop. It is helpful to be familiar with the route you are planning to take, but unforeseen hazards, such as pedestrians or spills, can occur on any route.

Inclines, declines and ramps pose special hazards. In these situations, the load should always be pointed uphill. Never try to turn a lift truck on an incline or decline.

REFUELING

Designated refueling areas are a best safety practice. These areas should have whatever emergency equipment is necessary, generally including fire extinguishers and eye-wash stations. Sparks, open flames, and smoking are prohibited in refueling areas. Refueling areas must also be well-ventilated to prevent flammable or otherwise dangerous gas buildup.

Changing Batteries:

You must be authorized to change or recharge batteries. Being qualified to drive a lift truck does not mean you are qualified to change or recharge batteries. To change a battery:

• Position the truck in the designated area
• Shut off the power
• Wear the proper personal protective equipment (PPE)
• Because batteries contain potentially harmful acids, it is necessary to protect yourself with PPE. When changing batteries, you must wear chemical-resistant gloves, safety glasses, footwear, and an apron.
• Disconnect the battery.
• Check condition. Make sure to look for missing caps or terminal covers, or damaged insulation. Make any necessary repairs before proceeding.
• Carefully remove the battery and place it in the charging station.
• Install the new battery.

Changing Propane Tanks:

As with changing batteries, you must be authorized to refuel a propane tank. Authorization requires unique training. To refuel:

• Position the truck in the designated propane refueling area
• Place the controls in neutral
• Wear the proper PPE. Safety glasses and temperature resistant gloves are required.
• Close the service valve and bleed the hose. The truck will stop when the hose is fully bled.
• Shut off power.
• Disconnect the tank from the hose and place the empty tank in a designated storage area.
• Place the new tank in the bracket.
• Inspect the hose. The hose must not be damaged, frayed, or misshapen.
• Tightly connect the hose to the service valve by hand.
• Lock the bracket down.
• Open the valve slowly to test the seal. If you smell propane, a proper seal has not been formed.

Gasoline/Diesel Trucks

Refueling a gasoline or diesel-powered lift truck is similar to fueling a car or truck. To refuel:

• Position the truck in the designated area. The area must be well-ventilated and have emergency fire-protection equipment nearby.
• Wear the proper PPE. Safety glasses are required, and gloves are recommended, especially with diesel fuel.
• Turn off the engine.
• Place the fueling spout into the truck’s fill pipe.
• Refill the gas tank.
• Remove the fueling spout and return it to the holder.
• Firmly tighten the gas tank cap.

LOCKOUT/TAGOUT

If your lift truck needs maintenance or repairs, it is imperative to follow lockout/tagout procedures before beginning performing any maintenance. Written procedures for the trucks are required by OSHA and must follow OSHA’s 6-step procedure for the isolation of hazardous energy. However, because forklifts have different power sources, lockout procedures will not be the same for every machine.

A forklift may have several energy sources that need to be identified and locked out before work can safely begin. This includes electric, hydraulic, kinetic, and gravitational energy. If your lift truck is battery-powered, electrical lockout must be performed. The negative battery terminal connection should be removed and a plug lockout device should be applied to the energy source. If your lift truck is powered by propane tanks, all energy must be dissipated and the tank set of the “OFF” position and locked out. The hydraulic lift must always be lowered and all latent hydraulic energy must be dissipated.

CONCLUSION

Lift trucks are a common feature in many warehouses and workplaces. The presence and operation of lift trucks can pose many hazards to operators and bystanders alike; as such, it is necessary to have a detailed safety program in place. Procedures must be compliant with OSHA standard 1910.178. For more information, visit: https://www.osha.gov/SLTC/poweredindustrialtrucks...

Buying lockout devices can be a stressful process. You want to be sure that:

• all potential energy hazards in your workplace are accounted for.
• workers are protected with high-quality, reliable devices.
• workers are comfortable using the devices supplied to them.

This guide will help make your decision easier. We will cover:

• Identifying energy sources
• Types of devices
• General lockout requirements

Types of Energy

The first step is to make a list of all potentially dangerous energy sources in your workplace. There are many types hazardous energy. Some of the most common energy types are listed below.

Electrical energy is the most common energy source. Many machines and workplace vehicles require electricity to run. Unwanted energization of equipment and electrical shock may occur if electrical sources are not properly locked out.

Chemical energy is result of a chemical reaction. Chemical energy may generate extreme heat or explosive reactions.

Hydraulic and Pneumatic energy is stored in pressurized liquid and air, respectively. Residual energy may still be present in a machine even after the relevant valves have been locked out, so it is important to make sure all energy has been carefully drained during the lockout process.

Mechanical energy refers to objects under tension, such as a springs or coils.

Once all energy sources are located, it is important to form a list of how the energy is initiated, whether through valve handles, switches, buttons, or plugs. This information will help you choose the most appropriate lockout devices.

OSHA’s Device Requirements

OSHA standard 1910.147 sets forth the following requirements:

• Lockout devices must be able to withstand workplace conditions.
• Devices must be standardized according to color, shape or size.
• Devices must indicate the identity of the employee who placed it.

In other words, lockout devices have to be dependable and easily identifiable. Devices should be tested before use in a real lockout situation, to ensure they work as they are designed to. Standardization and personalization help identify the purpose of the device, and firmly establish the identity of the person who can place or remove a given device.

Types of Lockout Devices

Lockout devices work by immobilizing energy sources, so that they cannot be turned on. Devices are usually locked into place with a safety padlock, so that only the worker who placed the lockout can remove it.

Hasp

Hasps isolate energy sources and hold multiple padlocks, which ensures the device cannot be energized until all workers have removed their padlocks. This is especially important in group lockout situations.

Plug Lockout

A plug lockout encloses the prong-end of a plug, making it impossible to insert into a power source. The device must be large enough to completely enclose the plug.

Circuit Breaker Lockout

Circuit breaker lockouts lock circuit breakers in the OFF position. Many devices snap or clamp into place. It is important to select the correct size; the switch should be completely secure while the lockout is applied.

Valve Lockouts

Valve lockouts are used to prevent valve-operated machinery from being energized. There are 3 common types of valve lockouts:

A Gate-Valve Lockout encloses a gate valve handle, so that it is impossible to turn. The lockout must be able to rotate freely around the handle.

A Ball Valve lockout locks out energy-carrying pipes by immobilizing the valve handles.

A Butterfly Valve lockout slides onto a butterfly valve, clamps into place, and locks the valve in the OFF position.

Push Button Lockout

Push button lockouts cover buttons commonly found on electrical panels and some machines, so that the buttons cannot be pressed.

Cable Lockout

Cable lockouts work in several lockout applications, and are usually used when handles, levers, or switches are difficult to reach, or when other devices are not applicable. The cable around the relevant valve handle or switch, which is then locked into place with a lockout padlock. Some devices include a cinching or squeezing component which allows the cable to be easily locked as tightly as possible.

Organizational Tools

Lockout Stations:

Stations provide a centralized, organizational tool for storing lockout devices, which makes it easier for workers to find the right device for a given job. The convenience and visibility of stations also encourages use. If a workplace is large, several stations may be necessary.

Lockout Kits:

Lockout kits emphasize portability. Usually in pouch or toolbox formats, lockout kits store a variety of devices, locks, and tags. Kits are an excellent choice if workers have to work on multiple job sites, or lock out several machines. Kits also help workers have the proper lockout devices at their disposal, whenever they need them.

Group Lockout Boxes:

Group Lockout Boxes are an important group lockout tool. Keys to lockout devices or disconnect master keys are placed inside of the group lockout box. Then each worker involved in the group lockout attaches his or her personal lock to the lockout box. This ensures the lockouts can only be removed after each employee has removed their lock from the box.

Training

Workers must understand how each device they use works. If introducing new devices, workers must be trained to use the new devices properly.