THE CONTROL OF HAZARDOUS

ENERGY (LOCKOUT/TAGOUT)
Lockout/Tagout Overview

 Covers the servicing and maintenance of equipment

where the unexpected energization or start up of
equipment, or release of stored energy could cause
injury
 Establishes minimum performance requirements for
controlling hazardous energy
 All new equipment installed after January 2, 1990, must
be designed to accept lockout of its energy-isolating
device
Lockout/Tagout Overview (continued)

 Promulgated January 2, 1990

 Covers 39 million workers
 Standard intended to
 Save 122 lives
 Reduce 28,400 lost-workday injuries
 Reduce 31,900 non-lost workday injuries
History

 More citations
 More costly fines
 95% of all lockout/tagout citations involve the failure to
have a formal Energy Control Program in place
 Remains near the top of OSHA’s list of most frequently
violated standard
Related References

 29 CFR 1910.147, The Control of Hazardous Energy

(Lockout/Tagout)
 29 CFR 1910.146, Permit-Required Confined Spaces
 29 CFR 1910.331-335, Safety-Related Work Practices
 29 CFR 1910.269, Electric Power Generation, Transmission, and
Distribution
 29 CFR 1926.417, Lockout and Tagging of Circuits
Purpose

 Requires employers to train “authorized” employees

 When and how to shut down machinery
 Drain and isolate all energy sources
 Verify the absence of energy
 Safely restart equipment when maintenance or repair is
complete
 Mandated awareness training of “affected” workers
(equipment operators, etc.)
Exemptions

 Construction
 Agriculture
 Maritime
 Installation under the exclusive control of electric utilities
for the purpose of power generation, transmission and
distribution, including related equipment for
communication or metering
 Oil and gas well drilling services
Exemptions (continued)

 Servicing and/or maintenance during normal

production unless the employee:
 Is required to remove or bypass a guard or other safety device
 Is required to place any part of his/her body into an area on a
machine or piece of equipment where:
– Work is actually performed upon the material being processed (point of
operation)
– An associated danger zone exists during a machine operating cycle
Exemptions (continued)

 If work is routine, repetitive, and integral to the use of

the equipment for production
 Minor tool changes
 Adjustments
 Other minor servicing activities
 Work on cord and plug
 Must be able to disconnect cord
 Must be under the exclusive control of the employee
Additional Exceptions

 Machine has no potential for stored or residual energy, or

reaccumulation of stored after shutdown
 Has a single source that can be easily identified and
isolated
 Isolating and locking out the energy source will completely
de-energize and deactivate the equipment
 The equipment is isolated from an energy source and
locked out during maintenance
 Additional Exceptions (continued)

 A single lockout device will achieve a lock condition

 The lockout is under the exclusive control of and in the view of
the authorized employee performing the servicing and
maintenance
 The servicing or maintenance does not create hazards for other
employees
 There have been no accidents involving unexpected energization
of the equipment while taking advantage of this exception
Definitions

 Authorized Employee:
 A person who locks or tags out equipment in order to perform
servicing or maintenance
Definitions (continued)

 Affected employee:
 Job requires employee to operate or use equipment on which
servicing or maintenance is being performed under lockout and
tagout conditions
 Job requires the employee to work in an area in which such
servicing or maintenance is being performed

Note: Becomes an authorized employee when that employee's

duties include performing servicing or maintenance
Definitions (continued)

 Capable of Being Locked Out:

 An energy isolating device is capable of being locked out if it
has a hasp or other means of attachment to which, or through
which, a lock can be affixed, or it has a locking mechanism
built into it
 Energized:
 Connected to an energy source or containing residual or
stored energy
Definitions (continued)

 Energy isolating device:

 A mechanical device that physically prevents the transmission
or release of energy:
– Manually operated electrical circuit breaker
– A disconnect switch
– Line valve
– A block
– Any similar device used to block or isolate energy
Note: Push button, selector switches and other control
devices are not energy isolating devices
Definitions (continued)

 Energy Sources:
 Mechanical
 Hydraulic
 Electrical
 Gas
 Pneumatic
 Water
 Chemical
 Thermal
 Other stored energy (Springs, capacitors, etc)
Definitions (continued)

 Lockout/Tagout:
 The placement of a lock/tag on an energy isolating device, in
accordance with an established procedure, to ensure that the
energy isolating device and the equipment being controlled
cannot be operated until the lock and tag is removed
Definitions (continued)

 Lockout device:
 A device that utilizes a positive means such as a lock either
key or combination type, to hold an energy isolating device in
the safe position and prevents the energizing of a equipment
 Included are blank flanges and bolted slip blinds
Definitions (continued)

 Servicing/maintenance activities
 Constructing
 Installing
 Setting up
 Adjusting
 Inspecting
 Modifying
 Lubricating
 Cleaning or unjamming equipment
 Making adjustments or tool changes
Definitions (continued)

 Tagout device:
 A warning device, such as a tag and a means of attachment
 Can be securely fastened to an energy isolating device in
accordance with an established procedure to indicate that the
energy isolating device and the equipment being controlled
can not be operated until the tag is removed
Energy Control Program

 Must clearly and specifically outline the:

 Scope
 Purpose
 Authorization
 Rules
 Techniques to be utilized for lockout/tagout, and means to
enforce compliance
Energy Control Program (continued)

 Must include:
 A statement of the intended used of the procedure
 Specific steps for shutting down, isolating, blocking, and
securing equipment to control hazardous energy
 Specific steps for the placement, removal and transfer of
lockout devices or tagout devices and the responsibility for
them
 Requirements for testing equipment to determine and verify
the effectiveness of lockout devices, tagout devices, and
other energy control measures
Where to Begin

 Conduct a hazard assessment by identifying each

piece of equipment that is used, serviced, or
maintained
 Include broken or stored equipment
 Determine the requirements for lockout
 If there is more than one primary energy source to the
equipment, document each source
Where to Begin (continued)

 Document all energy sources

 Hidden
 Direct
 The hazard posed
 The magnitude or measurable degree of danger
 Special or unusual conditions
 Proper isolations and devices
Hardware and Limitations
Lockout/Tagout Devices

 Durable
 All devices must be capable of withstanding the workplace
environment.
 All tags and their means of attachment must be sturdy enough
to prevent inadvertent removal
Lockout/Tagout Devices (continued)

 Standardized
 Lockout/tagout devices must be
– Singularly identified
– The only device(s) used for controlling energy
– Not be used for other purposes
 Devices must have the same color, shape, or size.
 The format and print of tags should be standardized
Lockout/Tagout Devices (continued)

 Substantial
 Removal of lockout devices should be extremely difficult to
remove, requiring the use of excessive force and the help of
tools such as bolt cutters
 Tagout devices and their attachments must be tough enough
so that they can’t be accidentally removed
Lockout

 Lockout is a more appropriate means of ensuring

deenergization of equipment than tagout
 If an energy-isolating device can’t be locked out,
tagout may be used
 Tagout may be used in place of lockout if it can be
demonstrated that it will offer equivalent protection to that
offered by lockout
Tagout

 When only a tag is used because equipment cannot be

locked out, the following steps must be taken:
 Removing an isolating circuit element (fuses)
 Block machine (control switch, die)
 Opening an extra disconnecting device
 Other means of isolation
Tagout (continued)

 Tags must be placed where the lockout device would

have been placed
 A legend must be used such as:
 Do not start
 Do not open
 Do not close
 Do not energize
 Do not operate
Tagout Limitations

 Tags are attached to energy isolation devices, but they

are only warning.
 They do not provide the protection offered by a
lockout procedure
 A tag is never to be bypassed or ignored, and it may
not be removed without the specific authorization of
person responsible for it
Tagout Limitations (continued)

 Tags must be clearly visible and easily understandable

by any employee who may be in the area
 Tags and their attaching materials must be able to
withstand any adverse environmental conditions in the
workplace
Tagout Limitations (continued)

 Tags must be clearly understood and respected to be

effective
 Workers should guard against false sense of security
 Tags must be carefully secured to the energy-
controlling devices so that they can’t easily be
detached by accident
during use
Safety Audit
Annual Inspections

 Certain circumstances lend themselves to the

opportunity for an inspection
 Construction of new equipment
 Installation of new equipment
 Modification or adjustment of equipment
 Routinely scheduled cleaning and maintenance
 Major repairs
Designating an Inspector

 Periodic inspections must be performed by an

authorized employee other than the one(s) using the
energy control procedure
 Who can inspect
 Department manager
 Plant management
 Safety manager
 Others
Employee Reviews

 Lockout
 Must include a review between the inspector and each
authorized employee
 Tagout
 Must be a review between the inspector and each authorized
and affected employee
 Review should cover each employee's responsibility under the
procedure being inspected, as well as the limitations of tags
Certifying Inspections

 Must certify that the required periodic inspections

have been performed
 Certification must identify the following:
 The equipment on which the energy control procedure was
used
 The date of the inspection
 The employee included in the inspection
 The name of the person performing the inspection
Follow-up audit

 A follow-up audit must be conducted to ensure that all

deficiencies noted have been corrected
 Documentation must identify:
 The equipment on which the lockout procedure is being
utilized
 The date of the inspection
 Employees interviewed
 Employee(s) performing the inspection
Training
Specific Requirements

 A training program must consist of:

 Effective initial training
 Periodic retraining as necessary
 Certification that training has been given to all employees
covered by the standard
 Certification must become part of employee record
and contain
 Employee's name
 Date of training
Specific Requirements (continued)

 Training must be provided to ensure that the purpose

and function of the energy control program are
understood by employees
 That the knowledge and skills required for the safe
application, usage, and removal of the energy controls
are acquired by employees
Type of Training

 The amount and kind of training is based upon

 The relationship of each employee’s job to the equipment
being locked or tagged out
 The degree of knowledge relevant to hazardous energy that
he/she must possess
– Need to know
Authorized Employee

 Each authorized employee must receive the

following training:
 The purpose of the procedure
 Ability to recognize applicable hazardous energy sources in the
workplace
 The type and magnitude of the energy available in the workplace
 Understanding the means and methods of isolating and/or
controlling the various types of energy sources
 Ways to verify that energy isolation is effective
Affected Employees

 All affected employees must be instructed in the

purpose and use of the lockout/tagout system
 Create awareness
Other Employees

 All other employees (including new hires) whose work

operations are or may be in an area where
lockout/tagout may be utilized
 These employees must be instructed:
 About the procedure
 That they are prohibited from starting up or reenergizing any
locked-out or tagged-out equipment they encounter
Retraining

 Must be conducted for all authorized and affected

employees whenever:
 There is a change in job assignment
 Change in equipment, machinery, or processes that presents
a new hazard
 A change in the lockout/tagout procedure
Retraining (continued)

 Must be conducted whenever a periodic inspection

reveals or whenever the authorized employee has
reason to believe that there are deviations from or
inadequacies in the employee's knowledge or use of
the lockout/tagout procedures
Group Lockout/Tagout

 When servicing and/or maintenance is performed by a

crew, craft, department or other group, they must
utilize a procedure that affords the employees a level
of protection equivalent to that provided by the
implementation of a personal lockout/tagout device
Group Lockout/Tagout (continued)

 Primary responsibility is vested in an authorized

employee for a set number of employees working
under the protection of a group lockout or tagout
device
 Provision for the authorized employee to ascertain the
exposure status of individual group members with
regard to the lockout/tagout of the equipment
Group Lockout/Tagout (continued)

 Lockout/tagout control responsibility is designated to an

authorized employee to coordinate affected work forces and
ensure continuity of protection
 Each authorized employee must affix a personal
lockout/tagout device to the group lockout device, group lock
box, or comparable mechanism when he/she begins work, and
must remove those devices when he/she stops working on the
equipment being serviced or maintained
Shift or personnel changes occur

 Continuity of lockout/tagout protection must be ensured by

following specific procedures for shift and personnel changes,
including the orderly hand-off of lockout of lockout/tagout
devices
Unusual Conditions

 Machines need to be tested or repositioned during

servicing
 When necessary, under special condition, OSHA allows
the temporary removal of locks or tags and the
reenergization of the equipment
– Example, when power is needed for the testing or positioning of
equipment
Unusual Conditions (continued)

 Subject to the follow restrictions:

 Equipment must be cleared of tools and material
 Employees must vacate the equipment areas
 The lockout/tagout device must be removed only by the
authorized employee who applied it
Unusual Conditions (continued)

 Energization may then be allowed by testing or positioning

 All systems must be de-energized, the employee or equipment
must be isolated from energy source, and the lockout/tagout
devices reapplied
Contractors

 Must inform each other of all applicable lockout/tagout

procedures.
 Both employer and contractor must ensue that their
employees understand and will respect the others Energy
Control Program
 Typical Shutdown Procedure

 Notify affected employees

 Use the specific procedures as outlined for the
appropriate situation
 Shut off energy source(s) to affected equipment
 Use normal stopping or running procedures for the machine
 Isolate the equipment from the energy source
Shutdown Procedures (continued)

 Affix lock(s) and tag(s) to each energy source

controlling device
 Relieve all stored energy from capacitor banks,
springs, compressed air, hydraulics, steam, etc.
 Verify isolation of energy has occurred by trying
equipment
Removal of Lockout/Tagout and Start-Up
Procedures

 Ensure that nonessential items are removed from equipment

 Ensure that equipment components are intact
 Check area to ensure that all affected employees are safely
positioned or removed from the area
 Notify all affected employees and site supervisor before
reenergizing the equipment
 Remove lockout/tagout device
 Reenergize equipment to ensure safe operation
Summary

 Accidents will happen

 Equipment will occasionally malfunction
 People will still make mistakes

There is no excuse for serious injury that results from ignorance,

carelessness, complacency, or lack of an Energy Control Program