LOCKOUT/TAGOUT

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Welcome!
LOCKOUT/TAGOUT Hazardous Energy Control
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Objectives

• Gain a greater awareness of the requirements
  detailed in Oregon Administrative Rules.
• Understand the importance of a hazardous control
  plan.
• Discuss energy control procedures, training, and
  periodic inspection criteria.

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Part I Scope and Application
29 CFR 1910.147 The Control of Hazardous Energy
(Lockout/Tagout)
(c)(1) Energy Control Program. The employer
shall establish a program consisting of energy
control procedures, employee training and
periodic inspections to ensure that before any
employee performs any servicing or maintenance on
a machine or equipment where the unexpected
energizing, start up or release of stored energy
could occur and cause injury, the machine or
equipment shall be isolated from the energy
source, and rendered inoperative.
What are the three key elements of an energy
control program? Procedures
Training Inspections
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Scope The lockout/tagout rule covers the
following employees
Authorized Affected Other
Person who services or performs maintenance on
machines or equipment.
__Affected Employee __Authorized
Employee __Other Employee
Person who operates or uses a machine or
equipment which is being serviced or has
maintenance being performed.
Person who works in an area where lockout/tagout
procedures are being used.
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Procedures must be followed when...
...servicing and/or maintenance when unexpected
energization, start-up or release of stored
energy could cause injury.
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What is servicing or maintenance? Some
workplace activities considered to be Servicing
and/or maintenance of machinery and equipment
include Adjusting... inspecting...
modifying... constructing... re-tooling... lubric
ating... removing jams... cleaning...
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Sources of Energy
List as many sources of energy as possible that
could cause injury
Pneumatic Hydraulic Mechanical
Kinetic Thermal Radiation Nuclear Electrical
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• This standard does not apply to
• Installations under the control of electric
  utilities.
• Exposure to electrical hazards from work on,
  near, or with conductors or equipment in electric
  utilization installations.
• Oil and gas well drilling and servicing.

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• Normal production operationsunless
• Guards, or other devices are removed/bypassed or
• Employees place themselves in an area where work
  on materials, etc., is actually being performed
  or
• Employees place themselves in any area considered
  dangerous during the normal operating cycle.
• Work on cord and plug connected equipment.
• Hot tap operations, under special conditions.

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Part 2 The Written Energy Control Plan
A written Energy Control Plan must include the
scope, purpose, authorization, rules, and
techniques used to control hazardous energy, and
the means to enforce compliance, including 1.
A specific statement of intent to use the
procedures 2. Specific procedures to shut
down, isolate, block and secure machines or
equipment 3. Specific procedures to place,
remove and transfer lockout/tagout devices 4.
Assigning responsibility for lockout/tagout
devices 5. Requirements and procedures to
test machines and machinery to determine and
verify effective lockout/tagout devices, and
other energy control measures.
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Why is a comprehensive written plan critical to a
successful lockout/tagout program?
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Why is a comprehensive written plan critical to a
successful lockout/tagout program?
It holds people accountable! It establishes a
boiler plate. It allows for effective
procedures. It ensures training will be
conducted. It ensures the periodic inspections
will be conducted.
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What are some reasons a lockout/tagout program
may not work effectively?
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What are some reasons a lockout/tagout program
may not work effectively?
People may not respect it. Leadership may be
lacking. Accountability may not be clearly
established. Training may not be effective
and/or monitored. Supervisors may be leading by
wrong example.
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Whos responsible.whos accountable.and for
what?
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Steps to developing a successful program
1. List all equipment or machines that need
servicing or maintenance. 2. Identify those
machines which could unexpectedly start up or
release stored energy while being serviced or
maintained. 3. Determine the steps in the
maintenance or servicing task and 4. Review
each step for the potential of a hazard from all
energy sources.
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Part III Lockout/Tagout Procedures

• Step 1 - Prepare for Lockout
• As a minimum the following information should be
  reviewed
• Types and magnitudes of energy
• Hazards posed by that energy and
• Methods to effectively control the energy.

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Particularly close attention must be given to
energies (such as gravity, electrical, high
pressure) that can be stored or re-accumulated
after shut-down. Prior to shutdown all affected
employees will be notified to clear their work
area and/or any other area that might be
hazardous. What means or methods can be used
to ensure the above review and notification is
conducted prior to lockout/tagout?
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• Step 2 - Shutdown
• Machinery and equipment that is capable of being
  locked out should be shut down in an orderly
  manner using shutdown checklist procedures.
• If more than one authorized employee is involved
  in shutdown, the maintenance team leader should
  make sure all assistants have accomplished their
  tasks and are aware that shutdown will occur.

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Step 3 - Isolation
All energy isolation devices should be located
and operated to completely de-energize and
isolate the equipment. The authorized
employee will verify operation of each energy
isolation device.
An energy isolating device physically
prevents ...the transmission or release of
energy. What are some examples of energy
isolation devices?
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T/F Pushbuttons, selector switches and other
control circuit type devices are energy
isolating devices.
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Step 4 - Lockout/Tagout Application

• Lockout Devices
• Lockout devices must be used to secure energy
  isolating devices unless the machinery or
  equipment is not capable of being locked out.
• Only authorized employees will affix
  lockout/tagout devices.
• Lockout devices must be able to hold energy
  isolation devices in a safe or off position.
  

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• Tagout Devices
• Tagout devices will be used only if machinery or
  equipment is not capable of being locked out.
• Only authorized employees can affex tagout
  devices.

• Tags will clearly state that moving energy
  isolating devices from the safe or off
  position is strictly prohibited.
• If a tag cannot be affixed to the energy
  isolating device, it will be located as close as
  safely possible to the device so that the tag is
  obvious to anyone attempting to operate the
  device.

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Which is the pereferred method Lockout or
Tagout?
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• Machinery or equipment is capable of being
  locked out if
• It has a hasp or other means to attach a lock or
• It has a built in locking mechanism
• Does not have to be dismantled or altered to
  achieve lockout.

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When can an employer use a tagout system? 1.
When an energy isolating device is not capable
of being locked out. 2. If employer can
demonstrate (prove) that using a tagout system
will provide full employee protection.
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What two tests must be met to demonstrate full
employee protection?
1. Tags can be placed where lockout devices
would have been placed. 2. The employer
demonstrates equivalent protection can be
obtained with tags.
Opening an extra disconnect Removing a valve
handle Removing a circuit or fuse Blocking a
ram etc.
How?
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More on Protective Hardware..
Materials and hardware must be provided by the
employer. Each lockout/tagout device must be
singularly identified as being used only for
lockout/tagout. Lockout/tagout devices must be
standardized and substantial. They must
identify the user Lockout devices must be
substantial enough to prevent removal without
excessive force or unusual techniques.
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• Tagout devices must be substantial enough to
  prevent inadvertent or accidental removal. They
  must be
• Non-reusable
• Attachable by hand
• Self-locking
• Non-releasable with not less than 50 lb locking
  strength
• Design/characteristics at least equivalent to a
  one-piece, all environment-tolerant nylon cable
  tie.

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What are some examples of lockout devices?
Padlocks Lockout hasps C/B lockouts Wall
switch lockouts Gate valve lockouts Ball valve
lockouts Fuse lockouts Plug lockouts
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Step 4 - Lockout/Tagout Application
Before applying and after removing lockout/tagout
devices, the authorized employee ...must
notify all affected employees.
A tagout device is a prominent warning device,
such as a tag and a means of attachment, which
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... ...
may not be operated until the tagout device is
removed.
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Step 4 - Lockout/Tagout Application
T/F All newly installed machines or equipment
must have energy isolating devices capable of
accepting a lockout device.
T/F If you replace, major repair, renovate or
modify a machine or piece of equipment it must
have an energy isolating device capable of
accepting a lockout device.
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Step 5 - Stored Energy

• Stored Energy. Immediately after applying
  lockout or tagout devices, the authorized
  employee will ensure all potentially hazardous
  stored or residual energy is relieved,
  disconnected, restrained, and otherwise rendered
  safe.

• What are some examples of stored or residual
  energy?
• Remember! If stored energy can be re-accumulated
  to a hazardous level, authorized employees must
  continually verify that the machinery or
  equipment is safely isolated until the
  possibility of re-accumulated energy no longer
  exists.

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Step 6 - Verify!!!!!

• Verification of Isolation. Before starting work
  on a machine or equipment that is locked or
  tagged out, the authorized employee will verify
  that the machinery or equipment is actually
  isolated and de-energized.

How do you verify that a machine or equipment is
actually isolated or deenergized?
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• Release from Lockout/Tagout
• Equipment.
• Make sure machinery or equipment is properly
  reassembled.
• Inspect machinery or equipment to make sure
  nonessential items have been removed.
• Employees.
• Make sure all employees are safely positioned
  outside danger zones.
• Notify affected employees that lockout/tagout
  devices have been removed and that energy is
  going to be reapplied.

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Release from Lockout/Tagout

• Removing lockout/tagout devices.
• Only the authorized employee who applied the
  lockout/tagout device may remove that device.

Exception - The employer can remove the lockout
device provided that specific procedures and
training for such removal have been developed,
documented, and incorporated in the employers
energy control program. At a minimum, the
following procedures must be in
writing Verification by the employer that the
authorized employee who applied the device is
not at the facility All reasonable efforts to
contact the authorized employee to inform
him/her that his/her lockout device has been
removed Ensure that the authorized employee
has this knowledge before resuming work at the
facility.
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Quick Review
Who does the authorized employee notify prior to
removing any lockout/tagout devices? T/F
The authorized employee also notifies the
affected employee after lockout/Tagout devices
have been removed and before equipment has been
started. If the authorized employee is not
available, who is authorized to remove the
lockout or tagout device?
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• Additional Requirements
• Testing/Positioning Machines or Equipment.
• Whenever lockout/tagout devices are removed to
  test or position machines and equipment, or their
  components, the authorized employee must complete
  full shutdown, isolation, and release from
  shutdown procedures.

T/F Modified/shortened procedures may be used to
isolate and startup equipment when testing?
Why are employees injured so frequently while
testing the machinery or equipment during
maintenance?
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• Outside Personnel
• Outside servicing personnel, contracted to
  perform maintenance or other services requiring
  lockout/tagout procedures, must not begin work
  until the maintenance supervisor is satisfied
  that their lockout/tagout procedures are at least
  equivalent to company procedures.
• The employer must also ensure company employees
  understand and comply with contracted personnel
  lockout/tagout procedures, is used.

Who is responsible if an employee is injured
because an outside contractor did not follow
proper lockout/tagout procedures?
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• Shift/Personnel Changes
• Written procedures must be developed to address
  lockout/tagout procedures during a shift change.

What is the intent or purpose of the procedures
above?
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• Shift/Personnel Changes
• Written procedures must be developed to address
  lockout/tagout procedures during a shift change.

What is the intent or purpose of the procedures
above?
Ensure the continuity of protection!
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Part IV Lockout/Tagout Training

• General Requirements
• Training in lockout/tagout must be provided to
  all employees who may be in an area where energy
  control procedures are used.
• This training will make sure that the purpose and
  function of the energy control program are
  understood and that employees gain the needed
  knowledge and skills to safely apply, use, and
  remove energy controls.

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Minimum training will include Authorized
employees must be able to recognize hazardous
energy sources, types and magnitudes of energy
in the workplace, and methods and means
necessary to isolate and control the
energy. Affected employees must be able to
recognize the purpose and use of energy control
procedures. Other employees must be able to
recognize procedures and prohibitions of the
energy control program.
What are effective training strategies for each
level of training?
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Training on Tagout Devices If tagout devices
are used, further training on tagout systems need
to emphasize that a. Tags are warning devices
only and do not provide a physical restraint that
lockout devices provide. b. Tags must not be
removed without the authorized employees
approval, and should never be bypassed, ignored,
or otherwise defeated. c. Tags must be
legible, and understandable by all employees.
d. Tags must be able to withstand
environmental conditions in the workplace. e.
Tags may give employees a false sense of
security. F. Tags must be securely attached to
prevent being accidentally detached during use.

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Retraining Employees will participate in
retraining at the following times 1. Change
in job assignment. 2. Change in machinery or
equipment, or 3. Change in operating
procedures, or 4. You note deficiencies in
their understanding or



performance!
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Part IV Lockout/Tagout Annual Inspections
Annual inspections on lockout/tagout procedures
must be conducted by an authorized employee other
than the one(s) using the energy control
procedure being inspected. The purpose of the
inspection is to correct any deviations or
inadequacies in the procedures. Are ALL the
energy sources deenergized? Is this level of
protection adequate? Do all authorized
employees know their responsibilities? The
inspector and authorized employee(s) will review
responsibilities under the energy control
procedure.
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Part IV Lockout/Tagout Annual Inspections
The employer must certify that the inspection was
conducted. Elements of the certification should
include a. Identification of equipment or
machinery b. Date of inspection c. Employees
included in the inspection d. Person performing
inspection
How often must lockout/tagout inspections occur?
Who must conduct the inspection?
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If any of the conditions below exist, the
employer must write procedures The machine or
equipment has potential for stored or residual
energy, or reaccumulation of stored energy after
shutdown which could endanger employees or The
machine or equipment has more than a single
energy source or The isolation and locking
out of any single energy source will not
completely de-energize and deactivate the machine
or equipment or The lockout device is not
under exclusive control of an authorized employee
performing the servicing or maintenance or
The servicing or maintenance of the machinery
or equipment creates hazards for other employees
or The employer has had accidents involving
the unexpected activation or re-energizing of the
machine or equipment during servicing or
maintenance.
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A lockout device must use a positive means such
as a lock, either key or combination type, to
hold an energy isolating device ...in a safe
position to prevent machinery or equipment from
being energized.
What are some examples of lockout devices?
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