Lockout/Tagout

Johnny Kirchner

Occupational Safety and Health Manager

South Dakota Safety Council

Control of Hazardous Energy

LOCKOUT/TAGOUT

1910.147

Uncontrolled Energy HazardsElectric ◦ Shock/Electrocution

◦ Arc Flash

Caught in/Caught on

Caught between

Contact with

Struck by

Exposure

Normal Production Operations

(using a machine/equipment for

its intended purpose)

Service and maintenance functions

where there is no hazard exposure

All other Servicing &

Maintenance

Machine Safeguarding Standards

29 CFR Subpart O

Minor servicing activities, like tool

changes, cleaning, or adjustments,

that are routine, repetitive and

integral to production

Full provisions for Control of Hazardous

Energy (Lockout) – 29 CFR 1910.147

OR

Alternative protective measures that

provide effective employee protection

Full provisions for Control of Hazardous

Energy (Lockout) – 29 CFR 1910.147

ACTIVITY APPLICABLE STANDARDS

Introduction• Primarily designed to protect employees who install,

repair, or service machinery and equipment.

• Many accidents and injuries are the result of someone

taking a shortcut or skipping a step when servicing

equipment.

• Violations consistently rank in OSHA’s top 10.

What is Lockout/Tagout?

• Goal is to prevent injuries and death from the unexpected energization, start

up, or release of hazardous energy from any machine or piece of equipment

while it’s being maintained

or repaired.

• Regulated by OSHA under the Control of Hazardous Energy Standard

(1910.147).

What is Lockout/Tagout?

Compliance Requirements

• Written lockout/tagout procedures.

• Employee training in lockout/tagout procedures.

• Periodic inspections of lockout/tagout

procedures.

• Records of lockout/tagout procedures,

training certifications, and periodic

inspection certifications.

Who is Involved in Lockout/Tagout?

Authorized Employees: Individuals responsible for initiating the lockout/tagout process and who physically apply locks and tags to the equipment they service

Must be able to:

• Recognize all hazardous energy sources,

• Know the types and amounts of hazardous energy available,

• Follow written lockout/tagout procedures

• Demonstrate proper lockout/tagout procedures, and

• Explain the limitations of using a tagout system alone.

Who is Involved in Lockout/Tagout?

Affected Employees: Individuals who operate

equipment being locked out and serviced, or who work

in areas where lockout/tagout is being used.

Must be able to:

• Understand the purpose and use of

lockout/tagout procedures,

• Know not to attempt to restart or

re-energize equipment that is locked or

tagged out, and

• Understand the limitations of using a tagout system

alone.

Who is Involved in Lockout/Tagout?

Other Employees: Individuals who may spend time in

production areas where equipment is being serviced, but

who usually work in areas away from machine operation.

Other employees must:

• Be properly instructed about

lockout/tagout procedures, and

• Know not to attempt to restart

or re-energize equipment that is

locked or tagged out.

Lockout/Tagout Basics

• Lockout/tagout is required any time a machine or

equipment is being repaired or serviced.

• During normal production operations, lockout/tagout

is required if an employee has to:

o Remove or bypass a machine guard or other safety

device, or

o Place any part of his body into a machine’s point of

operation or other danger zone.

Lockout/Tagout BasicsService activities that require lockout/tagout include:

• Constructing,

• Installing,

• Setting up,

• Inspecting,

• Modifying,

• Maintaining,

• Repairing, or

• Servicing.

Lockout/Tagout Basics

Tasks performed on equipment needing

lockout/tagout

protection include:

• Lubrication,

• Cleaning,

• Unjamming,

• Adjusting, and

• Performing tool changes.

Types of Energy

• Electrical

• Thermal

• Mechanical

• Hydraulic

• Pneumatic

• Chemical

• Gravitational

• Steam

Lockout/Tagout Basics

Energy-isolating devices:

• Circuit breakers,

• Disconnect switches,

• Line valves, or

• Machine blocks.

Lockout/Tagout Basics

Control devices that OSHA does not consider

energy-isolating devices include:

• Push buttons,

• Toggle switches,

• Dials,

• Emergency stops, and

• Interlocked barrier guards.

Lockout Defined

Physically placing a lock on all energy isolating

devices of a piece of equipment being serviced

to ensure that it cannot be operated.

Lockout:

• Physically prevents energy from being

restored to equipment.

• Most reliable method of energy control.

• OSHA requires employers to lock out all

equipment that can be locked out.

Lockout DefinedThe most common lockout devices include:

• Locks,

• Chains,

• Wedges,

• Key blocks,

• Adapter pins,

• Self-locking fasteners,

• Blank flanges, and

• Bolted slip blinds.

Lockout Defined

• Locks used to lock out equipment must be provided by the employer.

• Locks can only be applied by an authorized employee.

• Locks must physically hold all energy-isolating devices in the “off” or “safe” position.

• Locks may be used with:

o Circuit breaker covers,

o Valve covers,

o Blocks,

o Chains,

o Blank flanges, or

o Bolted slip blinds.

Tagout Defined

Applying a special tag to all energy-isolating devices of a piece

of equipment being serviced to indicate that the devices must

stay in the “off” position.

Tagout:

• Can only be applied by an authorized employee and the tag

must clearly identify the authorized employee.

• Must contain a clear warning statement, such as “Danger” or

“Do Not Operate.”

• Must be attached near the energy-isolating device with a

non-reusable, self-locking cable tie.

Tagout Defined• Does not physically prevent energy from being restored to the

equipment.

• Only a visual and written warning.

• Commonly used on equipment where lockout is not possible.

• Used in conjunction with other

protective measures, such as:

o Removing a valve handle,

o Removing a fuse, or

o Shutting off additional

isolating circuit elements.

Requirements of Locks and Tags

• Can only be applied and removed by an authorized employee;

• Must be provided by the employer;

• Must be used exclusively for lockout/tagout purposes;

• Must be durable;

• Must be standard throughout the facility and have the same:

o Color,

o Size, or

o Shape.

Standard Lockout/Tagout Procedure

Applying Lockout/Tagout

1. Prepare for shutdown: The authorized employee

reviews the written procedures for the equipment in need

of service. They must know:

o What types of energy are involved,

o How much energy is involved,

o What are the hazards and risks related to each type of

energy, and

o The types and locations of all the machine’s energy

isolating devices.

Standard Lockout/Tagout Procedure

3. Shutdown: The equipment is powered down using the established shut-down procedures.

4. Isolate the energy sources: The authorized employee locates all energy-isolating devices for the machine and places them in the “off” or “safe” position.

5. Apply lockout/tagout devices: The authorized employee applies a lock to each of the machine’s energy isolating devices.

6. Release Stored Energy: All potentially hazardous stored or residual energy shall be removed, disconnected, restrained and or otherwise rendered safe

7. Verification of isolation: (Try-out) Verify isolation and de-energization

***Return controls to neutral or off

Standard Lockout/Tagout Procedure

Removing Lockout/Tagout

• After service work is complete, the authorized employee will:

o Replace any guards and safety devices that were removed,

o Remove any tools and supplies,

o Inspect the work area to make sure all materials and anyone

nearby is a safe distance away,

o Verify that the machine is ready to operate,

o Remove the locks from the energy-isolating devices,

o Notify the affected employees.

o Restore energy to the equipment

Exceptions and Special Situations

Cord and Plug Equipment Exception

• For cord and plug electrically powered equipment,

lockout/tagout is not required if:

o The equipment is completely isolated by unplugging the

power cord, and

o The cord and plug remain under the exclusive control of the

authorized employee during the servicing or repair.

• If the 'exclusive control' over the plug

is not satisfied, the equipment must

be locked out during servicing.

Exceptions and Special Situations

Cord and Plug Equipment Exception

• The exception does not apply when:

o There are two or more authorized

employees servicing the equipment,

o The equipment has two or more

sources of energy, or

o The equipment is hard-wired to the

electrical supply.

Exceptions and Special Situations

Single Energy Source Exception

• For equipment operated by a single energy source, employers need to apply

lockout/tagout but do not need to have written procedures, if:

o The equipment has a single energy source,

o The equipment has no potential for residual or stored energy after

shut down,

o The isolation and lockout process completely de-energizes the equipment

during servicing,

o A single lockout device achieves a locked-out condition,

o The lockout device is under exclusive control of the authorized employee

servicing the equipment,

o The servicing activity does not create a hazard for other employees, and

o The employer has had no accidents involving the unexpected release of

hazardous energy during servicing operations.

Exceptions and Special Situations

Single Energy Source Exception

• The exception does not apply and the lockout/tagout

procedure must be in writing when:

o More than one energy source is present, and

o More than one authorized employee is servicing the

machine.

Exceptions and Special Situations

Temporary Testing and Positioning of Equipment Exception

• During temporary testing and positioning operations, guards and safety

devices don’t need to be reinstalled when the machine is

re-energized, however:

1. Employees must be safely positioned,

2. All tools and materials are removed from the area,

3. Lockout/tagout devices are removed, and

4. The machine is energized for testing or positioning purposes only.

• Once the testing is complete, turn off all systems and follow all

lockout/tagout procedures for the equipment before continuing the

service work.

Exceptions and Special Situations

Temporary Testing and Positioning of Equipment Exception

• This exception is temporary, and the rest of the service or repair

work must be done under lockout/tagout.

• This exception is reserved for testing and repositioning

purposes only.

• During normal servicing operations, the written lockout/tagout

procedures must be followed, and the machine must not be

energized during the servicing activity.

Exceptions and Special Situations

Lock Removal when the Authorized Employee is not Available

• Steps should be outlined in the employer’s overall energy control

program.

• Employer is allowed to have an extra set of keys.

• Employer must have exclusive access to the extra set of keys.

• Employer must verify the service work is complete and that the

equipment is safe and ready to use.

• The lockout/tagout devices can only be removed by another authorized

employee.

• The employer must inform the authorized employee who initiated the

lockout/tagout procedure that the lock was removed before he reports

back to work.

Conclusion

• Lockout/tagout is designed to protect everyone in the

workplace.

However…

• Lockout/tagout is only as effective as the employers and

employees who implement and follow procedures.

• All employees need to understand their role in following

those procedures.

• Doing so will protect life and limb from the dangers of

hazardous energy.

Training and Inspection

(c)(6) Periodic Inspection- annually

- by an Authorized employee other than the one performing the procedure being inspected

(c)(7) Training- Authorized

- Affected

- Other

Water in

Electrical

panel

Coffee500 gal capacity

Power

1. Prepare for Shutdown – gather necessary tools

2. Notify affected employees – clear work area

3. Turn power switch to “off” setting

4. Isolate energy sources

a. Turn appropriate circuit breaker to “off”

b. Close water valve

c. Open spout and lock in open position

5. Lockout water valve and circuit breaker

6. Remove residual energy

a. Drain coffee

b. Allow container to cool

7: Test power switch to verify zero-energy state;

**return switch to “off”**

Coffee Pot Lockout

Gate Valve

Brady Corp.

Ball Valve Device

Circuit Breaker

Toggle/ Light Switch

Disconnects

Bolted Slip Blinds

Quick Disconnect

Mohawk Plastic Products

Brady Corp.

Questions?