THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT )

THE CONTROL OF HAZARDOUS THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUTENERGY (LOCKOUT/TAGOUT))

Occupational Health and Safety ProgramOccupational Health and Safety Program

Getting Credit and CertificateGetting Credit and CertificateTo get full credit and certificate for this class, the class facilitator should do the following:

*Present the Power Point Presentation and have all students study any handouts.

*Enter the appropriate information into the facility’s training records.

*Send the following information by e-mail to the Cabinet’s Safety Coordinator for each student in the class:

-name,-work address,-work title,-name of class,-date of class.

Safety Coordinator-Richard T. Owen at [email protected] certificates will be returned to the class facilitator for distribution.

mailto:[email protected]

Basis for ImportanceBasis for Importance

95% of all lockout/tagout citations involve the failure to 95% of all lockout/tagout citations involve the failure to have a formal energy control program in place.have a formal energy control program in place.

Remains near the top of OSHA’s list of most frequently Remains near the top of OSHA’s list of most frequently violated standard.violated standard.

OSHA Lockout/Tagout StandardOSHA Lockout/Tagout Standard

Promulgated January 2, 1990.Promulgated January 2, 1990.Covers 39 million workers.Covers 39 million workers.Standard intended to:Standard intended to:

Save 122 lives.Save 122 lives.Reduce 28,400 lost-workday injuries.Reduce 28,400 lost-workday injuries.Reduce 31,900 non-lost workday injuries.Reduce 31,900 non-lost workday injuries.

Covers: Electrical, machines, vehicle maintenance, and Covers: Electrical, machines, vehicle maintenance, and any situation or device that has the potential to re-start, any situation or device that has the potential to re-start, release energy, and/or move when worked on.release energy, and/or move when worked on.

DefinitionsDefinitions

Authorized employeeAuthorized employeeA person who locks or tags out equipment in order to A person who locks or tags out equipment in order to perform servicing or maintenance.perform servicing or maintenance.

DefinitionsDefinitionsAffected employeeAffected employee

Job requires employee to operate or use equipment on Job requires employee to operate or use equipment on which servicing or maintenance is being performed under which servicing or maintenance is being performed under lockout and tagout conditions.lockout and tagout conditions.

ororJob requires the employee to work in an area in which Job requires the employee to work in an area in which such servicing or maintenance is being performed.such servicing or maintenance is being performed.

NoteNote:: Affected employee becomes an authorized Affected employee becomes an authorized employee when that employee's duties include employee when that employee's duties include

performing servicing or maintenance.performing servicing or maintenance.

DefinitionsDefinitions

Capable of being locked outCapable of being locked outAn energy isolating device is 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, if it has a hasp or other means of attachment to which, or through which, a lock can be affixed, or it has a or through which, a lock can be affixed, or it has a locking mechanism built into it.locking mechanism built into it.

EnergizedEnergizedConnected to an energy source or containing residual or Connected to an energy source or containing residual or stored energy.stored energy.

DefinitionsDefinitions Energy SourcesEnergy Sources

Mechanical Mechanical HydraulicHydraulic ElectricalElectrical GasGas PneumaticPneumatic WaterWater ChemicalChemical ThermalThermal Other stored energy (Springs, capacitors, etc)Other stored energy (Springs, capacitors, etc)

DefinitionsDefinitionsEnergy isolating deviceEnergy isolating device

A mechanical device that physically prevents the A mechanical device that physically prevents the transmission or release of energy:transmission or release of energy:

Manually operated electrical circuit breaker.Manually operated electrical circuit breaker.A disconnect switch.A disconnect switch.Line valve.Line valve.A block.A block.

Any similar device used to block or isolate energy.Any similar device used to block or isolate energy.

Note: PNote: Push button, selector switches and other ush button, selector switches and other control devices are not energy isolating control devices are not energy isolating

devices. devices...

OSHA Lockout/Tagout StandardOSHA Lockout/Tagout StandardCovers the servicing and maintenance of equipment Covers the servicing and maintenance of equipment where the unexpected energization or start up of where the unexpected energization or start up of equipment, or release of stored energy could cause injury.equipment, or release of stored energy could cause injury.

Establishes minimum performance requirements for Establishes minimum performance requirements for controlling hazardous energy.controlling hazardous energy.

Lockout/Tagout and Related Lockout/Tagout and Related RegulationsRegulations

29 CFR 1910.147, the control of hazardous energy 29 CFR 1910.147, the control of hazardous energy (Lockout/Tagout). (Lockout/Tagout).

29 CFR 1910.146, permit-required confined spaces. 29 CFR 1910.146, permit-required confined spaces. 29 CFR 1910.331-335, safety-related work practices. 29 CFR 1910.331-335, safety-related work practices. 29 CFR 1910.269, electric power generation, transmission, 29 CFR 1910.269, electric power generation, transmission,

and distribution.and distribution. 29 CFR 1926.417, lockout and tagging of circuits.29 CFR 1926.417, lockout and tagging of circuits.

LockoutLockoutThe placement of a lockout device on an energy The placement of a lockout device on an energy isolating device, in accordance with an established isolating device, in accordance with an established procedure, ensuring that the energy isolating device procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated and the equipment being controlled cannot be operated until the lockout device is removed.until the lockout device is removed.

TagoutTagout

The placement of a tagout device on an energy isolating The placement of a tagout device on an energy isolating device, in accordance with an established procedure, to device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device being controlled may not be operated until the tagout device is removed.is removed.

Lockout DeviceLockout Device

Any device that uses positive means such as a lock Any device that uses positive means such as a lock either key of combination type, to hold an energy either key of combination type, to hold an energy isolating device in a safe position, thereby preventing isolating device in a safe position, thereby preventing the energizing of machinery or equipmentthe energizing of machinery or equipment..

Purpose of Lockout/Tagout StandardPurpose of Lockout/Tagout Standard

Requires employers to train “authorized” employees:Requires employers to train “authorized” employees:

When and how to shut down machinery.When and how to shut down machinery.Drain and isolate all energy sources.Drain and isolate all energy sources.Verify the absence of energy.Verify the absence of energy.

Safely restart equipment when maintenance or repair is Safely restart equipment when maintenance or repair is complete. complete.

Mandates awareness training of “affected” workers Mandates awareness training of “affected” workers (equipment operators, etc.).(equipment operators, etc.).

ExemptionsExemptions Construction (new construction where no energy).Construction (new construction where no energy). Agriculture.Agriculture. Maritime.Maritime. Installation under the exclusive control of electric utilities for Installation under the exclusive control of electric utilities for

the purpose of power generation, transmission and the purpose of power generation, transmission and distribution, including related equipment for communication distribution, including related equipment for communication or metering.or metering.

Oil and gas well drilling services.Oil and gas well drilling services.

ExemptionsExemptionsServicing and/or maintenance during Servicing and/or maintenance during normalnormal production production

unlessunless the employee the employee::

Is required to remove or bypass a guard or other safety Is required to remove or bypass a guard or other safety device.device.

Is required to place any part of his/her body into an area Is required to place any part of his/her body into an area on a machine or piece of equipment where:on a machine or piece of equipment where:

Work is actually performed upon the material being Work is actually performed upon the material being processed (point of operation);processed (point of operation);An associated danger zone exists during a machine An associated danger zone exists during a machine operating cycle.operating cycle.

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

equipment for:equipment for: Production,Production,Minor tool changes,Minor tool changes,Adjustments,Adjustments,Other minor servicing activities.Other minor servicing activities.

Work on cord and plug:Work on cord and plug:Must be able to disconnect cord.Must be able to disconnect cord.Must be under the exclusive control of the employee.Must be under the exclusive control of the employee.

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

reaccumulation of stored after shutdown.reaccumulation of stored after shutdown.

Has a single source that can be easily identified and isolated.Has a single source that can be easily identified and isolated.

Isolating and locking out the energy source will completely de-Isolating and locking out the energy source will completely de-energize and deactivate the equipment.energize and deactivate the equipment.

The equipment is isolated from an energy source and locked The equipment is isolated from an energy source and locked out during maintenance.out during maintenance.

ExceptionsExceptions A single lockout device will achieve a lock condition.A single lockout device will achieve a lock condition.

The lockout is under the exclusive control of and in the view The lockout is under the exclusive control of and in the view of the authorized employee performing the servicing and of the authorized employee performing the servicing and maintenance.maintenance.

The servicing or maintenance does not create hazards for The servicing or maintenance does not create hazards for other employees.other employees.

There have been no accidents involving unexpected There have been no accidents involving unexpected energization of the equipment while taking advantage of this energization of the equipment while taking advantage of this exception.exception.

Servicing and MaintenanceServicing and Maintenance

• ConstructingConstructing• InstallingInstalling• Setting upSetting up• AdjustingAdjusting• InspectingInspecting• ModifyingModifying• LubricatingLubricating• Cleaning or unjamming equipmentCleaning or unjamming equipment• Making adjustments or tool changesMaking adjustments or tool changes

Lockout/Tagout DevicesLockout/Tagout Devices

DurableDurableAll devices must be capable of All devices must be capable of withstanding the workplace environment.withstanding the workplace environment.

All tags and their means of attachment All tags and their means of attachment must be sturdy enough to prevent must be sturdy enough to prevent inadvertent removal.inadvertent removal.


StandardizedStandardizedLockout/Tagout devices must be:Lockout/Tagout devices must be:

Singularly identified.Singularly identified.The only device(s) used for controlling energy.The only device(s) used for controlling energy.Not be used for other purposes.Not be used for other purposes.

Devices must have the same color, shape, or size.Devices must have the same color, shape, or size.

The format and print of tags should be standardizedThe format and print of tags should be standardized..

Lockout/Tagout DevicesLockout/Tagout DevicesSubstantialSubstantial

Removal of lockout devices should be extremely Removal of lockout devices should be extremely difficult to remove, requiring the use of difficult to remove, requiring the use of excessive force and the help of tools such as excessive force and the help of tools such as bolt cutters.bolt cutters.

Tagout devices and their attachments must be Tagout devices and their attachments must be tough enough so that they can’t be accidentally tough enough so that they can’t be accidentally removedremoved..

Lockout Lockout Lockout is a more appropriate means of ensuring Lockout is a more appropriate means of ensuring isolating energy of equipment than tagout.isolating energy of equipment than tagout.

If an energy-isolating device can’t be locked out, If an energy-isolating device can’t be locked out, tagout may be used.tagout may be used.

Tagout may be used in place of lockout if it can be Tagout may be used in place of lockout if it can be demonstrated that it will offer equivalent protection demonstrated that it will offer equivalent protection to that offered by lockout.to that offered by lockout.

TagoutTagout

When only a tag is used because equipment cannot be When only a tag is used because equipment cannot be locked out, the following steps must be taken:locked out, the following steps must be taken:

Remove an isolating circuit element (fuses).Remove an isolating circuit element (fuses). Block machine (control switch, die).Block machine (control switch, die). Open an extra disconnecting device.Open an extra disconnecting device. Other means of isolation.Other means of isolation.

TagoutTagoutTags must be placed where the lockout device Tags must be placed where the lockout device would have been placed. would have been placed.

A legend must be used such as: A legend must be used such as: Do not start.Do not start. Do not open.Do not open. Do not close.Do not close. Do not energize.Do not energize. Do not operate.Do not operate.

Tagout LimitationsTagout LimitationsTags are attached to energy isolation devices, but they are Tags are attached to energy isolation devices, but they are only warning. only warning.

They do not provide the protection offered by a lockout They do not provide the protection offered by a lockout procedure.procedure.

A tag is never to be bypassed or ignored, and it may not be A tag is never to be bypassed or ignored, and it may not be removed without the specific authorization of person removed without the specific authorization of person responsible for it.responsible for it.

Tagout LimitationsTagout Limitations

Tags must be clearly visible and easily understandable by Tags must be clearly visible and easily understandable by any employee who may be in the area.any employee who may be in the area.

Tags and their attaching materials must be able to Tags and their attaching materials must be able to withstand any adverse environmental conditions in the withstand any adverse environmental conditions in the workplace.workplace.

Tagout LimitationsTagout Limitations

Tags must be clearly understood and respected to be Tags must be clearly understood and respected to be effective.effective.

Workers should guard against false sense of security.Workers should guard against false sense of security.

Tags must be carefully secured to the energy-controlling Tags must be carefully secured to the energy-controlling devices so that they can’t easily be detached by accident devices so that they can’t easily be detached by accident during use.during use.

Annual InspectionsAnnual Inspections

Certain circumstances lend themselves to the opportunity Certain circumstances lend themselves to the opportunity for an inspection.for an inspection.

Construction of new equipment.Construction of new equipment. Installation of new equipment.Installation of new equipment. Modification or adjustment of equipment.Modification or adjustment of equipment. Routinely scheduled cleaning and maintenance.Routinely scheduled cleaning and maintenance. Major repairs.Major repairs.

Designating an InspectorDesignating an Inspector

Periodic inspections must be performed by an Periodic inspections must be performed by an authorized employee other than the one(s) using the authorized employee other than the one(s) using the energy control procedure.energy control procedure.

Who can inspect:Who can inspect:• Department ManagerDepartment Manager• Plant ManagementPlant Management• Safety ManagerSafety Manager• OthersOthers

Employee ReviewsEmployee Reviews

LockoutLockoutMust include a review between the inspector and each Must include a review between the inspector and each authorized employee.authorized employee.

TagoutTagoutMust be a review between the inspector and each authorized Must be a review between the inspector and each authorized and affected employee.and affected employee.

Review should cover each employee's responsibility under the Review should cover each employee's responsibility under the procedure being inspected, as well as the limitations of tagsprocedure being inspected, as well as the limitations of tags ..

Certifying InspectionsCertifying Inspections

Must certify that the required periodic inspections have Must certify that the required periodic inspections have been performed.been performed.

Certification must identify the following:Certification must identify the following: The equipment on which the energy control procedure The equipment on which the energy control procedure

was used.was used. The date of the inspection.The date of the inspection. The employee included in the inspection.The employee included in the inspection. The name of the person performing the inspection.The name of the person performing the inspection.

Follow-up AuditFollow-up AuditA follow-up audit must be conducted to ensure that all A follow-up audit must be conducted to ensure that all deficiencies noted have been corrected.deficiencies noted have been corrected.

Documentation must identify:Documentation must identify: The equipment on which the lockout procedure is being The equipment on which the lockout procedure is being

utilized.utilized. The date of the inspection.The date of the inspection. Employees interviewed.Employees interviewed. Employee(s) performing the inspection .Employee(s) performing the inspection .

Specific Training RequirementsSpecific Training Requirements

A training program must consist of:A training program must consist of:Effective initial training.Effective initial training.Periodic retraining as necessary.Periodic retraining as necessary.Certification that training has been given to all employees Certification that training has been given to all employees

covered by the standard.covered by the standard.

Certification must become part of employee record and Certification must become part of employee record and contain:contain:Employee's name.Employee's name.Date of training.Date of training.

Specific Training RequirementsSpecific Training Requirements Training must be provided to ensure that the purpose and Training must be provided to ensure that the purpose and function of the energy control program are understood by function of the energy control program are understood by employees. employees.

That the knowledge and skills required for the safe That the knowledge and skills required for the safe application, usage, and removal of the energy controls are application, usage, and removal of the energy controls are acquired by employees. acquired by employees.

Types of TrainingTypes of Training

The amount and kind of training is based upon:The amount and kind of training is based upon:

The relationship of each employee’s job to the The relationship of each employee’s job to the equipment being locked or tagged out.equipment being locked or tagged out.

The degree of knowledge relevant to hazardous The degree of knowledge relevant to hazardous energy energy that he/she must possess.that he/she must possess.

Need to know.Need to know.

Authorized EmployeeAuthorized EmployeeEach authorized employee must receive the following Each authorized employee must receive the following training:training: The purpose of the procedure.The purpose of the procedure. Ability to recognize applicable hazardous energy Ability to recognize applicable hazardous energy

sources in the workplace.sources in the workplace. The type and magnitude of the energy available in the The type and magnitude of the energy available in the

workplace.workplace. Understanding the means and methods of isolating Understanding the means and methods of isolating

and/or controlling the various types of energy and/or controlling the various types of energy sources.sources.

Ways to verify that energy isolation is effective.Ways to verify that energy isolation is effective.

Affected EmployeesAffected Employees

All affected employees must be instructed in the purpose All affected employees must be instructed in the purpose and use of the lockout/tagout system. and use of the lockout/tagout system. Create awareness.Create awareness.

Other EmployeesOther Employees

All other employees (including new hires) whose work All other employees (including new hires) whose work operations are or may be in an area where lockout/tagout operations are or may be in an area where lockout/tagout may be utilized.may be utilized.

These employees must be instructed:These employees must be instructed:• About the procedure.About the procedure.• That they are prohibited from starting up or reenergizing That they are prohibited from starting up or reenergizing

any locked-out or tagged-out equipment they encounter. any locked-out or tagged-out equipment they encounter.

RetrainingRetraining

Must be conducted for all authorized and affected Must be conducted for all authorized and affected employees whenever:employees whenever: There is a change in job assignment.There is a change in job assignment. Change in equipment, machinery, or processes that Change in equipment, machinery, or processes that

presents a new hazard.presents a new hazard. A change in the lockout/tagout procedureA change in the lockout/tagout procedure . .

RetrainingRetraining

Must be conducted whenever a periodic inspection reveals Must be conducted whenever a periodic inspection reveals or whenever the authorized employee has reason to believe or whenever the authorized employee has reason to believe that there are deviations from or inadequacies in the that there are deviations from or inadequacies in the employee's knowledge or use of the lockout/tagout employee's knowledge or use of the lockout/tagout procedures.procedures.

Group Lockout/TagoutGroup Lockout/Tagout

When servicing and/or maintenance is performed by a crew or When servicing and/or maintenance is performed by a crew or other group, they must utilize a procedure that affords the other group, they must utilize a procedure that affords the employees a level of protection equivalent to that provided by employees a level of protection equivalent to that provided by the implementation of personal lockout/tagout. the implementation of personal lockout/tagout.


Primary responsibility is vested in an authorized employee Primary responsibility is vested in an authorized employee for a set number of employees working under the protection for a set number of employees working under the protection of a group lockout or tagout device. of a group lockout or tagout device.

Provision for the authorized employee to ascertain the Provision for the authorized employee to ascertain the exposure status of individual group members with regard to exposure status of individual group members with regard to the lockout/tagout of the equipment. the lockout/tagout of the equipment.


Lockout/tagout control responsibility is designated Lockout/tagout control responsibility is designated to an authorized employee to coordinate affected to an authorized employee to coordinate affected work forces and ensure continuity of protection. work forces and ensure continuity of protection.

Each authorized employee must affix a personal Each authorized employee must affix a personal lockout/tagout device to the group lockout device, lockout/tagout device to the group lockout device, group lock box, or comparable mechanism when group lock box, or comparable mechanism when he/she begins work, and must remove those he/she begins work, and must remove those devices when he/she stops working on the devices when he/she stops working on the equipment being serviced or maintained.equipment being serviced or maintained.

Shift or Personnel Changes Shift or Personnel Changes

Continuity of lockout/tagout protection must be ensured by Continuity of lockout/tagout protection must be ensured by following specific procedures for shift and personnel following specific procedures for shift and personnel changes, including the orderly hand-off of lockout of changes, including the orderly hand-off of lockout of lockout/tagout devices.lockout/tagout devices.

Unusual ConditionsUnusual Conditions

Machines need to be tested or repositioned during servicing.Machines need to be tested or repositioned during servicing.

When necessary, When necessary, under special conditionunder special condition, OSHA allows the , OSHA allows the temporary removal of locks or tags so the equipment can be temporary removal of locks or tags so the equipment can be rre-energizede-energized..

Example, when power is needed for the testing or Example, when power is needed for the testing or positioning of equipment.positioning of equipment.

Unusual ConditionsUnusual Conditions Subject to the follow restrictions:Subject to the follow restrictions:

Equipment must be cleared of tools and material.Equipment must be cleared of tools and material. Employees must vacate the equipment areas.Employees must vacate the equipment areas. The lockout/tagout device must be removed only by The lockout/tagout device must be removed only by

the authorized employee who applied it.the authorized employee who applied it.

Unusual ConditionsUnusual Conditions

Applying energy may then be allowed by testing or Applying energy may then be allowed by testing or positioning.positioning.

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

ContractorsContractors

Must inform each other of all applicable lockout/tagout Must inform each other of all applicable lockout/tagout procedures.procedures.

Both employer and contractor must ensue that their Both employer and contractor must ensue that their employees understand and will respect the others energy employees understand and will respect the others energy control program.control program.

Typical Shutdown ProcedureTypical Shutdown Procedure

Notify affected employees.Notify affected employees. Use the specific procedures as outlined for the appropriate Use the specific procedures as outlined for the appropriate

situation.situation. Shut off energy source(s) to affected equipment.Shut off energy source(s) to affected equipment.

Use normal stopping or running procedures for the Use normal stopping or running procedures for the machine.machine.

Isolate the equipment from the energy source.Isolate the equipment from the energy source.

Shutdown ProceduresShutdown Procedures

Affix lock(s) and tag(s) to each energy isolating/controlling Affix lock(s) and tag(s) to each energy isolating/controlling device.device.

Relieve all stored energy from capacitor banks, springs, Relieve all stored energy from capacitor banks, springs, compressed air, hydraulics, steam, etc.compressed air, hydraulics, steam, etc.

Verify isolation of energy has occurred by trying equipment.Verify isolation of energy has occurred by trying equipment.

Removal of Lockout/Tagout and Start-Removal of Lockout/Tagout and Start-up Proceduresup Procedures

Ensure that nonessential items are removed from Ensure that nonessential items are removed from equipment. equipment.

Ensure that equipment components are intact. Ensure that equipment components are intact. Check area to ensure that all affected employees are Check area to ensure that all affected employees are

safely positioned or removed from the area. safely positioned or removed from the area. Notify all affected employees and site supervisor before Notify all affected employees and site supervisor before

reenergizing the equipment. reenergizing the equipment. Remove lockout/tagout device. Remove lockout/tagout device. Re-energize equipment to ensure safe operation.Re-energize equipment to ensure safe operation.


Examples:Examples:


Examples:Examples:


Examples:Examples:


Examples:Examples:

Thank You For Your Thank You For Your ParticipationParticipation

For additional assistance contact:For additional assistance contact:Richard T. OwenRichard T. Owen

Education Cabinet Safety CoordinatorEducation Cabinet Safety Coordinator601 East Main Street601 East Main Street

Frankfort, Kentucky 40601Frankfort, Kentucky 40601502-564-7346502-564-7346

[email protected]@ky.gov

mailto:[email protected]

Documents

THE CONTROL OF HAZARDOUS ENERGY (LOCKOUT/TAGOUT )