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CONSTRUCTION INDUSTRY REGULATIONS
CONTROL OF HAZARDOUS ENERGY
(LOCKOUT/TAGOUT)
29 CFR 1926.417
Overview
Every workplace has the need for on-going maintenance. Installation,
repair and servicing of machines and equipment may seem routine, but
can be dangerous to employees performing the work.
Serious injury can be caused by the sudden and unexpected startup of
the machinery or equipment, contact with live electrical circuit or the
unexpected release of stored energy.
Equipment that is shut down may inadvertently be re-started or re-
energized by a co-worker, or equipment that was thought to be shut
down may be controlled by automatic processors, timers or computers
and may be re-start automatically and without warning.
OSHA estimates that failure to control hazardous energy sources
results in:
10 % of serious industrial accidents.
28,000 lost work days injuries per year.
Approximately 120 deaths per year.
Fortunately, these hazards can be avoided through the use of lockout/tag-out
procedures.
The Lockout/Tagout standard requires the adoption andimplementation of practices and procedures to shut down equipment,
isolate it from its energy source(s), and prevent the release of potentially
hazardous energy while maintenance and servicing activities are being
performed. It contains minimum performance requirements, and
definitive criteria for establishing an effective program for the control
of hazardous energy.
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All new equipment installed after January 2, 1990 must be designed to
accept lockout of its energy-isolating device.
LOCKOUT/TAGOUT 1926.417
DEFINITIONS
Lockout The placement of a lockout device on an energy isolating
device, in accordance with an established procedure, ensuring that the
energy isolating device and the equipment being controlled cannot beoperated until the lockout device is removed.
Tag-out the placement of a tag-out device on an energy-isolating device,
in accordance with an established procedure, to indicate that the energy-
isolating device and the equipment being controlled may not operated until
the tag-out device is removed.
Lockout device Any device that uses positive means such as a lock, either
key or combination type, to hold an energy-isolating device in a safe
position, thereby preventing the energizing of machinery or equipment.
When properly installed, a blank flange or bolted slip blind are considered
equivalent to lockout devices.
Tag-out device Any prominent warning device, such as a tag and a means
of attachment, that can be securely fastened to an energy-isolating device in
accordance with an established procedure. The tag indicates that the machine
or equipment to which it is attached is not to be operated until the tag-out
device is removed in accordance with the energy control procedure.
Energy-isolating device Any mechanical device that physically preventsthe transmission or release of energy. These include, but are not limited to,
manually-operated electrical circuit breakers, disconnect switches, line
valves, and blocks.
Capable of being locked out An energy-isolating device is considered
capable of being locked out if it meets one of the following requirements:
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- It is designed with a hasp to which a lock can attached;
- It is designed with any other integral part through which a lock can be
affixed;
- It has a locking mechanism built into it; or
- It can be locked without dismantling, rebuilding, or replacing the
energy isolating device or permanently altering its energy control
capability.
Affected employee An employee who performs the duties of his or her job
in an area in which the energy control procedure is implemented andservicing or maintenance operations are performed. An affected employee
does not perform servicing or maintenance on machines or equipment that
must be locked or tagged.
Authorized employee An employee who performs servicing or
maintenance on machines and equipment. Lockout or tag-out is used by
these employees for their own protection.
Energy sources Any electrical, mechanical, hydraulic, pneumatic,chemical, gas, thermal or other energy source that could cause an injury to
the affected personnel.
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Residual pressure The remaining energy in a system after activation of
the disconnect (stored energy).
SCOPE AND APPLICATION
3 Applies to general industry employment and covers the servicing and
maintenance of machines and equipment in which the unexpected
start-up or the release of stored energy could cause injury to
employees.
ENERGY CONTROL PROGRAM
4 Intended to prevent the unexpected energizing or the release of stored
energy in machines or equipment on which servicing and
maintenance is being performed by employees.
5 Consists of documented energy control procedures, an employee
training program, and periodic inspections of the procedures.
6 Employers have flexibility to develop a program that meets the needs
of their particular workplace.
ENERGY CONTROL PROCEDURE
7 The written procedures must identify the information that authorized
employees must know in order to control hazardous energy during
service or maintenance.
8 At a minimum, it includes, but is not limited to, the following
elements:
- A statement on how the procedure will be used;
- The procedural steps needed to shut down, isolate, block, and
secure machines or equipment;
- The steps designating the safe placement, removal, and transfer
of lockout/tag-out devices and who has the responsibility for
them; and
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- The specific requirements for testing machines or equipment to
determine and verify the effectiveness of locks, tags, and other
energy control measures.
9 Procedure must include the following steps:
(1) Preparing for shutdown
(2) Shutting down the machine(s) or equipment
(3) Isolating the machine or equipment from the energy source(s),
(4) Applying the lockout or tag-out device(s) to the energy-
isolating device(s)
(5) Safely releasing all potentially hazardous stored or residualenergy, and
(6) Verifying the isolation of the machine(s) or equipment prior to
the start of service or maintenance work.
10 In addition, before lockout or tag-out devices are removed and
energy is restored to the machines or equipment, certain steps must
be taken to re-energize equipment after service is completed,
including:
(1) Assuring that machines or equipment components are
operationally intact(2) Notifying affected employees that lockout or tag-out devices
are removed from each energy-isolating device by the
employee who applied the device.
ENERGY-ISOLATING DEVICES
11 Guards against accidental machine or equipment start-up or the
unexpected re-energization of equipment during servicing or
maintenance.
12 These include, but are not limited to, manually-operated
electrical circuit breakers, disconnect switches, line valves, andblocks.
13 Two types: those capable of being locked and those that are not.
14 When the energy-isolating device cannot be locked out, the
employer must use tag-out or modify or replace the device to make it
capable of being locked.
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a legend such as the following: DO NOT START, DO NOT OPEN,
DO NOT CLOSE, DO NOT ENERGIZE, DO NOT OPERATE.
EMPLOYEE TRAINING
22 The employer must provide effective initial training and
retraining as necessary and must certify that such training has been
given to all employees covered by the standard. The certification
must contain each employees name and dates of training.
23 The employers training program for authorized employees
(those who are charged with the responsibility for implementing theenergy control procedures and performing the service and
maintenance) must cover, at minimum, the following areas:
- Details about the type and magnitude of the hazardous energy
sources present in the workplace, and
- The methods and means necessary to isolate and control those
energy sources (that is, the elements of the energy control
procedure)
24 Affected employees (usually the machine operators or users)
and all other employees need only be able to (1) recognize when thecontrol procedure is being implemented, and (2) understand the
purpose of the procedure and the importance of not attempting to
start up or use the equipment that has been locked or tagged out.
25 Every training program must ensure that all employees
understand the purpose, function and restrictions of the energy
control program and that authorized employees possess the
knowledge and skills necessary for the safe application, use, and
removal of energy controls.
26 Training programs used for compliance with this standard,
which is performance-oriented, should deal with the equipment,
type(s) of energy, and hazard(s) specific to the workplace being
covered.
27 Retraining must be provided, as required, whenever there is a
change in hob assignments, a change in machines, equipment or
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processes that present a new hazard, or a change in energy control
procedures.
28 Additional retraining must be conducted whenever a periodic
inspection reveals, or whenever the employer has reason to believe,
that there are deviations from or inadequacies in the employees
knowledge or use of the energy control procedure.
PERIODIC INSPECTIONS
29 Periodic inspections must be performed at least annually to
assure that the energy control procedures (locks and tags) continue tobe implemented properly and that the employees are familiar with
their responsibilities under those procedures.
30 In addition, the employer must certify that the periodic
inspections have been performed. The certification must identify the
machine or equipment on which the energy control procedure was
used, the date of the inspection, the employees included in the
inspection, and the name of the person performing the inspection.
31 For lockout procedures, the periodic inspection must include a
review, between the inspector and each authorized employee, of thatemployees responsibilities under the energy control procedure being
inspected.
32 When a tag-out procedure is inspected, a review on the
limitation of tags, in addition to the above requirements, must also be
included with each affected and authorized employee.
LOCKOUT/TAGOUT PROCEDURES
The following are the procedures necessary for effective lockout/tag-out:
Step 1: Preparation and Notification
Before servicing or installing equipment, you must be able to answer the
following questions:
33 What is the type of energy source on the equipment?
34 What are the potential hazards related to the energy source?
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35 What steps are necessary to control the energy source?
36 Who needs to be notified that the equipment will be shut down
for service?
Once these questions have been answered, notify all affected employees that
a lockout procedure is about to begin and that the equipment will be shut
down for service.
Step 2: Shut Down the EquipmentFollow the companys safety procedures and/or the manufacturers
instructions. Be aware that some equipment has special shut-down
procedures (for example, computer-controlled equipment)
Make sure all energy sources have located and shut down. (Some machines
have more than one power source all must be shut down).
Step 3: Isolate the Equipment
Equipment should be isolated by:
A. Shutting off the main breaker or control switch
B. Closing valves
C. Disconnecting process lines
D. Pulling plugs
Note: For complex machines or equipment, refer to the manufacturers
control diagram detailing the locations of all isolation points, including
breaker panels, switches, valves, etc.
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Step 4: Attach the Lock and Tag
Each employee who is performing maintenance is responsible for locking
and tagging the equipment. Each employee whose duties require them to
work on equipment must be provided with their own lock and key.
If more than one employee is involved in the maintenance, multiple locking
devices must be used to allow each maintenance employee to lock and tag.
This prevents one employee from accidentally starting up the equipment
while another employee is still working.
Never use another employees lock and never lend your own.
When all energy sources are locked, apply a tag to the power source. Makesure the tag is filled out completely and correctly.
Step 5: Release any Stored Energy
After locking and tagging equipment, you must make sure that any stored
energy on the equipment is released. This is done by:
37 Inspecting equipment to make sure all parts have stopped
moving.
38 Bleeding electrical capacitance (stored charge)39 Venting or isolating pressure or hydraulic lines from the work
area, leaving vent valves open
40 Draining tanks and valves
41 Releasing the tension on springs or blocking the movement of
spring-driven parts.
42 Blocking or bracing parts that could fall because of gravity
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43 Blocking, clamping or chaining any switches or levers that
could be moved into the start position
44 Clearing lines containing process materials that are toxic, hot,
cold, corrosive or asphyxiating
Monitoring the process to make sure that the work you are
doing will not result in an accumulation of stored energy.
Step 6: Test Equipment to Verify that All energy Has Been Released or
ControlledTo make sure that all kinetic and stored energy has been released or
controlled, you must:
46 Clear personnel from danger areas.
47 Test the start switches on the equipment to confirm that all
power sources have been shut down and switches cant be moved to
the on or start position.
48 Check pressure gauges to make sure that all lines are de-
pressurized and stored energy has been released.
49 Secure all blocks, clamps, chains and cribs.
50 Check electrical circuits to make sure that voltage is at zero.
51 Secure blanks (used to block feed chemicals) and make sure
they are not leaking.
Because some machinery and equipment can be remotely controlled, you
must consider equipment to be energized and in motion at all times except
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Once all three steps are completed, it is safe to start up the equipment.
LOCKOUT AND TAGOUT DEVICES
Lockout Devices:
58 Must be provided to each employee
59 Must only be used for the purposes of lockout/tagout
60 Must be able to withstand the environment that they are
exposed to for as they are in place.
61 Must be standardized by color, shape and size.
Tag-out Devices
62 Must be standardized by color, shape, size and format or print
63 Must contain warnings such as DANGER DO NOT
OPERATE THIS MACHINE
64 Must have space for the name of lock or tag owner, date and
purpose of the lockout/tag-out.
TAGOUT ONLY
A tag-out system can be used instead of a lockout system in the followingsituations only:
65 When an energy isolating device cannot be locked out
66 When the employer can prove that a tag-out system provides
the same amount of protection as a lockout system.
If a Tag-out Only system is used, the tags must be placed at all isolation
points, and you must follow all safety procedures.
Note: After January 2, 1990, any equipment that is replaced, renovated or
modified must be able to accept a lockout device.
SPECIAL SITUATIONS
Some situations may occur in the workplace that require additional
procedures to perform safe lockout/tag-out.
Removing someone elses lock: A lock may be removed by someone other
than the employee who placed the lock only under the following conditions:
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67 The employee whose lock is to be removed is not available to
remove the lock after servicing has been completed.
68 All reasonable efforts have been made to contact the employee
to inform him/her that the lock has been removed.
69 The employee is contacted and informed that the lock is
removed prior to the employee starting work on the next work shift.
Shift Changes: If maintenance on a piece of equipment will extend beyond
one shift, provisions must be made to have employees from the new shift
place their locks on the lockout device before they begin work on the
equipment. This must be done without any interruption in lockout/tag-out
protection.
Outside Contractors: If outside contractors will be working on equipment
inside your facility or workplace, you must make provisions to inform them
of your lockout/tag-out procedures. If the contractors procedures are
different from yours, you must make an agreement with the contractor as to
which procedures will be followed. All employees working on the project
must be notified of any changes in their own procedures.
Temporary Re-activation: If the equipment being serviced must be
temporarily re-activated (for example, to test the equipment as part ofinstallation), all startup and lockout/tag-out procedures must be followed.
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