ONLINE SELF-STUDY

The Control of Hazardous Energy (Lockout Tagout)

OSHA 29 CFR 1910.147

Objectives

The need for energy control procedures;

Methods of lockout/tagout;

Employer’s responsibilities;

Employee training needs; and

Inspection requirements.

This presentation will cover the following topics:

What is Lockout/Tagout?

Lockout/Tagout (LOTO) refers to the control of energy

sources to prevent the energizing, startup, or release of

stored energy in machinery or equipment which could

cause injury to employees during servicing or

maintenance activities.

LOTO is technically known as the Control of Hazardous

Energy.

LOTO involves the control of energy sources such as:

Mechanical

Hydraulic

Chemical

Pneumatic

Electrical

Thermal

What is Lockout/Tagout?

Why is LOTO Important?

Approximately 3 million workers service equipment and

face the risk of injury if LOTO is not performed.

An estimated 120 fatalities and 50,000 injuries occur each

year from exposure to hazardous energy.

LOTO procedures implemented properly will prevent

employee injury from hazardous energy.

Source: Washington State Department of Labor & Industries

When is LOTO Required?

LOTO is required during activities necessary to prepare or

maintain a machine or piece of equipment.

LOTO is also required during the installation of new

equipment or machinery.

What Activities are Included?

Servicing/maintenance activities may include:

Construction

Installation and set-up

Adjustment or maintenance

Inspection

Modification

Routine service

Lubrication

Cleaning

Servicing and/or maintenance which takes place

during normal production operations is covered

only if employees are required to:

Remove or bypass a guard or other safety device; or

Place any part of their body in or near a machine’s moving

parts; or

Place any part of their bodies in a danger zone associated with

machine operation.

What Activities are Included?

An employee who locks out or tags out machines

or equipment to perform servicing or maintenance

on that machine or equipment.

Lockout or tagout shall be performed only by authorized

employees.

Lockout or tagout is used by these employees for

their own protection.

Employees Involved in LOTO

Authorized Employee

Employees Involved in LOTO

Authorized employees include employees who:

1) Perform energy source isolation;

2) Implement LOTO on machines or equipment;

3) Dissipate potential (stored) energy;

4) Verify energy isolation;

5) Implement actions to release LOTO; or

6) Test or position machines or equipment.

Employees Involved in LOTO

An employee whose job duties require him/her to operate

equipment or work in an area in which the energy control

procedure is implemented and servicing or maintenance

operations are performed.

Affected employees may disable, shut down, or turn off

machines or equipment.

Affected employee

Energy Control Program

OSHA requires employers to establish a program

consisting of:

Written energy control procedures

Employee training

Periodic inspections

EHS maintains the general campus LOTO program.

Departments must develop specific LOTO procedures for

their equipment and machines.

Lockout Procedures Lockout Procedures

Equipment Specific Procedures

Departments shall develop and document equipment

specific lockout/tagout procedures.

Procedures must contain enough detail for authorized

employees to have a clear understanding of the energy

control measures.

The energy control procedures must clearly and

specifically outline the scope, purpose, authorization, rules,

and techniques that will be used to control hazardous

energy sources.

Equipment Specific Procedures

At a minimum, these procedures must also include the

following elements:

The specific intended use of the procedures;

The specific steps for shutting down, isolating, blocking

and securing machines or equipment to control

hazardous energy;

The specific steps for the placement, removal and

transfer of lockout or tagout devices and the

responsibility for them; and

The specific requirements for testing a machine to verify

equipment isolation.

Equipment Specific Procedures

Similar machines/equipment with the same or similar types

of controls, and which can be isolated using the same

sequential steps, can be covered by a single procedure.

For example, a single procedure may be used for a group

of woodworking machines, as long as the procedure has

sufficient details to allow effective isolation of the energy

sources and safely return each of the machines to service.

To assist with the development of equipment specific

procedures, fill out the Equipment Specific LOTO

Procedure Development Form.

LOTO Devices

The preferred method of isolation is lockout/tagout, using

department issued locks and tags.

The physical protection offered by the use of a lock, when

supported by the information on a tag, provides the

greatest assurance of employee protection from the

release of hazardous energy.

Designated devices must be used for controlling energy

only and not for other purposes.

LOTO Devices

Devices must meet the following criteria:

Durable

Standardized

Substantial

Identifiable

LOTO Devices

LOTO devices must be durable enough to withstand

conditions in the workplace environment.

LOTO devices must be standardized within a department

according to color, shape, or size. Tagout devices also

must be standardized according to print and format.

Tags must warn against hazardous conditions if the

machine is energized, and offer employees clear

instruction such as: “Do Not Start,” “Do Not Open,” “Do Not

Close,” “Do Not Energize,” or “Do Not Operate.”

LOTO Devices

LOTO devices must be substantial enough to minimize the

likelihood of early or accidental removal.

Other than using a key or combination, employees must be

able to remove locks only by using excessive force such

as using bolt cutters.

Tagout devices must be labeled to identify the specific

employees who are authorized to apply and remove them.

The label must contain the name, date, and contact

information for the person performing the LOTO.

Tagout Devices

Tags are warning devices that do not provide the physical

restraint on energy-isolating devices as offered by lockout

devices.

Tagout alone is only permitted when an energy-isolating

device is not capable of being locked.

Use of tagout alone instead of the preferred lockout/tagout

method requires written supervisor approval documented

on the Tagout System Justification Form.

Tagout Devices

The use of tagout alone requires at lease one added safety

measure such as:

Closure of a second in-line valve;

Removal of a valve handle;

Removal of an additional isolating circuit element (e.g.,

fuse);

Opening of an extra disconnecting device (e.g.,

disconnecting switch; circuit breaker);or

Opening and then racking out a circuit breaker switch.

Types of Devices

LOTO Sequence

LOTO procedures shall include the following sequence:

Preparation for shutdown

Machine or equipment shutdown

Machine or equipment isolation

LOTO device application

Release of stored energy

Verification of isolation

Release from LOTO

Inspection of machine or equipment work area

Location of employees

Preparation for LOTO

LOTO shall be performed only by authorized employees

who are performing the servicing or maintenance.

Authorized employees must know:

The types and magnitudes (amounts) of energy involved

The hazards of the energy to be controlled

The methods or means to control energy

Before performing LOTO, employees shall discuss any

questionable identification of energy sources with their

supervisors.

Notification of Employees

A supervisor or authorized employee must notify the

affected employees before LOTO devices are applied

and after they are removed.

Machine/Equipment Shutdown

The machine or equipment shall be turned off or shut

down using the procedures established for the machine

or equipment.

An orderly shutdown must be utilized to avoid any

additional or increased hazards to employees as a

result of equipment de-energization.

Machine/Equipment Isolation

All energy isolating devices needed to control energy shall be

physically located to isolate the machine or equipment from

the energy source(s).

The use of push buttons, selector switches, and other control

circuit type devices as energy isolating devices is prohibited.

Machine/Equipment Isolation

Stored energy such as capacitors, springs, elevator

machine members, rotating flywheels, hydraulic

systems and air, gas, steam or water pressure, etc.

must also be dissipated or restrained by methods such

as grounding, blocking, repositioning, bleeding down,

etc.

Compressed air, hydraulic or steam lines must be bled,

drained, and cleaned out.

Power Circuit Vs Control Circuit

Only power circuit devices are approved as energy-

isolating devices.

The power circuit distributes power from the source (main

disconnect) to the motor (connected load).

The control circuit controls the distribution of power

through the use of a motor controller, system interlock

device, on/off switch, or start/stop push button.

Power Circuit Vs Control Circuit

The use of a control circuit device as the primary means of

hazardous energy control does not adequately protect

employees.

Control circuit devices are vulnerable to hazards such as

component failure, program errors, magnetic field

interference, electrical surges, and improper use or

maintenance.

The next slide contains a diagram that illustrates why

locking out control circuit devices will not prevent a motor

from starting if voltage is present in the power circuit.

Power Circuit Vs Control Circuit

Locking out

the start/stop

button or

using the on-

off key (control

circuit) will not

prevent power

from getting to

the motor.

Only shutting

off the main

disconnect

(power circuit)

will ensure

power does

not get to the

motor.Figure : Diagram of power and control circuits. Source: OSHA Directive CPL 02-00-147

Lockout/Tagout Application

Lockout devices shall be affixed in a manner that will

hold the energy isolating devices in a "safe" or "off“

position.

Tagout devices shall be affixed in a manner indicating

that the operation or movement of energy isolating

devices from the "safe" or "off" position is prohibited.

Employees must not attempt to operate any switch,

valve, or other energy isolating device when it is locked

or tagged out.

Each employee must apply his/her own personal

Lockout/Tagout device on the energy isolating device.

Stored Energy

After application of device, all potentially hazardous stored

or residual energy shall be relieved, disconnected,

restrained, and otherwise rendered safe.

Verification of Isolation

Prior to starting work, authorized employees shall verify that:

The machines or equipment have been shutdown properly;

All of the energy-isolating devices were identified, located,

and operated appropriately;

The lockout/tagout devices have been attached to the

energy-isolating devices correctly; and

The stored energy has been rendered safe.

Verification of Isolation

A combination of visual inspections and physical tests are

required for proper verification of isolation.

Visual inspections verify that the correct devices have been

locked out in the correct position.

Use physical tests such as a deliberate attempt to start a

machine for further verification and/or the use of a voltage

test instrument.

If local control cannot be obtained for physical tests,

additional steps must be taken. Contact EHS for assistance

(962-0227).

Note: Verification by computerized control is not acceptable.

Voltage Testing

Voltage testing is required to verify that electrical equipment

has been de-energized when working on or near de-

energized electrical components or systems.

Until the absence of voltage is verified, opening an electrical

panel for testing is considered working on or near exposed

live parts.

Voltage testing is covered by the OSHA Electrical Standard

1910.333, Selection and Use of Work Practices, and the PPE

requirements of NFPA 70E, Standard for Electrical Safety in

the Workplace.

Only authorized and qualified employees as defined by

OSHA and NFPA are allowed to perform voltage testing.

Release from Lockout/Tagout

Before LOTO devices are removed and energy restored:

Each LOTO device must be removed by the employee

who applied the device.

Inspect machine/equipment system components to

ensure that: 1) non-essential tools and materials have

been removed; and 2) machine or equipment

components are operationally intact.

Check the work area to ensure all employees have

been safely positioned or removed.

Inform affected employees that the lockout or tagout

devices have been removed.

LOTO Device Removal

When the individual who applied the energy control

device is not available to remove it, that device may be

removed under the direction of a supervisor.

Removal may not be based on convenience and may not

be done simply because the employee is not available at

the LOTO location, but is still at the workplace.

LOTO Device Removal

The removal procedure shall include the following

elements:

1. Verification by a supervisor that the authorized

individual who applied the device is not at the

facility.

2. The supervisor will make all reasonable efforts to

contact the individual.

3. The supervisor will assure that the affected

individual has knowledge of the removal before

resuming work at the facility.

4. The supervisor shall document the removal on the

Absentee Lockout Tagout Removal Form.

Testing or Positioning of Machines

When LOTO devices must temporarily be removed for

testing/positioning:

Clear machine or equipment of tools and materials

Remove employees from area

Remove lockout/tagout device

Energize and proceed with testing or positioning

De-energize and reapply energy control measures

Shift/Personnel Changes

During shift/personnel changes there must a transition

period so that individuals may exchange their assigned

energy control devices.

The orderly transfer of devices between off-going and on-

coming employees must ensure that there is no gap in

coverage.

Individuals shall be fully briefed in the scope and strategy

of the work by those who are being relieved.

Outside Personnel

The on-site employer (UNC) and the contractor must

inform each other of their respective lockout or tagout

procedures.

Contractor is permitted to use either: UNC's energy

control procedure; its own procedures; or a combination

of the two procedures, provided the resulting procedure

meets the requirements of the LOTO standard.

Outside Personnel

The UNC employer and the contractor also must ensure

that its respective employees understand and comply

with all requirements of the energy control procedures

that will be used by the contractor.

Document the coordination of LOTO procedures on the

Contractor Notification Form.

If the contractor has no documented energy control

procedures, or if their procedure allows tagout in lieu of

lockout/tagout, they shall ensure that their personnel

understand and comply with the procedures established

in the UNC program.

Group Lockout/Tagout

When servicing and/or maintenance is performed by a

group, a procedure must be utilized that provides

employee protection equivalent to a personal LOTO

device.

Group Lockout/Tagout

One primary authorized employee performs LOTO on the equipment for the group and attaches his/her LOTO device to a multi-lock accepting device.

Each authorized employee must verify that all required equipment has been locked out.

Each authorized employee must apply his/her personal LOTO device to the multi-lock accepting device.

Each affected employee shall remove the personal LOTO device when stopping work on the machine/equipment.

Group Lockout/Tagout

After the work is completed, the primary authorized employee shall remove his/her LOTO device and multi-lock accepting device after all other authorized employees remove their devices.

Only the employee who attached the LOTO may remove the device, unless the “LOTO Removal When an Individual is not Available” procedure is followed.

Group Lockout/Tagout: Lock box

If multiple pieces of equipment are being locked out, a group lock box or cabinet can be used.

The keys from the locks placed on the equipment are placed in the box or cabinet. A multi-lock accepting device is placed on the outside of the box or cabinet.

Each employee will use a personal LOTO device to secure the box or cabinet. Each employee must verify that all required equipment has been locked out.

As each person completes work, that person will remove his/her device from the box or cabinet.

Group Lockout/Tagout: Lock box

Note: No one can get to the keys in the Lockbox unless all

authorized persons’ locks are removed

Periodic Inspection

Periodic inspections must be performed at least annually

to verify that LOTO procedures and requirements are

followed.

The inspections are performed by authorized employee

other than the one(s) using the procedure.

This process is designed to correct identified deficiencies

or inadequacies.

The inspections must contain at least two components: 1)

a review of the LOTO procedure and 2) a review of each

employee’s responsibilities under the procedure being

inspected.

Periodic Inspection

The inspector must certify on the Periodic Inspection

Form that periodic inspection has been performed by

documenting:

The machine or equipment on which the LOTO

procedure was used;

The date of the inspection;

The names of the employees included in the

inspection;

The names of the person who performed the

inspection.

Training and Communication

Employers must provide initial training for new hires

before they begin any servicing and maintenance

activities.

LOTO training must address, at a minimum:

The purpose and function of the LOTO program;

The elements of LOTO procedures relevant to

employee duties; and

The pertinent requirements and prohibitions of the

LOTO standard.

Training and Communication

Authorized employees must be trained on:

Recognition of hazardous energy sources

Type and magnitude of energy in workplace

Methods and means for energy isolation and control

Training and Communication

Affected employees must be trained on:

Purpose and use of LOTO procedures

Prohibition of restarting or reenergizing

machines that are locked or tagged out

For Tagout alone systems, all employees must receive training regarding the inherent limitations of tags:

Are warning devices only

Do not provide physical restraint

Must not be removed/bypassed/ignored

May evoke false sense of security

Must be securely attached

Training and Communication

Do not start

Retraining for authorized and affected employees must be provided annually or when the following occurs:

There is a change in job assignments, equipment,

processes, or LOTO procedures; or

Periodic inspections reveal, or employer has reason to believe, there are deviations in employee knowledge or use of procedures.

The scope and content of the retraining must be based on the identified changes or deviations and a elimination of the concerns.

Training and Communication

UNC-CH EHS would like to acknowledge the North

Carolina Department of Labor (DOL) for providing portions of the training content.