You are on page 1of 2



PROGRAM SYNOPSIS: Each of the machines we use is powered by energy: electricity, pneumatic, hydraulic or some other form. Because any of these forms of energy can be dangerous, we must be careful when working around them. To protect employees who set-up, repair or maintain machinery from energy related injuries, OSHA enacted Lockout/Tagout regulations in 1989. This video will show to your employees the potential dangers of working on energized machinery equipment as well as the rules for conducting safe Lockout/Tagout procedures. Other topics covered in the video include the Energy Control Plan, authorized and affected employees, types of lockout devices and lockout procedures required for special situations. SHOOTING LOCATIONS: A variety of industrial facilities PROGRAM COMPONENTS: Videotape and leaders guide PROGRAM OBJECTIVES: After watching the program, the participant will be able to explain the following: Situations where Lockout/Tagout should be used; Which procedures should be used in a given situation; Which lockout devices should be used for each situation; Procedures for working in special situations such as shift changes or groups. INSTRUCTIONAL CONTENT BACKGROUND Lockout/Tagout is a fairly simple concept in which the object is to disable the power to a machine being serviced. This is accomplished by isolating the machine from its energy sources through the use of locks, tags and other mechanisms. Some of the situations that require Lockout/Tagout procedures are repairing circuits, cleaning or oiling machinery, clearing jammed mechanisms and machine set-up. OSHAs Lockout/Tagout regulations mandate that companies establish an Energy Control Plan, which includes written lockout procedures and requires employee training. Typically we come into contact with five different types of energy: electrical, hydraulic, pneumatic, chemical and thermal. This energy can exist in an active or stored state. LOCKOUT/TAGOUT DEVICES Facilities use many types of lockout devices, including padlocks, chains, valve clamps, wedges, key blocks and pins. Tagout devices provide visual warnings and may indicate why the equipment is out of service and who is servicing it. Tags should only provide information and cannot serve as substitutions for locks. Your employer will provide Lockout/Tagout devices that are to be used for this purpose only. Never used a non-designated device. These devices must be easy to identify, durable and difficult to remove. AUTHORIZED & AFFECTED EMPLOYEES Only authorized employees may install Lockout/Tagout devices. These employees must be able to recognize hazardous energy sources, know the type and magnitude of energy in their work areas and know how to control this energy. Affected employees who work around locked out machines must know the facilitys energy control procedures. These workers must be informed whenever lockout procedures are performed. They are prohibited from restarting locked out machines.

LOCKOUT/TAGOUT PROCEDURES The types of energy isolation devices (electrical panels, circuit breakers, valves, etc) will dictate what type of lockout mechanisms you will need. When performing lockout procedures, make sure to follow your facilitys Energy Control Plan and also be aware of company policy. Once initial procedures are completed, you may need to dissipate stored energy, such bleeding systems, releasing spring tension or releasing extreme heat or cold. After dissipating residual energy, additional Lockout/Tagout mechanisms may need to be installed. Once these procedures are complete, verification should be performed that will make sure the machine cannot become energized. SPECIAL LOCKOUT PROCEDURES Special Situations that require additional lockout procedures include shift changes, functionally linked equipment and when contract work is involved. During shift change, the departing personnel must remove their lockout devices while the incoming personnel is installing theirs. Some situations, such as when the machines power source is not in sight of the operating controls, require the use of a buddy system. One person will lock out the power, while the buddy observes and tests machinery. When there are groups of people servicing equipment, special lockout devices that can accommodate multiple locks are used; each employee installs his own lock and tag to the device. Both outside contractors and facility representatives must inform each other about their Lockout/Tagout operations. LOCKOUT/TAGOUT RELEASE PROCEDURES After servicing is complete, remove all non-essential and tools from the area, clear personnel and check to make sure the machine is ready to operate. Lockout devices must be removed by the employees that installed them. Only in emergency situations can management remove an employees lock or tag. Machines that must undergo temporary restart while locked out should be handled exactly as normal release and restart. ELECTRICALLY POWERED EQUIPMENT When working with electrically powered equipment, identify all sources of power and shut off the equipment at the point of operation before disconnecting. Stand away from the switchbox or panel on the side where the switch is located and move the switch to the off position. Use appropriate procedures to lock out the energy sources. It may me best to lock out the main panel if there are more than one source of electrical energy. Some machinery may require the removal of fuses. Capacitors can store electrical charges and must be grounded before starting work. HYDRAULIC AND PNEUMATIC SYSTEMS Hydraulic and pneumatic systems usually involve pipes and valves and the hazards are usually pressure releases of steam, hydraulic fluid, etc. Lockout devices such as padlocks with chains and valve clamps are specifically made for these types of systems. Other steps that should be taken when working with these systems include bleeding pressurized lines, testing using downstream valves and installing blinds in piping when appropriate. OTHER SAFETY TIPS Additional precautions should be taken with major moving parts. Blocks, brackets or pins should be used and the equipment should be isolated from the vibrations of nearby traffic and other machines. The person removing the last lockout device must make sure the work is complete and that the equipment is safe to operate. Communication and working together are the keys to good Lockout/Tagout procedures.