Lockout / Tag out

Lightning in a Bottle

1. Lightning: Energy in its raw display of power. Lightning strikes can be as

powerful as one million volts. Lightning strikes can reach temperatures of fifty
thousand degrees F.

2. Lightning can not be controlled. You never know where it will strike. But that is
not the case with the energy sources that we work with.

3. These energy sources may be in various forms. But they can be controlled.

4. Think of it as catching lightning in a bottle. Raw power. Raw energy. Captured

and controlled for a moment by a lock and key.

5. Occupational Safety and Health Administration (OSHA) created the:

 “Lockout / Tag out” standard to protect employees from the unexpected

start-up or release of stored energy from equipment that could harm a
worker performing service or maintenance.

6. Employers must have a written, step-by-step energy control plan that follows the
OSHA standard.

7. Employees need to be familiar with and understand the Lockout/Tag out plan.

8. Energy Types: We usually associate electricity with the words lockout/tag out.
But there are other types of energy.
 Electricity: Electrical energy is present in power transmission lines,
circuit breakers, motors and even in devices such as batteries that store
electrical energy.
 Hydraulic: Hydraulic energy is fluid under pressure. Lift trucks are often
run by hydraulic energy.
 Pneumatic: Pneumatic energy is air under pressure. Pneumatic nailing
guns use this type of energy.
 Pressurized liquids and gases: Examples include steam and chemicals.
These energy sources are present in pipes, supply lines and storage tanks.
  Combined energy types: Many machines use combined energy types. For
example, some hydraulic systems use electric motors to run the pumps that
create the hydraulic energy.

9. The lockout/tag out standard applies to all of these types of energy as well as any
other energy source that can cause bodily harm.

10. Lockout and tag out basics: What do lockout and tag out mean? Both are
procedures that are used to prevent hazardous energy from injuring workers
 Lockout: A lock is put on a disconnect switch, circuit breaker, valve
handle or other energy isolating device in the closed or off position. The
lock commonly used for a lockout is a standard lock with a key. However, a
combination lock is also acceptable.
 Tag out: A written warning tag is placed in the lock out area of the
equipment or the machine. Tags do not provide the physical restriction of a
lock. The OSHA standard allows a tag in the place of a lock only if the tag
out provides the same amount of protection of a lockout.
i. Tags must be made so that if they are exposed to liquids or acids they
can still be read.
ii. Tags must have a warning on them that has the same wording and look
in order to make them easier to recognize.
iii. Tags must be attached securely so that they can’t accidentally fall off.

11. All lockouts and tags must be consistent in color, shape and size.

12. OSHA considers using a lock safer than just using a tag. Most companies
require both lockout and tag out.

13. When only tags are used, extra steps must be taken to prevent the
energizing of machinery. These extra steps may include removing a valve handle,
or blocking a control switch.

14. Employees should be trained in the limitations of the tag out system. It is
very important to obey the warnings on tags. Especially since they will not keep
you from turning on the power.

15. Employers provide all lockout/tag out materials needed. These items must
be long lasting and not easily removed.
16. Each lock and tag must have some way to identify who it belongs to . Each
person may be issued a lock or a series of locks. Never lend locks/tags to a co-
worker.

17. Devices used for lockout/tag out should be used solely for that purpose and
should never be used for anything else.

18. Applying and removing locks/tags can only be done by authorized (see #25
below) employees.

19. Never remove someone else’s lock or tag.

20. When working with outside contractors, learn their method of lockout/tag
out as well.

21. Remember that using a lock or a tag is a big responsibility. It should not be
taken lightly.

22. OSHA’s lockout/tag out standard:

 According to OSHA’s lockout/tag out standard, whenever performing
service maintenance on any machine where unexpected startup or the
release of stored energy could cause injury, lockout/tag out procedures
must be followed.
 Service and maintenance activities require a lockout/tag out if the
employee is required to:
i. remove or bypass a guard or safety device.
ii. place any part of his or her body into a machine process point of
operation or associated danger zone.
 Minor adjustments that take place during, or are part of normal
production, are not part of the standard.

23. Sometimes equipment may be de-energized simply by unplugging it.

Electrical cords and plugs are exempt from lockout/tag out if energy is
completely removed by unplugging the source, and if the plug is under the
exclusive control of the person working on the equipment.

24. The use of a plug lock prevents it from being put into a socket and is a good
option.
25. Authorized and affected employees:

 An authorized employee is the person who physically applies the lockout

or tag out on a machine in order to perform service or maintenance.
 An affected employee is someone who doesn’t actually perform service
and maintenance but may operate the machinery or work in the area where
the service or maintenance will be performed.

26. Six steps of lockout/tag out: There are six steps to proper lockout/tag out.
1. Prepare for shutdown.
 When preparing for a shutdown equipment, it is important to answer
the following questions:
 How many sources of energy does the machine have?
 How do I control these sources of energy to completely disable
the machine?
 Before working on any machinery or equipment, be familiar with how it
works, and how it receives and releases energy.
 A written procedure and checklist should be available.
2. Shutdown.
 Turn off the equipment according to procedure. This may involve
turning a switch to off, or a more complicated method.
 Ask a supervisor when unsure of any part of the procedure.
3. Isolate energy source.
 Isolating the equipment means finding and isolating every energy
source that feeds it. This includes switching off circuit breakers, tracing
lines or pipes, turning off disconnect switches and capping any
secondary sources of energy.
4. Apply lockout/tag out devices.
 Locks and or tags must be applied to all energy isolating equipment,
valves and switches to hold them in the off or safe position.
 Anything that could restore the flow of energy to the work area must
be locked out.
 The use of both locks and tags is preferred. Tags provide information
that a lock by itself will not. The type of work being done, estimated
work time and the name of the authorized person who is performing the
work are examples of the information provided by tags.
 A tag also helps clearly identify that the machine has been locked out.
 If only the tag out procedure is used, the tag should be placed where
the lock would go.
  When working on a piece of equipment that can’t physically be locked
out, place a tag as close to the energy isolating device as possible.
 OSHA now requires all new machinery come with an energy isolating
device that can be locked.
 OSHA also requires that older equipment being modified or renovated
must be outfitted for lockout.
 So far we have talked about only one person locking out a piece of
equipment. However, it is often necessary for several people to lockout
a piece of equipment. Employers have a written procedure explaining
how to do this.
 Generally, in multiple lockouts (when more than one energy source has
to be locked out) OSHA allows only one authorized person to lock out
each energy source. The key to each lock would be placed in the lock
box. Then all other authorized persons who will be working on the
equipment lock the lock box shut with their personal locks. No one can
get to the keys to unlock the equipment’s energy sources until all
personnel have removed their locks from the box. This method ensures
that each person is protected.
5. Release stored energy.
 True or false? Once locks and tags are placed on energy sources, the
worker is safe. The answer is sometimes true and sometimes false.
 What makes the difference? Some equipment stores up energy and
this is a hazard. To ensure protection relieve, disconnect or restrain any
hazardous energy that could be present.
 Check that all moving parts have stopped.
 Relieve trapped pressure.
 Blank out (insert plate to prevent any possible flow) pipe flanges.
 Block or support elevated equipment.
 If it is still possible that energy might still build up, check it
continuously until you have completed servicing or maintenance. Or
until the hazard no longer exists.
6. Verify:
 Check the steps.
 Make sure that every energy source is shut down, blocked off,
controlled and locked or tagged out.
 Tell everyone in the lockout area that the equipment will tested to
verify that all energy sources have been controlled.
 Make sure that everyone is away from the area.
 Press all start buttons.
  Pull all start levers.
 Try any other activating controls that might restore power to the
machine. This includes checking remote computer controls.
 After checking all power sources, make sure to return them to the off
position. This is very important. It prevents the equipment from starting
by itself when the energy is restored to it.
 After verifying that all energy sources have been controlled, it is safe
to begin working on the equipment.

27. Removal and re-energizing.

 When the work is complete, it is time to safely remove lockout/tag out
devices and re-energize the equipment. The OSHA standard has three steps
that cover this procedure:
1. Restore:
 Restore the work area to operating conditions. This means
ensuring that all tools have been removed from the work area. It also
means double checking that all equipment components are in place and
in working order. Machines must be operationally in tact.
 It is also important to replace safety features such as machine
guards and to close any access panels that were open.
2. Inform:
 Before removing any locks or tags, all affected employees must be
told that all the lockout/tag out devices are going to be removed.
 Employees must also be informed after all the lockout/tag out
devices have been removed.
 This can be done by gathering everyone together, or by a checklist
of affected employees.
 Before removing any devices, and before re-energizing equipment,
make sure that all employees are safely out of the operating area.
3. Remove:
 After notifying everyone that the lockout/tag out devices will be
removed, begin taking off the locks and tags.
 Each device must be removed by the same person who put it on.
 If the person who placed the device on the equipment is not
present, do not remove the device yourself.
 A written energy control procedure will list the specific steps to
follow for this situation.
  When re-energizing the equipment, follow the standard procedures.
From time to time, check the equipment and the work area during
startup to make sure that it is still safe.
 Finally, if there is a machine that is off but has no lock or tag on it,
do not assume that it is safe to turn it on. Double check before restoring
power to any machine.

28. Inspection and training:

 The OSHA lockout/tag out standard requires the employer to inspect the
energy control program each year.
o Energy control program: It describes the:
 Energy source for each machine.
 Company’s procedure for shutdown, lockout/tag out and restart
of equipment.
o During the inspection, the inspector will ask each of the authorized
employees about their responsibilities under this energy control
program.
o If the inspector has reason to believe that an employee does not have
satisfactory knowledge of procedures, that employee will be retrained.
o Otherwise, retraining is only required when there is:
 a change in job assignment
 a change in machines or processes where a new hazard is
present
 a change in procedures
 Lockout/tag out is such an important safety tool that most employers
retrain every year.

29. Review:
 Make sure to follow the six steps of lockout/tag out:
1. Prepare for shutdown.
2. Shutdown.
3. Isolate energy source.
4. Apply lockout/tag out devices.
5. Release stored energy.
6. Verify:
 When re-energizing equipment, follow the three steps:
1. Restore
2. Inform
3. Remove
 Skipping any of these steps is not worth the risk.
 Controlling the energy source is always critical to everyone’s safety.