OSHAcademy Course 710

LOCKOUT/TAGOUT
Hazardous Energy Control
 Objectives

• Gain a greater awareness of the requirements

detailed in Oregon Administrative Rules.

• Understand responsibilities.

• Understand lockout/tagout procedures.

Part I: Scope and Application

OAR 437, Div 2J, 1910.147,

The Control of Hazardous Energy (Lockout/Tagout)

(c)(1) Energy Control Program. The employer shall establish a program

consisting of energy control procedures, employee training and
periodic inspections to ensure that before any employee performs any
servicing or maintenance on a machine or equipment where the
unexpected energizing, start up or release of stored energy could occur
and cause injury, the machine or equipment shall be isolated from the
energy source, and rendered inoperative.

What are the three key elements of an energy control

program?

Procedures Training Inspections

Scope: The lockout/tagout rule covers the following employees:

Authorized Affected Other

Person who services or performs

maintenance on machines or equipment.
__Affected Employee

__Authorized Employee Person who operates or uses a machine

or equipment which is being serviced or
__Other Employee has maintenance being performed.

Person who works in an area where

lockout/tagout procedures are being
used.
Procedures must be followed when...

...servicing and/or maintenance when unexpected

energization, start-up or release of stored energy could
cause injury.
What is servicing or maintenance?

Some workplace activities considered to be

“Servicing and/or maintenance” of machinery and
equipment” include:

Adjusting... inspecting... modifying...

constructing... re-tooling...
lubricating... removing jams... cleaning...
 Sources of Energy

Sources of energy as possible that could

cause injury
Pneumatic Hydraulic Mechanical

Kinetic Thermal Radiation

Nuclear Electrical
This standard does not apply to:

•Installations under the control of electric utilities.

•Exposure to electrical hazards from work on, near,

or with conductors or equipment in electric
utilization installations.

•Oil and gas well drilling and servicing.

• Normal production operations…unless:

 Guards, or other devices are removed/bypassed; or

 Employees place themselves in an area where work on

materials, etc., is actually being performed; or

 Employees place themselves in any area considered

dangerous during the normal operating cycle.

• Work on cord and plug connected equipment.

• Hot tap operations, under special conditions.

Part 2: The Written Energy Control Plan

A written Energy Control Plan must include the scope,

purpose, authorization, rules, and techniques used to
control hazardous energy, and the means to enforce
compliance, including:

1. A specific statement of intent to use the

procedures;

2. Specific procedures to shut down, isolate, block

and secure machines or equipment;

3. Specific procedures to place, remove and transfer

lockout/tagout devices;
 4. Assigning responsibility for lockout/tagout devices;

5. Requirements and procedures to test machines

and machinery to determine and verify effective
lockout/tagout devices, and other energy control
measures.

Why is a comprehensive written plan critical to a

successful lockout/tagout program?
Why is a comprehensive written plan critical to a
successful lockout/tagout program?

• It informs and directs

• It clarifies duties and responsibilities

• It allows for effective procedures.

• It ensures training will be conducted.

• It ensures the periodic inspections will be

conducted.
What are some reasons a lockout/tagout program may
not work effectively?

• People may not respect it.

• Leadership may be lacking.

• Accountability may not be clearly established.

• Training may not be effective and/or

monitored.

• Supervisors may be leading by wrong

example.
Who’s responsible….who’s accountable….and
for what?

• Employer
• Managers Enforcement
Resources
• Supervisors Supervision
Leadership
• Employees Training
Steps to developing a successful program

1. List all equipment or machines that need servicing

or maintenance.

2. Identify those machines which could unexpectedly

start up or release stored energy while being
serviced or maintained.

3. Determine the steps in the maintenance or servicing

task; and

4. Review each step for the potential of a hazard from

all energy sources.
List three types of equipment/machinery and any
possible energy sources hazards, including
magnitudes.
If any of the conditions below exist, the employer
must include the machine or equipment in the
written program:

The machine or equipment has potential for stored or

residual energy, or reaccumulation of stored energy after
shutdown which could endanger employees; or

The machine or equipment has more than a single energy

source; or

The isolation and locking out of any single energy source

will not completely de-energize and deactivate the
machine or equipment; or
The lockout device is not under exclusive control of
an authorized employee performing the servicing or
maintenance; or

The servicing or maintenance of the machinery or

equipment creates hazards for other employees; or

The employer has had accidents involving the

unexpected activation or re-energizing of the machine
or equipment during servicing or maintenance.
Part III: Lockout/Tagout Procedures

Step 1 - Prepare for Lockout

As a minimum the following information should
be reviewed:

• Types and magnitudes of energy;

• Hazards posed by that energy; and

• Methods to effectively control the energy.

Particularly close attention must be given to energies
(such as gravity, electrical, high pressure) that can be
stored or re-accumulated after shut-down.

Prior to shutdown all affected employees will be

notified to clear their work area and/or any other area
that might be hazardous.

What means or methods can be used to ensure

the above review and notification is conducted
prior to lockout/tagout?
Step 2 - Shutdown

• Machinery and equipment that is capable of being

locked out should be shut down in an orderly
manner using shutdown checklist procedures.

• If more than one authorized employee is involved in

shutdown, the maintenance team leader should make
sure all assistants have accomplished their tasks
and are aware that shutdown will occur.

Why is the actual instant of shutdown or

startup so hazardous in the lockout/tagout
process?
Step 2 - Isolation

• All energy isolation devices should be located and

operated to completely de-energize and isolate the
equipment. The authorized employee will verify
operation of each energy isolation device.

An “energy isolating device” physically

prevents…

Transmission or __________
...the _____________ Release of energy.

What are some examples of energy isolation

devices?
T/F Pushbuttons, selector switches and other control
circuit type devices are energy isolating devices.
Step 4 - Lockout/Tagout Application
Lockout Devices

• Lockout devices must be used to secure energy

isolating devices unless the machinery or
equipment is not capable of being locked out.

• Only authorized employees will affix lockout/tagout

devices.

• Lockout devices must be able to hold energy

isolation devices in a “safe” or “off” position.
Before applying and after removing
lockout/tagout devices, the authorized
employee…

...must notify all affected employees.

 A lockout device must use a positive means
such as a lock, either key or combination type,
to hold energy isolation device…

In a safe or off position to prevent machinery of

equipment from being energized.
What are some examples of lockout devices?

Electrical Plug
Lockout Devices
Gate Valve Lockout

Fuse Lockout
Devices

Group Lock Box

 Ball Valve
Lockout Devices
Pneumatic
Lockout Devices

Wall Switch
Lockout Devices

Cable Lockout
System
 Tagout Devices

A “tagout device” is a prominent warning device, such

as a tag and a means of attachment, which can be
securely fastened to an energy isolating device in
accordance with an established procedure, to indicate
that the energy isolating device and the equipment
being controlled...
Operated
... may not be ______________ until the
Removed
tagout device is ____________.
 • Tagout devices will be used only if
machinery or equipment is not capable
of being locked out.

• Only authorized employees can affix

tagout devices.

• Tags will clearly state that moving energy isolating

devices from the “safe” or “off” position is strictly
prohibited.

• If a tag cannot be affixed to the energy isolating device,

it will be located as close as safely possible to the
device so that the tag is obvious to anyone attempting
to operate the device.
 Tagout Devices

• Tagout devices will be used only if machinery or

equipment is not capable of being locked out.

Machinery or equipment is “capable of being locked

out” if:

• It has a hasp or other means to attach a lock; or

• It has a built in locking mechanism

• Does not have to be dismantled or altered to

achieve lockout.
• Only authorized employees can affix tagout
devices.

• Tags will clearly state that moving energy isolating

devices from the “safe” or “off” position is strictly
prohibited.

• If a tag cannot be affixed to the energy isolating

device, it will be located as close as safely possible
to the device so that the tag is obvious to anyone
attempting to operate the device.
T/F All newly installed machines or equipment must
have energy isolating devices capable of accepting a
lockout device.

T/F If you replace, major repair, renovate or modify a

machine or piece of equipment it must have an
energy isolating device capable of accepting a
lockout device.
When can an employer use a tagout system?

1. When an energy isolating device is not capable

of being “locked out”.

2. If employer can demonstrate (prove) that using

a tagout system will provide full employee
protection.
What two tests must be met to demonstrate
full employee protection?

1. Tags can be placed where lockout devices would

have been placed.

2. The employer demonstrates equivalent protection

can be obtained with tags.

Opening an extra disconnect

How? Removing a valve handle
Removing a circuit or fuse
Blocking a ram
etc…….
Which is the preferred method: Lockout or
Tagout?
Protective materials and hardware

Materials and hardware must be provided by the

employer.

Each lockout/tagout device must be singularly identified

as being used only for lockout/tagout.

Lockout/tagout devices must be standardized and

substantial.

They must identify the user

Lockout devices must be substantial enough to prevent

removal without excessive force or unusual techniques.
Tagout devices must be substantial enough to prevent
inadvertent or accidental removal. They must be

• Non-reusable
• Attachable by hand
• Self-locking
• Non-releasable with not less than 50 lb locking
strength
• Design/characteristics at least equivalent to a one-
piece, all environment-tolerant nylon cable tie.

identify
Lockout/tagout devices must ______________ the user.
Step 5 - Controlling Stored Energy

• Stored Energy. Immediately after applying lockout or

tagout devices, the authorized employee will ensure all
potentially hazardous stored or residual energy is
relieved, disconnected, restrained, and otherwise
rendered safe.
Remember!

If stored energy can be re-accumulated to a hazardous

level, authorized employees must continually verify that
the machinery or equipment is safely isolated until the
possibility of re-accumulated energy no longer exists.

What are some examples of stored or residual energy?

Step 6 – Verifying Isolation

Verification of Isolation. Before starting work on a

machine or equipment that is locked or tagged out,
the authorized employee will verify that the
machinery or equipment is actually isolated and de-
energized.

VERIFY ZERO ENERGY STATE!

How do you verify that a machine or equipment is

actually isolated or deenergized?
Step 7. Release from Lockout/Tagout
Equipment.

• Make sure machinery or equipment is properly

reassembled.

• Inspect machinery or equipment to make sure

nonessential items have been removed.

Employees.

• Make sure all employees are outside danger zones.

• Notify affected employees that lockout/tagout devices

have been removed and that energy is going to be
reapplied.
Removing lockout/tagout devices.

• Only the authorized employee who applied the

lockout or tagout device may remove that
device.
Exception - When the authorized employee is not
available to remove it, the device can be removed
under the direction of the employer.

 Specific procedures and training must be developed,

documented, and implemented into your energy
control plan.

 At a minimum, the procedures must include:

 verification that the authorized employee who applied the

device is not at the facility;

 Making all reasonable efforts to contact him/her to inform

them that their lockout or tagout device has been removed;
and

 Ensuring that they are aware of this upon returning to work.

At a minimum, the procedures must include:

• verification that the authorized employee who

applied the device is not at the facility;

• Making all reasonable efforts to contact him/her to

inform them that their lockout or tagout device has
been removed; and

• Ensuring that they are aware of this upon returning

to work.
Who does the authorized employee notify prior to
removing any lockout/tagout devices?

T/F The authorized employee also notifies the affected

employee after lockout/Tagout devices have been
removed and before equipment has been started.

If the authorized employee is not available, who is

authorized to remove the lockout or tagout device?
Additional Requirements

Testing/Positioning Machines or Equipment.

Whenever lockout/tagout devices are removed to test or

position machines and equipment, or their components,
the authorized employee must complete full shutdown,
isolation, and release from shutdown procedures.

T/F Modified/shortened procedures may be used to

isolate and startup equipment when testing?

Why are employees injured so frequently while testing

the machinery or equipment during maintenance?
Outside Personnel

• Outside servicing personnel, contracted to perform

maintenance or other services requiring lockout/tagout
procedures, must not begin work until the
maintenance supervisor is satisfied that their
lockout/tagout procedures are at least equivalent to
company procedures.

• The host employer must also ensure company

employees understand and comply with contracted
personnel lockout/tagout procedures, is used.
Who is responsible if an employee is injured
because an outside contractor did not follow
proper lockout/tagout procedures?
Shift/Personnel Changes

• Specific procedures must be utilized during shift or

personnel changes to ensure the continuity of
lockout or tagout protection, including provision for
the orderly transfer of lockout or tagout device
protection between both off-going and oncoming
workers.

What is the intent or purpose of the

procedures above?

Ensure the continuity of protection!

The BIG exercise! Water
in
Design a lockout- Shut off
valve
tagout procedure.

500 gallon capacity

Spring
loaded lever
CB
Panel
2.5 KW heater
under tank
Coffee
220 vac out
Part 4: Lockout/Tagout Training

General Requirements

• Training in lockout/tagout must be provided to all

employees who may be in an area where energy
control procedures are used.

• This training will make sure that the purpose and

function of the energy control program are
understood and that employees gain the needed
knowledge and skills to safely apply, use, and
remove energy controls.
Minimum training will include:

Authorized employees must be able to recognize

hazardous energy sources, types and magnitudes
of energy in the workplace, and methods and
means necessary to isolate and control the energy.

Affected employees must be able to recognize the

purpose and use of energy control procedures.

Other employees must be able to recognize

procedures and prohibitions of the energy control
program.

What are effective training strategies for each level of

training?
 Two Types of Safety Training

Level One: General Safety

Education

• General/Specific information and instruction

• Knowledge and skills are not measured at the end of
training
• Write goals for students. Instructional objectives are
not required
• All you have to do is attend to get a certificate
• Measurement focuses on student's reaction to the
training session rather than learning
• Measurement tools include - "smile sheet" evaluation
forms
 Level Two: Technical Safety
Training

• Describes general/specific policies, procedures,

practices
• Write goals and operational objectives for students.
• Knowledge and skills are measured immediately after
training in the learning environment.
• You have to "pass the test" in class to get a certificate.
• Measurement tools - oral/written exam, skill
demonstration.
• This level is required for most safety training!
What’s On-the-Job Training
 The basic steps in OJT

Step 1. Introduction.
 The basic steps in OJT

Step 1. Introduction.
Step 2. Trainer show and tell.

Trainer: EXPLAINS and PERFORMS

each step.

Trainee: OBSERVES each step and

QUESTIONS .
 The basic steps in OJT

Step 1. Introduction.
Step 2. Trainer show and tell.
Step 3. Trainer ask and show.

Trainee: EXPLAINS each step and

RESPONDS.

Trainer: PERFORMS each step and

QUESTIONS.
 The basic steps in OJT

Step 1. Introduction.
Step 2. Trainer show and tell.
Step 3. Trainer ask and show.
Step 4. Trainee tell and show.

Trainee: EXPLAINS, GETS PERMISSION,

and then PERFORMS each step.

Trainer: GIVES PERMISSION,

OBSERVES each step and QUESTIONS .
 The basic steps in OJT

Step 1. Introduction.
Step 2. Trainer show and tell
Step 3. Trainer ask and show
Step 4. Trainee tell and show

Step 5. Conclusion
 The basic steps in OJT

Step 1. Introduction.
Step 2. Trainer show and tell
Step 3. Trainer ask and show
Step 4. Trainee tell and show
Step 5. Conclusion

Step 6. Document
 The basic steps in OJT

Step 1. Introduction.
Step 2. Trainer show and tell
Step 3. Trainer ask and show
Step 4. Trainee tell and show
Step 5. Conclusion
Step 6. Document

Step 7. Validate
Training on Tagout Devices

If tagout devices are used, further training on tagout

systems need to emphasize that:

1. Tags are warning devices only

2. Tags must not be removed without the authorized
employee’s approval, and never bypassed, ignored
3. Tags must be legible, and understandable
4. Tags must be able to withstand conditions
5. Tags may give employees a false sense of security
6. Tags must be securely attached
Retraining
Employees will participate in retraining at the following
times:

1. Change in job assignment.

2. Change in machinery or equipment, or
3. Change in operating procedures, or
4. You note deficiencies in their understanding or
performance!

Documentation! If it isn't in writing…it didn't get

done!
Part V: Lockout/Tagout Annual Inspections

Annual inspections on lockout/tagout procedures must

be conducted by an authorized employee other than the
one(s) using the energy control procedure being
inspected.

The purpose of the inspection is to correct any

deviations or inadequacies in the procedures.

The inspector and authorized employee(s) will review

responsibilities under the energy control procedure.
Documentation!

The employer must certify that the inspection was

conducted. Elements of the certification should include:

a. Identification of equipment or machinery

b. Date of inspection
c. Employees included in the inspection
d. Person performing inspection

How often must lockout/tagout inspections

occur?

Who must conduct the inspection?

Let's Review
That's it….

Thanks for coming and drive safe

because stuff happens