BASIC SAFETY

LOCKOUT/TAGOUT
POLICY
AND
PROCEDURE
 What do I need to know?
• The Lockout/Tagout Safety Policy and Procedures and its
intent.
• The operations and activities covered.
• Who can lockout equipment and machinery
• The types of energy sources.
• The types of lockout devices that are available and where they
are located.
• When to lockout.
• The sequence of lockout as listed in your location’s
procedures.
• What to do when machines and equipment cannot be locked
out.
• The procedure to re-energize machines and equipment.
• What to do when more than one person is required to
lockout on the same piece of equipment.
• The procedure for when and how to remove the lock of
another employee.
 Why Is Lockout/Tagout Important?
This practice helps safeguard employees from
hazardous energy while they are performing
service or maintenance on machines and
equipment.

The OSHA standard 29 CFR §1910.147, identifies

the practices and procedures necessary:

• a written program and lockout procedures,

• shut down and lockout or tagout of machines and
equipment,
• employees training in their role in the lockout/tagout
program, and
• periodic inspections conducted to maintain or
enhance the energy control program.
 What Is The Purpose Of The Lockout Program?

Our procedure is designed to ensure the safety of our

employees when working on and/or around equipment
and machinery during:
• set-ups
• corrective maintenance
• scheduled maintenance
• installation of equipment, and
• removal of equipment
The scope of our program covers all employees:
• full time
• part time, or
• temporary agency employees
Our program also covers all contractors performing
work at all division locations and job sites.
 Who can perform a lockout?
There are three classes of employees:
• Authorized employees: An employee who has
responsibility to lock or tag machines or equipment in
order to perform servicing or maintenance.
• Affected employees: An employee who is required to
use machines or equipment on which servicing is
performed under the Lockout/Tagout standard or who
performs other job responsibilities in an area where
such servicing is performed.
• Other employees: All employees who are or may be in
an area where energy control procedures may be
utilized.

At any facilities, the standard practice is that only

authorized employees can perform a lockout.
 What activities or operations are
covered?
• Any servicing and/or maintenance of
machines or equipment when the source of
energy to the machines or equipment is
electrical, mechanical, hydraulic, pneumatic,
chemical, thermal, or other energy.
• Constructing, installing, setting up, adjusting,
inspecting, modifying, maintaining and/or
servicing machines or equipment, including
lubrication, cleaning or unjamming of
machines or equipment, and making
adjustments or tool changes, where
employees could be exposed to the
unexpected energization or startup of the
equipment or release of hazardous energy.
 What are the sources of energy?
A survey was done at each facility to
locate and identify all energy sources
and isolating devices. Here are some
important definitions to know.
Energized: Machines and equipment
are energized when they are
connected to an energy source or they
contain residual or stored energy.
Energy source: Any source of
electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, or other
energy.
Electrical Mechanical

Hydraulic Pneumatic

Thermal Chemical

Gravity
 What are lockout devices?

Lockout device: Any device that uses a

positive means, such as a lock, blank
flanges and bolted slip blinds, to hold an
energy-isolating device in a safe position,
thereby preventing the energizing of
machinery or equipment.

At our facilities, you can find the lockout

devices stored in the lockout center.
 What are Energy-Isolating devices?

Energy-isolating device: A mechanical device that physically

prevents the transmission or release of energy, including but
not limited to the following: A manually operated electrical
circuit breaker; a disconnect switch; a line valve; a block;
and any similar device used to block or isolate energy. Push
buttons, selector switches and other control circuit type
devices are not energy isolating devices.

Plug out

Valve Devices

Circuit Breaker Device

 When do I lockout?
You must lockout before you begin any servicing
or maintenance activities where the unexpected
energization, (start-up or release of stored energy)
could cause injury.
Procedures for locking out equipment and
machinery are attached at the control panel.
Information in the procedure will provide the
location of energy sources, the magnitude of
energy, the isolation devices, and the sequence
required to shut down and restart the machine or
equipment.
A good rule of thumb is: whenever the guarding is
removed, or by-passed, or any part of your body
can come in contact with the working parts during
service/maintenance lockout must be done!

Basic Rules For Using Lockout Or Tagout System Procedure At Facilities

 What is the shut-down sequence?
If there are employees in the area, inform them that the
equipment will be taken off line for maintenance, repair, service,
etc.
1. If the machine is operating, shut it down by the normal stopping
procedure (depress stop button, open toggle switch, etc.).
2. Operate the switch valve, or other energy isolating device(s) so
that the equipment is isolated from its energy source(s). Stored
energy (such as that in springs, elevated machine members,
rotating flywheels, hydraulic systems, and air, gas, steam, or
water pressure, etc.) must be dissipated or restrained by
methods such as repositioning, blocking, bleeding down, etc.
3. Lockout and/or tagout the energy isolating devices with assigned
individual lock(s) or tag(s).
4. After ensuring that no personnel are exposed, and as a check on
having disconnected the energy sources, operate the push
button or other normal operating controls to make certain the
equipment will not operate.
CAUTION: Return operating control(s) to "neutral" or "off"
position after the test.
5. The equipment is now locked out or tagged out.
 What if I have to leave before service is
finished?
If you are involved with a lockout procedure
and must leave the job before completion
you should obtain a department lock, replace
your lock with the department lock, and
inform your supervisor that you are leaving
and have replaced your lock with the
department lock.
Similar procedures are followed for shift or
personnel changes at our facilities.
In all cases communication is the key and
the rule. You must inform your supervisor
that a change of personnel or that you are
leaving the facility.
 What if we have to call in an electrician?

Periodically, it may be necessary to use

contractors and/or outside personnel, such
as an electrician, to perform service or
maintenance.

All necessary information about our program

and the contractor’s program must be
exchanged.

When contractors or outside personnel

perform service or maintenance on the
grounds of any facility or job site, the
authorized employee of the organisation,
responsible for their work activity. must have
the contractor’s representative sign a Safety
Lockout/Tagout Outside Contractors
Acknowledgement.
What applies when two or more people work
on a machine?
When more than one person is required to
lockout or tagout equipment, each shall place
his/her own personal lockout device or tagout
device on the energy isolating device(s).

If the energy isolating device(s) can only

accept one locking device, then a hasp must
be used to insure continuity in protecting
everyone on the crew performing the service
or maintenance.

The employee initiating the lockout (primary

employee) should place his/her personal lock
in the upper right hand position. All other
locks (contractors too) would be placed
below the primary lock.
 What’s the Procedure for Removal of Locks and Tags?

Before your lockout or tagout devices are removed

and energy is restored to the machine or equipment,
you must take the following actions or observe the
following procedures:
1. Inspect the work area to ensure that non-essential
items have been removed and that machine or
equipment components are intact and capable of
operating properly;
2. Check the area around the machine or equipment to
ensure that all employees have been safely
positioned or removed,
3. Make sure that locks or tags are removed ONLY by
those employees who attached the locks or tags;
and
4. Notify affected employees after removing locks or
tags and before starting equipment or machines.
What happens if a Lockout procedure
changes?
The rule requires that a periodic
inspection or audit of each
procedure, be performed at least
annually to assure that the lockout
procedures continue to be
implemented properly and that our
employees are familiar with their
responsibilities under those
procedures.
At any facilities, It is the responsibility
of the Plant Manager to periodically
conduct audits to ensure compliance
with the Safety Lockout/Tagout
procedure.
The audits are to be performed on a
regular basis at least annually. A
copy of the audit report shall be
forwarded to the Safety Director.

1. Any deviations to the established

procedures found during the audit
could result in disciplinary action,
up to and including termination.

2. All deviations or inadequacies

shall be reported and the
procedures shall be changed or
corrected as necessary.
 PURPOSE
This procedure establishes the requirements for the
lockout or tagout of energy isolated devices. It shall be
used to ensure that the machine or equipment are
isolated from all potentially hazardous energy, and locked
out or tagged out before employees perform any
servicing or maintenance activities where the unexpected
energization, start-up or release of stored energy could
cause injury.
Responsibility
Appropriate employees shall be instructed in the safety
significance of the lockout (or tagout) procedure and shall
sign a training acknowledgement form (name(s)/job title(s)
of employees authorized to lockout or tagout). Each new
or transferred affected employee and other employees
whose work operations are or may be in the area shall be
instructed in the purpose and use of the lockout or tagout
procedure.
 Preparation For Lockout

Make a survey to locate and identify all isolating

devices to be certain which switch(s), valve(s) or other
energy isolating devices apply to the equipment to be
locked or tagged out. More than one energy source
(electrical, mechanical, or others) may be involved.
 Sequence Of Lockout or Tagout
System Procedure
1. Notify all affected employees that a lockout or
tagout systems is going to be utilized and the reason
therefore. The authorized employee shall know the
type and magnitude of energy that the machine or
equipment utilizes and shall understand the hazards
thereof.

2. If the machine is operating, shut it down by the normal

stopping procedure (depress stop button, open toggle
switch, etc.).

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 Sequence Of Lockout or Tagout
System Procedure

3. Operate the switch valve, or other energy isolating

device(s) so that the equipment is isolated from its
energy source(s). Stored energy (such as that in
springs, elevated machine members, rotating flywheels,
hydraulic systems, and air, gas, steam, or water pressure,
etc.) must be dissipated or restrained by methods such
as repositioning, blocking, bleeding down, etc.

4. Lockout and/or tagout the energy isolating devices

with assigned individual lock(s) or tag(s).

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 Sequence Of Lockout or Tagout
System Procedure

5. After ensuring that no personnel are exposed, and

as a check on having disconnected the energy sources,
operate the push button or other normal operating
controls to make certain the equipment will not
operate.
CAUTION: Return operating control(s) to "neutral"
or "off" position after the test.

6. The equipment is now locked out or tagged out.

 Procedure
Involving More Than One Person
In the preceding steps, if more than one individual is
required to lockout or tagout equipment, each shall
place his/her own personal lockout device or tagout
device on the energy isolating device(s). When an
energy isolating device cannot accept multiple locks or
tags, a multiple lockout or tagout device (hasp) may be
used. If lockout is used, a single lock may be used to
lockout the machine or equipment with the key being
placed in a lockout box or cabinet which allows the
use of multiple locks to secure it. Each employee will
then use his/her own lock to secure the box or
cabinet. As each person no longer needs to maintain
his or her lockout protection, that person will remove
his/her lock from the box or cabinet.
 Basic Rules For Using Lockout Or
Tagout System Procedure
All equipment shall be locked out or tagged out to
protect against accidental or inadvertent operation
when such operation could cause injury to personnel.
Do not attempt to operate any switch, valve, or other
energy-isolated device where it is locked or tagged
out.

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 Basic Rules For Using Lockout Or
Tagout System Procedure
1. If a device cannot be locked out due to the
unavailability of a lockout handle or shutoff, a tag is
affixed at the the point of control utilizing a nylon cable
tie requiring a force greater than 50 pounds to cause
its removal.
A. The tag’s positioning should be obvious to anyone attempting to
operate the equipment.
B. The operator's name, time, and date started should be displayed on
the tag.
C. The tags are a warning to others that work is in progress and to
leave equipment/energy source control off (i.e., DO NOT START, DO
NOT OPERATE, etc.).
 Outside Contractor
Lockout/Tagout Guidelines
Periodically, it may be necessary to utilize contractors
and/or outside personnel to perform service or
maintenance.

When contractors or outside personnel perform service

or maintenance on the grounds of a any facility or job site, a
Safety Lockout/Tagout Outside Contractors
Acknowledgement form is signed by the representative of
the outside contractor and the authorized employee
responsible for their work activity.

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 Outside Contractor
Lockout/Tagout Guidelines
The designated employee who is responsible for the project
ensures the following is adhered to when dealing with
contractors or personnel.

1. Necessary lockout/tagout information is exchanged between

ALL the parties involved in the project.
2. Outside contractor or personnel reviews and signs the Safety
Lockout/Tagout Outside Contractors Acknowledgement form.

A. The signed form indicates all the appropriate

lockout/tagout information was exchanged between
organisation and outside contractor or personnel.
B. The form is maintained with the project file.

3. Outside contractor or personnel understand that failure to

follow these guidelines could result in their not being
permitted to continue working with the organisation.
 Shift or Personnel Changes
If an authorized employee involved with a lockout
procedure must leave the job before completion, because
of job reassignment or shift change, the following steps
must be taken.

• The employee should remove his/her personal lock and

replace it with a department lock

• If the employee who is leaving will be replaced by another

employee, the replacement employee will place his/her lock
into correct lockout position.
Conclusion
 Lockout/tag-out procedure are designed
to prevent accidents when an equipment
or machine is undergoing any form of
maintenance, installation, repairs etc that
might result for accidentally energizing
the said equipment.
A VERY BIG THANK YOU
TO
ALL OF YOU
Any questions?