Lockout-Tagout

Training Program
 2006 RiskAnalytics,Page
LLC 1
 2006 RiskAnalytics, LLC
 Disclaimer

The information, suggestions and recommendations contained herein are for

general informational purposes only. This information has been compiled from
sources believed to be reliable. No warranty, guarantee, or representation,
either expressed or implied, is made as to the correctness or sufficiency of
any representation contained herein. Reliance upon, or compliance with, any
of the information, suggestions or recommendations contained herein in no
way guarantees the fulfillment of your obligations under your insurance policy
or as may otherwise be required by any laws, rules or regulations. This
Information should not be construed as business, risk management or legal
advice, or legal opinion.

 2006 RiskAnalytics, LLC Page 2

 Learning Objectives
 Understand the purpose of the energy control program
 Recognition of applicable hazardous energy sources,
and the methods necessary for energy control
 Discuss the primary causes of injury from hazardous
energy
 Understand the steps necessary to properly control
hazardous energy when servicing equipment
 Know the responsibilities of Authorized and Affected
employee in terms of logout / tagout

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 Introduction
 Workers servicing machinery and equipment are exposed to
injuries from the unexpected energization, startup of the
machinery or equipment, or release of stored energy in the
equipment
 120 fatalities and 50,000 injuries each year
 Workers injured from exposure to hazardous energy lose an
average of 24 work days for recovery
 Most injuries and fatalities are a result of improper hazardous
energy control procedures
 A Bureau of Labor Statistics study on injuries suffered
when servicing equipment showed
 80% failed to turn off equipment
 10% equipment activated by someone else
 5% failed to control potential energy
 Remaining 5% failed to verify effectiveness
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 The “Fatal Five”
 Main Causes of Lockout/Tagout Injuries:
1. Failure to stop equipment before servicing
2. Failure to disconnect equipment from power source
3. Failure to dissipate (bleed, neutralize) residual energy
4. Accidental restarting of equipment
5. Failure to clear work areas before restarting
 All injuries resulting from inadequate hazardous energy
control procedures can be prevented

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 Types of Hazardous Energy
 Mechanical – the potential energy and kinetic energy
present in the components of a mechanical system
 Kinetic – energy possessed by virtue of its motion
• Common injuries: fracture, contusion, laceration, and
amputation
 Potential – energy stored by the mechanical system
• Common injuries: fracture, contusion, laceration, and
amputation
 Electrical – energy as a result of a generated electrical
power source or a static source
 Common injuries: shock, burns, and electrocution
 Thermal – energy as a result of mechanical work,
radiation, chemical reaction or electrical resistance
 Common injuries: burns

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 Types of Hazardous Energy, continued
 Chemical -- energy released as a result of
chemical reactions
 Common injuries: burns
 Hydraulic – energy released as a result liquids
under pressure
 Common injuries: and contusions
 Pneumatic – energy released as a result of
compressed gasses under pressure
 Common injuries: burns and contusions

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 What is Lockout-Tagout?
 Lockout-Tagout is a hazard avoidance technique used to
prevent energy from being accidentally released during the
servicing of equipment
 The Lockout-Tagout standard requires the adoption and
implementation of written practices and procedures to:
 Shut down equipment
 Isolate it from its energy source or sources
 Prevent the release of potentially hazardous energy while maintenance
and servicing activities are being performed

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 Energy Control Program – 3 Core Components
 Energy control procedures that detail the scope, purpose,
authorization rules and techniques to be utilized for the
control of hazardous energy
 Periodic inspections of the energy control procedures to
ensure that the procedures and the requirements are being
followed
 Employee training and ongoing retraining to ensure that the
energy control programs are understood

 2006 RiskAnalytics, LLC

Written Procedures Inspections Training Page 9
 Lockout-Tagout Procedures are Required IF…
 A worker must remove or bypass machine guards or other
safety devices, or
 A worker is required to place any part of their body into a
point of operation or into the danger zone associated with the
machine's operation
 Examples of activities where proper Lockout-Tagout
procedures would be required include
 Installing
 Lubricating
 Cleaning and un-jamming machines or equipment, and
 Making adjustments or tool changes

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 Definition of Players
 Authorized employee: An employee who
locks or tags machines or equipment in order
to perform servicing or maintenance
 Affected employee: 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

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 Responsibilities of Authorized Employees
 Identify all energy sources
 Notify all affected employees in the area of work
 Shut down the equipment at the operating controls
 Isolate all energy sources to equipment
 Lock and tag all isolating devices
 Dissipate all stored or residual energy sources.
 Verify the isolation
 Remove lock and tag when repair and testing are
complete
 Notify all affected employees that lock and tag were
removed

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 Responsibilities of Affected Employees
 Never interfere or tamper with a lock or tag
 Stay clear of the area as much as possible
 Never attempt to assist
 Report any unusual situation or unsafe condition to your
supervisor

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 Energy Isolation Devices
A mechanical device that physically prevents the
transmission or release of energy such as…
 Circuit breakers;
 Disconnect switches
 Line valves
 Slide gates
 Blind flanges
NOTE: Push buttons, selector switches and other control circuit type
devices are not energy isolating devices

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 Types of Lockout Devices

 Keyed and combination locks

 Ball valve locks
 Gate valve locks
 Group lockout hasp
 Circuit breaker locks
 Valve hand wheel cover

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 Lockout Device Requirements
Devices Must...
 Be capable of withstanding the environment
to which they are exposed
 Be singularly identified
 Be the only devices used for controlling
energy
 Not be used for other purposes
 Be standardized within the facility in terms of
color, shape, or size.
 Indicate the identity of the employee
applying the devices
 Prevent removal without the use of
excessive force or unusual techniques

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 Tagout Requirements
Tagout must be…
 Be capable of withstanding the environment to
which they are exposed
 Able to withstand corrosive environments such as
areas where acid and alkali chemicals are
handled and stored
 Standardized in print and format
 Substantial in order to prevent inadvertent or
accidental removal
 Able to be attachable by hand, self-locking, and
non-releasable with a minimum unlocking
strength of no less than 50 pounds
 Inclusive of a legend such as: Do Not Start, Do
Not Open, Do Not Close, Do Not Energize, Do
Not Operate.

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 Lockout vs. Tagout

 If an energy-isolating device is capable of being locked

out, a lock out system must be used
 If an energy-isolating device is not capable of being
locked out tagout may be used, provided training and
more rigorous periodic inspections are implemented

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 General Energy Control Procedures

Step 1 Step 2 Step 3

Identify Energy Notify Others Shut Down
Sources Equipment

Step 4 Step 5 Step 6

Isolate Lockout-Tagout Release
Equipment Equipment Stored Energy

Step 7 Step 8 Step 9

Verify Isolation Service Release From
Equipment LOTO

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 General Energy Control Procedures
Step 1: Identify Energy Sources
 Understand the types and magnitude of
the specific energy associated with
equipment being serviced
 Hazards of energy being controlled
 Method or means to control the energy
 Identify all energy sources feeding the
equipment including potential energy
 Identify and obtain the appropriate
control devices
 Clarify any questionable identification of
energy sources before proceeding Step 1
Identify Energy
Sources

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 General Energy Control Procedures
Step 2: Notify Others
 Verbally notify all “affected” and
“other” employees of impending
shutdown
 Remember that not all equipment will
have someone “assigned” to it

Step 2

Notify Others

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 General Energy Control Procedures
Step 3: Shut Down Equipment
 Use standard equipment operating
procedures to shut down equipment
 Push “Stop” button
 Open Toggle switches
 Close valve

Step 3
Shut Down
Equipment

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 General Energy Control Procedures
Step 4: Isolate Equipment Energy Sources
 Operate all energy-isolating devices so that the
equipment is isolated from its energy sources
 Be sure to isolate ALL energy sources!
 Primary supplies
 Any secondary energy sources

Step 4
Isolate
Equipment

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 General Energy Control Procedures
Step 5: Lockout – Tagout the Equipment
 Locks or tags must be applied to each
device
 Must be applied by an Authorized
employee
 Locks must be affixed in a manner that
will hold the energy isolating devices in a
"safe" or "off" position
 Tags must be affixed in a manner that will
clearly indicate that the operation or
movement of energy isolating devices is
prohibited
Step 5
Lockout-Tagout
Equipment

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 General Energy Control Procedures
Step 6: Release Stored Energy
 Ensure all potential or residual
energy is controlled
 Block or brace springs and any
elevated parts that could fall due to
gravity
 Relieve trapped system pressure
 Bleed lines and vent valves to drain
fluids and gasses
 Discharge capacitors
 If stored energy can re-accumulate,
monitor it to make sure it stays below
hazardous levels Step 6
Release
Stored Energy
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 General Energy Control Procedures
Step 7: Verify Isolation
 Before work begins, an authorized employee
must verify that the machine has been properly
isolated and de-energized
 Make sure all danger areas are clear of
personnel
 Verify that the main disconnect switch or circuit
breaker can’t be moved to the on position.
 Use normal starting procedure or otherwise
verify the system is completely deenergized
 Return controls to “OFF” position after testing
 Verification is the step which is most frequently Step 7
skipped during evaluations
Verify Isolation

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 General Energy Control Procedures
Step 8: Service Equipment
 Complete required service work
according to manufacturer’s
recommendations
 Avoid doing anything that could
potentially reactivate the equipment
 Do not bypass the lockout if installing
new piping or wiring

Step 8
Service
Equipment
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 General Energy Control Procedures
Step 9: Release From Lockout-Tagout

 Inspect work area to ensure that all tools

and spare parts have been removed and
that all of the equipment components are
operationally intact
 Replace all machine guards
 Ensure that all employees have been safely
positioned or have cleared the area.
 Each logout / tagout device must be
removed from the energy-isolating device
by the employee who applied the device.
 Notify “affected” and “other” employees
that the logout / tagout devices have been Step 9
removed before the equipment is started Release From
LOTO
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 General Energy Control Procedures
Special Circumstances For Release - Testing
 Lockout-tagout devices may be removed
temporarily to test and /or reposition the
equipment under the following procedures:
 The equipment must be cleared of tools and
materials
 Employees must be removed from the
machine or equipment area
 All logout / tagout devices may then be
removed
 Authorized employees may then energize
and test or position the equipment
 Following testing or positioning, all systems
must be de-energized and energy control Special
Circumstances
measures reapplied
For Release

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 General Energy Control Procedures
Special Circumstances For Release – Shift Change
 If servicing lasts more than one shift,
lockout/tagout protection must not be
interrupted
 When the authorized employee who applied
the LOTO device is not available to remove it,
the device can only in an emergency and only
under the direction of the supervisor
 Must verify the authorized employee is not in
the facility
 Must make all reasonable efforts to contact
employee who applied the device
 Must insure that the authorized employee
knows the LOTO device has been removed Special
Circumstances
For Release

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 General Energy Control Procedures
Special Circumstances – Group Lockout-Tagout
 Group logout / tagout must afford protection
for each employee equivalent to that
provided by a personal lockout or tagout
device
 Each authorized employee must affix a
personal logout / tagout when work begins
and remove it when work is completed
 Group must designate a single authorized
employee to serve as overall supervisor

Special
Circumstances

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 Summary
 Lockout-Tagout prevents energy from accidentally being
released while a machine or equipment is being serviced
 There are 6 types of hazardous energy common to most
work environments – Mechanical, Electrical, Thermal,
Chemical, Hydraulic and Pneumatic
 Most injuries and fatalities are a result of improper
hazardous energy control procedures
 If an energy-isolating device is capable of being locked
out, a lock out system MUST be used
 General energy control procedures follow a 9-step
process
 Only the authorized employee may attach and remove
the logout / tagout device
 Affected employees or any other employees should
NEVER remove or tamper with a logout / tagout device

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