EM 385-1-1 Section 12

Control of Hazardous Energy

(Lockout/Tagout)
 Lockout/Tagout References

• EM 385-1-1 Section 12
• 29 CFR 1926.600 (a) (3) i Heavy
Equipment
• 29 CFR 1926.702 (j) (1) Concrete Tools
• 29 CFR 1926.417 Electrical Circuits
• 29 CFR 1910.147 ; Subpart J
• UFGS 01 35 29 (Latest)
• Accident Abstracts
 Lock-out/Tag-out Statistics
• Recent OSHA estimates indicate that each
year 120 deaths and 60,000 injuries occur
as the result of unexpected activation of
machinery, and nearly 75% of these
accidents occur on jobs of 15 minutes or
less.

“OSHA webpage dated 5-6-04”

Potential Mishap Outcomes
• Electric shock and electrocutions
• Thermal burns
• Struck by objects
• Crushed by and caught between
• Loss of limb
• Mechanical Entanglement
• Engulfment
Leading to property damage, injury, death
 Direct Causes
• Lack of notification prior to re-energizing.
• Not verifying de-energized state.
• Failure to adequately bleed pressurized
system before disassembly.
• Unauthorized work
• Lack of communication between workers.
• Worker ignoring safety procedures.
 Indirect Causes

• Lack of Lockout/tagout/tryout program.

• Specific SOPs not developed or utilized.
• Workers not adequately trained or
supervised.
• Approved safety plan not implemented.
• Regular site safety inspections not
performed.
• Lack of safety equipment and/or use.
 General
• 12.A.01 This Section shall apply to
contractor-managed Hazardous
Energy Control Programs (HECP)
only, as well as all requirements of
1910.147, ANSI Z244.1, and ANSI
A10.44. When a site is controlled by
a contractor and USACE employees
are affected by contractor-managed
HECP (e.g., QA’s on construction
sites, etc.), they shall comply with
the contractor’s HECP.
 Isolation
• Systems with
energy
isolating
devices that
are capable of
being locked
out shall be
locked out.

12.A.04
 Authorized Employee

• Lockout and tagout

shall be performed
only by Authorized
employees.

12.A.08
 Types of Lockout Devices

• Locks
• Blocks
• Chains
• Multi-lock hasps
• Wheel valve covers
• Ball valve covers
 Requirements for
Lockout/Tagout Devices
• Locks and tags
shall:
– a. Be capable of
withstanding the
environment
that they are
exposed to for
the maximum
period of time
the exposure is
expected, and

– b. Indicate the
identity of the
employee
applying the
device.
12.D.01
 Energy Sources

• Electricity
• Hydraulic
• Pneumatic
• Steam
• Thermal
• Chemical
• Gravity
Typical Equipment Requiring LOTO
• Presses
• Saws
• Conveyors
• Pumps
• Production
equipment
• Trash
compactors
• Ovens
Are wheels chocks LOTO???
LOTO??? Welding on Gas Tank

•
 Fatal Incident
• A 28 year old dump truck driver was
crushed when pinned between the
dump body and frame. The victim
elevated the empty body and tried to
lower it, but it had stuck in the elevated
position. He left the cab leaned over the
truck frame to look at the control valve.
The dump body suddenly lowered pining
him. He was found the next day by the
company owner who was his father.
 When Must LOTO Be Used?

When servicing or maintaining

equipment where:
• Hazardous energy exists
• Unexpected start-up
could occur
• Either of these
could harm an
employee
 LOTO Shall Be Used When:

• Employees are required to remove or

bypass a safety device
• Employees are required to place any
part
of their body in harm’s way
• Employees are exposed to hazardous
energy
 PERIODIC INSPECTIONS

• Daily inspections shall be conducted

to ensure that all requirements of the
HEC procedures are being followed.

12.C.01
 LOTO Exceptions

• Work where hazardous energy does

not exist
• Activities performed during routine
production processes
• Work on cord-controlled devices
• Hot tap operations where shutdown
is not feasible
 Typical LOTO Procedures

• Performing a shutdown
• Isolating equipment
• Applying and removing
lockout devices
• Safely releasing
stored energy
 Affected Employees

Employees who
• Operate
• Work around
• Occasionally
adjust equipment
that is subject
to LOTO
 Management Responsibilities
• Ensure de-energization of equipment
• Ensure employee awareness
• Provide appropriate levels of training
• Review program effectiveness
• Maintain and revise program
• Administer appropriate disciplinary
actions
 Maintenance Responsibilities
• Lockout/tagout prior
to service or repair
• Remove or cut locks
off isolation devices
• Ensure proper
training of authorized
employees
 Affected Employee
Responsibilities
• Notify maintenance, etc., when
equipment needs repair or adjustment
• Leave all LOTO devices in place
• Verify equipment is safe to operate
following LOTO
• Follow all safety rules while operating
the equipment
 Authorized Employee
Responsibilities
• 12.E.01 The authorized employee shall ensure
that all energy isolating devices needed to control
energy to or within the system are identified and
that the system is shut down, isolated, blocked
and secured in accordance with HEP procedures.
• 12.E.03 The authorized employee shall affix locks
and/or tags to each energy isolating device in
accordance with the HEC procedures.
• 12.E.05.b The authorized employee (or his
designee) is responsible for ensuring the control
of residual energy and for placing and removing
personal protective grounds in accordance with
the Contractor’s HECP and procedures.
 Authorized Employee
Responsibilities
• 12.E.09 Before locks or tags are removed
and energy restored to the system, the
authorized individual shall ensure that the
following actions have been taken:
– a. The work area has been inspected and all
nonessential items (e.g., tools and materials)
have been removed from the system, the
system components are operationally intact,
and all employees have been safely positioned
or removed from the area; and
– b. All affected individuals have been notified
that the locks or tags are about to be removed.
 Authorized Employee
Responsibilities (cont.)
• Obtain assistance
when necessary
• Remove locks
and/or
tags following
LOTO
• Coordinate
multi-shift repair
 12.B TRAINING

• Training shall be provided to ensure

that the purpose and function of the
HEC procedures are understood by
employees and that employees
possess the knowledge and skills
required for the safe application, usage,
and removal of HEC devices.

12.B.01
 Training
• a. Each Authorized Employee shall receive
training in the recognition of hazardous energy
sources, the type and magnitude of energy
available in the workplace, and the methods and
means for energy isolation and control.

• b. Each Affected employee shall be instructed in

the purpose and use of the HEC procedures.

• c. All incidental personnel shall be informed of the

procedures and prohibitions relating to restarting
or reenergizing systems which are locked or
tagged out.
 How to Perform LOTO Safely
• Follow company safety procedures for
LOTO
• Refer to procedures on how to lock out
specific equipment
• Keep everyone informed when equipment
is repaired or serviced
• Stay alert
• Use common sense
 Summary
• Lockout/tagout/tryout program must be
implemented.
• Specific SOPs must be developed and
utilized.
• Workers must be trained and/or
supervised.
• Approved safety plan AHA and ORM must
be implemented.
• Regular site safety inspections must be
conducted.
• Safety equipment must be used.