Lockout &tagout

Presented by

The Public Education Section

Oregon Occupational

Safety and Health

Division (OR-OSHA)

OR-OSHA 2049906-01

Introduction to

Lockout/Tagout

OR-OSHA 204 Lockout Tagout

This material for training use only

Objectives

1. Gain a greater awareness of the requirements

detailed in Oregon Administrative Rules 437, Div

2J, Control of Hazardous Energy.

2. Understand the responsibilities of the employer,

authorized employee, and the affected employee.

3. Understand lockout/tagout procedures for shutting

down, testing, and returning machinery and

equipment to operation.



Form Groups

Introductions - Get to know your NEIGHBOR!

Elect a group leader

Select a spokesperson

Recorders



Part I: Scope and Application

(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.

OAR 437, Div 2J, 1910.147,

The Control of Hazardous Energy

(Lockout/Tagout)

What are the three key elements of an energy control

program?



Authorized Affected Other

__Affected Employee

__Authorized Employee

__Other Employee

A. Person who services or

performs maintenance on

machines or equipment.

B. Person who operates or

uses a machine or equipment

which is being serviced or has

maintenance being performed.

C. Person who works in an

area where lockout/tagout

procedures are being used.

Scope: The lockout/tagout rule covers the

following employees:

Match the employee category on the left with its correct

definition



Application: Procedures must be followed when...

...servicing and/or maintenance when

______________________ 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...



Oregon exceptions:

• Applies to construction, agriculture, and

maritime.

• Group lockout/tagout not approved.

• Uniquely keyed locks.

Sources of Energy

List as many sources of energy as possible that could

cause injury



The standard does not apply to:

• Installations under the control of ___________.

• Exposure to electrical hazards from work on,

near, or with ____________ or __________ in

electric utilization installations.

• _________ and ______ drilling and servicing.



• Normal ______________ 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 _______ and __________ connected

equipment.

• _________ __________ operations, under

special conditions.



Part II: 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.

See appendix for a sample written plan.



Why is a comprehensive written plan critical to a

successful lockout/tagout program?

What are some reasons a lockout/tagout program

may not work effectively?

Who’s responsible….who’s accountable….and for

what?



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.



Equipment Identification List

Equipment / Machinery Basic Hazards

1. ________________________________

___________________________

___________________________

2. _______________________________

___________________________

___________________________

3. _______________________________

____________________________

____________________________

List three types of equipment/machinery and any

possible energy source hazards, including

magnitudes.



If any of the conditions below exist, the employer must

include the machine or equipment in the written

program:

1. The machine or equipment has potential for __________ or

____________ energy, or _______________ of stored energy

after shutdown which could endanger employees; or

2. The machine or equipment has more than a __________

energy source; or

3. The isolation and locking out of any single energy source

will not ___________ de-energize and deactivate the machine or

equipment; or

4. The lockout device is not under __________ control of an

authorized employee performing the servicing or maintenance;

or

5. The servicing or maintenance of the machinery or equipment

creates _________for other employees; or

6. The employer has had __________ 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?



Why is the actual instant of shutdown or startup so

hazardous in the lockout/tagout process?

Step 2 - Shutdown and isolation

• 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.

• 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…

...the ___________ or __________ 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.



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.

Tagout Devices

• Tagout devices will be used only if machinery or

equipment is not capable of being locked out.

• 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.



A “lockout device” must use a positive means such as a

lock, either key or combination type, to hold an energy

isolating device…

...in a ________ position to prevent machinery or

equipment from being ____________________.

What are some examples of lockout devices?

Padlocks Lockout hasps

C/B lockouts Wall switch lockouts

Gate valve lockouts Ball valve lockouts

Fuse lockouts Plug lockouts

Machinery or equipment is “capable of being locked out”

if:

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

• It has a ___________ _____ locking mechanism

• Does not have to be ________ to achieve lockout.



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...

... may not be ____ until the tagout device is ______.

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.

Before applying and after removing lockout/tagout

devices, the authorized employee…

...must notify all _____________ employees.



Protective materials and hardware

Materials and hardware must be provided by the

________.

Each lockout/tagout device must be ______ identified as

being used ____________ for lockout/tagout.

Lockout/tagout devices must be ____ and ______.

Lockout devices must be ______________ 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.

Lockout/tagout devices must _______________ the user.

Which is the preferred method: Lockout or Tagout?



When can an employer use a tagout system?

1. When an energy isolating device is not capable of

being ________________ __________________.

2. If employer can demonstrate (prove) that using a

tagout system will provide _______________

employee protection.

What tow tests must be met to demonstrate full

employee protection?

1. Tags can be placed where _________ _________

would have been placed.

2. The employer demonstrate _________________

protection can be obtained with tags.



What are some examples of stored or residual

energy?

• 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.

• 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.

How do you verify that a machine or equipment is

actually isolated or deenergized?

• 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.



Step 3. 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 safely positioned

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/tagout device may remove that device.

• Exception - When the authorized employee is not

at the facility and all reasonable efforts have been

taken to inform him/her that the lockout/tagout

device has been removed written procedures must

be in place to remove lockout/tagout devices.



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?



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?

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.



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 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?

What is the intent or purpose of the procedures above?

Shift/Personnel Changes

• Written procedures must be developed to address

lockout/tagout procedures during a shift change.



The BIG exercise!

Design a quality lockout-tagout procedure for a giant 500

gallon coffee pot (the company’s employees drink a lot

of coffee!).

500 gallon capacity

Spring loaded

lever

CB

Panel

Water

in

Coffee

out240 vac



Part IV: 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?



Training on Tagout Devices

• If tagout devices are used, further training on tagout

systems need to emphasize that:

a. Tags are warning devices only and do not provide

a physical restraint that lockout devices provide.

b. Tags must not be removed without the authorized

employee’s approval, and should never be

bypassed, ignored, or otherwise defeated.

c. Tags must be legible, and understandable by all

employees.

d. Tags must be able to withstand environmental

conditions in the workplace.

e. Tags may give employees a false sense of

security.

f. Tags must be securely attached to prevent being

accidentally detached during use.



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.



How often must lockout/tagout inspections occur?

Who must conduct the inspection?

• Annual inspection 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 will review

responsibilities under the energy control procedure.

• 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

Part IV: Lockout/Tagout Annual

Inspections