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7/30/2019 SAFTY TRAINING

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Occupational Safety and Health Administration

USA Department of Labor

OSHA OUTREACH SAFETY TRAINING

Mirdif Security & Safety Consultants

CONSTRUCTION INDUSTRY REGULATIONS

CONTROL OF HAZARDOUS ENERGY

(LOCKOUT/TAGOUT)

29 CFR 1926.417

Overview

Every workplace has the need for on-going maintenance. Installation,

repair and servicing of machines and equipment may seem routine, but

can be dangerous to employees performing the work.

Serious injury can be caused by the sudden and unexpected startup of

the machinery or equipment, contact with live electrical circuit or the

unexpected release of stored energy.

Equipment that is shut down may inadvertently be re-started or re-

energized by a co-worker, or equipment that was thought to be shut

down may be controlled by automatic processors, timers or computers

and may be re-start automatically and without warning.

OSHA estimates that failure to control hazardous energy sources

results in:

10 % of serious industrial accidents.

28,000 lost work days injuries per year.

Approximately 120 deaths per year.

Fortunately, these hazards can be avoided through the use of lockout/tag-out

procedures.

The Lockout/Tagout standard requires the adoption andimplementation of practices and procedures to shut down equipment,

isolate it from its energy source(s), and prevent the release of potentially

hazardous energy while maintenance and servicing activities are being

performed. It contains minimum performance requirements, and

definitive criteria for establishing an effective program for the control

of hazardous energy.

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All new equipment installed after January 2, 1990 must be designed to

accept lockout of its energy-isolating device.

LOCKOUT/TAGOUT 1926.417

DEFINITIONS

Lockout The placement of a lockout device on an energy isolating

device, in accordance with an established procedure, ensuring that the

energy isolating device and the equipment being controlled cannot beoperated until the lockout device is removed.

Tag-out the placement of a tag-out device on an energy-isolating device,

in accordance with an established procedure, to indicate that the energy-

isolating device and the equipment being controlled may not operated until

the tag-out device is removed.

Lockout device Any device that uses positive means such as a lock, either

key or combination type, to hold an energy-isolating device in a safe

position, thereby preventing the energizing of machinery or equipment.

When properly installed, a blank flange or bolted slip blind are considered

equivalent to lockout devices.

Tag-out device Any prominent warning device, such as a tag and a means

of attachment, that can be securely fastened to an energy-isolating device in

accordance with an established procedure. The tag indicates that the machine

or equipment to which it is attached is not to be operated until the tag-out

device is removed in accordance with the energy control procedure.

Energy-isolating device Any mechanical device that physically preventsthe transmission or release of energy. These include, but are not limited to,

manually-operated electrical circuit breakers, disconnect switches, line

valves, and blocks.

Capable of being locked out An energy-isolating device is considered

capable of being locked out if it meets one of the following requirements:

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- It is designed with a hasp to which a lock can attached;

- It is designed with any other integral part through which a lock can be

affixed;

- It has a locking mechanism built into it; or

- It can be locked without dismantling, rebuilding, or replacing the

energy isolating device or permanently altering its energy control

capability.

Affected employee An employee who performs the duties of his or her job

in an area in which the energy control procedure is implemented andservicing or maintenance operations are performed. An affected employee

does not perform servicing or maintenance on machines or equipment that

must be locked or tagged.

Authorized employee An employee who performs servicing or

maintenance on machines and equipment. Lockout or tag-out is used by

these employees for their own protection.

Energy sources Any electrical, mechanical, hydraulic, pneumatic,chemical, gas, thermal or other energy source that could cause an injury to

the affected personnel.

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Residual pressure The remaining energy in a system after activation of

the disconnect (stored energy).

SCOPE AND APPLICATION

3 Applies to general industry employment and covers the servicing and

maintenance of machines and equipment in which the unexpected

start-up or the release of stored energy could cause injury to

employees.

ENERGY CONTROL PROGRAM

4 Intended to prevent the unexpected energizing or the release of stored

energy in machines or equipment on which servicing and

maintenance is being performed by employees.

5 Consists of documented energy control procedures, an employee

training program, and periodic inspections of the procedures.

6 Employers have flexibility to develop a program that meets the needs

of their particular workplace.

ENERGY CONTROL PROCEDURE

7 The written procedures must identify the information that authorized

employees must know in order to control hazardous energy during

service or maintenance.

8 At a minimum, it includes, but is not limited to, the following

elements:

- A statement on how the procedure will be used;

- The procedural steps needed to shut down, isolate, block, and

secure machines or equipment;

- The steps designating the safe placement, removal, and transfer

of lockout/tag-out devices and who has the responsibility for

them; and

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- The specific requirements for testing machines or equipment to

determine and verify the effectiveness of locks, tags, and other

energy control measures.

9 Procedure must include the following steps:

(1) Preparing for shutdown

(2) Shutting down the machine(s) or equipment

(3) Isolating the machine or equipment from the energy source(s),

(4) Applying the lockout or tag-out device(s) to the energy-

isolating device(s)

(5) Safely releasing all potentially hazardous stored or residualenergy, and

(6) Verifying the isolation of the machine(s) or equipment prior to

the start of service or maintenance work.

10 In addition, before lockout or tag-out devices are removed and

energy is restored to the machines or equipment, certain steps must

be taken to re-energize equipment after service is completed,

including:

(1) Assuring that machines or equipment components are

operationally intact(2) Notifying affected employees that lockout or tag-out devices

are removed from each energy-isolating device by the

employee who applied the device.

ENERGY-ISOLATING DEVICES

11 Guards against accidental machine or equipment start-up or the

unexpected re-energization of equipment during servicing or

maintenance.

12 These include, but are not limited to, manually-operated

electrical circuit breakers, disconnect switches, line valves, andblocks.

13 Two types: those capable of being locked and those that are not.

14 When the energy-isolating device cannot be locked out, the

employer must use tag-out or modify or replace the device to make it

capable of being locked.

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a legend such as the following: DO NOT START, DO NOT OPEN,

DO NOT CLOSE, DO NOT ENERGIZE, DO NOT OPERATE.

EMPLOYEE TRAINING

22 The employer must provide effective initial training and

retraining as necessary and must certify that such training has been

given to all employees covered by the standard. The certification

must contain each employees name and dates of training.

23 The employers training program for authorized employees

(those who are charged with the responsibility for implementing theenergy control procedures and performing the service and

maintenance) must cover, at minimum, the following areas:

- Details about the type and magnitude of the hazardous energy

sources present in the workplace, and

- The methods and means necessary to isolate and control those

energy sources (that is, the elements of the energy control

procedure)

24 Affected employees (usually the machine operators or users)

and all other employees need only be able to (1) recognize when thecontrol procedure is being implemented, and (2) understand the

purpose of the procedure and the importance of not attempting to

start up or use the equipment that has been locked or tagged out.

25 Every training program must ensure that all employees

understand the purpose, function and restrictions of the energy

control program and that authorized employees possess the

knowledge and skills necessary for the safe application, use, and

removal of energy controls.

26 Training programs used for compliance with this standard,

which is performance-oriented, should deal with the equipment,

type(s) of energy, and hazard(s) specific to the workplace being

covered.

27 Retraining must be provided, as required, whenever there is a

change in hob assignments, a change in machines, equipment or

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processes that present a new hazard, or a change in energy control

procedures.

28 Additional retraining must be conducted whenever a periodic

inspection reveals, or whenever the employer has reason to believe,

that there are deviations from or inadequacies in the employees

knowledge or use of the energy control procedure.

PERIODIC INSPECTIONS

29 Periodic inspections must be performed at least annually to

assure that the energy control procedures (locks and tags) continue tobe implemented properly and that the employees are familiar with

their responsibilities under those procedures.

30 In addition, the employer must certify that the periodic

inspections have been performed. The certification must identify the

machine or equipment on which the energy control procedure was

used, the date of the inspection, the employees included in the

inspection, and the name of the person performing the inspection.

31 For lockout procedures, the periodic inspection must include a

review, between the inspector and each authorized employee, of thatemployees responsibilities under the energy control procedure being

inspected.

32 When a tag-out procedure is inspected, a review on the

limitation of tags, in addition to the above requirements, must also be

included with each affected and authorized employee.

LOCKOUT/TAGOUT PROCEDURES

The following are the procedures necessary for effective lockout/tag-out:

Step 1: Preparation and Notification

Before servicing or installing equipment, you must be able to answer the

following questions:

33 What is the type of energy source on the equipment?

34 What are the potential hazards related to the energy source?

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35 What steps are necessary to control the energy source?

36 Who needs to be notified that the equipment will be shut down

for service?

Once these questions have been answered, notify all affected employees that

a lockout procedure is about to begin and that the equipment will be shut

down for service.

Step 2: Shut Down the EquipmentFollow the companys safety procedures and/or the manufacturers

instructions. Be aware that some equipment has special shut-down

procedures (for example, computer-controlled equipment)

Make sure all energy sources have located and shut down. (Some machines

have more than one power source all must be shut down).

Step 3: Isolate the Equipment

Equipment should be isolated by:

A. Shutting off the main breaker or control switch

B. Closing valves

C. Disconnecting process lines

D. Pulling plugs

Note: For complex machines or equipment, refer to the manufacturers

control diagram detailing the locations of all isolation points, including

breaker panels, switches, valves, etc.

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Step 4: Attach the Lock and Tag

Each employee who is performing maintenance is responsible for locking

and tagging the equipment. Each employee whose duties require them to

work on equipment must be provided with their own lock and key.

If more than one employee is involved in the maintenance, multiple locking

devices must be used to allow each maintenance employee to lock and tag.

This prevents one employee from accidentally starting up the equipment

while another employee is still working.

Never use another employees lock and never lend your own.

When all energy sources are locked, apply a tag to the power source. Makesure the tag is filled out completely and correctly.

Step 5: Release any Stored Energy

After locking and tagging equipment, you must make sure that any stored

energy on the equipment is released. This is done by:

37 Inspecting equipment to make sure all parts have stopped

moving.

38 Bleeding electrical capacitance (stored charge)39 Venting or isolating pressure or hydraulic lines from the work

area, leaving vent valves open

40 Draining tanks and valves

41 Releasing the tension on springs or blocking the movement of

spring-driven parts.

42 Blocking or bracing parts that could fall because of gravity

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43 Blocking, clamping or chaining any switches or levers that

could be moved into the start position

44 Clearing lines containing process materials that are toxic, hot,

cold, corrosive or asphyxiating

Monitoring the process to make sure that the work you are

doing will not result in an accumulation of stored energy.

Step 6: Test Equipment to Verify that All energy Has Been Released or

ControlledTo make sure that all kinetic and stored energy has been released or

controlled, you must:

46 Clear personnel from danger areas.

47 Test the start switches on the equipment to confirm that all

power sources have been shut down and switches cant be moved to

the on or start position.

48 Check pressure gauges to make sure that all lines are de-

pressurized and stored energy has been released.

49 Secure all blocks, clamps, chains and cribs.

50 Check electrical circuits to make sure that voltage is at zero.

51 Secure blanks (used to block feed chemicals) and make sure

they are not leaking.

Because some machinery and equipment can be remotely controlled, you

must consider equipment to be energized and in motion at all times except

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Once all three steps are completed, it is safe to start up the equipment.

LOCKOUT AND TAGOUT DEVICES

Lockout Devices:

58 Must be provided to each employee

59 Must only be used for the purposes of lockout/tagout

60 Must be able to withstand the environment that they are

exposed to for as they are in place.

61 Must be standardized by color, shape and size.

Tag-out Devices

62 Must be standardized by color, shape, size and format or print

63 Must contain warnings such as DANGER DO NOT

OPERATE THIS MACHINE

64 Must have space for the name of lock or tag owner, date and

purpose of the lockout/tag-out.

TAGOUT ONLY

A tag-out system can be used instead of a lockout system in the followingsituations only:

65 When an energy isolating device cannot be locked out

66 When the employer can prove that a tag-out system provides

the same amount of protection as a lockout system.

If a Tag-out Only system is used, the tags must be placed at all isolation

points, and you must follow all safety procedures.

Note: After January 2, 1990, any equipment that is replaced, renovated or

modified must be able to accept a lockout device.

SPECIAL SITUATIONS

Some situations may occur in the workplace that require additional

procedures to perform safe lockout/tag-out.

Removing someone elses lock: A lock may be removed by someone other

than the employee who placed the lock only under the following conditions:

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67 The employee whose lock is to be removed is not available to

remove the lock after servicing has been completed.

68 All reasonable efforts have been made to contact the employee

to inform him/her that the lock has been removed.

69 The employee is contacted and informed that the lock is

removed prior to the employee starting work on the next work shift.

Shift Changes: If maintenance on a piece of equipment will extend beyond

one shift, provisions must be made to have employees from the new shift

place their locks on the lockout device before they begin work on the

equipment. This must be done without any interruption in lockout/tag-out

protection.

Outside Contractors: If outside contractors will be working on equipment

inside your facility or workplace, you must make provisions to inform them

of your lockout/tag-out procedures. If the contractors procedures are

different from yours, you must make an agreement with the contractor as to

which procedures will be followed. All employees working on the project

must be notified of any changes in their own procedures.

Temporary Re-activation: If the equipment being serviced must be

temporarily re-activated (for example, to test the equipment as part ofinstallation), all startup and lockout/tag-out procedures must be followed.

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