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ONLINE SELF-STUDY
The Control of Hazardous Energy (Lockout Tagout)
OSHA 29 CFR 1910.147
Objectives
This presentation will cover the following topics:
The need for energy control procedures;
Methods of lockout/tagout;
Employer’s responsibilities;
Employee training needs; and
Inspection requirements.
What is Lockout/Tagout?
Lockout/Tagout (LOTO) refers to the control of energy
sources to prevent the energizing, startup, or release of
stored energy in machinery or equipment which could
cause injury to employees during servicing or
maintenance activities.
LOTO is technically known as the Control of Hazardous
Energy.
What is Lockout/Tagout?
LOTO involves the control of energy sources such as:
Mechanical
Hydraulic
Chemical
Pneumatic
Electrical
Thermal
Why is LOTO Important?
Approximately 3 million workers service equipment and
face the risk of injury if LOTO is not performed.
An estimated 120 fatalities and 50,000 injuries occur each
year from exposure to hazardous energy.
LOTO procedures implemented properly will prevent
employee injury from hazardous energy.
Source: Washington State Department of Labor & Industries
When is LOTO Required?
LOTO is required during activities necessary to prepare or
maintain a machine or piece of equipment.
LOTO is also required during the installation of new
equipment or machinery.
What Activities are Included?
Servicing/maintenance activities may include:
Construction
Installation and set-up
Adjustment or maintenance
Inspection
Modification
Routine service
Lubrication
Cleaning
What Activities are Included?
Servicing and/or maintenance which takes place
during normal production operations is covered
only if employees are required to:
Remove or bypass a guard or other safety device; or
Place any part of their body in or near a machine’s moving
parts; or
Place any part of their bodies in a danger zone associated with
machine operation.
Employees Involved in LOTO
Authorized Employee
An employee who locks out or tags out machines
or equipment to perform servicing or maintenance
on that machine or equipment.
Lockout or tagout shall be performed only by authorized
employees.
Lockout or tagout is used by these employees for
their own protection.
Employees Involved in LOTO
Authorized employees include employees who:
1) Perform energy source isolation;
2) Implement LOTO on machines or equipment;
3) Dissipate potential (stored) energy;
4) Verify energy isolation;
5) Implement actions to release LOTO; or
6) Test or position machines or equipment.
Employees Involved in LOTO
Affected employee
An employee whose job duties require him/her to operate
equipment or work in an area in which the energy control
procedure is implemented and servicing or maintenance
operations are performed.
Affected employees may disable, shut down, or turn off
machines or equipment.
Energy Control Program
OSHA requires employers to establish a program
consisting of:
Lockout Procedures
Lockout Procedures
Written energy control procedures
Employee training
Periodic inspections
EHS maintains the general campus LOTO program.
Departments must develop specific LOTO procedures for
their equipment and machines.
Equipment Specific Procedures
Departments shall develop and document equipment
specific lockout/tagout procedures.
Procedures must contain enough detail for authorized
employees to have a clear understanding of the energy
control measures.
The energy control procedures must clearly and
specifically outline the scope, purpose, authorization, rules,
and techniques that will be used to control hazardous
energy sources.
Equipment Specific Procedures
At a minimum, these procedures must also include the
following elements:
The specific intended use of the procedures;
The specific steps for shutting down, isolating, blocking
and securing machines or equipment to control
hazardous energy;
The specific steps for the placement, removal and
transfer of lockout or tagout devices and the
responsibility for them; and
The specific requirements for testing a machine to verify
equipment isolation.
Equipment Specific Procedures
Similar machines/equipment with the same or similar types
of controls, and which can be isolated using the same
sequential steps, can be covered by a single procedure.
For example, a single procedure may be used for a group
of woodworking machines, as long as the procedure has
sufficient details to allow effective isolation of the energy
sources and safely return each of the machines to service.
To assist with the development of equipment specific
procedures, fill out the Equipment Specific LOTO
Procedure Development Form.
LOTO Devices
The preferred method of isolation is lockout/tagout, using
department issued locks and tags.
The physical protection offered by the use of a lock, when
supported by the information on a tag, provides the
greatest assurance of employee protection from the
release of hazardous energy.
Designated devices must be used for controlling energy
only and not for other purposes.
LOTO Devices
Devices must meet the following criteria:
Durable
Standardized
Substantial
Identifiable
LOTO Devices
LOTO devices must be durable enough to withstand
conditions in the workplace environment.
LOTO devices must be standardized within a department
according to color, shape, or size. Tagout devices also
must be standardized according to print and format.
Tags must warn against hazardous conditions if the
machine is energized, and offer employees clear
instruction such as: “Do Not Start,” “Do Not Open,” “Do Not
Close,” “Do Not Energize,” or “Do Not Operate.”
LOTO Devices
LOTO devices must be substantial enough to minimize the
likelihood of early or accidental removal.
Other than using a key or combination, employees must be
able to remove locks only by using excessive force such
as using bolt cutters.
Tagout devices must be labeled to identify the specific
employees who are authorized to apply and remove them.
The label must contain the name, date, and contact
information for the person performing the LOTO.
Tagout Devices
Tags are warning devices that do not provide the physical
restraint on energy-isolating devices as offered by lockout
devices.
Tagout alone is only permitted when an energy-isolating
device is not capable of being locked.
Use of tagout alone instead of the preferred lockout/tagout
method requires written supervisor approval documented
on the Tagout System Justification Form.
Tagout Devices
The use of tagout alone requires at lease one added safety
measure such as:
Closure of a second in-line valve;
Removal of a valve handle;
Removal of an additional isolating circuit element (e.g.,
fuse);
Opening of an extra disconnecting device (e.g.,
disconnecting switch; circuit breaker);or
Opening and then racking out a circuit breaker switch.
Types of Devices
LOTO Sequence
LOTO procedures shall include the following sequence:
Preparation for shutdown
Machine or equipment shutdown
Machine or equipment isolation
LOTO device application
Release of stored energy
Verification of isolation
Release from LOTO
Inspection of machine or equipment work area
Location of employees
Preparation for LOTO
LOTO shall be performed only by authorized employees
who are performing the servicing or maintenance.
Authorized employees must know:
The types and magnitudes (amounts) of energy involved
The hazards of the energy to be controlled
The methods or means to control energy
Before performing LOTO, employees shall discuss any
questionable identification of energy sources with their
supervisors.
Notification of Employees
A supervisor or authorized employee must notify the
affected employees before LOTO devices are applied
and after they are removed.
Machine/Equipment Shutdown
The machine or equipment shall be turned off or shut
down using the procedures established for the machine
or equipment.
An orderly shutdown must be utilized to avoid any
additional or increased hazards to employees as a
result of equipment de-energization.
Machine/Equipment Isolation
All energy isolating devices needed to control energy shall be
physically located to isolate the machine or equipment from
the energy source(s).
The use of push buttons, selector switches, and other control
circuit type devices as energy isolating devices is prohibited.
Machine/Equipment Isolation
Stored energy such as capacitors, springs, elevator
machine members, rotating flywheels, hydraulic
systems and air, gas, steam or water pressure, etc.
must also be dissipated or restrained by methods such
as grounding, blocking, repositioning, bleeding down,
etc.
Compressed air, hydraulic or steam lines must be bled,
drained, and cleaned out.
Power Circuit Vs Control Circuit
Only power circuit devices are approved as energyisolating devices.
The power circuit distributes power from the source (main
disconnect) to the motor (connected load).
The control circuit controls the distribution of power
through the use of a motor controller, system interlock
device, on/off switch, or start/stop push button.
Power Circuit Vs Control Circuit
The use of a control circuit device as the primary means of
hazardous energy control does not adequately protect
employees.
Control circuit devices are vulnerable to hazards such as
component failure, program errors, magnetic field
interference, electrical surges, and improper use or
maintenance.
The next slide contains a diagram that illustrates why
locking out control circuit devices will not prevent a motor
from starting if voltage is present in the power circuit.
Power Circuit Vs Control Circuit
Locking out
the start/stop
button or
using the onoff key (control
circuit) will not
prevent power
from getting to
the motor.
Figure : Diagram of power and control circuits. Source: OSHA Directive CPL 02-00-147
Only shutting
off the main
disconnect
(power circuit)
will ensure
power does
not get to the
motor.
Lockout/Tagout Application
Lockout devices shall be affixed in a manner that will
hold the energy isolating devices in a "safe" or "off“
position.
Tagout devices shall be affixed in a manner indicating
that the operation or movement of energy isolating
devices from the "safe" or "off" position is prohibited.
Employees must not attempt to operate any switch,
valve, or other energy isolating device when it is locked
or tagged out.
Each employee must apply his/her own personal
Lockout/Tagout device on the energy isolating device.
Stored Energy
After application of device, all potentially hazardous stored
or residual energy shall be relieved, disconnected,
restrained, and otherwise rendered safe.
Verification of Isolation
Prior to starting work, authorized employees shall verify that:
The machines or equipment have been shutdown properly;
All of the energy-isolating devices were identified, located,
and operated appropriately;
The lockout/tagout devices have been attached to the
energy-isolating devices correctly; and
The stored energy has been rendered safe.
Verification of Isolation
A combination of visual inspections and physical tests are
required for proper verification of isolation.
Visual inspections verify that the correct devices have been
locked out in the correct position.
Use physical tests such as a deliberate attempt to start a
machine for further verification and/or the use of a voltage
test instrument.
If local control cannot be obtained for physical tests,
additional steps must be taken. Contact EHS for assistance
(962-0227).
Note: Verification by computerized control is not acceptable.
Voltage Testing
Voltage testing is required to verify that electrical equipment
has been de-energized when working on or near deenergized electrical components or systems.
Until the absence of voltage is verified, opening an electrical
panel for testing is considered working on or near exposed
live parts.
Voltage testing is covered by the OSHA Electrical Standard
1910.333, Selection and Use of Work Practices, and the PPE
requirements of NFPA 70E, Standard for Electrical Safety in
the Workplace.
Only authorized and qualified employees as defined by
OSHA and NFPA are allowed to perform voltage testing.
Release from Lockout/Tagout
Before LOTO devices are removed and energy restored:
Each LOTO device must be removed by the employee
who applied the device.
Inspect machine/equipment system components to
ensure that: 1) non-essential tools and materials have
been removed; and 2) machine or equipment
components are operationally intact.
Check the work area to ensure all employees have
been safely positioned or removed.
Inform affected employees that the lockout or tagout
devices have been removed.
LOTO Device Removal
When the individual who applied the energy control
device is not available to remove it, that device may be
removed under the direction of a supervisor.
Removal may not be based on convenience and may not
be done simply because the employee is not available at
the LOTO location, but is still at the workplace.
LOTO Device Removal
The removal procedure shall include the following
elements:
1. Verification by a supervisor that the authorized
individual who applied the device is not at the
facility.
2. The supervisor will make all reasonable efforts to
contact the individual.
3. The supervisor will assure that the affected
individual has knowledge of the removal before
resuming work at the facility.
4. The supervisor shall document the removal on the
Absentee Lockout Tagout Removal Form.
Testing or Positioning of Machines
When LOTO devices must temporarily be removed for
testing/positioning:
Clear machine or equipment of tools and materials
Remove employees from area
Remove lockout/tagout device
Energize and proceed with testing or positioning
De-energize and reapply energy control measures
Shift/Personnel Changes
During shift/personnel changes there must a transition
period so that individuals may exchange their assigned
energy control devices.
The orderly transfer of devices between off-going and oncoming employees must ensure that there is no gap in
coverage.
Individuals shall be fully briefed in the scope and strategy
of the work by those who are being relieved.
Outside Personnel
The on-site employer (UNC) and the contractor must
inform each other of their respective lockout or tagout
procedures.
Contractor is permitted to use either: UNC's energy
control procedure; its own procedures; or a combination
of the two procedures, provided the resulting procedure
meets the requirements of the LOTO standard.
Outside Personnel
The UNC employer and the contractor also must ensure
that its respective employees understand and comply
with all requirements of the energy control procedures
that will be used by the contractor.
Document the coordination of LOTO procedures on the
Contractor Notification Form.
If the contractor has no documented energy control
procedures, or if their procedure allows tagout in lieu of
lockout/tagout, they shall ensure that their personnel
understand and comply with the procedures established
in the UNC program.
Group Lockout/Tagout
When servicing and/or maintenance is performed by a
group, a procedure must be utilized that provides
employee protection equivalent to a personal LOTO
device.
Group Lockout/Tagout
One primary authorized employee performs LOTO on the
equipment for the group and attaches his/her LOTO device
to a multi-lock accepting device.
Each authorized employee must verify that all required
equipment has been locked out.
Each authorized employee must apply his/her personal
LOTO device to the multi-lock accepting device.
Each affected employee shall remove the personal LOTO
device when stopping work on the machine/equipment.
Group Lockout/Tagout
After the work is completed, the primary authorized
employee shall remove his/her LOTO device and multilock accepting device after all other authorized
employees remove their devices.
Only the employee who attached the LOTO may remove
the device, unless the “LOTO Removal When an
Individual is not Available” procedure is followed.
Group Lockout/Tagout: Lock box
If multiple pieces of equipment are being locked out, a
group lock box or cabinet can be used.
The keys from the locks placed on the equipment are
placed in the box or cabinet. A multi-lock accepting
device is placed on the outside of the box or cabinet.
Each employee will use a personal LOTO device to
secure the box or cabinet. Each employee must verify
that all required equipment has been locked out.
As each person completes work, that person will remove
his/her device from the box or cabinet.
Group Lockout/Tagout: Lock box
Note: No one can get to the keys in the Lockbox unless all
authorized persons’ locks are removed
Periodic Inspection
Periodic inspections must be performed at least annually
to verify that LOTO procedures and requirements are
followed.
The inspections are performed by authorized employee
other than the one(s) using the procedure.
This process is designed to correct identified deficiencies
or inadequacies.
The inspections must contain at least two components: 1)
a review of the LOTO procedure and 2) a review of each
employee’s responsibilities under the procedure being
inspected.
Periodic Inspection
The inspector must certify on the Periodic Inspection
Form that periodic inspection has been performed by
documenting:
The machine or equipment on which the LOTO
procedure was used;
The date of the inspection;
The names of the employees included in the
inspection;
The names of the person who performed the
inspection.
Training and Communication
Employers must provide initial training for new hires
before they begin any servicing and maintenance
activities.
LOTO training must address, at a minimum:
The purpose and function of the LOTO program;
The elements of LOTO procedures relevant to
employee duties; and
The pertinent requirements and prohibitions of the
LOTO standard.
Training and Communication
Authorized employees must be trained on:
Recognition of hazardous energy sources
Type and magnitude of energy in workplace
Methods and means for energy isolation and control
Training and Communication
Affected employees must be trained on:
Purpose and use of LOTO procedures
Prohibition of restarting or reenergizing
machines that are locked or tagged out
Training and Communication
For Tagout alone systems, all employees must receive
training regarding the inherent limitations of tags:
Are warning devices only
Do not provide physical restraint
Do not start
Must not be removed/bypassed/ignored
May evoke false sense of security
Must be securely attached
Training and Communication
Retraining for authorized and affected employees must be
provided annually or when the following occurs:
There is a change in job assignments, equipment,
processes, or LOTO procedures; or
Periodic inspections reveal, or employer has reason to
believe, there are deviations in employee knowledge
or use of procedures.
The scope and content of the retraining must be based on
the identified changes or deviations and a elimination of
the concerns.
UNC-CH EHS would like to acknowledge the North
Carolina Department of Labor (DOL) for providing
portions of the training content.