Occupational Safety and Health Administration USA Department of Labor OSHA OUTREACH SAFETY TRAINING

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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 reenergized 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: 0 10 % of serious industrial accidents. 1 28,000 lost work days injuries per year. 2 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 and implementation 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 be operated 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 energyisolating 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 prevents the 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 and servicing 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 energyisolating device(s) (5) Safely releasing all potentially hazardous stored or residual energy, 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, and blocks. 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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15 When using tag-out, employers must train their employees in the limitations or tags. 16 Whenever major replacement, repair, renovation or modification of machines or equipment is performed and whenever new machines or equipment are installed or purchased, the energyisolating devices for such machines or equipment must be lockable.
REQUIREMENTS FOR LOCKOUT-TAGOUT DEVICES

Whichever devices are used, they must be singularly identified, must be the only devices used for controlling hazardous energy, and must meet the following requirements: 17 Durable Lockout and tag-out devices must withstand the environment to which they are exposed for the maximum duration of the expected exposure. Tag-out devices must be constructed and printed so that they do not deteriorate or become illegible, 18 Especially when used in corrosive (acid and alkali chemicals) or wet environments. 19 Standardized Both lockout and tag-out devices must be standardized according to either color, shape, or size. Tag-out devices must also be standardized according to print and format. 20 Substantial lockout and tag-out devices must be substantial enough to minimize early or accidental removal. Locks must be substantial to prevent removal except by excessive force of special tools such as bolt cutters or other metal cutting tools. Tag means of attachment must be non-reusable, attachable by hand, self-locking and non-releasable, with a minimum unlocking strength of no less than 50 pounds. The device for attaching the tag also must have the general design and basic characteristics equivalent to a one-piece nylon cable tie that will withstand all environments and conditions. 21 Identifiable Locks and tags must clearly identify the employee who applies them. Tags must also warn against hazardous conditions if the machine or equipment is energized and must include

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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 the energy 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 the control 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 to be 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 that employees 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 Equipment

Follow 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. Make sure 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 45 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 Controlled To 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 depressurized 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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when you have personally locked it out of operation and tested equipment to verify that the energy state is zero. If all tests are passed, begin working on equipment. Once you have confirmed that all energy sources have been controlled and locks and tags are in place, it is safe to begin the maintenance work. While working, you should avoid any actions that could re-activate the equipment. When installing new piping or wiring, you should make sure the lockout is not bypassed.

SAFE STARTUP PROCEDURES

Once the maintenance or installation is completed, the equipment can be restarted. These are the procedures to follow for safe startup:
Step 1: Preparing for Startup

You must make sure the area is safe for restart by: 52 Making sure all equipment components are fully assembled and operational. 53 Making sure all safety guards are in place. 54 Removing all tools from the equipment and the work area. 55 Removing all braces, pins, blocks, cribs and chains. 56 Reconnecting all pressure tubing, pipes and hoses and closing all valves. 57 Clearing the work area of all personnel.
Step 2: Remove Lockout Devices and Tags

Except in emergencies, each lockout device must be removed by the employee who put it on.
Step 3: Notify Affected Employees

Notify all personnel in the area that maintenance, servicing or installation is complete, lockout/tag-out has been removed and the machine/equipment is ready to be re-started.

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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 following situations 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 of installation), all startup and lockout/tag-out procedures must be followed. *************************************************************

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