Introduction to Lockout/Tagout

Introduction to Lockout/Tagout
Lesson 13 Study Guide

LESSON PURPOSE:
In this lesson, we will study the OSHA requirements for lock-
out/tagout procedures. These procedures help keep workers
safe from the accidental release of hazardous energy.

LESSON OBJECTIVES:
By the end of this lesson, you will be able to:
Identify the requirements and procedures for
locking and tagging out machines and equipment

Describe major hazards that can occur when the ac-

cidental release of hazardous energy is not controlled

List ways to prevent injuries by controlling the

release of hazardous energy

Explain employer training responsibilities and

requirements for authorized employees

151

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Introduction to Lockout/Tagout

What is the lockout/tagout standard,

and where does it apply?

Lockout/Tagout Standard Lockout/Tagout Features

The lockout/tagout standard outlines the re- Features of a lockout/tagout system include:
quirements for the service and maintenance yy If an energy isolating device is capable
of machines and equipment to prevent of being locked out, the employer’s
potential hazards from occurring on the energy control program must utilize a
jobsite. This standard establishes minimum lockout system
performance requirements for the control of yy If an energy isolating device is not ca-
such hazardous energy. pable of being locked out, the employ-
er’s energy control program must utilize
The lockout/tagout standard has require- a tagout system
ments in place to help prevent hazards from yy A lockout/tagout device must be placed
affecting workers. on the energy isolating device associated
with that equipment whenever there is:
Employers are required to demonstrate how ·· New equipment
to utilize a tagout system to provide full em- ·· Replacement of equipment
ployee protection, establish a regular train- ·· Repair or maintenance
ing program, and conduct periodic inspec- ·· Renovation/modification
tions, as set forth by OSHA regulations. yy The machine or equipment must be
isolated from the energy source and
rendered inoperative

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Introduction to Lockout/Tagout

Defining the Lockout/Tagout Standard

What is the lockout/tagout standard, and where does it apply?

Workers may find themselves exposed to

hazards when performing service or mainte-
nance on machinery and equipment. Here’s
a list of workplace hazards and prevention
techniques that can be implemented by
using the lockout/tagout standard:

The lockout/tagout standard does not cover

the following:
yy Construction, agriculture, and maritime
employment
yy Installations under the exclusive control
of electric utilities for power generation,
transmission, and distribution, includ-
ing equipment for communication or
metering
yy Live or stored energy – Not properly yy Exposure to electrical hazards with con-
shutting down and locking out an en- ductors in electric use (this is covered
ergy source can result in the electro- by electrical regulations)
cution of employees yy The drilling and servicing of oil and gas
yy Moving machine parts on mechani- wells
cal equipment – Not properly locking yy Work on cords and plugs connected to
out mechanical equipment can lead electrical equipment that is exposed to
to trapped or crushed employees unexpected hazards
yy Stored heat that can be released yy The startup of equipment that is con-
(e.g. steam or hot liquids) – Not trolled by unplugging the equipment
properly locking out energy sources from a source
to pipes can cause injuries to workers
if they are unexpectedly sprayed or
splashed.

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Introduction to Lockout/Tagout

Defining the Lockout/Tagout Standard

Lockout and tagout devices must be consistent within the workplace.

Lockout and tagout devices must be singularly

identified, used exclusively for controlling energy (in
comparison to other devices), and must not be used
for any other purposes.

Lockout and tagout devices are required to

do the following:
yy Withstand the environment to which
they are exposed, for as long they are
exposed
yy Be constructed and printed so that
weather conditions, wet locations, Tagout devices (i.e. tags) function similar-
and corrosive environments will not ly, but may evoke a false sense of security
cause the tag to become illegible because they do not provide the physical
yy Specify the identity of the employee restraint that is provided by a lock. Because
applying the device(s) of this, both lockout and tagout devices need
to be understood as part of the overall energy
control program.

Locks and tags can only be placed or removed

from machinery or equipment by an autho-
rized employee. This individual is the only one
allowed to lock out/tag out equipment and are
trained to do so.
A lock is an example of a lockout device. To
prevent a machine from activating, a lock is
designed to set the energy-isolating device
of said machine in the off or safe position.
The placement of a lockout device is import-
ant for its functionality.
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Introduction to Lockout/Tagout

Defining the Lockout/Tagout Standard

Lockout and tagout devices must be consistent within the workplace.

OSHA has created a procedures checklist yy Is it required that only the employee ex-
to use when applying lockout/tagout devic- posed to the hazard can place or remove
es. It determines the completeness of the the safety lock?
lockout/tagout procedure. The checklist yy Are employees instructed to always
includes the following questions: push the control circuit stop button prior
yy Is all machinery or equipment capable to re-energizing the main power switch?
of movement required to be locked out yy Is there a means provided to identify
during cleaning, servicing, adjusting, or any or all employees who are working
setting up operations? on lockout equipment by their locks or
yy If the power disconnect for equipment accompanying tags?
does not result in the disconnect of yy Are enough accident prevention signs,
the electrical control circuit, can the locks, and/or tags provided for any
control circuit be disconnected and potential repair emergency?
locked out, or is it prohibited? yy If part of a machine is accidentally
yy Are all equipment control valve han- activated after an operator leaves the
dles provided with a means for locking control station, is that part required to
out? be separately locked out or blocked?
yy Does the lockout procedure require yy If equipment cannot be shut down,
that stored energy (mechanical, hy- locked out, and tagged, can an estab-
draulic, air, etc.) be released or blocked lished procedure be followed to main-
before equipment is locked out for tain job safety?
repairs?
yy Are appropriate employees provided
with individually-keyed personal safety REMEMBER
locks, and are they required to keep
personal control of their key(s) while The lockout/tagout procedures
they have safety locks in use? checklist is not all-inclusive for
yy Is it required that employees check the every workplace or equipment.
safety of the lockout by attempting a
startup?

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Introduction to Lockout/Tagout

Using the Lockout/Tagout Standard to Protect Yourself

Working with active energy is dangerous, but understanding the lockout/tagout standard will keep
you safe at work.

It is important to learn how to protect 3. Machine or equipment isolation – All

yourself using lockout/tagout procedures. energy-isolating devices that are need-
The authorized employee must follow these ed to control the energy must be phys-
preparations when shutting down machines ically located to detach the machine or
or equipment, and they must be done in the equipment from the energy sources
following sequence to prevent hazards:
When tagout devices are used with ener-
1. Preparation for shutdown – Before gy-isolating devices instead of being locked
an authorized employee turns off a out, the tag attachment must be secured at
machine, they must have knowledge the same point of the lock that would have
of the following: been attached. When a tag cannot be affixed
·· The type and magnitude of the directly to the energy-isolating device, the tag
energy being used must be in a position that can easily be seen
·· The hazards of the energy being to anyone attempting to operate the device.
controlled
·· A method to control the energy Following the lockout or tagout of an ener-
2. Machine or equipment shutdown – gy-isolating device, all potentially hazardous
The machine or equipment must be energy must be rendered safe. Even if there is
turned off or shut down using the a possibility of said energy rising to a hazard-
procedures established for the equip- ous level, the energy-isolating device must
ment. An orderly shutdown must be be watched until the possibility of danger is
used to avoid any additional hazards non-existent.
as the equipment stops moving

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Introduction to Lockout/Tagout

Using the Lockout/Tagout Standard to Protect Yourself

Working with active energy is dangerous, but understanding the lockout/tagout standard will keep
you safe at work.

When removing lockout and tagout devices, procedure for doing so must include at least
protect yourself and other employees by ver- the following elements:
ifying these conditions and following these yy Contacting the authorized employee
rules: to inform that their lockout or tagout
yy The machine and equipment must be device has been removed
fully operational and intact yy Checking the work area to ensure that
yy All nonessential items must be re- all employees have been safely posi-
moved from the work area tioned or removed
yy All employees must be safely posi- yy Informing all affected employees that
tioned or absent from the area the lockout or tagout devices have been
removed before a machine/equipment
In situations where the lockout or tagout is started
devices must be temporarily removed, and
the machine or equipment is energized to Be mindful of the following when working with
test, certain steps must be taken to prevent lockout/tagout devices:
any electrical hazards or injuries: yy Lockout devices are more effective and
1. Clear the machine or equipment of secure than tagout devices for protect-
tools and materials ing employees from hazards
2. Remove unauthorized employees yy When a tagout device is used instead
from the machine or equipment area of a lockout device, the tagout device
3. Following testing, deenergize all sys- must be attached at the same location
tems and reapply all locks that the lockout device would have
been attached
Each lockout/tagout device should be yy When using only a tagout device, the
removed by the authorized employee who tag must demonstrate that the safety
originally applied the device, but if it must be achieved is equivalent to the level of
removed by another employee, the specific safety a lockout device would accom-
plish

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Introduction to Lockout/Tagout

Employer Requirements
The employer is responsible for providing the appropriate training and retraining
for all employees who qualify.

Where appropriate, the employer must provide locks,

tags, and chains for isolating, securing, or blocking
machines or equipment from energy sources.

When employees are engaged in maintenance

or servicing of machinery, their employers
required to develop, document, and use pro-
Employer-led training should ensure that the cedures that control potentially hazardous
purpose of the energy control program is under- energy. The energy control procedure must
stood by employees and that the skills required specify the following:
for the safe application, usage, and removal of
yy How to use the procedure
the energy controls are learned by employees.
yy Steps for shutting down, isolating,
blocking, and securing equipment to
Each authorized employee must receive train-
control hazardous energy
ing in the following areas:
yy Procedural steps for the placement,
yy Recognizing hazardous energy sources removal, and transfer of lockout/tagout
yy The type of energy available in the workplace devices and who is responsible for
yy The necessary methods for energy them
isolation and control yy Requirements for testing machines/
equipment to determine the effective-
Employees should be retrained when there is ness of the lockout/tagout devices and
a change in the following areas: other energy control measures
yy Job assignments
yy Machinery It is important that employers conduct a
yy Processes that present new hazards periodic inspection of the energy control
yy Energy control procedures procedure at least once a year to ensure that
it is being followed. The inspection must be
Additional training must also be conducted performed by an authorized employee other
whenever an employer as reason to believe that than the one utilizing the energy control proce-
there are inadequacies in the employee’s knowl- dure being inspected, and all inadequacies
edge of the use of the lockout/tagout procedure. revealed by the inspection must be corrected.

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 Introduction to Lockout/Tagout

NOTES:

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 Introduction to Lockout/Tagout

NOTES:

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