Lockout/Tagout

Controlling Hazardous Energy

Gene Patrick, CSP, ARM Bill Wood Jr., ARM, CHST
Construction & Maintenance Safety Manager Safety Director
Power Boiler Erection by PSF Industries
LOTO Information Covered:

1. Hazardous Energy

2. Lockout-Related
Accidents

3. Scope & Application

4. Type of Devices

5. Procedures

6. Responsibilities

7. Questions
Examples of Hazardous Energy

• Mechanical

• Hydraulic

• Pneumatic

• Chemical

• Electrical

• Thermal
 Hazardous Energy

• Mechanical
– Kinetic (in motion)
• Energy of moving machinery can cause…
– Amputations
– Lacerations
– Fractures
– Loss of life
– Potential (stored)
• Energy stored in…
– Machinery
– Weights & springs
– Pistons under pressure
– Hydraulic controls
• Stored potential energy can be released
during work causing injury or death
 Hazardous Energy

• Hydraulic
– Energy of Liquids Under Pressure
• Pressure can cause equipment to move
• Rapid release can cause injury
– Relieve pressure slowly into a proper container

High pressure paint injection injury

 Hazardous Energy

• Pneumatic
– Energy of Compressed Gases
• uncontrolled release can cause injury
• rapid de-pressurization creates extreme low
temperature
– Properly vent all systems before starting work

Dry ice bomb injury

 Hazardous Energy

• Chemical
– Chemicals have energy that can
• start fires
• cause skin burns
• generate harmful gases or fumes
• cause explosions
– Before working –release, drain or vent
chemicals safely
 Hazardous Energy

• Electrical
– Potential exposure from energized
distribution systems, circuits and
equipment.
– Injuries from electric shock, thermal
burns, arc flash explosions.
– Examples include open bus bars,
electrical motors, generators.
– Capacitors can deliver potential
(stored) electrical energy.
 Hazardous Energy

• Thermal
– Energy of Heat (and cold)
• Hot equipment & fluids
• Cryogenic liquids
• Quick release of compressed gases
• Allow equipment to reach a safe temperature before
starting work
 Hazardous Energy Gone Bad

• What kind of injuries can result?

• The Fatal Five – Main Causes of

Lockout/Tagout Incidents

– Failure to stop equipment.

– Failure to disconnect from power

source.

– Failure to dissipate residual energy.

– Accidental restarting of equipment.

– Failure to clear work areas before

starting.
 Hazardous Energy Gone Bad

NIOSH’s review of 152 fatal LOTO incidents suggests

that three related factors contributed to these fatalities:

•Failure to completely de-energize, isolate, block,

and/or dissipate the energy source (82% of the
incidents, or 124 of 152)

•Failure to lockout and tagout energy control devices

and isolation points after de-energization (11% of the
incidents, or 17 of 152)

•Failure to verify that the energy source was de-

energized before beginning work (7% of the incidents,
or 11 of 152)
 Hazardous Energy Gone Bad

On the 2008 “10 Most Cited OSHA Violations” list, #5 is Lockout/Tagout

Lockout/Tagout is listed as #4 under “Highest Penalties”

Breakdown of 2006 Total LOTO Violations: 3,659

• 1910.147 (c)(4)(i) — Failure to develop equipment-specific lockout
procedures: 658
• 1910.147 (c)(1) — Lack of a written program: 624
• 1910.147 (c)(6) — Failure to conduct periodic (annual) inspections of
energy control program: 500
• 1910.147 (c)(7)(i) — Failure to train employees: 480
• 1910.147 (c)(4)(ii) — Inadequate equipment-specific procedures: 233
 Scope & Application

• The OSHA Standard for the Control of Hazardous Energy

(Lockout/Tagout) 29 CFR 1910.147 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.
 Scope & Application

• Covered Activities
– Constructing, installing, setting up, adjusting, inspecting,
modifying, maintaining and/or servicing machines or
equipment where employees could be exposed to the
unexpected energizing or release of hazardous energy
 Scope & Application

• Exceptions to LOTO provisions:

– Work on cord and plug connected equipment if the equipment is
unplugged from the energy source and the authorized employee
has exclusive control of the plug
– Hot tap operations (with adequate protective measures)
– Energized electrical work (with adequate protective measures)
 Scope & Application

• Lockout/Tagout Rules
– The equipment must be de-energized and
locks or tags must be applied to the
energy-isolation devices) to servicing and
maintenance activities when:
• The employee must either remove or
bypass machine guards or other safety
devices, resulting in exposure to
hazards at the point of operation.
• The employee is required to place any
part of his or her body in contact with
the point of operation of the
operational machine or piece of
equipment.
• The employee is required to place any
part of his or her body into a danger
zone associated with a machine
operating cycle.
 Scope & Application

• Lockout/Tagout or Tagout Only

– If an energy-isolating device is capable of being locked
out, it must be locked out.
– Tagout may be used if an energy isolating device is not
capable of being locked out.
– Tagout must be used where a lockout device would have
been attached, and it must provide full employee
protection through additional measures.
Types of Devices
Types of Devices
 Types of Devices

• Durable
– Lockout and tagout devices must withstand the
environment to which they are exposed for the maximum
duration of the expected exposure. Tagout devices must
be constructed and printed so that they do not deteriorate
or become illegible, especially when used in corrosive or
wet environments.

• Standardized
– Both lockout and tagout devices must be standardized
according to either color, shape, or size. Tagout devices
must also be standardized according to print and format.
 Types of Devices

• Substantial
– Lockout and tagout devices must be substantial enough to
minimize early or accidental removal. 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 (one-piece nylon cable
tie).

• 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 a legend such as: DO NOT START, DO NOT
OPEN, DO NOT CLOSE, DO NOT ENERGIZE, DO NOT
OPERATE.
 Procedures

• Basic Steps:

– Shut down equipment

– Isolate all energy sources
– Apply lockout devices
– Release all energy
– Verify zero energy state
– Perform work
– Remove lockout devices
 Procedures

• Preparation for Shutdown

– Know the types and amounts of energy that power it.
– Know the hazards of that energy.
– Know how the energy can be controlled.
– Notify all affected employees of shutdown & lockout
procedure.
 Procedures

• Shutting Down the Equipment

– Shut the system down by using operating controls.
– Follow whatever procedure is right for the equipment to
avoid endangering anyone during shutdown.
 Procedures

• Equipment Isolation
– Operate all energy-isolating devices so that the equipment
is isolated from its energy sources.
– Be sure to isolate all energy sources (secondary power
supplies as well as the primary supplies).
 Procedures

• Application of Devices
– All energy-isolating devices are to be locked, tagged or
both.
– Only standardized devices can be used and they are not to
be used for anything else.
– Use a lockout device if your lock cannot be placed directly
on the energy control.
– When more then one lockout is used, every employee
must attach his/her personal lock.
 Group Lockout

• When servicing and/or maintenance is performed by a

crew, craft, department or other group, they shall
utilize a procedure which affords the employees a level
of protection equivalent to that provided by the
implementation of a personal lockout or tagout device.
– Primary responsibility is vested in an authorized employee
for a set of employees working under the protection of a
group lockout or tag out device.
– Provision for the authorized employee to ascertain the
exposure status on individual group members with regard
to the lockout.
– When more than one crew, craft, etc. is involved an
authorized employee is designated to coordinate.
– Each employee shall affix a personal lockout or tag out
device to the group lock out device.
 Procedures

• Release Stored Energy

– Inspect the system to make sure all parts have stopped
moving.
– Relieve trapped pressure.
– Block or brace parts that could fall due to gravity.
– Bleed lines and vent valves open.
– If stored energy can reaccumulate, monitor it to make
sure it stays below hazardous levels.
 Procedures

• Verify Zero Energy State

– Make sure all danger areas are clear of personnel.
– Verify that the main disconnect switch or circuit breaker
can’t be moved to the on position.
– Press all start buttons and other activating controls on the
equipment itself and return controls to the off position
when the testing is complete.
 Procedures

• Perform Work
– Look ahead and avoid doing anything that could reactivate
system and/or equipment.
– Don’t bypass the lockout when installing new piping or
wiring.
 Procedures

• Remove Lockout/Tagout
– Make sure the equipment is safe to operate by removing
all tools from the work area and making sure the system is
fully assembled.
– Safeguard all employees by conducting a head count to
make sure everyone is clear of the equipment. Also notify
everyone in the work area that lockout/tagout is being
removed.
– Remove the lockout/tagout devices. Each device must be
removed by the person who put it on.
 Lock Removal
• Each lockout or tagout device shall be removed from
each energy isolating device by the employee who
applied the device. When the employee who applied the
lock is not available to remove it, that device may be
removed by the employer if documented in their energy
control program and must include the following.
– Verification by the employer that the authorized employee who
applied the device is not at the facility;
– Making all reasonable efforts to contact the authorized employee
to inform him/her lockout or tagout device has been removed;
and
– Ensuring that the authorized employee has the knowledge
before he/she resumes work at that facility.
 Procedures

• Contractors
– Contractors and the Facilities staff must exchange
lockout/tagout information.
– Employees on site must understand rules used by the
contractor and vice versa (policy requires pre-meeting).
– Contractors must apply their own locks and tags
 Procedures

• Work with Shift Changes

– If servicing lasts more than one shift, lockout/tagout
protection must not be interrupted.
– When the employee who applied device is not there to
remove it, it can be removed only under the direction of a
responsible supervisor (policy must cover required steps)
 Procedures

• Written procedures are not required if all of the following

conditions are met:
1. There is no potential for stored energy;
2. There is only a single energy source and it is easily identified and
isolated by a single lockout device;
3. Isolation results in complete deenergization;
4. The machine or equipment is isolated from that energy source and
locked out during servicing or maintenance;
5. A single lockout device will achieve a locked-out condition;
6. Lockout is under the compete control of the authorized employee;
7. The servicing or maintenance does not create hazards for other
employees; and
8. There is no history of accidents with the specific machine or equipment
being serviced or maintained.
 Procedures

• If written procedures are required, they must cover:

– Scope of the procedure;
– Specific steps for shutting down, isolating, blocking and securing
machines or equipment to control hazardous energy;
– Specific procedural steps for the placement, removal and transfer of
lockout devices or tagout devices and the responsibility for them; and
– Specific requirements for testing a machine or equipment to determine
and verify the effectiveness of lockout devices, tagout devices, and
other energy control measures; and
– Communication between, and roles of, all affected and authorized
employees
 Responsibilities

• Authorized employee
– An employee who performs servicing or maintenance on
machines and equipment. Lockout or tagout is used by
these employees for their own protection.
– Follow established procedures.
– Reporting any problems to your supervisor.
– Notifying affected employees of shutdowns/lockout
situations and before energy is restored to systems or
equipment.
– Attend training sessions (required every two years)
 Responsibilities

• 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.
– Understand basic requirements of LOTO procedures
– Not attempt to operate any system or equipment during
lockout
– Not attempt to remove any lockout devices
 Responsibilities

• Supervisors
– Ensure energy control procedures are established and
followed
– Employees are trained
– Employees have proper equipment
– Designate primary responsibility for group lockout
situations
– Maintain exclusive control over master or duplicate keys
– Conduct periodic inspections
 Responsibilities

• Management
– Develop, maintain, and support the LOTO policy
– Maintain policy by reviewing and revising as necessary
– Facilitate training
 Periodic Inspections

• Inspections must be performed at least annually to assure

that the energy control procedures continue to be
implemented properly and that the employees are familiar
with their responsibilities.

• Supervisors are responsible for conducting this annual

inspection and they must certify that the inspections have
been performed. The certification must identify the machine
or equipment, the date of the inspection, the employees
included, and the name of the person performing the
inspection. Must identify any deficiencies or deviations and
correct them.
 Questions?

Resources & Assistance

Gene Patrick, OHSU Construction and Maintenance Safety

Manager: patrickg@ohsu.edu
Bill Wood Jr., PSF Industries, Inc.
Safety Director: bill@psfindustries.com

Oregon OSHA Consultative Services or Technical Services

OAR 437, Division 2, Subdivision J, “THE CONTROL OF
HAZARDOUS ENERGY (LOCKOUT/TAGOUT)”

Fed OSHA (http://www.osha.gov) CPL 02-00-147 LOTO

Enforcement Policy and Inspection Procedures

GEW, LLC. Safety Consultants GEWLLC@aol.com