About this Course

• The purpose of this Lockout/Tagout program is to prevent inadvertent operation or energization of machines, equipment, or processes in order to protect employees and equipment, and establish methods for achieving zero energy state.
• This program applies to energy sources such as: electrical, mechanical, hydraulic, pneumatic, chemical, radiation, thermal, compressed air, potential energy stored in springs, and potential energy from suspended parts (gravity).
• This program applies to activities such as: erecting, installing, constructing, repairing, adjusting, inspecting, cleaning, operating, or maintaining equipment and processes.

Governing Regulations

• Occupational Safety and Health Administration (OSHA) 29 CFR 1910.147, The control of hazardous energy (lockout/tagout)
• Lockout/Tagout and Alternative Methods, ANSI/ASSE Z244.1-2003

Learning Objectives

Key Definitions

The following terms and definitions are key components of an effective Lockout/Tagout program.

Definitions

• Lockout/Tagout is a procedure for a safe shut down and restart of equipment that is serviced, cleaned, or maintained.
• Lockout/Tagout protects employees who service and maintain equipment by placing a lock/tag on a device that prevents the energy from reaching the machine that is being serviced or maintained. This lock and tag ensures that the equipment cannot be turned on while the work is occurring.
• Equipment that is not properly locked out and tagged out can result in serious injury or death.

Definitions

• Energy-Isolating Device: Any mechanical device that physically prevents the transmission or release of energy including but not limited to the following: a manually operated electrical circuit breaker, a disconnect switch, a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors.
• Energy Source: Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy

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
• Lockout device: Any device that uses positive means such as a lock to hold any energy-isolating device in a safe position, thereby preventing the energizing of machinery, equipment, or any other energized system in order to prevent release of harmful kinetic or potential energy.

Definitions

• Tagout: The placement of a tagout 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 be operated until the tagout device is removed.
• Tagout 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 tagout device is removed in accordance with the energy-control procedure.

Definitions

• Try (AKA Verification of Isolation): Prior to starting work on machines or equipment that have been locked out or tagged out, the authorized employee shall verify that isolation and deenergization of the machine or equipment have been accomplished.

Definitions

• Affected employee: An employee whose job requires him/her to operate or use a machine or equipment on which servicing, or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed.
• Authorized employee: An employee who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee’s duties include performing servicing or maintenance covered by this program.

Definitions

• Primary authorized employee: An authorized employee who has been assigned the responsibility of coordinating the overall lockout/tagout control when more than one department or other group is involved, coordinates the affected work forces, and ensures the continuity of protection.
• Other employee: An employee whose job requires him/her to work in an area in which machine/equipment servicing or maintaining is being performed.

Definitions

An authorized employee is an employee whose job requires him/her to work in an area in which machine/equipment servicing or maintenance is being performed.

• True
Incorrect. The is the definition of "Other Employee". An Authorized employee is an employee who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee’s duties include performing servicing or maintenance covered by this program.
• False
Correct. The is the definition of "Other Employee". An Authorized employee is an employee who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee’s duties include performing servicing or maintenance covered by this program.

Definitions

A Lockout device is any device that uses positive means such as a lock to hold any energy-isolating device in a safe position, thereby preventing the energizing of machinery or equipment.

• True
Correct.
• False
Incorrect.

Definitions

Finish the sentence: Equipment that is not properly locked out and tagged out

1. can still be worked on if the power is shut off.
Incorrect
2. can be worked on as long as the right people are notified.
Incorrect
3. can result in serious injury or death.
Correct
4. is still safe to work on.
Incorrect

Roles and Responsibilities

This module will look at the various roles and the responsibilities involved in a successful Lockout/Tagout.

Authorized Employees

You’re classified as an authorized employee whenever you maintain, service, or clean equipment. You’re the person who is most at risk of being injured from an unexpected start-up of equipment.

It’s your responsibility to recognize all of the dangerous energy sources in the workplace, identify their potential hazards, and know how to avoid the dangers associated with them.

You must inform all affected and other employees why the equipment is being taken out of service and for how long. This will help prevent affected and other employees from trying to restart equipment when you’re working on it.

Authorized Employees Must

Authorized Employees

Affected Employees

You’re classified as an affected employee if you operate or use the equipment that is being serviced or maintained. You must understand all lockout/tagout procedures so that you will not unintentionally restart the equipment. An unintentional restart could result in injury or death of an employee servicing or maintaining the equipment.

An affected employee shall never remove locks or tags that they did not attach themselves. Removal would place the authorized employee in immediate risk of injury or death.

An affected employee shall never try to restart equipment if it is locked or tagged. Always assume that machines with locks or tags are being serviced (cleaning included) or maintained by an authorized employee.

Affected Employees Must

Understand all lockout/tagout procedures

Never remove locks or tags

Never restart equipment that is Locked and/or Tagged out

Primary Authorized Employee

They are the first person to hang a lock on a system and the last to remove it.

They will have the training and experience to exercise group and system judgements.

They coordinate the work involved in the lockout and ensure continuity of their protection.

Other Employees

Are not authorized or affected employees

Must be able to identify locks and tags

Must be aware of lockout/tagout procedures

Never restart equipment that is Locked and/or Tagged out

Never remove locks or tags from equipment.

Employee Training

• All authorized and affected employees should be retrained whenever there is a change in:
• Job assignments
• Machines, equipment, or processes that present a new hazard
• Energy control procedures
• Additional retraining should occur whenever the employer has reason to believe that there are deviations from established procedures or inadequacies in the employee’s knowledge or use of the energy control procedures.
• Retraining should re-establish employee proficiency and introduce new or revised control methods and procedures, as necessary.

Periodic Inspections

Roles and Responsibilities

You are classified as an authorized employee whenever you maintain or service (cleaning included) equipment. You are the person who is most at risk of being injured from an unexpected start-up of equipment.

• True
Correct
• False
Incorrect

Roles and Responsibilities

An affected employee can remove locks or tags that they did not attach themselves. Removal will not place the authorized employee in immediate risk of injury or death.

• True
Incorrect. Only the person who applied the Lock and Tag are authorized to remove them. Affected and other employees must never remove locks and tags.
• False
Correct. Only the person who applied the Lock and Tag are authorized to remove them. Affected and other employees must never remove locks and tags.

Roles and Responsibilities

Which of the following are true of energy control program periodic inspections?

1. Occur at least annually
Incorrect. Inspections are required annually, must be performed by authorized employee other than those who use the procedure being inspected, and are used to identify and correct inadequacies.
2. Performed by authorized employee other than those who use the procedure being inspected
Incorrect. Inspections are required annually, must be performed by authorized employee other than those who use the procedure being inspected, and are used to identify and correct inadequacies.
3. Used to identify and correct inadequacies
Incorrect. Inspections are required annually, must be performed by authorized employee other than those who use the procedure being inspected, and are used to identify and correct inadequacies.
4. All of the above
Correct

Hazards

The following module covers the hazards that exist and injuries that can occur if a lockout/tagout is not applied properly.

What is Hazardous Energy?

What is Hazardous Energy?

Leading Causes of Lockout/Tagout Injuries

Shock

Arc Flash

An Arc Flash is a short circuit through the air when insulation or isolation between electrical conductors is breached or can no longer withstand the applied voltage.

In an arc flash incident, an enormous amount of concentrated radiant energy explodes outwards from the electrical equipment creating pressure waves that can damage a person’s hearing, a high-intensity flash that can damage their eyesight, and a superheated ball of gas that can severely burn a worker’s body and melt metal. The pressure wave can send loose material like pieces of damaged equipment, tools, and other objects flying through the air. The best way to prevent Arc Flash from occurring is to de-energize the system before beginning any work and always verify the fact the energy is controlled.

Examples:

• Arc flash incidents typically occur when electrical equipment is being shut down, serviced, or inspected.
• Some incidents occur when a worker is removing a cover or trim from a piece of equipment.

Hazardous Energy Injuries

Millions of workers in the U.S. are at risk every day from uncontrolled energy when servicing equipment—These include disabling and non-disabling electrical contact injuries.

Injuries include:

• Electrocution
• Burns
• Amputation
• Cuts
• Scalding
• Crushing

Energy Sources: 2 Major Categories

There are 2 major categories of energy:

• Primary Energy is energy that comes into a machine and supplies it with its "primary" motive power
• Secondary Energy is energy that may be stored in a machine (potential energy)

What is most important is not whether an energy source is primary or secondary, but that all energy sources are identified.

Primary Energy Sources

Electrical – For example, electrical energy is used to run motors. Prior to servicing an electric motor, the primary electrical energy must be removed. Also, any stored or secondary energy must be removed from the motor.

Secondary Energy Sources

Residual pressure - can be stored in hydraulic, pneumatic, water, or vacuum systems which requires dissipation.

Dissipation may result in a hissing noise or loud popping sound when released (be prepared and prepare personnel in the area).

Secondary Energy Sources

Residual electrical energy – stored electrical energy such as that found in batteries, static electricity, capacitors, or electrical energy in a power line that can be dissipated after powered down by pushing the start button or turning the switch to the "On" position.

Stored mechanical energy and gravity – can be found in compressed air and steam systems, extended or coiled springs, open bay doors, lift tables in the upper position, and in the vertical ram of a cardboard baler.

Secondary Energy Sources

Mechanical motion (flywheel) – such as fan blades that when turned off and unplugged must dissipate their energy on their own in their own time (e.g. see below for the DR (Dissipate Rotation) placard).

Thermal energy – can be present in solids, liquids, or gases with high or low temperatures – i.e. walk-in ovens and equipment washers that when “Off” may take hours to cool before work can be performed.

Chemical energy – may be residual chemicals in pipes that could be under pressure or thermal extremes.

Energy Control and Protective Devices

Energy Control and Protective Devices

Energy Control and Protective Devices

Energy Control and Protective Devices

Hazards

The following are all causes of lockout/tagout injuries except

1. Failure to shut off equipment.
Incorrect
2. Failure to disconnect from power source.
Incorrect
3. Not wearing a hard hat.
Correct
4. Unexpected restarting of equipment.
Incorrect

Hazards

Hazardous energy is

1. Often invisible
Incorrect
2. Live or stored electricity
Incorrect
3. Moving machine or equipment parts
Incorrect
4. All of the above
Correct

Hazards

An arc flash is a short circuit through the air when insulation or isolation between electrical conductors is breached or can no longer withstand the applied voltage.

• True
Correct
• False
Incorrect

Lockout/Tagout Procedures

The module covers lockout/tagout procedures used for the control hazardous energy.

Energy Control Procedures

When implementing a lockout/Tagout procedure the following steps must be followed:

• Prepare
• Lock
• Tag
• Clear
• Try (Verification of Isolation)

Energy Control Procedures

Energy Control Procedures

Energy Control Procedures

Apply Tagout Device

1. Alert everyone that the machine or equipment is not in service by attaching a proper tag to all locks or energy isolating devices (in the case where locks cannot be used).
2. Write your name, the date, and the purpose for the lockout/tagout on the tag.

Energy Control Procedures

Energy Control Procedures

Try or Test Operating Controls

1. Try or test the operating controls to make sure that the machine or equipment will not operate or release other potentially hazardous energies.
1. If the machine or equipment uses electricity, a qualified person (i.e., one who is knowledgeable in electrical hazards and safety measures) must verify the absence of voltage. If the circuit to be tested is over 600 volts (nominal), the test equipment must be checked for proper operation immediately before and after this test.
2. Interlocked equipment must be checked carefully to make sure that the equipment is locked-out properly and not temporarily inoperative because of an interlock.
3. Check the equipment or process by use of test instruments and/or visual inspection to verify that energy isolation has been accomplished. If drains or other pressure relief valves/devices are used to verify zero energy they must also be locked and tagged out. Never rely on a pressure gauge or similar device to verify zero energy.
4. These are not reliable for verifying zero energy.
5. The equipment/process shall be examined to detect any residual energy. If detected, action must be taken to relieve or restrain the stored energy.

Energy Control Procedures

Try or Test Operating Controls

1. Return the energy isolating device(s) to their “off” or “safe” position. The equipment has now been locked and/or tagged out by the owner (i.e., the principle authorized employee). Any other authorized employees wishing to work on this machine or equipment must apply their own locks and tags. This means, if there are 10 people working on the machine at any one time, there will be 10 locks and/or tags on the energy isolating devices (for example by using multi-lock hasps), unless the owner uses a group lock out system, such as a lock box, where he/she performs lockout/tagout on the machine and places his/her keys in a lock box and other authorized employees verify lockout/tagout of the machine (if desired) and place their locks and tags on the lock box.

Release of Control Mechanisms after Work is Complete

The removal procedure must be followed in sequence by authorized employees to remove locks and tags and restore energy to the machine or equipment.

1. Clear the equipment and the area around the equipment of personnel, tools, or other nonessential items.
2. Ensure that all guards are in place. Remove locks, lockout devices, and/or tags. Only the same authorized employee who installed the lock(s) and/or tag(s) may remove them (there are limited exceptions which are described under, "Removal of Locks by Others").

Additional Requirements

Group Lockout

For major process or equipment overhaul, rebuilds, etc., which require group lockout/tagout, a system is required that affords employees a level of protection equivalent to that provided by personal lockout/tagout. Overall responsibility is vested in a Primary Authorized Employee for a set number of employees working under the protection of a group lockout or tagout device. There shall be provisions for the Primary Authorized Employee to ascertain the exposure status of individual group members with regard to the lockout or tagout of the machine or equipment. Each authorized employee shall affix his or her personal lockout/tagout device to the group lockout device, group lockbox, or comparable mechanism when he or she begins work, and shall remove those devices when he or she stops working on the machine or equipment being serviced or maintained.

Shift or Personnel Changes

Specific procedures shall be utilized during shift or personnel changes to ensure the continuity of lockout/tagout protection, including provision for the orderly transfer of lockout/tagout device protection between off-going and oncoming employees, to minimize exposure to hazards from the unexpected energization or start-up of the machine or equipment, or the release of stored energy. Departments shall develop specific written procedures to accommodate those situations where it is necessary to continue the current lockout/tagout of the equipment/process into subsequent shifts.

Removal of Locks and Tags by Others

If the authorized employee is still on site, or not known to have left the site, that employee’s locks and tags must not be removed by any other person. During an emergency while the authorized employee is off site, the authorized employee’s immediate supervisor or other management personnel above them can remove their lock and/or tag after a complete check of the equipment to determine that no hazard can result from the lock/tag removal. The authorized employee that established the Lockout/Tagout must be informed that their lock and tag were removed before their return to work.

Contractors

Project Managers or administrators who hire or oversee contracted projects shall communicate this program and specific procedures to contractors whose work necessitates performing lockout/tagout procedures.

Contractors and their subcontractors shall comply with all provisions of the University’s Lockout/Tagout program and ensure that their employees are appropriately trained and authorized.

Contractors and their subcontractors shall comply with any shut down procedures that have been developed by the University for each machine or piece of equipment that the contractor must service or maintain or other such project where energy sources are present.

When shut down procedures are not available from the University, the contractor shall develop and provide the University with their own shut down procedures for that machine or piece of equipment or project. Prior to start of work, the shutdown procedures shall be submitted for approval to the project manager responsible for the project.

Lockout/Tagout Procedures

What is the first step in a lockout/tagout procedure?

1. Lockout Energy Sources.
Incorrect
2. Return controls to off or neutral.
Incorrect
3. Prepare for shutdown.
Correct
4. Apply Tagout Device.
Incorrect

Lockout/Tagout Procedures

Try or test the operating controls to make sure that the machine or equipment will not operate or release other potentially hazardous energies. This process is used to verify that equipment, machines and systems are de-energized and isolated from unexpected start-up before any work is initiated.

• True
Correct
• False
Incorrect

Lockout/Tagout Procedures

During an emergency while the authorized employee is off site, the authorized employee’s immediate supervisor or other management personnel above them can remove their lock and tag after a complete check of the equipment to determine that no hazard can result from the lock and tag removal. The authorized employee must be informed before their return to work.

• True
Correct
• False
Incorrect

Review

Protect Yourself and Others!

Do not remove locks/tags except for your own.

Do not bypass locks/tags.

Always Lockout/Tagout all energy sources and verify a zero energy state before performing servicing, maintenance, or other work on equipment.

Only the direct supervisor of an employee may remove an employee’s lock/tag following the lock removal procedure.

Affected and Other employees must not attempt to restart or energize equipment that is locked/tagged out.

Your life or someone else’s depends on it!