OR-OSHA 204

Oregon OSHA

LOCKOUT/TAGOUT
Hazardous Energy Control

and

MACHINE SAFEGUARDING

Presented by the Public Education Section

Oregon OSHA
Department of Consumer and Business Services

1005-02
 Oregon OSHA Public Education Mission:
We provide knowledge and tools to advance
self-sufficiency in workplace safety and health

Consultative Services:
Offers no-cost on-site assistance to help Oregon employers recognize and
correct safety and health problems

Enforcement:
Inspects places of employment for occupational safety and health rule
violations and investigates complaints and accidents

Public Education and Conferences:

Presents educational opportunities to employers and employees on a variety of
safety and health topics throughout the state

Standards and Technical Resources:

Develops, interprets, and provides technical advice on safety and health
standards
Publishes booklets, pamphlets, and other materials to assist in the
implementation of safety and health rules

Field Offices:
Questions?
Call us Portland 503-229-5910
Salem 503-378-3274
Eugene 541-686-7562
Medford 541-776-6030
Bend 541-388-6066
Pendleton 541-276-2353

Salem Central Office:

Toll Free number in English: 800-922-2689
Toll Free number in Spanish: 800-843-8086
Web site: www.orosha.org
 This material for training use only

Introduction
Many serious injuries and fatalities have occurred when someone thought a machine
was safely turned off and/or assumed all energy sources were correctly disconnected.
This problem has resulted in many preventable injuries and deaths.

This is where OSHAs Hazardous Energy Control standard comes in. Routinely
referred to as Lockout/Tagout, this regulation covers servicing and maintenance of
machines and equipment in which the unexpected energization or start-up of the
machines or equipment, or release of stored energy could cause injury to employees.
This standard is found in OR-OSHAs Division 2/Subdivision J 29 CFR 1910.147 and it
sets minimum performance criteria for the control of hazardous energy.

In general, the standard requires that all energy sources for equipment be turned off,
isolated (disconnected), and physically locked out. Bleeding, relieving, or blocking
other stored and residual energy must also be done to achieve zero energy state.
Finally, the last important function before service begins is to verify all energy has been
deenergized and/or isolated.
The key is that the equipment or machines are
returned to a ZERO energy state before work begins.
Objectives

Gain a greater awareness of all requirements in OR-OSHA Div 2/Sub J
29 CFR 1910.147 The Control of Hazardous Energy

Discuss the importance of a hazardous energy control plan

Discuss energy control procedures, training, and periodic inspection criteria

This standard applies to all Oregon employers including construction and maritime.
Refer to OR-OSHA Div 4/Sub J for hazardous energy control in agriculture.

OSHA requirements for installations under the exclusive control of electric utilities for
the purpose of power generation, transmission, and distribution are covered in OR-
OSHA Div 2/Sub R 29 CFR 1910.269. Furthermore, exposures to electrical hazards
from work on, near, or with conductors or equipment in electric utilization installations
are regulated in OR-OSHA Div 2/Sub S 29 CFR 1910.331-335.

Please Note: This material, or any other material used to inform employers of compliance requirements of Oregon OSHA
standards through simplification of the regulations should not be considered a substitute for any provisions of the Oregon
Safe Employment Act or for any standards issued by Oregon OSHA. The information in this workbook is intended for
classroom use only.

Lockout/Tagout & Machine Safeguarding

1
 This material for training use only

Part 1: Scope and Application

OR-OSHA Div 2/Sub J 29 CFR 1910.147

The Control of Hazardous Energy (Lockout/Tagout)
(c)(1) Energy Control Program. The employer shall establish a program consisting of
energy control procedures, employee training, and periodic inspections to ensure that
before any employee performs any servicing or maintenance on a machine or
equipment where the unexpected energizing, start up or release of stored energy could
occur and cause injury, the machine or equipment shall be isolated from the energy
source, and rendered inoperative.

What are the three key elements of an energy control program?

1.

2. See paragraph above:

1. Energy Control Procedures
3. 2. Employee Training
3. Periodic Inspections

Scope: The lockout/tagout rule covers the following employees:

Authorized Employee Affected Employee Other Employee

The person who operates or uses a machine or piece of equipment which is being
serviced is an:
Authorized Employee Affected Employee Other Employee

The person who works in an area where lockout procedures are being used is an:
Authorized Employee Affected Employee Other Employee

The person who services or performs maintenance on machines and equipment is

an:
Authorized Employee Affected Employee Other Employee

Lockout/Tagout & Machine Safeguarding

2
 This material for training use only

Procedures must be followed when...

Unexpected
...servicing and/or maintenance is being done when __________________
energization, start-up or release of stored energy could cause injury.

What is servicing or maintenance?

Some workplace activities considered to be servicing and/or maintenance include:

Adjusting...inspecting...modifying...constructing...re-tooling...

lubricating...installingsetting up...removing jams...cleaning...

Sources of Energy

Sources of energy capable of causing serious injury include:

Brainstorm with the class

____________________
about the type of energy they
____________________
may find in their workplaces.
____________________
Some examples may be:
Electrical
____________________
Pneumatic
____________________
Gravity
____________________
Hydraulic
Radiation
____________________
Kinetic
____________________
____________________

Lockout/Tagout & Machine Safeguarding

3
 This material for training use only

This standard {OR-OSHA Div 2/Sub J 29 CFR 1910.147} does not apply to:

Installations under the control of electric utilities for the purpose of

power generation, transmission, and distribution
{OAR Div 2/Sub R 29 CFR 1910.269}

Exposure to electrical hazards from work on, near, or with conductors

or equipment in electric utilization installations
{OAR Div 2/Sub S 29 CFR 1910.331-335}

Oil and gas well drilling and servicing

Servicing/maintenance during normal production operations* unless:

guards, or other devices are removed/bypassed
employees place themselves in the point of operation (the area of the
machine where work is actually performed)
employees place themselves in any area considered dangerous during a
machine operating cycle

* Servicing and/or maintenance during normal production operations can

include minor tool changes and adjustments that are routine, repetitive, and
integral to the use of the equipment for production.

Plug and Cord

Work on _____ and _____ connected equipment
only when under the exclusive control of the
authorized person

Hot tap operations involving transmission and distribution systems for

gas, steam, petroleum, etc., when performed on pressurized lines and
when the employer demonstrates that:

continuity of service is essential

shutdown of the system is impractical
documented procedures are followed
special equipment is used which will provide
proven effective protection for employees
Lockout/Tagout & Machine Safeguarding
4
 This material for training use only

Part 2: The Energy Control Plan

Your hazardous energy control plan must specifically outline the scope, purpose,
authorization, rules, and techniques to be utilized for the control of hazardous energy.
The plan must also include your methods to enforce compliance.

At a minimum, the following steps must be taken:

1. A specific statement of the intended use of your procedures

2. Specific procedures to shut down, isolate, block and secure machines or

equipment

3. Specific procedures to place, remove and transfer lockout/tagout devices

4. Assigning responsibility for lockout/tagout devices

5. Requirements and procedures to test machines and machinery to

determine and verify effective lockout/tagout devices, and other energy
control measures

Why is a comprehensive written plan critical to a successful

lockout/tagout program?

Talk with the class about why they feel it is important

to have a LOTO program and why the beginning of it
should be the comprehensive written program.

What are some reasons a lockout/tagout program may not work

effectively?

Brainstorm these failings with the class. There may

be many reasons why. Focus on training and
supervision for a start.

Who is responsible.who is accountable.and for what?

Talk about the people responsible. Why is it
important to do that?

Lockout/Tagout & Machine Safeguarding

5
 This material for training use only

Steps to developing a successful program

1. List all equipment or machines that need servicing or maintenance;

2. Identify those machines which could unexpectedly start up or release stored

energy while being serviced or maintained;

3. Determine the steps in the maintenance or servicing task; and

4. Review each step for the potential of a hazard from all energy sources.

Good Idea
Post user-friendly procedures on each piece of equipment.
Identify energy sources, hazards, and energy isolating devices.

These steps listed above will help as an outline for

creating the LOTO program.

Portland area example!

Lockout/Tagout & Machine Safeguarding
6
 This material for training use only

Part 3: Lockout/Tagout Procedures

Step 1 - Prepare for Lockout

The first step in the lockout/tagout procedure is preparing to shut down the equipment
or machinery.

Before shutting down, the authorized employee(s) must know the :

Types and magnitudes of energy

Hazards posed by that energy

Methods to effectively control the energy

Pay close attention to energies (such as gravity, electrical, high pressure) that can be
stored or re-accumulated after shut-down.

Notify all affected employees prior to shutdown so they can clear their work area and/or
any other area that might be hazardous.

What can you do to ensure the above review and notification is conducted
prior to lockout?
Create a checklist

Step 2 - Shutdown

Machinery and equipment must be turned off or shut down using the procedures youve
established for the machine or equipment.

An orderly shutdown must be utilized to avoid any additional or increased hazards due
to equipment stoppage.

If more than one authorized employee is involved in shutdown, a team leader should
make sure everyone has accomplished their tasks and are aware that shutdown will
occur.

Lockout/Tagout & Machine Safeguarding

7
 This material for training use only

Step 3 - Energy Isolation

All energy isolating devices must be located and operated to completely de-energize
and isolate the equipment.

The authorized employee(s) will verify operation of each energy isolating device. If
more than one authorized employee is involved, a team leader should make sure
everyone has accomplished their task.

An energy isolating device physically prevents

...the t____________
Transfer oror r_______ of energy.
Release

Some examples of energy isolating devices include:

Have the class list as many items as they can think of

to block energy flow. What have they seen in their
workplace or other workplaces.

You may also want to get a catalog from a supplier to

show what is available.

Pushbuttons, selector switches and

other control circuit type devices
are energy isolating devices.

TRUE FALSE

Why?

Lockout/Tagout & Machine Safeguarding

8
 This material for training use only

Step 4 - Lockout or Tagout Application

Take note of the bolded words

Lockout v. Tagout: There is a difference!

Lockout is 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.

Tagout is 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.

Lockout Devices
A lockout device is a device that uses a positive means
such as a lock to hold an energy isolating device in a safe
position to prevent the energizing of a machine or piece of
equipment
Only authorized employees can affix lockout devices
Lockout devices must be able to hold energy isolation
devices in a safe or off position

Tagout Devices Brady Corp.

A tagout device is a prominent warning device, such as a tag and a means of

attachment, which can be securely fastened to 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
Only authorized employees can affix tagout devices
Tagout devices must be affixed in such a manner as will clearly indicate that the
moving of energy isolating devices from the safe or off position is strictly
prohibited
Must warn against hazardous conditions if the machine or equipment is
energized and must include a message such as Do Not Start, Do Not
Close, Do Not Energize, Do Not Operate.

If a tag cannot be affixed directly to the energy isolating device,

it must be located as close as safely possible to the device so
that the tag is obvious to anyone attempting to operate the device
Brady Corp.
Lockout/Tagout & Machine Safeguarding
9
 This material for training use only

Which is the preferred method: Lockout or Tagout?

An energy isolating device is capable of being locked out if

it has a hasp or other means to attach a lock

it has a built in locking mechanism

it does not have to be dismantled or rebuilt to achieve lockout

After 1/2/90, whenever replacement or major repair, renovation, or

modification of a machine or piece of equipment is performed; and
whenever new machines or equipment are installed, energy isolating
devices for such machines or equipment must be designed to accept a
lockout device.

When can an employer use a tagout system?

1. Locked o___,
When an energy isolating device is not capable of being l______ Out or

2. When the employer can demonstrate (prove) that using a tagout system
will provide full employee protection.

How? Tags must be affixed on the energy isolating device at the

same location the lock would have been attached, and

The employer demonstrates that equivalent protection can

be obtained

How?
Must demonstrate full compliance with all tagout-related
provisions (e.g. p. 9), and

Implement additional safety measures such as removing an

isolating circuit element, blocking of a controlling switch,
opening an extra disconnect, removing a valve handle,
blocking a ram, etc.

Lockout/Tagout & Machine Safeguarding

10
 This material for training use only

More on the protective hardware!

Use the
following terms
Protective materials and hardware must be provided by the to fill in the
e_________.
Employer blanks:
Each lockout and tagout device must be singularly identified as standardized
being used o___
Only for lockout or tagout. substantial
Standardized employer
Lockout and tagout devices must be s_____________ within identify
the facility (i.e. color, size, print and format of tags, etc.). substantial
only
Lockout and tagout devices must i_________
Identify the user.

Lockout and tagout devices must be capable of withstanding the environment to which
they are exposed for the maximum period of time the exposure is expected:

 Tagout devices must be constructed and printed so that exposure to

weather conditions or wet and damp locations will not cause the tag to
deteriorate or the message on the tag to become illegible

 Tags must not deteriorate when used in corrosive environments such

as areas where acid and alkali chemicals are handled and stored

Substantial
Lockout devices must be s___________ enough to prevent removal except with the use
of excessive force or unusual techniques (i.e. bolt cutters).

Substantial enough to prevent inadvertent or accidental

Tagout devices must be s___________
removal.

 Attachment means must be non-reusable, attachable

by hand, self-locking, and non-releasable with a minimum
unlocking strength of 50 lbs., and designed equivalent to
a one-piece, all environment-tolerant nylon cable tie

Idesco Corp.

What are some examples of lockout

devices?

Brady Corp.
Lockout/Tagout & Machine Safeguarding
11
 This material for training use only

Step 5 - Controlling Stored Energy

Immediately after applying lockout or tagout devices, the authorized employee must ensure
all potentially hazardous stored or residual energy is:

 relieved
 disconnected
 restrained

If there is a possibility of stored energy reaccumulating to a hazardous level...

 continue to verify isolation until the servicing or maintenance is completed or until

the possibility of such accumulation no longer exists.

What are some examples of stored or residual

energy?

Brady Corp.

Step 6 - VERIFY

Before starting work on a machine or piece of equipment that has been locked or tagged
out, the authorized employee must v______
Verify that the machine or piece of equipment has
been isolated and deenergized.

VERIFY ZERO ENERGY STATE!

How do you verify that a machine or piece of equipment

is actually isolated and deenergized?

Lockout/Tagout & Machine Safeguarding

12
 This material for training use only

Release from Lockout or Tagout

The authorized employee must follow the procedures below prior to

removing lockout/tagout devices and restoring
Take some time to walkenergy.
through this page with the
class. Spend time on the exception and make sure the
Equipment class understands it.

Make sure machinery or equipment is properly reassembled

Inspect machinery or equipment to make sure nonessential items have

been removed

Employees

Make sure all employees are safely positioned outside dangerous areas

Notify affected employees that lockout or tagout devices have been

removed and that energy is going to be reapplied

Removing lockout/tagout devices

Only the authorized employee who applied the lockout or tagout device may
remove that device

Exception - When the authorized employee is not available to remove it, the
device can be removed under the direction of the employer

 Specific procedures and training must be developed,

documented, and placed in your energy control plan

 At a minimum, the procedures must include:

Verification that the authorized employee who applied the

device is not at the facility

Making all reasonable efforts to contact him/her to inform

them that their lockout or tagout device has been removed

Ensuring that they are aware of this upon returning to work

If the authorized employee is not available, who is authorized to remove

the lockout or tagout device?

Lockout/Tagout & Machine Safeguarding

13
 This material for training use only

Testing/Positioning Machines or Equipment

Whenever lockout or tagout devices must be temporarily removed to test or position
the machine or equipment, the following sequence must be conducted:

1. Clear the machine or equipment of tools and materials

2. Remove employees from the machine or equipment area
3. Remove the lockout or tagout devices
4. Energize and proceed with testing or positioning
5. Deenergize all systems and reapply energy control measures

How can employees be injured while testing the machinery or equipment

during maintenance?
If a step is missed or not done adequately employees
are exposed to the same hazards as running the
machine without guards.

Outside Personnel
Outside servicing personnel, contracted to perform maintenance or other services
requiring lockout or tagout procedures, must not begin work until the host employer
and the contractor inform each other of their respective hazardous energy control
procedures.

The host employer must also ensure company employees understand and comply
with the contractors lockout or tagout procedures.

What does this basically involve? Share Information

S_______ I___________.

Who is responsible if an employee is injured because an outside contractor

did not follow proper lockout/tagout procedures?

Shift/Personnel Changes
Specific procedures must be utilized during shift or personnel changes to ensure the
Continuity of lockout or tagout protection, including provision for the orderly
c__________
transfer of lockout or tagout device protection between both off-going and oncoming
workers

What is the intent of these shift change procedures?

Share Information

Lockout/Tagout & Machine Safeguarding

14
 This material for training use only

Group Lockout or Tagout

When servicing and/or maintenance is performed by a group (crew, craft, department,
etc.), they must utilize a procedure which affords the employees a level of protection
equivalent to that provided by a personal lockout or tagout device.

Group lockout or tagout devices must be used in accordance with specific procedures
and must include the following requirements, at a minimum:

 Primary responsibility is vested in an authorized employee for a set

number of employees working under the protection of a group lockout
or tagout device (e.g. an operations lock)

 Provision for the authorized employee to monitor the exposure status of

individual workers with regard to the lockout or tagout of the machine or
equipment

 When more than one group is involved, assignment of overall job-

associated lockout or tagout control responsibility to an authorized
employee designated to coordinate all affected groups and ensure
continuity of protection

 Each authorized employee must affix a personal lockout or tagout

device to the group lockout device (group lockbox or comparable
mechanism) when he/she begins work, and must remove the device
when he/she stops working on the machine or equipment being
serviced or maintained

Brady Corp.

Lockout/Tagout & Machine Safeguarding

15
 This material for training use only

Part 4: Lockout/Tagout Training

General requirements
Training must ensure that the purpose and function of your energy control plan are
understood and that employees gain the needed knowledge and skills to safely
apply, use, and remove hazardous energy controls.

Minimum training must include:

Authorized employees must be able to recognize:
hazardous energy sources
types and magnitudes of energy in the workplace
methods and means necessary to isolate and control the energy

Affected employees must be instructed on the:

purpose and use of your energy control procedures

Other employees must be instructed about:

the energy control procedure in general
prohibitions relating to attempts to restart/reenergize equipment

What are effective training strategies for each level of training?

Authorized employee ____________________________

Classroom, on the job, and verification
Affected employee ____________________________
Classroom, on the job
Other employee ____________________________
Classroom

What are some other training considerations?

Education level, reading and writing skills, prior
knowledge, generational differences, learning style
preferences, language barriers, trust
Brady Corp.
Lockout/Tagout & Machine Safeguarding
16
 This material for training use only

Training on Tagout Devices

If tagout devices are used, further training on tagout systems need to emphasize that:

 Tags are warning devices only and do not provide a physical restraint that
lockout devices provide
 Tags must not be removed without the authorized employees approval
and should never be bypassed, ignored, or otherwise defeated
 Tags must be legible and understandable by all employees
 Tags must be able to withstand environmental conditions in the workplace
 Tags may give employees a false sense of security
 Tags must be securely attached to prevent inadvertent or accidental
detachment

Retraining
When should employees be retrained?

Activities
Whenever there is a change in their job a__________

Whenever there is a change in m________,

Machine equipment, or process that
present a new hazard

Control Procedures
Whenever there is a change in your energy c_______ p____________

Employees
Whenever there are deviations from or inadequacies in the e___________
knowledge or use of the energy control procedures

The retraining must reestablish employee proficiency and introduce new or revised
control methods and procedures, as necessary.

Documentation
A training certification must contain each employees name and date(s) of training.

Whats missing?
Did the employee understand (pass/fail), What they
were trained on (topics), and Who trained them.

Lockout/Tagout & Machine Safeguarding

17
 This material for training use only

Part 5: Lockout/Tagout Periodic Inspections

An inspection of each energy control procedure must be conducted at least annually.

These inspections must at least include a demonstration of the procedures (steps) and
may be implemented through random audits and/or planned visual observations.

Inspections must be performed by an authorized employee other than the

one(s) using the energy control procedure being inspected

The purpose of the inspection is to correct deviations or inadequacies

relating to your procedures and/or trainingbut should also point out the
good!

Where lockout is used, the inspector and authorized employee(s) involved

in the procedure being inspected must review applicable controls and
responsibilities.

Where tagout is used, the inspector and each authorized and affected
employee involved in the procedure being inspected must review
applicable controls and responsibilities, and the limitations a tagout system
provides.

Documentation
The employer must certify that the periodic inspections are being performed. This
certification must identify:

The equipment or machine being serviced

The date(s) of inspection
The employees included in the inspection
The authorized employee performing the inspection

Whats missing? Did the control work? Did the

employee follow the procedures? Any
changes needed?

What questions would you consider when conducting your inspection?

How often must lockout/tagout inspections occur?

At least annually by an authorized employee

Who must conduct the inspection?

Lockout/Tagout & Machine Safeguarding

18
This material for training use only

Reference
SAMPLE Training Certification
The Lockout/Tagout Two-Pager

Lockout/Tagout & Machine Safeguarding

19
This material for training use only

Lockout/Tagout & Machine Safeguarding

20
 This material for training use only

SAMPLE
Hazardous Energy Control Training Certification Date _________

(Company Name) policy and procedure for

Trainee certification. I have received training on __________________
controlling hazardous energies (lockout/tagout).
This training has provided me adequate opportunity to ask questions and practice procedures to
determine and correct skill deficiencies. I understand that performing these procedures/practices safely
is a condition of employment. I fully intend to comply with all safety and operational requirements
discussed. I understand that failure to comply with these requirements may result in progressive
discipline (or corrective actions) up to and including termination.
____________________________ ____________________________
Employee Name Signature

This training primarily covered the following:

Roles and responsibilities of authorized and affected employees.
Specific machinery and equipment subjected to energy control procedures (including energy sources).
Hazardous energy control procedures (prep, shutdown, isolating energies, applying devices, relieving
stored energy, verification of isolation; releasing lockout; adjusting/troubleshooting).
Periodic inspection procedures.
Procedures for contractors, shift changes, and/or group lockout (if applicable).
Other specific aspects (e.g. tagout, manufacturer specs, ):_____________________________________
This training was conducted in the following form(s):
This training included the following demonstrations:
This training qualified the trainees understanding by (test, observation, etc.):

Trainer certification. I have conducted orientation/on-the-job training to the employees(s) listed

above. I have explained related procedures, practices and policies. Employees were each given
opportunity to ask questions and practice procedures taught under my supervision. Based on each
student's performance, I have determined that each employee trained has adequate knowledge and skills
to safely perform these procedures/practices.
________________________ ____________________________ _________
Trainer Signature Date

Supervisor validation. I have observed the above employee(s) on _______________ and certify
that he/she/they correctly completed all steps and employed safe practices as trained.
________________________ ____________________________ __________
Supervisor Signature Date

Lockout/Tagout & Machine Safeguarding

21
 This material for training use only

The Importance of Controlling Hazardous Energy

8/28/02
An Oregon worker was pulled into a machine by a moving belt
and was crushed. He was 61 years old.

8/12/02
An Oregon worker was crushed by a machine that moves
blanks for cans. He was 25 years old.

12/21/99
An Oregon worker was caught between an in-feed frame and
accumulator arm of a veneer dryer. He was 62 years old and
two weeks from retirement.

5/9/99
An Oregon worker was caught in a wood/bark shredder. He
was 52 years old.

5/3/99
An Oregon worker was pinned under the fuel tank of a dump
truck when the lowering control valve was opened. He was 34
years old.

9/24/98
An Oregon workers head was crushed between a trucks lift
gate and frame.

9/3/98
An Oregon worker was crushed between glass and the machine.
He was 39 years old.

7/28/98
An Oregon worker was performing end of the day cleanup and
was struck by a hydraulic powered log kicker. He was
28 years old.
* as of 9/1/02
Lockout/Tagout & Machine Safeguarding
22
 This material for training use only

The Control Of Hazardous Energy {Lockout/Tagout}

The standard for the control of hazardous energy sources (Lockout/Tagout) covers
servicing and maintenance of machines and equipment in which the unexpected
energization or start-up of the machines or equipment, or release of stored energy
could cause injury to employees.

In general, the rule requires that all energy sources for equipment be turned off, isolated
(disconnected), and physically locked out. Bleeding, relieving, or blocking other stored
and residual energy must also be done to achieve zero energy state. Finally, the last
important function before maintenance begins is to verify all energy has been
deenergized and/or isolated.

This two-page document only serves as a supplement to the safety standard. In

addition to OR-OSHAs hazardous energy control (lockout/tagout) standard, OR-OSHA
Div 2/Sub J 29 CFR 1910.147, the following resources can provide assistance in
developing and/or improving your hazardous energy control plan:
 OR-OSHAs Guide to Controlling Hazardous Energy (publication #3326)
 OSHAs Control of Hazardous Energy (OSHA #3120)
 Preventing Worker Deaths from Uncontrolled Release of Electrical, Mechanical, and
Other Types of Hazardous Energy {DHHS (NIOSH) Publication No. 99-110}
NOTE: OSHA requirements for installations under the exclusive control of electric utilities for the purpose of power generation,
transmission, and distribution are covered in OR-OSHA Div 2/Sub R (29 CFR 1910.269). Exposures to electrical hazards from work on,
near, or with conductors or equipment in electric utilization installations are regulated in OR-OSHA Div 2/Sub S (29 CFR 1910.331-335).

Specific Written Procedures

For Shut Down
For Isolating/Blocking
For Applying Individual Locks or Tags
For Relieving Stored/Residual Energy
For Verifying Zero Energy State
For Removing & Transferring Locks

Training
Authorized Employees
Affected Employees
Other Employees
Certify (Document/Authorize)

Periodic Inspections
Conducted By Authorized Employee(s)
Evaluate Each Authorized Employee During Procedure
Are The Steps In The Energy Control Procedure Being Followed?
Do The Employees Involved Know Their Responsibilities?
Is The Procedure Adequate And What Changes, If Any, Are Needed?
Certify (Document)
Lockout/Tagout & Machine Safeguarding
23
 This material for training use only

Develop a hazardous energy control program consisting of written procedures, effective

training, and periodic inspections.

Develop and implement specific written procedures for the control of hazardous energy
including preparation for shutdown, actual shutdown, equipment isolation, lockout
application, release of stored energy, verification of isolation, and removal of device(s).

The procedures must clearly and specifically outline the scope, purpose, authorization, rules,
and techniques to be utilized for controlling hazardous energy. The procedures must also
clearly and specifically outline the means to enforce compliance. The procedures must
address release of lockout/tagout including machine inspection, notification and safe
positioning of employees, lockout transfer (shift changes), equipment testing/adjusting,
group lockout (if done), and communications with outside contractors.

Furthermore, use locks when equipment can be locked out (new /overhauled equipment
must accommodate locks). Employ additional means to ensure equivalent protection when
tags are used by developing an effective tagout program consisting of additional training and
additional means of protection (i.e. removing a circuit element, valve handle, battery, etc.).
Provide standardized locks and tags which identify the authorized employee using them and
are of sufficient quality and durability to ensure effectiveness.

Develop a hazardous energy control program consisting of written procedures, effective

training, and periodic inspections.

Train authorized employees in the recognition of applicable hazardous energy sources, the
type and magnitude of the energy available in the workplace, and the methods and means
necessary for energy isolation and control. Instruct affected and other employees on the
purpose of energy control procedures and the prohibition relating to attempts to restart and
reenergize equipment.

Retrain employees whenever there is a job change; a change in machinery, equipment,

and/or processes; a change in the energy control procedures; or whenever the periodic
inspection identifies deficiencies.

Document this training by listing the trainees, trainer(s), and date(s). It is recommended to
also document specific equipment procedures, energy sources and methods of isolation and
relief, lockout devices, lockout release/transfer, periodic inspection criteria, etc.).

Develop a hazardous energy control program consisting of written procedures, effective training,
and periodic inspections.

Designate authorized employees to conduct inspections of energy control procedures at

least annually. Evaluate each authorized employee during procedure to ensure all steps are
being followed, employees involved know their responsibilities, and to ensure if the
procedure is adequate. This is your means of enforcement! Document the good and bad
found during your inspections! Document the machine/equipment involved, your inspector,
authorized employee(s) involved, and the date(s), at a minimum. It is recommended to
document everything found for training purposes, program evaluation, and accountability.
Lockout/Tagout & Machine Safeguarding
24
 Principles of
Machine Safeguarding
Instructor Guide
This material for training use only

Lockout/Tagout & Machine Safeguarding

26
 This material for training use only

Welcome
Crushed hands and arms, severed fingers, blindness -- the list of possible machinery-
related injuries is as long as it is horrifying. There seem to be as many hazards
created by moving machine parts as there are types of machines. Safeguards are
essential for protecting workers from needless and preventable injuries.

A good rule to remember is:

Any machine part, function, or process which may cause injury must be safeguarded.
Where the operation of a machine or contact with it can injure the operator or others in
the vicinity, the hazards must be either eliminated or controlled.

This workbook overviews the various hazards of mechanical motion and actions and
presents some techniques for protecting workers from these hazards. General
information covered in this workbook includes where mechanical hazards occur, the
hazards created by different kinds of motions and the requirements for effective
safeguards, as well as a brief discussion of training guidelines.
Speak about the goals of the class

Goals
 Describe the basic hazards involving machinery including point of
operation and power transmission devices
 Introduce control measures through effective machine guarding principles
and methods

Please Note: This material or any other material used to inform employers of compliance requirements of Oregon OSHA standards
through simplification of the regulation should not be considered a substitute for any provisions of the Oregon Safe Employment Act or for
any standards issued by Oregon OSHA. This workbook contains many photos which, in some cases, represent non-compliance with
machine guarding rules. If you reproduce these photo for training, make certain the related non-compliance issue is properly addressed
when referring to the photo.

Lockout/Tagout & Machine Safeguarding

27
 This material for training use only

Machine Guarding Principles

A good rule to remember is:
Any machine part, function, or process which may cause injury must be safeguarded.
Where the operation of a machine or contact with it can injure the operator or others in
the vicinity, the hazards must be either eliminated or controlled.

If it moves, it merits your attention!

The purpose of machine guarding is to protect against and prevent injury from point of
operation, in-running nip points, rotating parts, flying chips, and sparks.
Although some OR-OSHA standards provide certain machine guarding requirements,
OR-OSHAs Div 2/Sub O Machine Guarding standard provides general guarding
requirements in addition to specific requirements for woodworking machinery, abrasive
wheel machinery, mechanical power presses, and power transmission devices.

Spend time talking about these three categories.

Dangerous moving parts in three basic areas
Brainstorm require
with the classsafeguarding :
about where they find these
items in their workplace.
1. The point of operation
That point where work is performed
Cutting Shaping Boring Forming Grinding
Turning Shearing Punching Bending Drilling

2. Power transmission apparatus

All components of the mechanical system
which transmit energy to the part of the
machine performing the work
Flywheels Couplings Pulleys
Cams Spindles Belts
Chains Cranks Sprockets
Gears Shafts Rods

3. Other moving parts

All parts of the machine which move while the machine is working
Reciprocating Rotating
Transverse Feed mechanisms

Lockout/Tagout & Machine Safeguarding

28
 This material for training use only

Hazardous Mechanical Motions & Actions

A wide variety of mechanical motions and actions may present hazards to the worker.
These can include the movement of rotating members, reciprocating arms, moving
belts, meshing gears, cutting teeth, and any parts that impact or shear.
These different types of hazardous mechanical motions and actions are basic in
varying combinations to nearly all machines, and recognizing them is the first step
toward protecting workers from the danger they present.

Motions: 1. Rotating 2. Reciprocating 3. Transverse

1. Rotating motion
Sprockets Flywheels
Couplings Shafts
Fans Pulleys
Clutches Gears

In-running nip point hazards

There are three main types of in-running nips: Parts rotating in opposite direction

Parts rotating in opposite direction

Rotating and tangentially moving
parts

Rotating and fixed parts

Rotating and tangentially moving parts

Rotating and fixed parts

Lockout/Tagout & Machine Safeguarding

29
 This material for training use only

2. Reciprocating motion
Back & forth; Up & down
May be struck by or caught between
a moving and stationary part
Scissor lifts, shaker screens, feed
tables, knife sharpeners, slicers,
feeding/ejecting parts, etc.

3. Transverse motion
Straight & continuous line
Conveyor lines
Lengthy belts
May be struck or caught in a pinch or
shear point by the moving part

Actions: 1. Cutting 2. Shearing 3. Bending 4. Punching

Punching Bending
Cutting

Shearing

Lockout/Tagout & Machine Safeguarding

30
 This material for training use only

Machine Safeguarding
There are many ways to safeguard machines. The type of operation, the size or shape
of stock, the method of handling, the physical layout of the work area, the type of
material, and production requirements or limitations will help determine the appropriate
safeguarding method for the individual machine.
As a general rule, power transmission apparatus is best protected by fixed guards that
enclose the danger areas. For hazards at the point of operation, where moving parts
actually perform work on stock, several kinds of safeguarding may be possible. One
must always choose the most effective and practical means available.

Safeguarding strategies include:

Guards Fixed; Interlocked; Adjustable; Self-adjusting

Devices Presence-sensing; Pullback; Restraints; Controls/Trips; Gates

Guards Devices

Other safeguarding strategies may include:

Location and/or Distance
Feeding/Ejection Methods Auto/semi-auto feeding/ejection; Robotics

Miscellaneous aids can help reduce exposure

Awareness barriers
Protective shields
Hand-feeding/holding tools
Anti-restart devices

Lockout/Tagout & Machine Safeguarding

31
 This material for training use only

What makes a guard effective?

 Must prevent any contact to the machine hazard and installed to prevent
contact from around, over, through, or under the guard
so designed and constructed as to prevent the operator from having any
part of his/her body in the danger zone during the operating cycle.
OR-OSHA Div 2/Sub O 29 CFR 1910.212(a)(3)(ii)

 Must not present a hazard in itself or create interference

 Must not allow objects to fall into moving parts
 Allows safe maintenance and lubrication
 Affixed to the machine where possible and remains secure
 Conforms with other appropriate standards
ANSI, manufacturer specifications, etc.

Not Effective Effective

Lockout/Tagout & Machine Safeguarding

32
 This material for training use only

First Safeguarding Strategy: Guards

Guards are physical barriers which prevent access to danger areas.

Guards: Fixed Interlocked Adjustable Self-adjusting

Fixed Guards
Permanent part of the machine
Not dependent upon moving parts
to perform its intended function
Constructed of sheet metal, screen,
wire cloth, bars, plastic, or other
substantial material
Usually preferable to all other types
because of its relative simplicity and
permanence

Interlocked Guards
When opened or removed, the tripping
mechanism and/or power automatically
shuts off or disengages
Machine cannot cycle or be started until
the guard is back in place
Electrical, mechanical, hydraulic, or
pneumatic power
Replacing the guard should not
automatically restart the machine

Careful!
Interlocked guards can
be bypassed - this This is NEVER energy isolation
electric interlock on a for lockout/tagout purposes!!!
trash compactor was Never rely on interlocks for
taped down energy control protection!
Machine is still energized even
when disengaged by interlock.
Lockout/Tagout & Machine Safeguarding
33
 This material for training use only

Adjustable Guards
Allow flexibility in accommodating various sizes of stock

Self-adjusting Guards
Openings are determined by
the movement of stock
Guard is pushed away as stock
is introduced
Opening is only large enough to
admit the stock
Guard returns to rest position
after stock passes through

Lockout/Tagout & Machine Safeguarding

34
 This material for training use only

Second Safeguarding Strategy: Devices

A safety device controls access to danger areas and may perform one of
several functions:
It may stop the machine if a hand or any part of the body is inadvertently
placed in the danger area
Restrain or withdraw the operator's hands from the danger area during
operation
Require the operator to use both hands on machine controls
Provide a barrier which is synchronized with the operating cycle of the
machine in order to prevent entry to the danger area during the
hazardous part of the cycle

Presence-Sensing Devices
Photoelectric (optical)
Uses a system of light sources and controls
which can interrupt the machine's operating cycle.

Radiofrequency (capacitance)
Uses a radio beam that is part of the machine control
circuit. When the capacitance field is broken, the machine
will stop or will not activate.

Electromechanical
Has a probe or contact bar which descends to a
predetermined distance when the operator initiates
the machine cycle. If there is an obstruction preventing
it from descending its full predetermined distance, the
control circuit does not activate the machine cycle.

Lockout/Tagout & Machine Safeguarding

35
 This material for training use only

Pullback
Pullback devices utilize a series of cables
attached to the operator's hands, wrists,
and/or arms.
This type of device is primarily used on
machines with stroking action. Slack is taken
up during the downstroke cycle pulling the
operators hands from the point of operation,
if still there.
When the slide/ram is up between cycles, the
operator is allowed access to the point of
operation.

Restraint
The restraint (holdout) device utilizes cables
or straps that are attached to the operator's
hands at a fixed point.
The cables or straps must be adjusted to let
the operator's hands travel within a
predetermined safe area. There is no
extending or retracting action involved.
Consequently, hand-feeding tools are often
necessary if the operation involves placing
material into the danger area.

Safety Trip Controls

Provides a quick means for deactivating the
machine in an emergency situation.
A pressure-sensitive bar, strategically
placed, will deactivate the machine when
depressed.
Safety tripwire cables may also be located
around the perimeter or near the danger area.

Lockout/Tagout & Machine Safeguarding

36
 This material for training use only

Two-Hand Controls Two-Hand Trip

Requires constant, concurrent pressure This device requires concurrent
by the operator to activate the machine. application of both the operators
control buttons to activate the
With this type of device, the operators
machine cycle, after which the
hands are required to be at a safe
hands are free.
location (on the control buttons) and at
a safe distance from the danger area.

Two-hand controls and two-hand trips must

incorporate both anti-tiedown and anti-repeat
features:
Anti-tiedown prevents tying one button down
and still being able to cycle the machine by
depressing the other
Anti-repeat prevents continuous cycling

Gate
A gate is a movable barrier which protects the operator at
the point of operation before the machine cycle can be
started. They are usually designed to operate with each
machine cycle.
Two types:
Type A - remains closed during entire cycle
Type B - remains closed during downstroke only

Lockout/Tagout & Machine Safeguarding

37
 This material for training use only

Third Safeguarding Strategy: Location & Distance

The machine or its dangerous moving parts are positioned so that the hazardous
areas are not accessible or do not present a hazard during normal operation.

Walls
Barriers/Fences
Height above worker
Size of stock (single end feed, punching)
Controls (positioned at a safe distance)

Factors to consider when guarding by location/distance:

Can it still be accessed, even with great effort?
Can pieces/parts break and fall onto someone/something?
Are sparks or other flying debris being produced from the
equipment?
OSHA still has the 7 foot rule for fan blades and power
transmission devices but think twice about it - seven feet isnt
much and can still be easily reached!

Fourth Safeguarding Strategy: Feeding & Ejection

Automatic Designing exposure out!

Feeding/Ejection
Operator involvement is
not necessary after the
Semi-Automatic
machine is set up
Feeding/Ejection
Manually feed
without reaching into
the point of
operation or other
danger zones

Lockout/Tagout & Machine Safeguarding

38
 This material for training use only

Robots
Machines that load and unload stock,
assemble parts, transfer objects, and perform
other tasks - otherwise done by the operator.

Robot concerns include being struck by robotic arms and other

mechanisms within or near its working envelope. Most common
injuries are being struck by the end effector (claw on the end) and
being pinned between end effector and a stationary object.
Also, possible malfunctions and/or missed steps can surprise nearby
workers!
Recommended safety standard - ANSI/RIA 15.06-1999

Miscellaneous Aids
Does not give complete protection from machine hazards, but can
assist in moving stock, deflecting minor chips, or providing
awareness. Examples include awareness barriers, ropes, shields,
holding tools, and push sticks or blocks. Ensure hand feeding
tools are made of soft materials to prevent shattering.

Does not replace the need for personal protective equipment or guarding! For example,
plexiglass shields on abrasive wheel grinders do not substitute the requirement for
eye/face protection or a tongue guard if distance from safety guard and top periphery of
stone exceeds 1/4 in. Plus, they can get in the way and are often broken or dirty -
creating a hazard in themselves!
Metal turning machines (lathes, grinders, drills/mills, gear cutters, etc.) require
chip/coolant shields and chuck shields. A spring loaded chuck wrench should always
be used on metal lathes! Automated cutting/turning machines require point of operation
guarding.
Anti-restart devices are required if machinery can automatically
start when power is restored (i.e. after a power failure).
Idesco Corp.
Lockout/Tagout & Machine Safeguarding
39
This material for training use only

Lockout/Tagout & Machine Safeguarding

40
This material for training use only

Reference
Machine Safeguarding Training Guidelines
Guard Opening Scale
ANSI references for machine safeguarding

Lockout/Tagout & Machine Safeguarding

41
This material for training use only

Lockout/Tagout & Machine Safeguarding

42
 This material for training use only

Machine Safeguarding Training Guidelines

An extremely important step in machine safeguarding - a step which oftentimes is
overlooked - is providing safety instruction and training on the various types of equipment
the worker is expected to operate and the safeguarding the worker is expected to use. At a
minimum, this education should include:

Discussion of hazardous exposures and control measures
Hazardous motions
Hazardous actions
Potential of flying/ejected material
Effective guarding methods and/or other control measures
Ergonomics
Fire/combustion potential
Appropriate personal protective equipment and clothing
Health hazards
Dont forget safeguarding
- Air quality strategies also include
management controls such as
- Noise & vibration enforcing, training, inspecting,
- Metal-working fluids maintenance and repair! For
example, clean and roomy work
areas, lubricated self-adjusting
guards, ring testing abrasive

Equipment-specific training (hands-on) stones, ensuring stable fixed
guarding, smooth edges, etc.
Proper operation of safeguards
- Limitations Also, dont forget personal
disabilities (i.e. color blindness,
- Maintenance & care hearing impaired) if relying on
visual warnings (colors) and/or
- Inspection audible warnings (machine
startup).
- Adjustment/placement
Clarification of manufacturer requirements
Instruction on when safeguard is discovered damaged, missing, etc.

Retraining?
Training, and relevant retraining, must be provided for new operators and
maintenance/setup employees. Also, retrain affected employees when new or altered
safeguards are used, when the employee(s) is assigned to a new machine or
operation, and whenever worker deficiencies are discovered.

Lockout/Tagout & Machine Safeguarding

43
 This material for training use only

Placing guards at a safe distance from point of operation

This diagram shows the accepted safe openings between the bottom edge of a guard and
feed table at various distances from the point of operation hazard.
The various openings are such that for average size hands, an operators fingers wont
reach the point of operation.
After installation of point of operation guards and before a job is released for operation, a
check should be made to verify that the guard will prevent the operators hands or fingers
from reaching the point of operation.

Not to scale
Guard Opening Line
Point of operation

Typical guard locations

1 1/2 3 1/2 6 1/2 12 1/2 17 1/2 31 1/2

2 1/2 5 1/2 7 1/2 15 1/2

Distance of opening from Maximum width of

point of operation hazard (inches) opening (inches)

1/2 to 1 1/2 1/4

1 1/2 to 2 1/2 3/8
2 1/2 to 3 1/2 1/2
3 1/2 to 5 1/2 5/8
5 1/2 to 6 1/2 3/4
6 1/2 to 7 1/2 7/8
7 1/2 to 12 1/2 1 1/4
12 1/2 to 15 1/2 1 1/2
15 1/2 to 17 1/2 1 7/8
17 1/2 to 31 1/2 2 1/8
Over 31 1/2 6
Lockout/Tagout & Machine Safeguarding
44
 This material for training use only
ANSI B11.1 Mechanical Power Presses
ANSI B11.2 Hydraulic Power Presses
ANSI B11.3 Power Press Brakes
ANSI B11.4 Shears Listing of Specific ANSI Safety Standards
ANSI B11.5 Iron Workers
ANSI B11.6 Lathes
ANSI B11.7 Cold Headers and Cold Formers
ANSI B11.8 Drilling, Milling, and Boring Machines
ANSI B11.9 Grinding Machines
ANSI B11.10 Metal Sawing Machines
ANSI B11.11 Gear Cutting Machines
ANSI B11.12 Roll Forming and Roll Bending Machines
ANSI B11.13 Single- and Multiple-Spindle Automatic Screw/Bar and Chucking Machines
ANSI B11.14 Coil Slitting Machines/Equipment
ANSI B11.15 Pipe, Tube, and Shape Bending Machines
ANSI B11.17 Horizontal Hydraulic Extrusion Presses
ANSI B11.18 Machinery and Machine Systems for the Processing of Coiled Strip, Sheet, & Plate
ANSI B11.19 Machine Tools, Safeguarding
ANSI B11.20 Manufacturing Systems/Cells
ANSI B15.1 Power Transmission Apparatus
ANSI B19.1 Air Compressor Systems
ANSI B19.3 Compressors for Process Industries
ANSI B20.1 Conveyors and Related Equipment
ANSI B24.1 Forging Machinery
ANSI B28.6 Rubber Machinery, Hose
ANSI B28.7 Rubber Machinery, Hose
ANSI B28.8 Rubber Machinery, Hose
ANSI B28.9 Rubber Machinery, Hose
ANSI B28.10 Rubber Machinery, Endless Belt
ANSI B30.16 Overhead Hoists
ANSI B151.1 Plastics Injection Molding Machinery, Horizontal
ANSI B151.2 Plastics Machinery, Film Casting
ANSI B151.3 Plastics Machinery, Screen Changers
ANSI B151.4 Plastics Machinery, Blown Film Takeoff & Auxiliary Equipment
ANSI B151.5 Plastics Machinery, Film & Sheet Winding
ANSI B151.6 Plastics Machinery, Slit Tape & Monofilament Postextrusion Equipment
ANSI B151.7 Plastics & Rubber Extrusion Machinery
ANSI B151.11 Plastics Machinery, Granulators, Pelletizers, & Dicers
ANSI B151.15 Plastics Machinery, Extrusion Blow Molding
ANSI B151.21 Plastics Machinery, Injection Blow Molding
ANSI B151.25 Plastics Machinery, Injection Molding
ANSI B152.2 Permanent-Mold Casting Machines (Other than Gray Iron)
ANSI B153.1 Automotive Lifts
ANSI B155.1 Packaging Machinery
ANSI B169.1 Envelope Manufacturing Machinery
ANSI B177.2 Printing Ink Vertical Post Mixers
ANSI/NEMA ICS2:225.95 Interlocking Control Circuits for Personnel Protection
ANSI/NFPA 79 Electrical Standard for Industrial Machinery
ANSI/RIA R15.06 Industrial Robots and Robot Systems
ANSI Z8.1 Commercial Laundry & Dry-Cleaning Equipment
ANSI Z241.1 Foundry, Sand Prep., Molding, & Core-Making
ANSI Z241.2 Foundry, Melting & Pouring of Metals
ANSI Z241.3 Foundry, Cleaning & Finishing of Castings
ANSI Z245.1 Refuse Collecting & Compacting Equipment
ANSI Z245.3 Stability of Refuse Bins
ANSI Z245.5 Bailing Equipment
ANSI Z268.1 Metal Scrap Processing Equipment
Lockout/Tagout & Machine Safeguarding
45
In Compliance with the Americans with Disabilities Act (ADA),
this publication is available in alternative formats by calling the
OR-OSHA Public Relations Manager at (503) 378-3272 (V/TTY).