OSHA Academy - USA

CONTROL OF HAZARDOUS ENERGY

(LOCKOUT/TAGOUT)
Overview
Every workplace has the need for on-going maintenance. Installation, repair
and servicing of machines and equipment may seem routine, but can be
dangerous to employees performing the work.

Serious injury can be caused by the sudden and unexpected startup of the
machinery or equipment, contact with live electrical circuit or the
unexpected release of stored energy.
Equipment that is shut down may inadvertently be re-started or re-energized
by a co-worker, or equipment that was thought to be shut down may be
controlled by automatic processors, timers or computers and may be re-start
automatically and without warning.

OSHA estimates that failure to control hazardous energy sources results in:
• 10 % of serious industrial accidents.
• 28,000 lost work days injuries per year.
• Approximately 120 deaths per year.

Fortunately, these hazards can be avoided through the use of lockout/tag-out

procedures.
The Lockout/Tagout standard requires the adoption and implementation of
practices and procedures to shut down equipment, isolate it from its energy
source(s), and prevent the release of potentially hazardous energy while
maintenance and servicing activities are being performed. It contains
minimum performance requirements, and definitive criteria for establishing
an effective program for the control of hazardous energy.

All new equipment installed after January 2, 1990 must be designed to

accept lockout of its energy-isolating device.

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LOCKOUT/TAGOUT
DEFINITIONS

Lockout – The placement of a lockout device on an energy – isolating

device, in accordance with an established procedure, ensuring that the
energy – isolating device and the equipment being controlled cannot be
operated until the lockout device is removed.

Tag-out – the placement of a tag-out device on an energy-isolating device,

in accordance with an established procedure, to indicate that the energy-
isolating device and the equipment being controlled may not operated until
the tag-out device is removed.

Lockout device – Any device that uses positive means such as a lock, either
key or combination type, to hold an energy-isolating device in a safe
position, thereby preventing the energizing of machinery or equipment.
When properly installed, a blank flange or bolted slip blind are considered
equivalent to lockout devices.

Tag-out device – Any prominent warning device, such as a tag and a means
of attachment, that can be securely fastened to an energy-isolating device in
accordance with an established procedure. The tag indicates that the machine
or equipment to which it is attached is not to be operated until the tag-out
device is removed in accordance with the energy control procedure.
Energy-isolating device – Any mechanical device that physically prevents
the transmission or release of energy. These include, but are not limited to,
manually-operated electrical circuit breakers, disconnect switches, line
valves, and blocks.

Capable of being locked out – An energy-isolating device is considered

capable of being locked out if it meets one of the following requirements:
- It is designed with a hasp to which a lock can attached;
- It is designed with any other integral part through which a lock
can be affixed;
- It has a locking mechanism built into it; or
- It can be locked without dismantling, rebuilding, or replacing
the energy isolating device or permanently altering its energy
control capability.

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Affected employee – An employee who performs the duties of his or her job
in an area in which the energy control procedure is implemented and
servicing or maintenance operations are performed. An affected employee
does not perform servicing or maintenance on machines or equipment that
must be locked or tagged.

Authorized employee – An employee who performs servicing or

maintenance on machines and equipment. Lockout or tag-out is used by
these employees for their own protection.

Energy sources – Any electrical, mechanical, hydraulic, pneumatic,

chemical, gas, thermal or other energy source that could cause an injury to
the affected personnel.

Residual pressure – The remaining energy in a system after activation of

the disconnect (stored energy).

SCOPE AND APPLICATION

• Applies to general industry employment and covers the
servicing and maintenance of machines and equipment in
which the unexpected start-up or the release of stored energy
could cause injury to employees.

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ENERGY CONTROL PROGRAM
• Intended to prevent the unexpected energizing or the release
of stored energy in machines or equipment on which servicing
and maintenance is being performed by employees.

• Consists of documented energy control procedures, an

employee training program, and periodic inspections of the
procedures.

• Employers have flexibility to develop a program that meets

the needs of their particular workplace.

ENERGY CONTROL PROCEDURE

• The written procedures must identify the information that
authorized employees must know in order to control
hazardous energy during service or maintenance.

• At a minimum, it includes, but is not limited to, the following

elements:
- A statement on how the procedure will be used;
- The procedural steps needed to shut down, isolate, block,
and secure machines or equipment;
- The steps designating the safe placement, removal, and
transfer of lockout/tag-out devices and who has the
responsibility for them; and
- The specific requirements for testing machines or
equipment to determine and verify the effectiveness of
locks, tags, and other energy control measures.

• Procedure must include the following steps:

(1) Preparing for shutdown
(2) Shutting down the machine(s) or equipment
(3) Isolating the machine or equipment from the
energy source(s),
(4) Applying the lockout or tag-out device(s) to the
energy-isolating device(s)
(5) Safely releasing all potentially hazardous stored or
residual energy, and
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(6) Verifying the isolation of the machine(s) or
equipment prior to the start of service or
maintenance work.

• In addition, before lockout or tag-out devices are removed and

energy is restored to the machines or equipment, certain steps
must be taken to re-energize equipment after service is
completed, including:
(1) Assuring that machines or equipment components
are operationally intact
(2) Notifying affected employees that lockout or tag-
out devices are removed from each energy-
isolating device by the employee who applied the
device.

ENERGY-ISOLATING DEVICES
• Guards against accidental machine or equipment start-up or
the unexpected re-energization of equipment during servicing
or maintenance.
• These include, but are not limited to, manually-operated
electrical circuit breakers, disconnect switches, line valves,
and blocks.
• Two types: those capable of being locked and those that are
not.
• When the energy-isolating device cannot be locked out, the
employer must use tag-out or modify or replace the device to
make it capable of being locked.
• When using tag-out, employers must train their employees in
the limitations or tags.
• Whenever major replacement, repair, renovation or
modification of machines or equipment is performed and
whenever new machines or equipment are installed or
purchased, the energy-isolating devices for such machines or
equipment must be lockable.

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

• 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 the following: DO NOT
START, DO NOT OPEN, DO NOT CLOSE, DO NOT
ENERGIZE, DO NOT OPERATE.

EMPLOYEE TRAINING
• The employer must provide effective initial training and
retraining as necessary and must certify that such training has
been given to all employees covered by the standard. The

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certification must contain each employee’s name and dates of
training.
• The employer’s training program for authorized employees
(those who are charged with the responsibility for
implementing the energy control procedures and performing
the service and maintenance) must cover, at minimum, the
following areas:
- Details about the type and magnitude of the hazardous
energy sources present in the workplace, and
- The methods and means necessary to isolate and control
those energy sources (that is, the elements of the energy
control procedure)
• Affected employees (usually the machine operators or users)
and all other employees need only be able to (1) recognize
when the control procedure is being implemented, and (2)
understand the purpose of the procedure and the importance
of not attempting to start up or use the equipment that has
been locked or tagged out.
• Every training program must ensure that all employees
understand the purpose, function and restrictions of the energy
control program and that authorized employees possess the
knowledge and skills necessary for the safe application, use,
and removal of energy controls.
• Training programs used for compliance with this standard,
which is performance-oriented, should deal with the
equipment, type(s) of energy, and hazard(s) specific to the
workplace being covered.
• Retraining must be provided, as required, whenever there is a
change in hob assignments, a change in machines, equipment
or processes that present a new hazard, or a change in energy
control procedures.
• Additional retraining must be conducted whenever a periodic
inspection reveals, or whenever the employer has reason to
believe, that there are deviations from or inadequacies in the
employee’s knowledge or use of the energy control procedure.

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PERIODIC INSPECTIONS
• Periodic inspections must be performed at least annually to
assure that the energy control procedures (locks and tags)
continue to be implemented properly and that the employees
are familiar with their responsibilities under those procedures.
• In addition, the employer must certify that the periodic
inspections have been performed. The certification must
identify the machine or equipment on which the energy
control procedure was used, the date of the inspection, the
employees included in the inspection, and the name of the
person performing the inspection.
• For lockout procedures, the periodic inspection must include a
review, between the inspector and each authorized employee,
of that employee’s responsibilities under the energy control
procedure being inspected.
• When a tag-out procedure is inspected, a review on the
limitation of tags, in addition to the above requirements, must
also be included with each affected and authorized employee.

LOCKOUT/TAGOUT PROCEDURES
The following are the procedures necessary for effective lockout/tag-out:

Step 1: Preparation and Notification

Before servicing or installing equipment, you must be able to answer the
following questions:
• What is the type of energy source on the equipment?
• What are the potential hazards related to the energy source?
• What steps are necessary to control the energy source?
• Who needs to be notified that the equipment will be shut
down for service?

Once these questions have been answered, notify all affected employees that
a lockout procedure is about to begin and that the equipment will be shut
down for service.

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Step 2: Shut Down the Equipment
Follow the company’s safety procedures and/or the manufacturer’s
instructions. Be aware that some equipment has special shut-down
procedures (for example, computer-controlled equipment)
Make sure all energy sources have located and shut down. (Some machines
have more than one power source – all must be shut down).

Step 3: Isolate the Equipment

Equipment should be isolated by:
A. Shutting off the main breaker or control switch
B. Closing valves
C. Disconnecting process lines
D. Pulling plugs

Note: For complex machines or equipment, refer to the manufacturer’s

control diagram detailing the locations of all isolation points, including
breaker panels, switches, valves, etc.

Step 4: Attach the Lock and Tag

Each employee who is performing maintenance is responsible for locking
and tagging the equipment. Each employee whose duties require them to
work on equipment must be provided with their own lock and key.
If more than one employee is involved in the maintenance, multiple locking
devices must be used to allow each maintenance employee to lock and tag.
This prevents one employee from accidentally starting up the equipment
while another employee is still working.
Never use another employee’s lock and never lend your own.
When all energy sources are locked, apply a tag to the power source. Make
sure the tag is filled out completely and correctly.

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Step 5: Release any Stored Energy

After locking and tagging equipment, you must make sure that any stored
energy on the equipment is released. This is done by:
• Inspecting equipment to make sure all parts have stopped
moving.
• Bleeding electrical capacitance (stored charge)
• Venting or isolating pressure or hydraulic lines from the work
area, leaving vent valves open
• Draining tanks and valves
• Releasing the tension on springs or blocking the movement of
spring-driven parts.
• Blocking or bracing parts that could fall because of gravity
• Blocking, clamping or chaining any switches or levers that
could be moved into the start position
• Clearing lines containing process materials that are toxic, hot,
cold, corrosive or asphyxiating
• Monitoring the process to make sure that the work you are
doing will not result in an accumulation of stored energy.

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Step 6: Test Equipment to Verify that All energy Has Been Released or
Controlled
To make sure that all kinetic and stored energy has been released or
controlled, you must:
• Clear personnel from danger areas.
• Test the start switches on the equipment to confirm that all
power sources have been shut down and switches can’t be
moved to the “on” or “start” position.
• Check pressure gauges to make sure that all lines are de-
pressurized and stored energy has been released.
• Secure all blocks, clamps, chains and cribs.
• Check electrical circuits to make sure that voltage is at zero.
• Secure blanks (used to block feed chemicals) and make sure
they are not leaking.

Because some machinery and equipment can be remotely controlled, you

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

SAFE STARTUP PROCEDURES

Once the maintenance or installation is completed, the equipment can be re-
started. These are the procedures to follow for safe startup:

Step 1: Preparing for Startup

You must make sure the area is safe for restart by:
• Making sure all equipment components are fully assembled
and operational.
• Making sure all safety guards are in place.

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• Removing all tools from the equipment and the work area.
• Removing all braces, pins, blocks, cribs and chains.
• Reconnecting all pressure tubing, pipes and hoses and closing
all valves.
• Clearing the work area of all personnel.

Step 2: Remove Lockout Devices and Tags

Except in emergencies, each lockout device must be removed by the
employee who put it on.

Step 3: Notify Affected Employees

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

Once all three steps are completed, it is safe to start up the equipment.

LOCKOUT AND TAGOUT DEVICES

Lockout Devices:
• Must be provided to each employee
• Must only be used for the purposes of lockout/tagout
• Must be able to withstand the environment that they are
exposed to for as they are in place.
• Must be standardized by color, shape and size.

Tag-out Devices
• Must be standardized by color, shape, size and format or print
• Must contain warnings such as “DANGER – DO NOT
OPERATE THIS MACHINE”
• Must have space for the name of lock or tag owner, date and
purpose of the lockout/tag-out.

TAGOUT ONLY
A tag-out system can be used instead of a lockout system in the following
situations only:
• When an energy isolating device cannot be locked out

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• When the employer can prove that a tag-out system provides
the same amount of protection as a lockout system.

If a “Tag-out Only” system is used, the tags must be placed at all isolation
points, and you must follow all safety procedures.

Note: After January 2, 1990, any equipment that is replaced, renovated or

modified must be able to accept a lockout device.

SPECIAL SITUATIONS
Some situations may occur in the workplace that require additional
procedures to perform safe lockout/tag-out.

Removing someone else’s lock: A lock may be removed by someone other

than the employee who placed the lock only under the following conditions:
• The employee whose lock is to be removed is not available to
remove the lock after servicing has been completed.
• All reasonable efforts have been made to contact the
employee to inform him/her that the lock has been removed.
• The employee is contacted and informed that the lock is
removed prior to the employee starting work on the next work
shift.

Shift Changes: If maintenance on a piece of equipment will extend beyond

one shift, provisions must be made to have employees from the new shift
place their locks on the lockout device before they begin work on the
equipment. This must be done without any interruption in lockout/tag-out
protection.

Outside Contractors: If outside contractors will be working on equipment

inside your facility or workplace, you must make provisions to inform them
of your lockout/tag-out procedures. If the contractor’s procedures are
different from yours, you must make an agreement with the contractor as to
which procedures will be followed. All employees working on the project
must be notified of any changes in their own procedures.

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Temporary Re-activation: If the equipment being serviced must be
temporarily re-activated (for example, to test the equipment as part of
installation), all startup and lockout/tag-out procedures must be followed.

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