The Control of Hazardous Energy Lockout/Tagout 1910.147

Control of Hazardous Energy 29 CFR 1910.147 The standard covers the servicing and maintenance of machines and equipment in which the unexpected energizing or start up of the machines or equipment , or release of stored energy could cause injury to employees.

29 CFR 1910.147

The standard covers the servicing and maintenance of machines and equipment in which the unexpected energizing or start up of the machines or equipment , or release of stored energy could cause injury to employees.

What Is Hazardous Energy? Often invisible Live or stored electricity Moving machine or equipment parts

Often invisible

Live or stored electricity

Moving machine or equipment parts

What Is Hazardous Energy? (cont.) Stored energy in equipment Heat Gravity Pneumatic, hydraulic, air and water pressure Steam Chemical Photo credit: State of WA-WISHA Services

Stored energy in equipment

Heat

Gravity

Pneumatic, hydraulic, air and water pressure

Steam

Chemical

Hazardous Energy Injuries 7,600 injuries per year 80% of workers fail to turn off equipment Causes Unexpected startup Release of stored energy Fail to Lockout/tagout Photo credit: State of WA-WISHA Services

7,600 injuries per year

80% of workers fail to turn off equipment

Causes

Unexpected startup

Release of stored

energy

Fail to Lockout/tagout

When does LOTO apply?

Application Of The Standard An employee is required to remove or bypass a guard or other safety device An employee is required to place any part of their body in contact with the point of operation of the operational machine or piece of equipment An employee is required to place any part of their body into a danger zone associated with a machine operating cycle

An employee is required to remove or bypass a guard or other safety device

An employee is required to place any part of their body in contact with the point of operation of the operational machine or piece of equipment

An employee is required to place any part of their body into a danger zone associated with a machine operating cycle

Purpose Establish a program of procedures for appropriate energy isolation Prevent unexpected energizing

Establish a program of procedures for

appropriate energy isolation

Prevent unexpected energizing

General Requirements Employer shall establish a program consisting of Energy control procedures Employee training Periodic inspections To ensure energy is isolated Energy control procedures Developed, documented, and utilized

Employer shall establish a program consisting of

Energy control procedures

Employee training

Periodic inspections

To ensure energy is isolated

Energy control procedures

Developed, documented, and utilized

Scope and Exemptions Scope – Servicing and maintenance of machines and equipment Exemptions Construction, agriculture, and maritime Electrical utilities Electrical utilization installations ( Subpart S ) Oil and gas well drilling and servicing

Scope – Servicing and maintenance of machines and equipment

Exemptions

Construction, agriculture, and maritime

Electrical utilities

Electrical utilization installations ( Subpart S )

Oil and gas well drilling and servicing

Exception Has no potential for stored or residual energy Single energy source (ext cord) Lockout completely de-energizes Machine is isolated Single lockout device achieves lockout

Has no potential for stored or residual energy

Single energy source (ext cord)

Lockout completely de-energizes

Machine is isolated

Single lockout device achieves lockout

Lockout under exclusive control Servicing does not create hazards Hot Tap Operations Involving Utility Company Transmission and Distribution Systems Exception

Lockout under exclusive control

Servicing does not create hazards

Hot Tap Operations Involving Utility Company Transmission and Distribution Systems

Minor Servicing Tasks Employees performing minor tool changes and adjustments that are routine, repetitive, and integral to the use of the equipment and that occur during normal operations are not covered by the lockout/tagout standard, provided the work is performed using alternative measures that provide effective protection.

Employees performing minor tool changes and adjustments that are routine, repetitive, and integral to the use of the equipment and that occur during normal operations are not covered by the lockout/tagout standard, provided the work is performed using alternative measures that provide effective protection.

LOTO Does Not Apply To Installations Under the Control of Electric Utilities If De-energizing Introduces Additional or Increased Hazards or is Infeasible Due to Design

Installations Under the Control of Electric Utilities

If De-energizing Introduces Additional or Increased Hazards or is Infeasible Due to Design

Energy Control Procedure Procedures shall clearly specify Scope Purpose Authorization Rules Techniques

Procedures shall clearly specify

Scope

Purpose

Authorization

Rules

Techniques

Energy Control Procedure A specific statement of intended use Specific procedural steps for shutting down, blocking, and securing Specific procedural steps for placement, removal, and transfer

A specific statement of intended use

Specific procedural steps for shutting down, blocking, and securing

Specific procedural steps for placement, removal, and transfer

Safety Work Practices Selection and use of work practices ( 1910.333 ) Working on or near de-energized parts that are not locked out or tagged are treated as energized Only qualified personnel can work on electrical circuits

Selection and use of work practices ( 1910.333 )

Working on or near de-energized parts that are not locked out or tagged are treated as energized

Only qualified personnel can work on electrical circuits

Both Standards Mandate Both standards mandate the use of locks and/or tags to control potential energy 1910.147 1910.333 Subpart S

Both standards mandate the use of locks and/or tags to control potential energy

1910.147

1910.333

Subpart S

Isolation and Verification Employees working on de-energized utilization systems covered under Subpart S allows both the authorized employee and qualified employee are permitted to verify Employees working on a mechanical hazardous energy covered under 1910.147 can verify

Employees working on de-energized utilization systems covered under Subpart S allows both the authorized employee and qualified employee are permitted to verify

Employees working on a mechanical hazardous energy covered under 1910.147 can verify

Periodic Inspection Energy control program Shall conduct periodic inspection Performed by authorized employee Conducted to correct deviations or inadequacies Lockout versus tagout Certification required

Energy control program

Shall conduct periodic inspection

Performed by authorized employee

Conducted to correct deviations or inadequacies

Lockout versus tagout

Certification required

Periodic Inspection Shall be performed by an authorized employee other than the person(s) utilizing the energy control procedure being inspected Shall be conducted to correct any deviations or inadequacies identified

Shall be performed by an authorized employee other than the person(s) utilizing the energy control procedure being inspected

Shall be conducted to correct any deviations or inadequacies identified

Periodic Inspection Where lockout is used, the inspection shall include a review between the inspector and each authorized employee Where tagout is used, the inspection shall include a review between the inspector and each authorized and affected employees

Where lockout is used, the inspection shall include a review between the inspector and each authorized employee

Where tagout is used, the inspection shall include a review between the inspector and each authorized and affected employees

The employer shall: Certify that the periodic inspections have been performed Identify the machine or equipment on which energy control procedures were used The employer shall also note: The date of the inspection The employees included in the inspection The person performing the inspection Periodic Inspections

The employer shall:

Certify that the periodic inspections have been performed

Identify the machine or equipment on which energy control procedures were used

The employer shall also note:

The date of the inspection

The employees included in the inspection

The person performing the inspection

Definitions

The placement of a lockout device on an energy isolating device to ensure that the equipment being controlled cannot be operated until the lockout device is removed Lockout

The placement of a lockout device on an energy isolating device to ensure that the equipment being controlled cannot be operated until the lockout device is removed

The placement of a tagout device on an energy isolating device to indicate the equipment being controlled may not be operated until the tagout device is removed Tagout

The placement of a tagout device on an energy isolating device to indicate the equipment being controlled may not be operated until the tagout device is removed

Tags must also include a legend such as: Do not start Do not open Do not close Do not energize Do not operate Tag Requirements

Tags must also include a legend such as:

Do not start

Do not open

Do not close

Do not energize

Do not operate

Tagout Tags

Tagout Tag

Authorized Employee Locks out/Tags out equipment in order to perform maintenance Authorized by line mgmt Qualified by training and experience Must determine if a written procedure exists Trained in written LOTO procedure

Locks out/Tags out equipment in order to perform maintenance

Authorized by line mgmt

Qualified by training

and experience

Must determine if a written

procedure exists

Trained in written LOTO

procedure

Authorized Employee Trained to perform locking or tagging procedures No other employee can attach or remove lock or tag devices

Trained to perform locking or tagging procedures

No other employee can attach or remove lock or tag devices

Authorized Employee Responsibilities Obtain assistance when necessary Remove locks and/or tags following lockout/tagout Coordinate multi-shift repair

Obtain assistance when necessary

Remove locks and/or tags following lockout/tagout

Coordinate multi-shift repair

Authorized Lead Employee Authorized employee who performs or coordinates one or more LOTO activity for multiple personnel

Authorized employee who performs or coordinates one or more LOTO activity for multiple personnel

Affected Employee An Employee whose Job Requires Operation or Use of the Machine or Equipment on Which Servicing or Maintenance is to be Performed Under Lockout or Tagout An Employee whose Job Requires Work in an Area where such Servicing or Maintenance is Being Performed Aware of energy control procedure

An Employee whose Job Requires Operation or Use of the Machine or Equipment on Which Servicing or Maintenance is to be Performed Under Lockout or Tagout

An Employee whose Job Requires Work in an Area where such Servicing or Maintenance is Being Performed

Aware of energy control procedure

Who is an Affected Employee? Everyone in the building

Affected Employee Responsibilities Notify maintenance when equipment needs repair or adjustment Leave all lockout/tagout devices in place Verify equipment is safe to operate following lockout/tagout Follow all safety rules while operating the equipment

Notify maintenance when equipment needs repair or adjustment

Leave all lockout/tagout devices in place

Verify equipment is safe to operate following lockout/tagout

Follow all safety rules while operating the equipment

Training and Communication Each authorized employee shall receive training in: Recognition of applicable hazardous energy sources Type and magnitude of the energy available in the workplace Methods and means necessary for energy isolation and control

Each authorized employee shall receive training in:

Recognition of applicable hazardous energy sources

Type and magnitude of the energy available in the workplace

Methods and means necessary for energy isolation and control

Each affected employee shall be instructed in the purpose and use of the energy control procedure All other employees shall be instructed about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out Training and Communication

Each affected employee shall be instructed in the purpose and use of the energy control procedure

All other employees shall be instructed about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out

The employer shall certify that employee training has been accomplished and is being kept up to date Certification shall contain employee names and dates of training Training and Communication

The employer shall certify that employee training has been accomplished and is being kept up to date

Certification shall contain employee names and dates of training

Group Lockout or Tagout 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 Each authorized employee shall affix a personal lockout or tagout device to the group lockout device

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

Each authorized employee shall affix a personal lockout or tagout device to the group lockout device

Outside Personnel Whenever outside servicing personnel are engaged in activities covered by lockout/tagout, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures

Whenever outside servicing personnel are engaged in activities covered by lockout/tagout, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures

Energy Sources Electrical Mechanical Pressurized Fluids Pressurized Gasses Including cryogens Radiation Gravity

Electrical

Mechanical

Pressurized Fluids

Pressurized Gasses

Including cryogens

Radiation

Gravity

Lockout/Tagout The Placement of a Lockout and/or Tagout Device on an Energy Isolating Device In accordance with procedures Ensures equipment cannot be operated until lockout device is removed

The Placement of a Lockout and/or Tagout Device on an Energy Isolating Device

In accordance with procedures

Ensures equipment cannot be operated until lockout device is removed

Exclusive Control If Equipment is Under Exclusive Control, the Plug is Within Your Sight and Reach

If Equipment is Under Exclusive Control, the Plug is Within Your Sight and Reach

Lockout/Tagout The Placement of a Lockout and/or Tagout Device on an Energy Isolating Device In accordance with procedures Ensures equipment cannot be operated until lockout device is removed

The Placement of a Lockout and/or Tagout Device on an Energy Isolating Device

In accordance with procedures

Ensures equipment cannot be operated until lockout device is removed

Interpretations Hazardous Energy 1910.147 Machine Guarding 1910.212

Hazardous Energy 1910.147

Machine Guarding 1910.212

Company Responsibilities Ensure de-energizing of equipment Ensure employee awareness Provide appropriate levels of training Review program effectiveness Maintain and revise program Administer appropriate disciplinary actions

Ensure de-energizing of equipment

Ensure employee awareness

Provide appropriate levels of training

Review program effectiveness

Maintain and revise program

Administer appropriate disciplinary actions

Devices

Energy Isolation Device Isolate the equipment from the energy source Isolation device Circuit breaker Pressure valve Machine block Photo credit: State of WA-WISHA Services

Isolate the equipment from the energy source

Isolation device

Circuit breaker

Pressure valve

Machine block

Lockout and Tagout Devices LOTO Locks are RED Do not use red-colored locks for any other purpose 1 Key per lock Destroy any other keys immediately Combination locks are Not Allowed When multiple locks are required for a single LOTO activity, locks with a common key may be used

LOTO Locks are RED

Do not use red-colored locks for any other purpose

1 Key per lock

Destroy any other keys immediately

Combination locks are Not Allowed

When multiple locks are required for a single LOTO activity, locks with a common key may be used

Lockout Device

Lockout and Tagout Devices Tagout device states “ DANGER - DO NOT OPERATE ”. Shall be white, black and red Shall have a space for the authorized employee’s name. Must have a reinforced eyelet capable of accepting a lock shackle of 0.25 inch diameter

Tagout device states “ DANGER - DO NOT OPERATE ”.

Shall be white, black and red

Shall have a space for the authorized employee’s name.

Must have a reinforced eyelet capable of accepting a lock shackle of 0.25 inch diameter

Lockout Device Lock Block Chain Multilock hasp Wheel valve cover Ball valve cover

Lock

Block

Chain

Multilock hasp

Wheel valve cover

Ball valve cover

Requirements for Lockout/Tagout Devices They must be: Durable Standardized Substantial Identifiable Photo credit: State of WA-WISHA Services

They must be:

Durable

Standardized

Substantial

Identifiable

Group Lockout

Lockout Signage

Device Application

Lockout/Tagout Device Application Each employee must apply their own locks. Lockout devices are applied to hold the isolating device in a “safe” or “off” position. The employee must maintain exclusive control of the key

Each employee must apply their own locks.

Lockout devices are applied to hold the isolating device in a “safe” or “off” position.

The employee must maintain exclusive control of the key

Lockout/Tagout Device Application Only the authorized employee may remove his/her LOTO device Supervisor may overlock for additional control

Only the authorized employee may remove his/her LOTO device

Supervisor may overlock for additional control

Lockout/Tagout Device Application A Tag must always accompany a lock. The tag must be placed as close as possible to the lock The tag must be securely attached The tag must clearly display the name of the authorized employee

A Tag must always accompany a lock.

The tag must be placed as close as possible to the lock

The tag must be securely attached

The tag must clearly display the name of the authorized employee

Lockout/Tagout Device Application The Tag may also display: a picture of the authorized employee the date of application Other pertinent information Do not use string or tape to apply tags

The Tag may also display:

a picture of the authorized employee

the date of application

Other pertinent information

Do not use string or tape to apply tags

Lockout/Tagout Device Application A tagout device only is allowed when the energy isolating device is not capable of accepting a lockout device. The tag must clearly indicate that operation or movement is prohibited Tags must be securely attached to prevent inadvertent detachment

A tagout device only is allowed when the energy isolating device is not capable of accepting a lockout device.

The tag must clearly indicate that operation or movement is prohibited

Tags must be securely attached to prevent inadvertent detachment

Typical Equipment Requiring Lockout/Tagout Presses Saws Conveyors Pumps Production equipment Trash compactors

Presses

Saws

Conveyors

Pumps

Production equipment

Trash compactors

When to Use Lockout/Tagout Devices Servicing or maintaining machinery or equipment Hazardous energy exists Unexpected start-up could occur

Servicing or maintaining machinery or equipment

Hazardous energy exists

Unexpected start-up could occur

Actions that Trigger Lockout/Tagout Removing or bypassing a safety device Any part of the body is placed in harm’s way Exposure to hazardous energy

Removing or bypassing a safety device

Any part of the body is placed in harm’s way

Exposure to hazardous energy

Alternative Removal of Locks and Tags

Temporary Removal of Locks/Tags for Testing or Positioning Follow Five Steps for Return to Service When done, use your procedure General or Written

Follow Five Steps for Return to Service

When done, use your procedure

General or Written

Removal of Lock & Tags: Authorized Employee Not Available Supervisory personnel shall: Make every effort to locate the Authorized Employee Get written approval from Department Head/Supervisor Follow Five Steps for Return to Service Inform Authorized Employee before he/she resumes work activities Keep copy of written approval on file

Supervisory personnel shall:

Make every effort to locate the Authorized Employee

Get written approval from Department Head/Supervisor

Follow Five Steps for Return to Service

Inform Authorized Employee before he/she resumes work activities

Keep copy of written approval on file

Group LOTO Explained

GROUP Lockout/Tagout Two Types Type A Type B

Type A Group LOTO Lead Authorized Employee places lock & tag Everyone else locks behind him Everyone verifies equipment is de-energized Each worker removes his/her lock If there is a written procedure, only lead Authorized Employee needs to be trained

Lead Authorized Employee places lock & tag

Everyone else locks behind him

Everyone verifies equipment is de-energized

Each worker removes his/her lock

If there is a written procedure, only lead Authorized Employee needs to be trained

Type B Group LOTO More complex activities Lead Authorized Employee performs LOTO Key goes into lockbox Everyone places lock on lockbox If there is a written procedure, only lead Authorized Employee needs to be trained

More complex activities

Lead Authorized Employee performs LOTO

Key goes into lockbox

Everyone places lock on lockbox

If there is a written procedure, only lead Authorized Employee needs to be trained

Shift or Personnel Changes

Shift or Personnel Change If no one else will be working on system: Leave LOTO as is If someone else will be working on system: Transfer keys/locks Off-going employee unlocks On-coming employee locks Verification is very important!!

If no one else will be working on system:

Leave LOTO as is

If someone else will be working on system:

Transfer keys/locks

Off-going employee unlocks

On-coming employee locks

Verification is very important!!

Shift or Personnel Change Group LOTO: Lead places his own lock to lock box. The job lockbox and captured keys remain under the control of the lead authorized employee. If absent, the lead authorized employee may designate someone else the lead while retaining control of job lockbox

Group LOTO:

Lead places his own lock to lock box.

The job lockbox and captured keys remain under the control of the lead authorized employee.

If absent, the lead authorized employee may designate someone else the lead while retaining control of job lockbox

Shift or Personnel Change Group LOTO Special circumstances ,may warrant the complete transfer of responsibility The off-going and on-coming leads would simultaneously remove and apply locks.

Group LOTO

Special circumstances ,may warrant the complete transfer of responsibility

The off-going and on-coming leads would simultaneously remove and apply locks.

Supervised LOTO

Supervised LOTO If an employee or non-employee needs to perform LOTO and training is unavailable, an authorized employee may supervise the application of LOTO

If an employee or non-employee needs to perform LOTO and training is unavailable, an authorized employee may supervise the application of LOTO

Supervised LOTO Conditions apply: System must be able to accept LOTO device The individual is briefed by the authorized employee If there is a written procedure, authorized employee follows procedure and applies LOTO – individual applies LOTO and verifies

Conditions apply:

System must be able to accept LOTO device

The individual is briefed by the authorized employee

If there is a written procedure, authorized employee follows procedure and applies LOTO – individual applies LOTO and verifies

Lockout/Tagout Procedure Notify affected employees Shut down energized equipment Isolate energy sources from equipment Lockout or tagout the energy isolation device Release stored energy Test

Notify affected employees

Shut down energized equipment

Isolate energy sources from equipment

Lockout or tagout the energy isolation device

Release stored energy

Test

5 Step Restart Procedure 1. Clean up and inspect work area 2. Clear personnel from the startup area and notify affected employees of startup 3. Verify that the controls are in neutral 4. Remove lockout devices and reenergize the machine 5. Start machinery or equipment

1. Clean up and inspect work area

2. Clear personnel from the startup area

and notify affected employees of startup

3. Verify that the controls are in neutral

4. Remove lockout devices and reenergize

the machine

5. Start machinery or equipment

Sub-Contractors

Subcontractors Required to have their own LOTO program Must share that information with Task Manager Must attend LOTO training or prove they have been trained

Required to have their own LOTO program

Must share that information with Task Manager

Must attend LOTO training or prove they have been trained

Subcontractors Overlocking is allowed Sub locks first, then the you overlock

Overlocking is allowed

Sub locks first, then the you overlock

Configuration Control Locks and Tags

Configuration Control Used if equipment must remain unattended for long periods of time w/out being worked on Provides management control Removal of locks/tags may result in injury, damage, disruption of normal processes, or degradation of system

Used if equipment must remain unattended for long periods of time w/out being worked on

Provides management control

Removal of locks/tags may result in injury, damage, disruption of normal processes, or degradation of system

Configuration Control - Examples Locking out overhead crane electrical disconnect Locking equipment while awaiting repair or parts Locking a valve to control the flow of fluids Locking radioactive waste container

Locking out overhead crane electrical disconnect

Locking equipment while awaiting repair or parts

Locking a valve to control the flow of fluids

Locking radioactive waste container

Configuration Control Locks Can use any shape or color of lock EXCEPT RED. Tags: YELLOW, MANILA or RED (w/o DO NOT OPERATE wording are allowed. RED locks and DANGER: Do not Operate tags are used exclusively for LOTO Not for Configuration Control

Can use any shape or color of lock EXCEPT RED.

Tags: YELLOW, MANILA or RED (w/o DO NOT OPERATE wording are allowed.

RED locks and DANGER: Do not Operate tags are used exclusively for LOTO

Not for Configuration Control

Configuration Control Locks Can use lock w/out tags if use is obvious Combination locks are allowed Keyed locks may have more than one key.

Can use lock w/out tags if use is obvious

Combination locks are allowed

Keyed locks may have more than one key.

Configuration Control Locks Removal of lock is by person or group who applied it. Removal by other authorized or qualified person permissible if there is assurance that removal will not create unsafe condition

Removal of lock is by person or group who applied it.

Removal by other authorized or qualified person permissible if there is assurance that removal will not create unsafe condition

SUMMARY

Key Points to Remember Hazardous energy is dangerous and deadly Use lockout/tagout wherever unexpected startup or stored energy release may occur Adhere to lockout/tagout and restart procedures Keep everyone informed

Hazardous energy is dangerous and deadly

Use lockout/tagout wherever unexpected startup or stored energy release may occur

Adhere to lockout/tagout and restart procedures

Keep everyone informed

5 Step Restart Procedure 1. Clean up and inspect work area 2. Clear personnel from the startup area and notify affected employees of startup 3. Verify that the controls are in neutral 4. Remove lockout devices and reenergize the machine 5. Start machinery or equipment

1. Clean up and inspect work area

2. Clear personnel from the startup area

and notify affected employees of startup

3. Verify that the controls are in neutral

4. Remove lockout devices and reenergize

the machine

5. Start machinery or equipment

Questions? Ron Kravitz