The document discusses lockout and tagout procedures for machine maintenance and repair. It defines lockout as cutting all energy sources and installing a personal lock and tag at the source to prevent machine startup. Employers must establish a written lockout procedure and train employees. The lockout procedure involves preparing for shutdown, shutting down equipment, isolating all energy sources, applying lockout devices, controlling stored energy, and verifying isolation before work begins. Removing locks incorrectly can result in injuries, fines and penalties under the zero tolerance policy.

1. Lockout & Tag
Presented by
Name
Title
Date

2. Course Outline
• Lock-out definitions
• Legal responsibilities
• Lock-out procedure
• Frequent mistakes
• Removing a lock
• Code of practice
• Zero Tolerance

3. Definition: Locking
• Lockout means cutting all sources of energy
and installing a personal lock and tag at the
source, to prevent the starting of this piece of
machinery while it is being cleaned, maintained,
adjusted or repaired

4. Definitions
• Zero energy state
-The machine is incapable of spontaneous or
unexpected action
-There is no residual energy left in the
machine

5. Energy Types
• Electrical energy
- power transmission lines, transformers,
- circuit breakers
• Hydraulic energy
- fluid under pressure (cylinders and lift trucks)
• Pneumatic energy
- air under pressure (pipes, tanks and vessels)

6. Energy Types
• Kinetic energy
- Kinetic = caused by motion
- Examples: moving conveyor, flywheel, moving
saw blade
• Potential energy
- Potential = stored energy
- Examples: spring, battery or elevated weight

7. Definition: Tagging
•Tagging is the addition of a tag to the
lock which indicates the date, time and
the name of the worker as well as a
warning not to start the machine
•Important Note: This
never replaces a lock!

8. Employer Responsibilities
• 239 (1)...ensure that each machine has a
means of isolating the energy source that...is
lockable…in a location that is familiar to all
employees...is properly identified
• 239 (2)...provide a safety lock and key
• 239 (3)...establish a written lock-out
procedure...adequately train employees

9. Employer Responsibilities
• 239(4)...ensure that no employee works on a
machine until…
• a competent person puts the machine in a zero
energy state and
• employee
- verifies zero energy state
- locks out the machine using the safety lock and
key provided
- adds a safety tag that contains
› a warning not to start the machine
› the employee’s name and signature
› the date and time

10. Employer Responsibilities
• 239 (5) No employee shall work on a machine...until
he...
• verifies that a competent person has put the machine
in a zero energy state and
• locks out the machine using the safety lock and key
provided
• adds a safety tag that contains
› a warning not to start the machine
› the name and signature of the employee
› the date and time
• tests that the machine is inoperative

11. Lockout Policy
• Policy: a statement that explain the
company’s directives concerning tagging
and locking out
Where
When
Why

12. When?
• Any time you service or perform maintenance
on any machinery or equipment that includes:
 constructing
 installing
 setting up
 adjusting
 inspecting
 repairing

13. Where?
• Locks and tags are applied to all primary and
secondary energy sources:
electrical
hydraulic
pneumatic
mechanical
kinetic
chemical
thermal

14. Why?
•To save workers from serious injuries or death,
and it’s the law

15. Lockout/Tagout Program
Training & Communication
Hardware (devices)
Written Policy
& Procedures

16. Lockout Procedures
• Procedure: a set of steps is used to lock out
specific machines
- A list and location of all energy sources
- Other equipment in the area that must be
locked out
- Special hazards/circumstances
- Sequential steps (can be in a checklist format)
- Testing methods
- Start-up

17. Tag and Lock Procedure
1. Prepare for shutdown
2. Shut down the equipment
3. Isolate the equipment (stand on the right hand
side of the panel, use your left hand to pull the
breaker)
4. Apply lockout and tag devices
5. Control stored energy
6. Verify isolation of equipment
6
Step
Procedure....

18. Step 1
Preparing for shutdown
-Do you know your machine?
-What kind of energy are we dealing with?
More than one type?
-What are the hazards present and what
are the controls necessary?
6
Step
Procedure....

19. Step 2
Shut down the equipment
-Have you advised other workers?
-Do you know the normal stopping
procedure?
›‘Off’ switch, pedals, controls?
›Other method?
6
Step
Procedure....

20. Step 3
• Isolate the equipment
- cut-off EVERY source of energy
› valves, main disconnects, circuit
breakers
- do not forget auxiliary power (electrical,
secondary steam, hydraulic, pneumatic)
- do not forget secondary sources of energy
such as backup generators
Pulling the fuse is NOT locking out!
6
Step
Procedure....

21. Step 4
Apply lockout and tag devices
- attach to isolating devices to prevent
someone restoring the energy flow
6
Step
Procedure....

22. Other Equipment
• Scissors: whenever more than one person has to work
on locked out equipment, a multiple locking device
(sometimes referred to as scissors) must be used so
each worker can secure their own safety
• Tags: extra protection and provide vital information;
NEVER to substitute for lock-out
• Blanks: for piping
• Covers: for connectors and valves
• Chains: for valve handles

23. Scissors (rasp)

24. Tags

25. Covers

26. Chains

27. Lockout Box/Boards

28. Lock Station

29. Step 5:
Control stored energy
- restrain hazardous energy
- make sure parts have stopped turning
- relieve trapped pressure
- install ground wires for charge dissipation
- block/support elevated equipment
- block all secondary sources of energy
6
Step
Procedure....

30. Step 6
Verify isolation of equipment
- DO NOT take anything for granted
- double-check your steps (with checklist)
- TEST BEFORE YOU WORK – Do it
yourself! Don’t rely on someone else!
6
Step
Procedure....

31. Removing a Lock
• 239 (6) No person shall remove the lock on a
machine except...
-a) the person who installed it
-b) in an emergency... where attempts are
made to contact the person and this person is
not available...a competent employee
designated by the employer.

32. Removing Locks and Tags
• Notify affected employees
Check and re-check

33. What if you can’t lock out?
• 240. Code of Practice
- Procedures that are outlined for working in
certain situations where regulations do not fit
- A code of practice must be written in great
detail and posted at the worksite

34. Frequent Mistakes
• Misplaced multiple lock device (scissors)
• Cut-off not closed
• Improperly closed multiple lock
• No tag, no lock or no tag and lock
• Lock not closed or key left in the lock
• One lock for several workers

35. Causes of Injuries
1. Failure to completely stop equipment
2. Failure to disconnect from all the power sources
3. Failure to dissipate residual energy
4. Accidental restarting of equipment
5. Failure to clear work area before reactivation
6. Lack of training
7. Lack of procedures

36. Famous Last Words...
• It will take longer to lock out than to do the
repair...
• It will only take a minute...
• It’s lunch time, no one is around...
• The machine is stopped, it must be locked out...
• It’s OK to do it this way, right?

37. What does Zero Tolerance mean?
Zero Tolerance

38. Zero Tolerance
Zero Tolerance means any or all of the following:
•Stop work orders
• Restricting use of equipment
• Fines
• Imprisonment
• An additional assessment for violations of the
lockout provisions found in the OSH Act

39. CSA Standard Z460-05
• This CSA standard can help you develop an
effective lockout program
• www.csa.ca

40. Summary
 Tag and lockout definitions
 Legal responsibilities
 Lockout procedure
 Frequent mistakes
 Removing a lock
 Code of practice
 Zero Tolerance