This document provides an overview of lockout/tagout procedures for hazardous energy sources. It defines who needs lockout/tagout training, what hazardous energy is, and the different types of lockout devices. Lockout procedures involve 6 steps - notifying employees, shutting down equipment, isolating energy, attaching lockout devices, releasing stored energy, and verifying lockout before servicing. The document lists examples of hazardous energy sources and injuries that can occur if energy is not properly locked out, and emphasizes the importance of following energy control programs and written lockout procedures.

1. Lockout/Tagout
What This Training Will Cover:
Who needs training?
What is hazardous energy?
What is lockout/tagout?
What are the different types of lockout
devices?
What is the requirement for tags?
What lockout/tagout procedures are required?
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2. Who Needs Training?
•Authorized employees –people who lock or tag out
machines or equipment to perform servicing.
•Affected employees –people who use machines or
equipment on which servicing is performed under
lockout/tagout.
•Other employees –people who work in the area of
locked out machinery or equipment
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3. What is Hazardous Energy?
Hazardous energy is any of the following:
Electricity – live or stored
Moving machinery parts
Stored mechanical
movement in machinery
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4. What is Hazardous Energy?
Stored heat (steam lines or hot
liquids)
Hazardous chemicals in pipelines
under pressure or force of gravity
Any other active or stored energy
sources that could harm a worker
--such as:
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5. Hazardous Energy Source Examples
Live electrical lines
Electrical capacitors
Lasers
Engines that move machinery parts
Hydraulic lifts
Pneumatic (air pressure) lines
Pressurized water lines
Springs
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6. Lockout/Tagout and Confined Spaces
Lockout/Tagout is important in
confined spaces since it is easy to
get trapped and hard to escape.
Pipelines leading into tanks must
be blanked off before entering the
space.
All electrical and mechanical
hazardous energy must be
addressed and locked out or
tagged as needed.
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7. Our Hazardous Energy Sources
(examples)
The following hazardous energy sources
require lockout/tag-out procedures:
Examples:
• Laboratory equipment (examples)
• Field equipment (examples)
Inventory list example (handout)
Please refresh the inventory list for your laboratory or
site
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8. What kind of injuries can happen?
Electrocution from live parts
Scalding from steam or hot liquids
Chemical burns or poisoning
From machinery:
- Deep cuts and gashes
- Crushing injuries
- Amputations
All of these can be fatal when severe
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9. Fatality Example
A man working inside a
supermarket cardboard compactor
was crushed when the unblocked
compactor suddenly came down on
top of him.
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10. More Examples
Three men were doing maintenance inside an asphalt pug mill mixer. One employee
was still inside the mixer when the power was turned back on, thereby starting the
mixer. He was killed instantly.
Cause: failure to disconnect power source and lock out.
A cotton gin operator climbed into a jammed cotton cleaner/separator. The toggle
switch controlling the operation of the gin was turned off but not locked out. For
some reason, someone accidentally turned the machine back on, not knowing the
gin operator was inside the gin. His leg was pulled through the feed rollers.
Cause: failure to disconnect power source and lock out.
A warehouseman was repairing an air-operated valve which he had turned off but
not disconnected and locked out. During the repair operation he slipped and
inadvertently turned on the switch which let air into the valve. His hand was caught
and crushed in the valve.
Cause: failure to disconnect power source and lock out.
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11. More Examples
A maintenance employee was changing V-belts on an exhaust fan. He de-energized
the fan before starting work. However, he did not block the blades of the fan. The
suction in the duct work turned the fan blades, and his hand was caught in the Vbelt drive. Cause: failure to block out potential energy sources.
One study on servicing equipment injuries found that 80 percent of the workers
surveyed failed to even turn off the equipment before performing the service work.
There is a difference between turning off a machine and actually disengaging or deenergizing a piece of equipment. When you turn off a control switch, you are
opening a circuit. There is still electrical energy at the switch, and a short in the
switch or someone inadvertently turning on the machine may start the machine
running again.
Of the 20 percent of the injured workers who did turn off the machinery, about half of
them were injured when someone, generally a coworker who was unaware that the
machine was being serviced, accidentally reactivated the machinery.
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12. More Examples
Of those workers who turned off the control switch, another 20% were injured by the
energy still in the machine which should have been blocked. The moving parts of
the machine either continued to coast, or the parts moved when a jam was cleared.
In an accident in California, a table saw was turned off, but the saw blade was still
silently coasting and had not come to a complete stop. An employee began cleaning
the machine, and his finger was amputated by the blade.
Other accidents have occurred when the control switch on a machine was turned
off, but a short in the switch restarted the machine.
Accidents have also occurred even when workers did take the necessary steps of
disconnecting the main power source. But they did not perform a crucial step for a
complete lockout procedure: They did not test the equipment to make sure the
machinery was, in fact, de-energized.
One case, the lockout had been done on the wrong power line. In another case, a
second power line had been spliced into the wiring beyond the point of the lockout.
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13. When is Lockout/Tag-out required?
When someone will be servicing
or repairing machinery or
equipment
AND
the unexpected machinery startup or release of stored energy
could cause injury
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14. Service and Maintenance Examples
Installing, constructing,
adjusting, modifying,
unjamming, cleaning,
lubrication, inspecting,
setup - preparing for
normal function
These activities often require a worker to place all or
part of their body into the machine’s hazard zone
(“the line of fire”).
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15. What is an energy-isolating device?
A device that physically prevents transmission
or release of energy such as:
An electrical circuit breaker,
A pipeline valve,
A machine block,
Anything else that positively
blocks or isolates energy.
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16. What is a Lockout Device?
A device that positively:
prevents a machine from being started
up or turned on,
prevents a machinery part from moving,
prevents electrical energizing,
blocks a pipeline, steam line or air line
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17. Electrical Lockout Devices
Locked out circuit breaker
Locked out electrical panel
Locked out electrical plug
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18. Fluid & Gas Lockout Devices
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19. Pipe Lockout Examples
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20. Pneumatic Lockout Examples
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21. Physical Blocks
Punch press blocks
Truck bed lockout
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22. Group Lockout Devices
Used when more than one person
doing maintenance or repair on
same machine or equipment.
Machinery or equipment can’t be
started up until all locks are
removed.
Each person places and removes
their own lock.
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23. Example of a bad lockout/tagout
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24. Lockout Devices We Use
Personally-identified lock
E-Z Panel LocTM snap-on breaker lockout device
More examples?
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25. What is Tag-out?
Tags are warning devices only
They don’t provide the same level of protection as lockout devices. We
only use for information, along with a locked device.
They can only be removed by an authorized person.
They must be legible (use a sharpie), securely attached (e.g., zip-tie not
string) and resistant to degradation.
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26. Energy Control Program
Our energy control program consists of:
1. Training for Authorized and Affected employees;
2. A current inventory of equipment requiring lockout;
3. A description of general energy control procedures,
4. Development and use of a specific written stepwise
procedure for all equipment on the inventory; and
5. Periodic inspection of the implementation of the
energy control procedures
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27. Lockout Procedures
Six Steps to Follow:
1. Notify affected employees (anybody in the
area) that the machine or equipment will be
shut down and locked out
2. Shut down the machinery or equipment using
normal procedure
3. Isolate energy sources with energy-isolating
devices
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28. Lockout Procedures
Six Steps
4. Lock out energy-isolating devices with assigned
locks.
5. Release or restrain stored or residual energy
(capacitors, pressure, vacuum, blades, etc.)
6. Test machinery to make sure it can’t start up
(use the normal start procedure)
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29. Single Breaker Lock Use

30. Dual Breaker Lock Use

31. Lockout Steps
Notify
employees
Shutdown
Equipment
Isolate
Energy
Attach Lockout
Device
Release
Stored Energy
Verify Lockout
Service &
Maintenance
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32. Examples of Release of Stored Energy
• “Slowly open the receiver tank port and bleed off
any internal pressure.”
• “Loosen both line valves to relieve all pressure in
the cooling circuit.”
• “Ground out capacitor…”
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33. Examples of Attempt to Operate
•
“…adjust the temperature cycle thermostat to
check that all electrical inputs have been shut
off.”
• “Push the start function button to verify that
electric power has been removed.”
• “Crack the steam inlet and discharge line outlet
valves…”
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34. Start-up Procedures
Only Authorized employee can do startup
Warn everyone present to stay clear
Remove all tools, locks and tags
Remove, reverse, open or reactivate isolating devices
Visual check that all is clear
Start up machine, process or line flow
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