Lockout &tagout

Presented by
The Public Education Section
Oregon Occupational
Safety and Health
Division (OR-OSHA)
OR-OSHA 204
9906-01
Introduction to
Lockout/Tagout

OR-OSHA 204 Lockout Tagout
This material for training use only
Objectives
1. Gain a greater awareness of the requirements
detailed in Oregon Administrative Rules 437, Div
2J, Control of Hazardous Energy.
2. Understand the responsibilities of the employer,
authorized employee, and the affected employee.
3. Understand lockout/tagout procedures for shutting
down, testing, and returning machinery and
equipment to operation.

Form Groups
Introductions - Get to know your NEIGHBOR!
Elect a group leader
Select a spokesperson
Recorders

Part I: Scope and Application
(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.
OAR 437, Div 2J, 1910.147,
The Control of Hazardous Energy
(Lockout/Tagout)
What are the three key elements of an energy control
program?

Authorized Affected Other
__Affected Employee
__Authorized Employee
__Other Employee
A. Person who services or
performs maintenance on
machines or equipment.
B. Person who operates or
uses a machine or equipment
which is being serviced or has
maintenance being performed.
C. Person who works in an
area where lockout/tagout
procedures are being used.
Scope: The lockout/tagout rule covers the
following employees:
Match the employee category on the left with its correct
definition

Application: Procedures must be followed when...
...servicing and/or maintenance 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” of machinery and equipment” include:
Adjusting... inspecting... modifying...
constructing... re-tooling...
lubricating... removing jams... cleaning...

Oregon exceptions:
• Applies to construction, agriculture, and
maritime.
• Group lockout/tagout not approved.
• Uniquely keyed locks.
Sources of Energy
List as many sources of energy as possible that could
cause injury

The standard does not apply to:
•Installations under the control of ___________.
•Exposure to electrical hazards from work on,
near, or with ____________ or __________ in
electric utilization installations.
•_________ and ______ drilling and servicing.

• Normal ______________ operations…unless:
Guards, or other devices are
removed/bypassed; or
Employees place themselves in an area where
work on materials, etc., is actually being
performed; or
Employees place themselves in any area
considered dangerous during the normal
operating cycle.
•Work on _______ and __________ connected
equipment.
•_________ __________ operations, under
special conditions.

Part II: The Written Energy Control Plan
A written Energy Control Plan must include the scope,
purpose, authorization, rules, and techniques used to
control hazardous energy, and the means to enforce
compliance, including:
1. A specific statement of intent to use the
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.
See appendix for a sample written plan.

Why is a comprehensive written plan critical to a
successful lockout/tagout program?
What are some reasons a lockout/tagout program
may not work effectively?
Who’s responsible….who’s accountable….and for
what?

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.

Equipment Identification List
Equipment / Machinery Basic Hazards
1. ________________________________
___________________________
___________________________
2. _______________________________
___________________________
___________________________
3. _______________________________
____________________________
____________________________
List three types of equipment/machinery and any
possible energy source hazards, including
magnitudes.

If any of the conditions below exist, the employer must
include the machine or equipment in the written
program:
1. The machine or equipment has potential for __________ or
____________ energy, or _______________ of stored energy
after shutdown which could endanger employees; or
2. The machine or equipment has more than a __________
energy source; or
3. The isolation and locking out of any single energy source
will not ___________ de-energize and deactivate the machine or
equipment; or
4. The lockout device is not under __________ control of an
authorized employee performing the servicing or maintenance;
or
5. The servicing or maintenance of the machinery or equipment
creates _________for other employees; or
6. The employer has had __________ involving the unexpected
activation or re-energizing of the machine or equipment during
servicing or maintenance.

Part III: Lockout/Tagout Procedures
Step 1 - Prepare for Lockout.
As a minimum the following information should be
reviewed:
•Types and magnitudes of energy;
•Hazards posed by that energy; and
•Methods to effectively control the energy.
Particularly close attention must be given to energies
(such as gravity, electrical, high pressure) that can be
stored or re-accumulated after shut-down.
Prior to shutdown all affected employees will be notified
to clear their work area and/or any other area that might
be hazardous.
What means or methods can be used to ensure the
above review and notification is conducted prior to
lockout/tagout?

Why is the actual instant of shutdown or startup so
hazardous in the lockout/tagout process?
Step 2 - Shutdown and isolation
• Machinery and equipment that is capable of being
locked out should be shut down in an orderly
manner using shutdown checklist procedures.
• If more than one authorized employee is involved in
shutdown, the maintenance team leader should
make sure all assistants have accomplished their
tasks and are aware that shutdown will occur.
•All energy isolation devices should be located and
operated to completely de-energize and isolate the
equipment. The authorized employee will verify
operation of each energy isolation device.

An “energy isolating device” physically prevents…
...the ___________ or __________ of energy.
What are some examples of energy isolation devices?
T/F Pushbuttons, selector switches and other control
circuit type devices are energy isolating devices.

Lockout Devices
• Lockout devices must be used to secure energy
isolating devices unless the machinery or equipment
is not capable of being locked out.
• Only authorized employees will affix lockout/tagout
devices. Lockout devices must be able to hold
energy isolation devices in a “safe” or “off” position.
Tagout Devices
• Tagout devices will be used only if machinery or
equipment is not capable of being locked out.
• Tags will clearly state that moving energy isolating
devices from the “safe” or “off” position is strictly
prohibited.
• If a tag cannot be affixed to the energy isolating
device, it will be located as close as safely possible
to the device so that the tag is obvious to anyone
attempting to operate the device.

A “lockout device” must use a positive means such as a
lock, either key or combination type, to hold an energy
isolating device…
...in a ________ position to prevent machinery or
equipment from being ____________________.
What are some examples of lockout devices?
Padlocks Lockout hasps
C/B lockouts Wall switch lockouts
Gate valve lockouts Ball valve lockouts
Fuse lockouts Plug lockouts
Machinery or equipment is “capable of being locked out”
if:
•It has a _______ or other means to attach a lock; or
•It has a ___________ _____ locking mechanism
•Does not have to be ________ to achieve lockout.

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 ____ until the tagout device is ______.
T/F All newly installed machines or equipment must
have energy isolating devices capable of accepting a
lockout device.
T/F If you replace, major repair, renovate or modify a
machine or piece of equipment it must have an energy
isolating device capable of accepting a lockout device.
Before applying and after removing lockout/tagout
devices, the authorized employee…
...must notify all _____________ employees.

Protective materials and hardware
Materials and hardware must be provided by the
________.
Each lockout/tagout device must be ______ identified as
being used ____________ for lockout/tagout.
Lockout/tagout devices must be ____ and ______.
Lockout devices must be ______________ to prevent
removal without excessive force or unusual techniques.

Tagout devices must be substantial enough to prevent
inadvertent or accidental removal. They must be
• Non-reusable,
• Attachable by hand,
• Self-locking,
• Non-releasable with not less than 50 lb locking
strength
• Design/characteristics at least equivalent to a one-
piece, all environment-tolerant nylon cable tie.
Lockout/tagout devices must _______________ the user.
Which is the preferred method: Lockout or Tagout?

When can an employer use a tagout system?
1. When an energy isolating device is not capable of
being ________________ __________________.
2. If employer can demonstrate (prove) that using a
tagout system will provide _______________
employee protection.
What tow tests must be met to demonstrate full
employee protection?
1. Tags can be placed where _________ _________
would have been placed.
2. The employer demonstrate _________________
protection can be obtained with tags.

What are some examples of stored or residual
energy?
• Remember! If stored energy can be re-accumulated
to a hazardous level, authorized employees must
continually verify that the machinery or equipment is
safely isolated until the possibility of re-accumulated
energy no longer exists.
• Verification of Isolation. Before starting work on a
machine or equipment that is locked or tagged out,
the authorized employee will verify that the machinery
or equipment is actually isolated and de-energized.
How do you verify that a machine or equipment is
actually isolated or deenergized?
• Stored Energy. Immediately after applying lockout or
tagout devices, the authorized employee will ensure all
potentially hazardous stored or residual energy is
relieved, disconnected, restrained, and otherwise
rendered safe.

Step 3. Release from Lockout/Tagout.
Equipment.
• 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 danger zones.
• Notify affected employees that lockout/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/tagout device may remove that device.
• Exception - When the authorized employee is not
at the facility and all reasonable efforts have been
taken to inform him/her that the lockout/tagout
device has been removed written procedures must
be in place to remove lockout/tagout devices.

Who does the authorized employee notify prior to
removing any lockout/tagout devices?
T/F The authorized employee also notifies the affected
employee after lockout/Tagout devices have been
removed and before equipment has been started.
If the authorized employee is not available, who is
authorized to remove the lockout or tagout device?

T/F Modified/shortened procedures may be used to
isolate and startup equipment when testing?
Why are employees injured so frequently while testing
the machinery or equipment during maintenance?
Additional Requirements
•Testing/Positioning Machines or Equipment.
Whenever lockout/tagout devices are removed to
test or position machines and equipment, or their
components, the authorized employee must
complete full shutdown, isolation, and release from
shutdown procedures.

Outside Personnel
• Outside servicing personnel, contracted to perform
maintenance or other services requiring
lockout/tagout procedures, must not begin work until
the maintenance supervisor is satisfied that their
lockout/tagout procedures are at least equivalent to
company procedures.
• The employer must also ensure company employees
understand and comply with contracted personnel
lockout/tagout procedures, is used.
Who is responsible if an employee is injured because an
outside contractor did not follow proper lockout/tagout
procedures?
What is the intent or purpose of the procedures above?
Shift/Personnel Changes
• Written procedures must be developed to address
lockout/tagout procedures during a shift change.

The BIG exercise!
Design a quality lockout-tagout procedure for a giant 500
gallon coffee pot (the company’s employees drink a lot
of coffee!).
500 gallon capacity
Spring loaded
lever
CB
Panel
Water
in
Coffee
out
240 vac

Part IV: Lockout/Tagout Training
General requirements
• Training in lockout/tagout must be provided to all
employees who may be in an area where energy
control procedures are used.
• This training will make sure that the purpose and
function of the energy control program are
understood and that employees gain the needed
knowledge and skills to safely apply, use, and
remove energy controls.

Minimum training will include:
Authorized employees must be able to
recognize hazardous energy sources, types and
magnitudes of energy in the workplace, and
methods and means necessary to isolate and
control the energy.
Affected employees must be able to recognize
the purpose and use of energy control
procedures.
Other employees must be able to recognize
procedures and prohibitions of the energy
control program.
What are effective training strategies for each level of
training?

Training on Tagout Devices
• If tagout devices are used, further training on tagout
systems need to emphasize that:
a. Tags are warning devices only and do not provide
a physical restraint that lockout devices provide.
b. Tags must not be removed without the authorized
employee’s approval, and should never be
bypassed, ignored, or otherwise defeated.
c. Tags must be legible, and understandable by all
employees.
d. Tags must be able to withstand environmental
conditions in the workplace.
e. Tags may give employees a false sense of
security.
f. Tags must be securely attached to prevent being
accidentally detached during use.

Retraining
• Employees will participate in retraining at the
following times:
1. Change in job assignment.
2. Change in machinery or equipment, or
3. Change in operating procedures.

How often must lockout/tagout inspections occur?
Who must conduct the inspection?
• Annual inspection on lockout/tagout procedures must
be conducted by an authorized employee other than the
one(s) using the energy control procedure being
inspected.
• The purpose of the inspection is to correct any
deviations or inadequacies in the procedures.
• The inspector and authorized employee will review
responsibilities under the energy control procedure.
• The employer must certify that the inspection was
conducted. Elements of the certification should
include:
a. Identification of equipment or machinery
b. Date of inspection
c. Employees included in the inspection
d. Person performing inspection
Part IV: Lockout/Tagout Annual
Inspections

Lockout &tagout

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