How to Lockout/Tagout

Step 1-Before the Shutdown

THE STANDARD: (d)(1) "Preparation for shutdown." Before an authorized or affected employee turns off a machine or equipment, the authorized employee shall have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy.

DISCUSSION: When developing these procedures, it may be helpful to have floor drawings and the assistance of the facility electrician and employees who work with the equipment. Keep in mind that lockout should be utilized if at all feasible. If you feel that you want to go with tagout, which I adamantly discourage, you must do so according to (c)(3). It is necessary to stipulate who is an "authorized" and who is an "affected" employee with respect to the procedures and equipment. Authorized employees are those who physically lockout/tagout equipment in order to perform servicing or maintenance on the equipment/machine. An affected employee is one who operate or uses equipment on which service or maintenance is performed under lockout/tagout or an employee who must work in an area in which such servicing or maintenance is performed. Both affected and authorized employees must be trained according to .147(c)(7).

Step 2-Powering Down

THE STANDARD: (d)(2) "Machine or equipment shutdown." The machine or equipment shall be turned off or shut down using the procedures established for the machine or equipment. An orderly shutdown must be utilized to avoid any additional or increased hazard(s) to employees as a result of the equipment stoppage.

DISCUSSION: Use the specific procedures for the individual unit of equipment. General procedures to cover all machines with one procedure is not acceptable unless the criteria of .147(c)(4)NOTE: Exception. Equipment that is operated by cord and plug will not require written procedures for LO/TO in most cases; however, be sure that the employees are trained on the hazards of the specific equipment and that the plug/power source is to be in their control at all times (have 'em put the plug in their pocket).

Step 3-Isolating the power source

THE STANDARD: (d)(3) "Machine or equipment isolation." All energy isolating devices that are needed to control the energy to the machine or equipment shall be physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s).

DISCUSSION: This step involves flipping a power switch, breaking a circuit, closing a valve, etc. If the equipment has more than one shutdown point, be sure that all are isolated from power.

Step 4-Applying the Lock and/or Tag

THE STANDARD: (d)(4) "Lockout or tagout device application." (i) Lockout or tagout devices shall be affixed to each energy isolating device by authorized employees.
(ii) Lockout devices, where used, shall be affixed in a manner to that will hold the energy isolating devices in a "safe" or "off" position.
(iii) Tagout devices, where used, shall be affixed in such a manner as will clearly indicate that the operation or movement of energy isolating devices from the "safe" or "off" position is prohibited.

(A) Where tagout devices are used with energy isolating devices designed with the capability of being locked, the tag attachment shall be fastened at the same point at which the lock would have been attached.
(B) Where a tag cannot be affixed directly to the energy isolating device, the tag shall be located as close as safely possible to the device, in a position that will be immediately obvious to anyone attempting to operate the device.

DISCUSSION: As mentioned in step 1, I suggest lockout whenever feasible, as does OSHA. Additionally, the use of both is preferable. If more than one person is working on equipment, each must lockout the equipment individually using something such as a hasp. As for the LO/TO devices, they must be standardized in size, color, or shape (tagout devices must also be uniform in print and format). The devices must indicate the employee who applied the device. Each authorized employee should have an individual lock and key with duplicate keys in a supervisors office for emergency only use. Lockout devices must only be removable by bolt cutters or like equipment. Tagout devices must not deteriorate or become illegible and must be attached by material with not less than 50 lbs. of strength. Each tag must have a prominent hazard warnings such as "Do Not Start," "Do Not Open," "Do Not Close," "Do Not Energize," "Do Not Operate." Additionally, tags must identify the worker by name, including the date/time work began and the type of work being performed.

Step 5-Releasing Residual Energy

THE STANDARD: (d)(5) "Stored energy." (i) Following the application of lockout or tagout devices to energy isolating devices, all potentially hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise rendered safe.
(ii) If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists.

DISCUSSION: After all LOTO devices have been applied, employees must ensure that no hazardous energy is still stored in the equipment or machinery. This kinetic energy may be found in flywheels, steam lines, hydraulic systems, springs, capacitors, etc. Energy may need bleeding from capacitors or grounded from electrical circuits. Steam lines and hydraulic and pneumatic systems need activated to determine all energy has been released. Additionally, any water, chemical, sewer, or other liquid lines need emptied, e.g. block and bleed.

Step 6-Try to Power Up

THE STANDARD: (d)(6) "Verification of isolation." Prior to starting work on machines or equipment that have been locked out or tagged out, the authorized employee shall verify that isolation and de-energization of the machine or equipment have been accomplished.

DISCUSSION: This step requires the employee to turn all controls of the equipment or machinery in the "ON" position to ensure that all energy sources have been isolated and that it will not start up while work is being performed on it. Before trying to power up, be sure that no one is near the equipment or machinery in case the equipment should operate. Lastly, the employee should verify that the isolation point cannot be moved to the "ON" position. The employee can then perform his servicing or maintenance.

Step 1-Machine and/or Equipment Inspection

THE STANDARD: (e)(1) "The machine or equipment." The work area shall be inspected to ensure that nonessential items have been removed and to ensure that machine or equipment components are operationally intact.

DISCUSSION: After the authorized employee has performed his work, he must ensure that all tools, spare parts, debris, etc. have been removed from the area. Any guards that were removed to perform the work must be put back into place so that the equipment is safe to operate.

Step 2-Give Notification to All Employees

THE STANDARD: (e)(2) "Employees." (i) The work area shall be checked to ensure that all employees have been safely positioned or removed. (ii) Before lockout or tagout devices are removed and before machines or equipment are energized, affected employees shall be notified that the lockout or tagout devices have been removed. (iii) After lockout or tagout devices have been removed and before a machine or equipment is started, affected employees shall be notified that the lockout or tagout device(s) have been removed.

DISCUSSION: Notify all workers in the vicinity before removal of the lockout and start up. Be sure that no one is in the way of possible danger upon start up.

Step 3- Remove the Lockout/Tagout Device

THE STANDARD: (e)(3) "Lockout or tagout devices removal." Each lockout or tagout device shall be removed from each energy isolating device by the employee who applied the device. Exception to paragraph (e)(3). When the authorized employee who applied the lockout or tagout device is not available to remove it, that device may be removed under the direction of the employer, provided that specific procedures and training for such removal have been developed, documented and incorporated into the employer's energy control program. The employer shall demonstrate that the specific procedure shall include at least the following elements:

(i) Verification by the employer that the authorized employee who applied the device is not at the facility:
(ii) Making all reasonable efforts to contact the authorized employee to inform him/her that his/her lockout or tagout device has been removed; and
(iii) Ensuring that the authorized employee has this knowledge before he/she resumes work at that facility.