Lockout/Tagout

MODULE 20

1910.147(a)(1) Scope
Covers servicing and maintenance of machines and equipment in which
Unexpected energization or start up or Release of stored energy could cause Injury to employees

Normal operation is covered in 1910 Subpart O

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1910.147(a)(1)(ii) Exemptions
Construction, agriculture and maritime employment; Electrical Utilities; Electrical equipment (covered by Subpart S) Oil and gas well drilling and servicing So why comply?
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Control of Hazardous Energy

Why use lockout/tagout? Protects maintenance personnel from power being reapplied by mistake Recommended by API RP 54 for electrical systems in drilling and servicing operations Recognized hazard
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1910.147(a)(2) Application
Service and maintenance:
Employee required to remove or bypass a guard or safety device Employee required to place part of body into area that would be a danger zone during machine operation cycle

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1910.147(a)(2) Application
Exception: Minor adjustments and servicing activities during normal production if
Routine Repetitive Integral to production

Provided that alternative measures provide effective protection

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1910.147(a)(2) Application
Does not apply to cord and plug connected equipment for which
Exposure to hazard is controlled by unplugging and Plug under exclusive control of employee performing service or maintenance

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1910.147(a)(2) Application
Does not apply to hot tap operations in transmission and distribution operations in pressurized pipelines provided that:
Continuity of service is essential, Shutdown of system is impractical, and Documented procedures and special equipment provide proven effective protection for employees
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1910.147(a)(3) Purpose
Establish a program and utilize procedures for affixing appropriate lockout devices or tagout devices to energy isolating devices Prevent unexpected energization, start up or release of stored energy in order to prevent injury to employees Training and procedural requirements for other sections LO/TO requirements
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Definitions

1910.147(b)

Affected employee
Job requires employee to
operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or work in an area in which such servicing or maintenance is being performed

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Authorized employee
Locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment Affected employee whose duties include servicing or maintenance under this section

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Energized
Connected to an energy source OR Containing residual or stored energy

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Energy isolating device

A mechanical device that physically prevents the transmission or release or energy
Circuit breakers included NOT push buttons NOT selector switches NOT control circuits

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Energy source
Any source of:

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Electrical, Mechanical, Hydraulic, Pneumatic, Chemical, Thermal, or Other energy

What kind of energy did the rock have?

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Lockout
Placement of a lockout device on an energy isolating device, in accordance with an established procedure, ensuring that energy isolating device and equipment being controlled cannot be operated until lockout device is removed

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Lockout device
Device that uses a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment Blank flanges and bolted slip blinds included
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Servicing and/or maintenance

Workplace activities such as:

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Constructing, Installing, Setting up, Adjusting, Inspecting, Modifying, and Maintaining and/or servicing machines or equipment
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Tagout
Placement of tagout device
on an energy isolating device, in accordance with an established procedure, to indicate that energy isolating device and equipment being controlled may not be operated until tagout device is removed
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General Requirements

1910.147(c)

Energy control program

Energy control procedures Employee training Periodic inspections Any employee who services/maintains any equipment where unexpected energizing or stored energy release could cause injury isolates and renders it inoperative first.
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1910.147(c)(ii) General Requirements

If an energy isolating device is capable of being locked out, the employer's energy control program shall utilize lockout, unless the employer can demonstrate that the utilization of a tagout system will provide full employee protection
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1910.147(c)(iii) General Requirements

Energy isolating devices designed to accept lockout devices whenever:
Replacement or major repair, renovation or modification of equipment is performed or New machines or equipment are installed

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1910.147(c)(3) Full employee protection

When tagout device used on energy isolation device capable of being locked out:
Same location as potential lockout device Demonstrably equivalent program

May require additional safety elements

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1910.147(c)(4) Energy control procedure

Procedures shall be developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section.
Exception with all 8 elements listed in standard

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1910.147(c)(4) Energy control procedure

Outline scope, purpose, authorization, rules, techniques for control of hazardous energy, including:
Specific intended use of the procedure; Specific steps for shutting down, isolating, blocking and securing equipment Specific steps for placement, removal, transfer of lockout/tagout devices and responsibility for them Specific requirements for testing equipment to verify effectiveness of lockout devices, tagout devices, and other energy control measures
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1910.147(c)(5) Protective materials and hardware

Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware shall be provided by the employer for isolating, securing or blocking of equipment from energy sources

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1910.147(c)(5) Protective materials and hardware

Lockout and tagout devices must be:
Singularly identified The only device(s) used for controlling energy Not used for other purposes And shall meet the following requirements:

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1910.147(c)(5) Protective materials and hardware

Capable of withstanding environment for maximum time period Moisture or corrosives must not make tag deteriorate Standardized:

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Color Shape Size Print/Format

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1910.147(c)(5) Protective materials and hardware

Lockout devices:
Substantial enough to prevent removal without excessive force or unusual techniques such as bolt cutters

Tagout devices:
Substantial enough to prevent inadvertent or accidental removal Non-reusable attachment means Attachable by hand, self-lockable At least equivalent to nylon cable tie
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1910.147(c)(5) Protective materials and hardware

Lockout and tagout devices indicate identity of employee applying devices

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1910.147(c)(6) Periodic Inspection

Energy control procedure inspected at least annually:
By authorized employee not using the procedure being inspected Correct any deviations Review employee responsibilities with:
each authorized employee lockout each affected or authorized employee tagout
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1910.147 (c)(7) Training and communication

Ensure employees understand purpose and function of energy control program Ensure employees acquire skills required for safe application, usage, removal of energy controls

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Employee Training Requirements

Authorized employee:
Recognition of hazardous energy sources Type and amount of energy in workplace Methods and means for energy isolation

Affected employee:
Purpose and use of procedure

Other employees in area:

Procedure and prohibition on restarting
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Employee Training Requirements for Tagout

Train on limitations of tags:
Warning devices do not provide physical restraint that a lock would Tag not to be removed without owners authorization, bypassed, ignored, defeated Must be legible / understandable to work Must withstand environmental conditions False sense of security Attach securely: avoid accidental removal
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Employee Retraining
For all authorized or affected employees when:
Job assignment changes Equipment or processes present new hazard Energy control procedure changes Knowledge / use of program is inadequate

Certify employee training up to date

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1910.147(c)(8) Energy Isolation

Only the authorized employees performing the servicing or maintenance may apply lockout/tagout

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1910.147(c)(9) Notification of Employees

Affected employees must be notified
By employer or authorized employee Of application and removal of lockout and tagout devices Before controls are applied After controls are removed

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Application of Control

1910.147(d)

Order of Operation for Application of Control

1. 2. 3. 4. 5. Preparation for shutdown Equipment shutdown orderly Equipment isolation Lockout or tagout device application Stored energy relieved; continue while reaccumulating 6. Verification of isolation

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Test and return to off position

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Release from Lockout/Tagout

1910.147(e)

1910.147(e) Release from Lockout

Before lockout or tagout devices removed and energy restored, ensure: Machine or equipment:
Inspect area; remove nonessential items Ensure equipment components intact

Employees:
Ensure all employees safe or removed Before restart, notify affected employees of removal
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1910.147(e) Release from Lockout

Each lockout/tagout device removed by employee who applied the device
If not available, removed under employer direction Specific procedures and training from energy control program must be in use!
Verify that applying employee is not at facility Make all reasonable efforts to contact/notify Ensure authorized employee knows of removal before resuming work at facility
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Additional Requirements

1910.147(f)

1910.147(f)(1) Testing or Positioning

Temporary removal of lockout/tagout devices for testing/positioning:
Clear tools and materials Remove employees from equipment area Remove lockout/tagout devices (as in (e)) Energize and test or position Deenergize systems and reapply energy control measures to continue servicing
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1910.147(f)(2) Outside Personnel

Contractors and other outside personnel:
On-site employer and outside employer inform each other of lockout/tagout procedures On-site employer complies with outside employers energy control program

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1910.147(f)(3) Group Lockout or Tagout

Procedure must provide protection equivalent to personal lockout/tagout 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 (such as an operations lock);
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1910.147(f)(3) Group Lockout or Tagout

When more than one crew, craft, department, etc. is involved:
Designated authorized employee takes lockout/tagout control responsibility Coordinates affected work forces Ensures continuity of protection

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1910.147(f)(3) Group Lockout or Tagout

Each authorized employee affixes personal lockout/tagout device to group lockout device when beginning work Each removes personal device when stopping work on this equipment

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1910.147(f)(4) Shift or Personnel Changes

Specific procedures in energy control plan Ensure continuity of lockout/tagout protection Orderly transfer of lockout/tagout device protection between shifts Minimize exposure to hazards from unexpected energization or release
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