Lockout-Tagout - Study Guide

Control of Hazardous Energy
(Lockout-Tagout)

Study Guide

(In Compliance with OSHA 29 CFR 1910.147(c) (7)

Version 3.0

2013 Americana Safety. All rights reserved.
Control of Hazardous Energy (Lockout-Tagout) Study Guide

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Table of Contents

Section Description Page

1. Scope and Purpose 3
2. Definitions 4
3. Training Objectives 6
4. Energy Control Techniques 9
5. Protective Materials & Hardware 14
6 Application of Control Procedures 16
7. Lockout / Tagout Steps 21

Appendix: Program Document

SF-105, Employee Safety Training Record 24


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Section 1

Scope and Purpose

For purposes of this training guide the following definitions shall apply:

Scope
This safety training guide specifically outlines the purpose, authorization, rules, and
techniques to be utilized by employees on a daily basis to guard against the
unexpected energizing, start-up, or release of stored energy which could cause
injury. It shall be the duty of each employee to become familiar with the contents of
this guide. It shall also be the duty of each employee to become familiar and ensure
compliance with the companys written Control of Hazardous Energy (Lockout-
Tagout) Program. A record of your training in this subject matter will be generated
and maintained by your employer.

Purpose
The purpose of this training is to establish procedures for affixing appropriate lockout
or tagout devices to energy-isolating devices, and to otherwise disable machines or
equipment to prevent unexpected energization, start-up or release of stored energy
in order to prevent injury to employees.

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Section 2

Definitions

For purposes of this training guide the following definitions shall apply:
1. Affected employee. An employee whose job requires him/her to operate or use
a machine or equipment on which servicing or maintenance is being performed
under lockout or tagout, or whose job requires him/her to work in an area in
which such servicing or maintenance is being performed.
2. Authorized employee. A person who locks or implements a tagout system
procedure on machines or equipment to perform the servicing or maintenance on
that machine or equipment. An authorized employee and an affected employee
may be the same person when the affected employee's duties also include
performing maintenance or service on a machine or piece of equipment which
must be locked, or a tagout system implemented. Energy Source: Any source of
electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy.
3. Capable of being locked out. An energy-isolating device is capable of being
locked out if it has a hasp or other means of attachment to which, or through
which, a lock can be affixed, or it has a locking mechanism built into it. Other
energy isolating devices are capable of being locked out, if lockout can be
achieved without the need to dismantle, rebuild, or replace the energy-isolating
device or permanently alter its energy control capability.
4. Energized. Connected to an energy source or containing residual or stored
energy.
5. Energy isolating device. A mechanical device that physically prevents the
transmission or release of energy, including but not limited to the following: A
guidely operated electrical circuit breaker; a disconnect switch; a guidely
operated switch by which the conductors of a circuit can be disconnected from all
ungrounded supply conductors, and, in addition, no pole can be operated
independently; a line valve; a block; and any similar device used to block or
isolate energy. Push buttons, selector switches and other control circuit type
devices are not energy isolating devices.

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6. Energy source. Any source of electrical, mechanical, hydraulic, pneumatic,
chemical, thermal, or other energy.
7. Hot tap. A procedure used in the repair, maintenance and services activities
which involves welding on a piece of equipment (pipelines, vessels or tanks)
under pressure, in order to install connections or appurtenances. it is commonly
used to replace or add sections of pipeline without the interruption of service for
air, gas, water, steam, and petrochemical distribution systems.
8. Lockout. The placement of a lockout device on an energy-isolating device, in
accordance with an established procedure, ensuring that the energy- isolating
device and the equipment being controlled cannot be operated until the lockout
device is removed.
9. Lockout device. A device that utilizes 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.
10. Normal production operations. The utilization of a machine or equipment to
perform its intended production function.
11. Primary Authorized Employee. The authorized employee who has been vested
with responsibility for a set number or group of employees performing service or
maintenance on machines or equipment subject to lockout or tagout procedures.
12. Servicing and/or maintenance. Workplace activities such as constructing,
installing, setting up, adjusting, inspecting, modifying, and maintaining and/or
servicing machines or equipment. These activities include lubrication, cleaning or
unjamming of machines, equipment and making adjustments, or tool changes,
where the employee may be exposed to the unexpected energization or startup
of the equipment or release of hazardous energy.
13. Setting up. Any work performed to prepare a machine or equipment to perform
its normal production operation.
14. Tagout. The placement of a tagout device on 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 operated until the tagout
device is removed.

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15. Tagout device. 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 operated until the tagout
device is removed.

Section 3

Training Objectives

The heads of affected departments or their designated representatives are required
to provide training to ensure that the purpose and function of the energy control
program are understood by employees. Through training, employees will be required
to possess the knowledge and skills required for safe application, usage, and removal
of energy controls. Employees who require training under OSHA's Lockout/Tagout
standard include:
1. Authorized employees Each authorized employee shall receive training in the
recognition of applicable hazardous energy sources, the type and magnitude of
the energy available in the workplace, and the methods and means necessary for
energy isolation and control.
2. Affected employees Each affected employee shall be instructed in the
purpose and use of the energy control procedure.
3. Other employees All other employees are those whose work operations are or
may be in an area where energy control procedures may be utilized, shall be
instructed about the procedure, and about the prohibition relating to attempts to
restart or re-energize machines or equipment which are locked-out or tagged-
out.

This program is designed to satisfy, in whole or in part, the training requirements of
29 CFR 1910.147(c)(7).


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Upon successful completion of this training, you should demonstrate an
understanding of:
The purpose of the OSHA standard and the hazards controlled
Circumstances under which the OSHA standard applies
The equipment used for lockout/tagout
The procedures for:
o Shutdown, isolation, and blocking
o Notification of affected employees
o Release of stored energy
o Testing to verify effectiveness and energy control
o Release from lockout/tagout
o Release if employee who applied device is no longer at facility
Special procedures for:
o Use of tags
o Shift and personnel changes
o Group lockout/tagout
o Turnarounds
o Inspection program
o Communication and reporting of problems

Affected employees should demonstrate an understanding of:
Knowledge and skills required for safe application, use, and removal of energy
controls
The purpose and function of the energy control program

When tagout systems are used, employees shall also be trained in the following
limitations of tags:
1. Tags are essentially warning devices affixed to energy-isolating devices, and do
not provide the physical restraint on those devices that is provided by lockout.
2. When a tag is attached to an energy-isolating means, it is not to be removed
without authorization of the authorized person responsible for it, and it is never
to be bypassed, ignored or otherwise defeated.
3. Tags must be legible and understandable by all authorized employees, affected
employees, and all other employees whose work operations are or may be in the
area, in order to be effective.

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4. Tags and their means of attachment must be made of materials which will
withstand the environmental conditions encountered in the workplace.
5. Tags may evoke a false sense of security, and their meaning needs to be
understood as part of the overall energy control program.
6. Tags must be securely attached to energy- isolating devices so that they cannot
be inadvertently or accidentally detached during use.

Employee retraining
1. Retraining shall be provided for all authorized and affected employees whenever
there is a change in their job assignments, a change in machines, equipment or
processes that present a new hazard, or when there is a change in the energy
control procedures.
2. Additional retraining shall also be conducted whenever a periodic inspection
under Section F, paragraph 1 A reveals, or whenever the employer has reason to
believe that there are deviations from or inadequacies in the employee's
knowledge or use of the energy control procedures.
3. The retraining shall reestablish employee proficiency and introduce new or
revised control methods and procedures, as necessary.

The company shall certify that employee training has been accomplished and is being
kept up to date. The certification shall contain each employee's name and dates of
training. Employee Safety Training Record. (See Appendix).


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Section 4

Energy Control Techniques

Implementation of the lockout or tagout system shall be performed only by
authorized employees.

Affected employees shall be notified by heads of departments, or their designated
representatives, of the application and removal of lockout or tagout devices.
Notification shall be given before the controls are applied, and after they are
removed from the machine or equipment.

The established procedure for the application of energy control shall cover the
following elements and actions and shall be done in the following sequence:

1. Preparation for shutdown: Before an authorized or affected employee turns off
a machine or piece of equipment, they 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.

2. Machine or equipment shutdown: An orderly shutdown must be utilized to
avoid any additional or increased hazard(s) to employees as a result of
equipment deenergization.

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).


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4. Lockout or tagout device application: Lockout or tagout devices shall be
affixed to each energy-isolating device by authorized employees. Lockout
devices, where used, shall be affixed in a manner that will hold the energy in a
"safe" or "off" position. 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.
Where tagout devices are used with energy- isolating devices designed with the
capability of being locked, the tag shall be fastened at the same point at which
the lock would have been attached.

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.

5. Stored Energy: Following the application of lockout or tagout devices to energy-
isolating devices, all potentially hazardous stored energy shall be rendered safe.
If there is a possibility of re-accumulation 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.

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 deenergization of the machine or equipment has been
accomplished.

7. Release from Lockout or Tagout: Before lockout or tagout devices are
removed and energy is restored to the machine or equipment, procedures shall
be followed and actions taken by the authorized employee(s) to ensure the
following:
The Machine or Equipment: The work area shall be inspected to ensure
that nonessential items have been removed and that machine or equipment
components are operationally intact.
Employees: The work area shall be checked to ensure that all employees
have been safely positioned or removed. Before lockout or tagout devices are

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removed and before machines or equipment are energized, affected
employees shall be notified.

8. Lockout or Tagout Device Removal: Each lockout or tagout device shall be
removed from each energy-isolating device by the employee who applied the
device.
Exception: When the authorized employee who applied the lockout or tagout
device (installer) is not available to remove it, that device may be removed
under the direction of the installer's immediate supervisor. Specific training
and procedures for such removal shall be provided by each department
involved in lockout or tagout operations. The procedures and training shall be
documented.
The documentation shall demonstrate that safety equivalent to the original
process of having only the installer remove the device is maintained. The
specific procedure shall include at least the following elements:
Verification by the immediate supervisor that the employee who applied
the device is not at the facility,
Making all reasonable efforts to contact the authorized employee to inform
them that his/her lockout or tagout device has been removed, and
Ensuring that the authorized employee has this knowledge before they
resume work at the facility.

9. Testing or Positioning of machines, equipment, or components thereof:
In situations where lockout or tagout devices must be temporarily removed from
the energy- isolating device and the machine or equipment energized to test or
position the equipment or component thereof, the following sequence of actions
shall be followed:
Clear the machine or equipment of tools and materials.
Remove employees from the machine or equipment area.
Remove the lockout or tagout devices.
Energize and proceed with testing or positioning.
De-energize all systems and reapply energy control measures to continue the
servicing and/or maintenance.


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10. Outside Personnel (contractors, etc.): Whenever outside servicing
personnel are to be engaged in activities covered by the scope and application
of companys lockout-tagout program, a designated company representative
and the outside employer shall inform each other of their respective lockout or
tagout procedures.

The designated representative shall ensure that his/her personnel understand
and comply with restrictions and prohibitions of the outside employer's energy
control procedures.

If the outside employer has no documented lockout or tagout procedures, they
shall ensure that their personnel understand and comply with the procedures
established in the companys lockout-tagout program.
11. Group Lockout or Tagout: When servicing and/or maintenance is performed
by a crew or department, they shall utilize a procedure which affords the
employees a level of protection equivalent to that provided by the
implementation of a personal lockout or tagout device. This shall be
accomplished by:
The application of a multi-lock accepting device by the primary authorized
employee to the energy- isolating device.
The primary authorized employee attaching his/her lock to the multi-
accepting device.
Each authorized employee shall affix a personal lockout or tagout device
to the multi-lock accepting device when they begin work, and shall
remove those devices when they stop working on the machine or
equipment being serviced or maintained.
The primary authorized employee removing his/her lock and the multi-
lock accepting device when all service or maintenance has been
completed.


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12. Shift or Personnel Changes: To insure the orderly transfer of lockout or
tagout devices between off-going and on-coming employees and minimize
exposure to hazards from unexpected energization, start-up of the machine or
equipment, or release of stored energy, these procedures shall be followed:
The on-coming personnel shall notify the off-going personnel that they are
ready to begin work on the machine or equipment.
All lockout and/or tagout devices attached to the machine or equipment
by the off-going personnel shall be removed and immediately replaced
with like devices by the on-coming authorized personnel.
The primary authorized employee shall insure that all pertinent co-
ordination between off-going and on-coming personnel has been
completed before the on-coming authorized personnel begin work on the
machine or equipment and that all necessary energy has been rendered
safe.

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Section 5

Protective Materials & Hardware

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

2. Lockout devices and tagout devices shall be singularly identified; shall be the only
devices(s) used for controlling energy; shall not be used for other purposes; and
shall meet the following requirements:

A. Durable.
1) Lockout and tagout devices shall be capable of withstanding the
environment to which they are exposed for the maximum period of
time that exposure is expected.
2) Tagout devices shall be constructed and printed so that exposure to
weather conditions or wet and damp locations will not cause the tag to
deteriorate or the message on the tag to become illegible.
3) Tags shall not deteriorate when used in corrosive environments such
as areas where acid and alkali chemicals are handled and stored.

B. Standardized. Lockout and tagout devices shall be standardized within the
facility in at least one of the following criteria:
1) Color; shape; or size; and
2) In the case of tagout devices, print and format shall be standardized.

C. Substantial.
1) Lockout devices. Lockout devices shall be substantial enough to prevent
removal without the use of excessive force or unusual techniques, such as
with the use of bolt cutters or other metal cutting tools.

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2) Tagout devices. Tagout devices, including their means of attachment,
shall be substantial enough to prevent inadvertent or accidental removal.
Tagout device attachment means shall be of a non-reusable type,
attachable by hand, self-locking, and non-releasable with a minimum
unlocking strength of no less than 50 pounds and having the general
design and basic characteristics of being at least equivalent to a one-
piece, all environment-tolerant nylon cable tie.

D. Identifiable.
1) Lockout devices and tagout devices shall indicate the identity of the
employee applying the device(s).
2) Tagout devices shall warn against hazardous conditions if the machine or
equipment is energized and shall include a legend such as the following:
Do Not Start
Do Not Open
Do Not Close
Do Not Energize
Do Not Operate

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Section 6

Application of Energy Control Procedures

1. Application of control.
The established procedures for the application of energy control (the lockout or
tagout) procedures for the company cover the following elements and actions and
shall be done in the following sequence:

A. 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.

B. 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.

C. 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).

D. Lockout or tagout device application.
1) Lockout or tagout devices shall be affixed to each energy-isolating device
by authorized employees.
2) Lockout devices, where used, shall be affixed in a manner to that will hold
the energy isolating devices in a "safe" or "off" position.

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3) 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.
4) 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.
5) 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.

E. Stored energy.
1) 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.
2) 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.

F. 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
deenergization of the machine or equipment have been accomplished.

2. Release from lockout or tagout.
Before lockout or tagout devices are removed and energy is restored to the
machine or equipment, procedures shall be followed and actions taken by the
authorized employee(s) to ensure the following:

A. 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.


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B. Employees.
1) The work area shall be checked to ensure that all employees have been
safely positioned or removed.
2) 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.

C. 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 C:
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
that persons supervisor, provided that specific procedures and training for
such removal are fully understood.

The supervisor shall demonstrate that the specific procedure provides
equivalent safety to the removal of the device by the authorized employee
who applied it.

The specific procedure shall include at least the following elements:
1) Verification by the company that the authorized employee who applied the
device is not at the facility:
2) Making all reasonable efforts to contact the authorized employee to inform
him/her that his/her lockout or tagout device has been removed; and
3) Ensuring that the authorized employee has this knowledge before he/she
resumes work at that facility.


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3. Additional requirements.

A. Testing or positioning of machines, equipment or components
thereof.

In situations in which lockout or tagout devices must be temporarily removed
from the energy isolating device and the machine or equipment energized to
test or position the machine, equipment or component thereof, the following
sequence of actions shall be followed:

1) Clear the machine or equipment of tools and materials in accordance with
paragraph 2 A of this section;
2) Remove employees from the machine or equipment area in accordance
with paragraph 2 B of this section;
3) Remove the lockout or tagout devices as specified in paragraph 2 C of this
section;
4) Energize and proceed with testing or positioning;
5) Deenergize all systems and reapply energy control measures in
accordance with paragraph 1 of this section to continue the servicing
and/or maintenance.

B. Shift or personnel changes.
Specific procedures shall be utilized during shift or personnel changes to
ensure the continuity of lockout or tagout protection, including provision for
the orderly transfer of lockout or tagout device protection between off-going
and oncoming employees, to minimize exposure to hazards from the
unexpected energization or start-up of the machine or equipment, or the
release of stored energy.

4. General Rules

A. Each workplace, project and/or facility must have at least one authorized
person with the responsibility to administer the Lockout/Tagout program.
B. All affected employees must be familiar with and adhere to the terms of this
procedure. Failure to do so shall result in disciplinary action.

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C. The owner's representative must be contacted prior to locking out any portion
of an active or existing facility. When approval is required, it should be in
writing.
D. Locks must be purchased specifically for the Lockout/Tagout program and
must be individually keyed. Locks and keys must be controlled and
maintained by the Director of Facilities, electrical superintendent or his
appointed designee.
E. When one or more authorized person must lock out the same
equipment/process, separate locks and/or tags shall be applied by the use of
a multi-lockable hasp or similar device.

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Section 7

Lockout / Tagout Steps

Preparing for Shutdown

1. Step One Preparation.

A. Prior to beginning any work a survey must be performed by a person
authorized to identify any/all energy sources to determine if the need for
Lockout/Tagout exists.

B. The Director of Facilities, electrical superintendent, or his appointed
designee shall ensure that shut down does not affect existing operations.
Coordination with existing facility representatives and affected
subcontractors shall be accomplished.

C. All employees working on or around the locked out energy source must
receive specific instructions regarding their work under these conditions.

2. Step Two Shutdown, Lockout / Tagout.

A. Turn off all energy to isolate the machine/equipment in an orderly manner
to avoid any additional or increased hazard.

B. The "Danger - Do Not Operate" tag shall be fastened to the same point
where the lock is attached. The information on the tag must include:
Name of the installer,
Date installed, and
Expected completion date.


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3. Step Three Removing Stored Energy.

Following the application of a lock and tag, all potential hazardous stored or
residual energy shall be relieved, disconnected, restrained, and otherwise
rendered safe.

4. Step Four Assuring Equipment is De-energized.

Prior to starting work on any machine or equipment that has been locked and
tagged out, verify by a functional and/or technical test that isolation and/or
de-energization has been accomplished.

Release From Lockout/Tagout.

1. Step One Before the Lockout / Tagout Devices are Removed.

A. A qualified person to ensure that the equipment is free of obstructing
materials (tools, dropped parts, etc) shall inspect the machine or
equipment.

B. Affected employees shall be notified that the Lockout/Tagout devices are
to be removed.

C. Ensure all necessary adjustments, settings, and other conditions are in
proper order for the unit's start-up.

2. Step Two Lockout / Tagout Device Removal

A. Each Lockout/Tagout device shall be removed from each energy-isolating
device by the authorized person who installed the device.

B. When the person who applied the lock or tag is unavailable, another
employee designated by the Director of Facilities, electrical

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superintendent, or his appointed designee if the following conditions are
met may remove it:
1) A reasonable attempt has been made to contact the person who
applied the devices.
2) A thorough inspection of the process has taken place.
3) The person who applied the devices is notified of the Lockout/Tagout
release before he/she resumes work.

Note: When more than one crew, shift, craft, department, or personnel is involved,
the Director of Facilities or similar company official, electrical superintendent, or his
appointed designee will assure that all affected persons are properly notified.

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Appendix

Training Record

26

Reserved for SF-105,
Employee Safety Training Record

27
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Given the changing nature of laws, rules and regulations, there may be omissions or inaccuracies
in information contained in this document. Accordingly, the information in this document is
provided with the understanding that the authors and publishers are proving guidance with
respect to the information contained herein and that the performance or non-performance of
this guidance shall be the responsibility of the user of this information.

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Control of Hazardous Energy

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