BLR’s Safety Training
Presentations
Lockout/Tagout Refresher 29 CFR 1910.147
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Lockout/Tagout Goals
 OSHA violations, written program, and training
 Energy sources and general procedures
 Quiz
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Why Use Lockout?
 Machine guards removed
 Exposed to
machine hazards
 Unexpectedly energizing
 Unexpected start-up
 Release of stored energy
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Frequent OSHA Violations
 Lockout/tagout program
 721 violations with
$993,089 in penalties
 Lockout/tagout
procedures
 672 violations with
$936,606 in penalties
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Lockout/Tagout Program
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Energy control procedures
Employee training
Periodic inspections
Unexpected energizing,
start up, release
of stored energy
 Isolation of energy
sources before servicing
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Specific Lockout/Tagout
Procedures
 Development and use of specific procedures
 General lockout
procedures
 Shutting down
and isolating energy
 Placement and
removal of locks
 Testing machine
and verifying
control of energy
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Exception to Specific Procedures
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No stored energy
Single energy source
Single lockout device needed
No hazards for others
No accidents
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
“Authorized” Employees
 Permitted to implement
lockout/tagout
 Receive specific
training
 Identify hazardous
energy sources
 Trained in
procedures to
control energy
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
“Affected” Employees
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Work near lockout/tagout process
Operate machines that might be locked out
Never conduct lockout/tagout
Never tamper with lockout/tagout device
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Annual Inspections
 Verification of specific written procedures
 Competency of authorized employees
 Observation by
another authorized
employee
 Correction of
the procedure
or employee
 Documentation
of inspection
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Retraining
 Annual retraining
recommended
 Change in job
assignment
 New machines
or processes
 Change in a
specific procedure
 Employee incorrectly
performs lockout
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Lockout/Tagout Goals
 OSHA violations, written program
and training
 Energy sources and general procedures
 Quiz
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Hazardous Energy Sources
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Electricity
Hydraulic systems
Pneumatic pressure
Mechanical energy
Chemical systems
Thermal devices
Steam systems
Gravity
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Controlling Energy Sources
 Move electrical disconnect switch to “off”
 Close valve
 Bleed off
remaining pressure
 Release
mechanical springs
 Block in the
“up” position
 Allow equipment to cool
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
General Lockout Procedures
1. Identify hazards and
get lockout equipment
2. Notify “affected”
employees
3. Shut down machine
4. Turn off all
energy sources
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
General Lockout Procedures (cont.)
5. Apply locks to control energy
6. Test operating controls
7. Perform repair or service
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
General Lockout Procedures (cont.)
8. Remove tools, install guards, notify workers
9. Remove locks and apply energy
10. Start up equipment
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Tagout
 Energy source not
designed for a lock
 Printed “danger”
warning
 Does not prevent
reenergizing
 Does not protect
the worker
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Special Locks
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Standardized
Durable
Strong
Identified
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Group Lockout
 Two people cannot
work under one lock
 Each person must
apply lock
 Groups must use
group lockout device
 One person must be
in charge of lockout
 Review procedures
before starting
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Removing Locks
 “Authorized” person
not available
 Verify person is not
at the facility
 Contact person
for permission
 Remove lock
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Changing Shifts
 Must be coordinated between
persons responsible
 Completed shift removes locks
 Starting shift applies locks
 Verifies equipment is de-energized
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Cord and Plug
 Lockout not required
 Unplugging controls
energy source
 Plug under control
of employee
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Outside Contractors
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Provide copy of company procedures
Review copy of contractor’s procedures
Determine optimum lockout procedure
Train “authorized” workers
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Lockout/Tagout Goals
 OSHA violations, written program,
and training
 Energy sources and general procedures
 Quiz
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Summary
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Know how to recognize energy sources
Learn to control energy sources
Follow specific written procedures
Annual inspections
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Quiz
1. Name the two reasons for frequent
2.
3.
4.
5.
lockout/tagout violations.
What must be done before someone else
can remove your lock?
After applying locks and before entering
the hazard area, what must you do?
Name three sources of energy.
When should you apply lockout/tagout
to a machine?
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Quiz (cont.)
6. Name two reasons for doing lockout/
7.
8.
9.
10.
tagout retraining.
When doing annual inspections, what are
the two things you are inspecting?
For group lockout, only the “responsible”
person applies locks.
True or False
Name three things you need to do before
removing the locks.
What should you do with stored hydraulic
or air pressure?
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Quiz Answers
1. No written program, no specific procedures
2. Verify not at the facility, contact to get
permission
3. Test the machine to verify energy sources
are controlled
4. Electricity, hydraulics, pneumatics,
mechanical, chemical, thermal, gravity
5. Removing machine guards, exposed to
machine hazards
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.
Quiz Answers (cont.)
6. Job change, new machine, procedure
7.
8.
9.
10.
change, lockout performed incorrectly
Inspect procedure and inspect
“authorized” employee
False, every “authorized” person must
apply a lock to each energy source
Remove tools, install guards,
notify nearby workers
Bleed off remaining pressure
11017100/0309 Copyright ©2003 Business and Legal Reports, Inc.