Control of Hazardous Energy - National Precast Concrete Association

Control of Hazardous Energy – Lockout/Tagout
29 CFR 1910.147
Compliance Training Presentation
NPCA Safety, Health and Environmental Committee
• As a committee of a national organization, the
Safety, Health & Environmental Committee of
NPCA must reference federal standards.
However, users of this information are informed
that state and local agencies may have more
stringent standards than those cited here. It is
the users responsibility to ensure that the federal
standards referenced herein are applicable in
their locale. If more stringent standards apply
locally, you must adhere to those local
• The purpose of this standard is to
establish requirements and procedures to
prevent the unintended release of energy.
• This applies to electrical energy, potential
energy, gravity, hydraulics, pneumatics,
• When present this energy could cause a
circuit to energize, or a machine / machine
part to move or fall, causing injury to an
• Affected Employee – an employee whose job requires
him/her to operate equipment or work in an area where
lockout / tagout is performed.
• Authorized Employee – A person who services or
performs maintenance on equipment that requires
lockout / tagout.
• Energy Isolation Device – A mechanical device that
physically prevents the transmission or release of
Definitions (cont)
• Lockout – The placement of a device, such as a keyed
lock, or other energy isolation device to prevent the
operation of the equipment until the device is removed.
• Lockout Device – a device that utilizes a positive
means such as a lock to hold an energy isolating device
in the safe position and prevent the energizing of the
machine or equipment.
• Servicing and/or Maintenance – Workplace activities
where the employee may be exposed to the unexpected
energizing or startup of the equipment or released
hazardous energy.
• Tagout – The placement of a tag, in conjunction with a
lockout device, to indicate the owner of the lockout
• Tagout Device – A prominent warning device, such as a
tag and a means of attachment, which can be securely
fastened to the energy isolating device, to indicate that
the equipment may not be operated until the device is
• Minor tool changes and adjustments, or;
• Servicing or maintenance of equipment
during normal production if:
– The safeguards are effective in
preventing worker exposure to hazards
that could be created.
• Work on cord and plug connected
electrical equipment if the equipment is
unplugged and the authorized employee is
in control of the plug.
General Requirements
Locks and Tags:
• Make locks and tags available to all
authorized employees
• Each authorized employee must use his
or her own lock/tag. They are to keep the
key with them while performing the work
• Each lock must have only one key. Locks
with a master key are not permitted.
• Only the authorized user removes the
lock they installed.
General Requirements
Written Procedures
• The energy control procedures contain
the instructions for the means to control
the hazardous energy.
• Specific steps should be included.
• Pictures of disconnect equipment or shut
off devices are helpful.
• Explain how to test the machine to
determine if the lockout is effective in
controlling the hazard.
General Requirements
• Procedures are not required when all of
the following exist:
– The machine has no stored or residual energy
– The machine has a single energy source
– The lockout of the single source will
completely de-energize the equipment
– The machine is isolated and locked out from
that source during serving or maintenance
General Requirements
• Procedures are not required when all of
the following exist (continued):
– The lock out device is under the exclusive
control of the authorized user
– No other hazards for employees are created
– No accidents involving the release of
hazardous energy have occurred on this
machine or equipment
Generic Procedure for LOTO
• Only authorized employees
perform LOTO
• All affected employees are
notified of LOTO
• Identify the powers source(s)
for the equipment
• Perform normal shutdown on
the equipment
• De-energize the power source
Generic Procedure for LOTO
• Place lockout and tagout
devices on the power source
• Test the equipment for potential
• Return all controls to the neutral
of off position
• Maintenance or servicing can
now be performed
Removal of LOTO
• Make sure all tools are stored
• Verify that the switches are in the neutral
or off position
• All guards must be in place
Removal of LOTO
• Personnel must be clear of the equipment
• Each authorized person shall remove only
his or her own lockout and/or tagout
• Return to energy isolating device to its on
Additional Instructions
• When the authorized employee is not available,
the following actions may be taken:
– Make a reasonable attempt to contact the authorized
– Remove all tools and material from the equipment
– Make sure all affected employees are clear of the
Additional Instructions
• When the authorized employee is not available,
the following actions may be taken: (cont)
– With the approval of the Plant Manager, the lock
and/or tag can be removed.
– Upon the return of the authorized employee,
immediately notify them of the removal of their lockout
• Authorized Employees:
– Instructed in the recognition of applicable
hazardous energy sources.
– Instructed in the procedures for lockout /
– Instructed in the proper procedures for deenergizing an energy control device.
– Instructed in the use of the locks and tags.
– Instructed in the procedures for restoring
• Affected Employees
– Instructed in the purpose of lockout / tagout
– Instructed to refrain from attempting to start or
re-energize any machine or equipment that is
locked out or tagged out
• Other Employees
– All employees will be instructed to stay clear
of equipment or machines that are locked out
or tagged out
• Authorized and Affected Employees need to be
retrained when:
– there is a change in job assignment
– there is a change in machines, equipment, or
processes that present a new hazard
– there is a change in the energy control procedures
– periodic inspections reveal that there are deviations in
the energy control procedures
– the employer believes that there are deviations from,
or inadequacies in, the employee’s knowledge or use
of the energy control procedures
• The objective of retraining is:
– to introduce new or revised control methods
and procedures as necessary, and
– to reestablish employee proficiency
• Initial training and retraining needs to be
certified by the employer
• The certification needs to contain the
instructor, date of training, and content of
the training, as well as the employees name
Monitoring and Enforcement
• The use of the energy control procedures
must be periodically monitored.
• The Plant Manager will be responsible for
the implementation and enforcement of
this policy.
• Failure to follow this energy control policy
will result in disciplinary action.
• Disciplinary action may lead to employee’s
termination of employment.
Failing to enforce
these procedures
could lead to
Annual Review and Inspection
• The hazardous control policy must be reviewed
annually. This review will include:
– an inspection of the written procedures;
– a review that the procedures are being followed.
• The Plant Manager and Safety Department will
ensure that this review and inspection is
• A lockout / tagout inspection checklist will be
used to document this inspection
• Procedures will be updated as necessary
• Employees re-trained as necessary
Annual Review and Inspection
• The annual review and inspection will be
documented. The following shall be recorded:
The date of the review
The procedure(s) or equipment being reviewed
The employees performing the procedure if applicable
The name of the employee performing the inspection
• The annual review and inspection must be
performed by an authorized employee other
than the one being reviewed.
Additional Resources
• 29 CFR 1910.147 Control of Hazardous
Energy (Lockout/Tagout)
• 29 CFR 1910.333 Selection and Use of
Electrical Work Practices
• The NPCA Safety Manual
• This publication is designed to provide accurate and
authoritative information in regard to the subject matter
covered; however, National Precast Concrete Association acts
as mediator without approving, disapproving, or guaranteeing
the validity or accuracy of any data, claim or opinion
appearing herein. Information is provided and disseminated
with the understanding that National Precast Concrete
Association is not engaged in rendering engineering, legal, or
any other professional services. If engineering, legal, or other
professional assistance is required, the services of a competent
professional should be obtained. National Precast Concrete
Association does not assume and hereby disclaims liability to
any person for any loss or damage caused by errors or
omissions in the material contained herein, regardless of
whether such errors result from negligence, accident, or any
other cause whatsoever.
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