Guide to Lockout / Tagout
Energy isolation devices are responsible for many work related injuries and deaths each year. It is important to keep employees aware and educated on how to avoid such accidents. Lockout/Tagout procedures can help employees stay safe. Check out PE Facts to learn more about lockout/tagout procedure standards!
The Lockout/Tagout Standard, 29 CFR 1910.147 was established on October 30, 1989. Its purpose is to reduce the rate of death and injury due to the unexpected release of stored energy, energization or start-up of machines. Each year, 122 deaths and 28,400 lost workdays are due to this problem. Lockout/Tagout was the eighth most cited OSHA standard in 1993.
This standard addresses the maintenance and servicing of equipment and machines in which there is a risk of injury due to the unexpected energization, release of stored energy or start-up[29 CFR 1910.147 (a)(l)(i), 1910.147 (a)(2)(i)]. Normal production operations, hot tap operations, and cords and plugs under exclusive control are not dealt with [29 CFR 1910.147 (a)(2)(ii)]. This is intended to pertain to energy sources such as electrical, hydraulic, mechanical, nuclear, chemical, and thermal.
Lockout refers to placing a lockout device on an energy isolation device (circuit breaker, slide gate, line valve, disconnect switch, etc.) to make sure that the energy isolating device and equipment being controlled cannot operate until the lockout device is removed. A lockout device uses a positive means, such as a lock (key or combination type), to hold an energy isolation apparatus in a safe position in order to prevent the unexpected energization of a machine or equipment. The lockout device must be durable enough to stay in place unless extreme force or an unusual technique is used to release it.
Tagout refers to placing a tag or other significant warning device and a strong means of attachment on an energy isolation device to signify that the energy isolating apparatus and equipment that is being controlled may not be activated until the tagout device has been removed.
It is necessary to use a lockout system unless the employer can prove that a tagout system can provide equivalent protection to employees. The tagout device is attached by hand, self-locking, non-reusable, and non-releasing. It must have a minimum unlocking strength of at least 50 pounds, and must be as strong as, or stronger than an all-environment tolerant nylon cable tie.
Written Program
OSHA 29 CFR 1910.147 (c)(4) identifies the minimal acceptable written program procedures. It must include:
- A detailed written statement of the intended use of the procedure.
- recise procedural steps are taken to isolate, shut down, block and secure machines or equipment to control dangerous energy. This must be done for every piece of equipment, unless it is a duplicate.
- Specific procedural steps for the attachment, removal and transfer of lockout devices and the responsibility for them.
- Exact requirements for testing the effectiveness of the lockout devices, tagout devices and other energy control measures.
Training
Employees must be trained by an authorized employee [29 CFR 1910.147 (c)(7)(I)]. All affected employees must be educated in the purpose and use of the energy control procedures, as well as any other employee who works in or near an area where energy control procedures my be used. If tagouts are used, employees must also be taught the limitations of these devices.
Whenever there is a change in machines, equipment or processes that present a new hazard, a change in an employee's job assignment, or when there is a change in the energy control procedures, all authorized and affected employees must be retrained. As of January 2, 1990, whenever replacement or major alteration of a machine or equipment is made, and whenever new machines or equipment are installed, energy isolating devices for such machines or equipment must be made to fit a lockout device. [29 CFR 1910.147 (c)(2)(iii)]
Removal of Lockout/Tagout Devices
Before lockout or tagout devices are removed, an authorized employee must guarantee that non-essential items are removed and machine components are operationally intact. The surrounding area should be checked to make sure that all employees are in a safe place and that all affected employees are notified and aware that the lockout/tagout devices have been removed. The lockout/tagout device has to be removed by the same person who attached it. If the person who originally applied the device is not available, another employee may remove the device if the employer has established a specific procedure and training for this. When group lockout/tagout devices are used, a procedure similar to the personal lockout/tagout system should be followed. (29 CFR 1910.147 (f)(3)
Commonly Asked Questions
Q. If it is impossible to lockout, can I use a tagout instead?
A. When it is impossible to lockout, or in fields where the use of tags has been long established and widely accepted as prohibiting the use of energy isolating devices, a tagout procedure that has been proven to be equal in protection to a lockout procedure may be used.
Q. Is it necessary to lockout/tagout a machine that only requires the unit to be unplugged?
A. This standard does not apply in situations where work on cord-and-plug-connected electric equipment is under the exclusive control of the employee performing the maintenance or servicing.
Q. Are there any other lockout/tagout standards?
A.Yes. OSHA can use 29 CFR 1910.212, General Requirements for All Machines, and 29 CFR 1910.219, Mechanical Power Transmission Apparatus, to cite business for lack of compliance. These two other areas allow OSHA to issue a double citation for non-compliance.
Sources for More Information
29 CFR 1910.147, 1910.212 and 1910.219.Please Note: The information contained in this publication is intended for general information purposes only. This publication is not a substitute for review of the applicable government regulations and standards, and should not be construed as legal advice or opinion. Readers with specific questions should refer to the cited regulation or consult with an attorney.
