Hazardous Energy Control Lock Out Tag Out

Lock Out Tag Out
Hazardous Energy Control

Sponsorship - Disclaimer
Department of Labor
Occupational Health and Safety Administration (OSHA)
Susan Harwood Training Grant
This material was produced by the SPI-OSHA Alliance, and distributed by the
Occupational Safety and Health Administration, U.S. Department of Labor. The
contents in this presentation do not necessarily reflect the views or policies of the
U.S. Department of Labor, nor does the mention of trade names, commercial
products, or organizations imply endorsement by the U.S. Government.
Revisions were made to this material under grant number SH-05059-SH8 from the
Occupational Safety and Health Administration, U.S. Department of Labor.
Learning Objectives
• Understand the purpose of the energy control

program
• Recognition of hazardous energy sources, and the
methods necessary for energy control
• Discuss the primary causes of injury from hazardous
energy
• Understand the steps necessary to properly control
hazardous energy when servicing equipment
• Know the responsibilities of Authorized and Affected
employee in terms of logout / tagout
Preventing Unexpected Startup or Release of Energy
Energy isolation:
• Minimize potential for inadvertent

activation and/or release of stored
energy
• Ensure power to the machine is

isolated and locked at control
points
• Use a method that cannot readily

be removed, bypassed, overridden
or otherwise defeated
Types of Hazardous Energy
Mechanical – the potential energy and kinetic
energy present in the components of a mechanical
system
• Kinetic – energy possessed by virtue of its
motion
• Potential – energy stored by the mechanical
system
Electrical – energy as a result of a generated

electrical power source or a static source
Thermal – energy as a result of mechanical work,

radiation, chemical reaction or electrical resistance
Types of Hazardous Energy, continued
Chemical – energy released as a result of

chemical reactions
Hydraulic – energy released as a result liquids

under pressure
Pneumatic – energy released as a result of

compressed gasses under pressure
Definitions
Servicing and/or maintenance where employees may be

exposed to unexpected start-up or release of hazardous
energy
• Construction
• Installing and setting up
• Adjusting, inspecting, modifying
• Lubricating, cleaning or unjamming
• Tool changes
Definitions (continued)
• Set-up - Work to prepare a machine to

perform its normal production operation
• Lockout – Placement of lockout device

on an energy isolating device
• Lockout device – Device that uses a

physical means to prevent operation of
a machine or equipment
Definitions (cont’d)
• Energized - Connected to an energy source, or containing

residual or stored energy
• Energy isolating device - A mechanical device that

physically prevents the transmission or release of energy
• Energy source - Any source of electrical, mechanical,

hydraulic, pneumatic, chemical, thermal, or other energy
LOTO applies when:
Employees are performing servicing or maintenance and

there is a potential for injury from unexpected start-up or
release of stored energy
Service and maintenance that takes place during normal

production if the employee:
• Must remove or bypass a guard or safety device
• Must place any part of their body into the danger
zone
Exception to LOTO
Minor servicing activities that takes place

during normal production when alternative
effective protection is used
Minor Servicing during Normal Production Operations
• Routine
• Repetitive
• Integral to the use of the
equipment for production
Alternative effective protection such as:
• Remote lubricators or other remote devices
• Interlocked gates and barriers
• Other effective guarding devices as described in OSHA’s

Subpart O and the most current ANSI B 151.1 standard
Core Components of an Energy Control Program
• Energy control procedures for each

type of machine
• Training and retraining to ensure

employees understand the program
• Periodic inspection to ensure

procedures are being followed
Energy Control Procedures
Must be specific to each type of machine and equipment

you are working on
Must include
• Statement of intended use of the procedure
• Steps for shutting down and securing machines
and equipment
• Steps for placing, removing, and transferring of
lockout devices
• Requirements for testing and verifying
effectiveness of lockout devices
Required Training
Authorized employees
• Recognition of hazardous energy
sources
• Type and magnitude of energy in the
workplace
• Methods for energy isolation / control
Affected employees
• Purpose and use of energy control
procedures
Other employees in work area
• Procedures related to restarting
machines
Retraining Requirements
Retraining is required if:
• Change in job assignments
• Change in machines
• Change in energy control procedures
• Equipment or processes present new hazards
• Inspections reveal deficiencies in employee's
knowledge of energy control procedures
• Retraining must reestablish employee proficiency
Periodic Inspections
• Performed at least annually
• Conducted by authorized
employees
• Intended to correct
inadequacies identified in the
program
• Certified
Certification Requirements
• Identification of equipment or machinery
• Date of inspection
• Names of employees involved in the inspection
• Name of person(s) performing inspection

Steps of Lockout Procedure
1. Prepare for shutdown

2. Shut down equipment
3. Isolate all energy sources
4. Apply locks & tags
5. Release stored energy
6. Verify equipment isolation
7. Perform the task
8. Release from Lockout
Step 1: Prepare for Shutdown
• Understand equipment hazards
• Notify other workers of shutdown

Step 2: Shut down equipment
• Use the normal shutdown procedures
• Turn all switches to Off or Neutral

Step 3: Isolate all Energy Sources
Use energy isolation devices

in accordance with established
procedures to prevent
transmission or release of
energy
Valve lockout device

Step 4: Apply Locks & Tags
Apply locks and tags to:
• Valves
• Breakers/electrical
disconnects
• Mechanical blocks
Step 5: Release or Block all Stored Energy
• Discharge capacitors
• Block/disconnect lines
• Block or release springs
• Block elevated parts
• Relieve system pressure
• Drain fluids
• Vent gases
• Allow system to cool (or use PPE)
• Apply any additional locks and tags needed
Step 6: Verify Equipment Isolation
• Check that other workers are

clear of potential hazards
• Check that locking devices are
secure
• Attempt normal startup
• Return control to Off or Neutral
Step 7: Perform the Task
Perform maintenance or service

Step 8: Release from Lockout
• Ensure machinery is properly assembled and all

tools removed
• Ensure that employees are outside of danger

zones and are notified that devices are being
removed
• Remove LOTO devices

• Must be removed by authorized employee who
applied it
Summary
• Lockout-Tagout prevents energy from accidentally being released while a
machine or equipment is being serviced
• There are 6 types of hazardous energy common to most work
environments – Mechanical, Electrical, Thermal, Chemical, Hydraulic and
Pneumatic
• Most injuries and fatalities are a result of improper hazardous energy
control procedures
• If an energy-isolating device is capable of being locked out, a lock out
system MUST be used
• General energy control procedures follow an 8-step process
• Only the authorized employee may attach and remove the logout / tagout
device
• Affected employees or any other employees should NEVER remove or
tamper with a logout / tagout device
Questions?

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Hazardous Energy Control

• Understand the purpose of the energy control

• Minimize potential for inadvertent

• Ensure power to the machine is

• Use a method that cannot readily

Electrical – energy as a result of a generated

Thermal – energy as a result of mechanical work,

Chemical – energy released as a result of

Hydraulic – energy released as a result liquids

Pneumatic – energy released as a result of

Servicing and/or maintenance where employees may be

• Set-up - Work to prepare a machine to

• Lockout – Placement of lockout device

• Lockout device – Device that uses a

• Energized - Connected to an energy source, or containing

• Energy isolating device - A mechanical device that

• Energy source - Any source of electrical, mechanical,

Employees are performing servicing or maintenance and

Service and maintenance that takes place during normal

Minor servicing activities that takes place

• Remote lubricators or other remote devices

• Interlocked gates and barriers

• Other effective guarding devices as described in OSHA’s

• Energy control procedures for each

• Training and retraining to ensure

• Periodic inspection to ensure

Must be specific to each type of machine and equipment

• Performed at least annually

• Identification of equipment or machinery

• Names of employees involved in the inspection

• Name of person(s) performing inspection

1. Prepare for shutdown

• Understand equipment hazards

• Notify other workers of shutdown

• Use the normal shutdown procedures

• Turn all switches to Off or Neutral

Use energy isolation devices

Valve lockout device

Apply locks and tags to:

• Check that other workers are

Perform maintenance or service

• Ensure machinery is properly assembled and all

• Ensure that employees are outside of danger

• Remove LOTO devices

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