lockout tagout refresher training

OSHA Standard29 CFR 1910.147

Lockout/tagout Refresher Training

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Training must :Be provided for all authorized and affected

employees whenever a change in job assignments or a change in machines, equipment or processes present a new hazard, or when there is a change in the energy control procedures;

Be conducted whenever a periodic inspection reveals, or whenever the employer has reason to believe, that there are deviations from or inadequacies in the employees knowledge or use of the energy control procedures; and

Reestablish employee proficiency and introduce new or revised control methods and procedures, as necessary.

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Purpose of Training

This training reviews some of the key elements of lockout/tagout that are necessary for all employees to understand whether the employee is authorized, affected or works in an area where energy control procedures may be utilized.

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Types of EmployeesLockout/tagout involves three types of employees

with different levels of responsibility:Authorized- Employees who lock out or tag out

machines to perform servicing or maintenance on the machines.

Affected- Employees who operate or use the equipment or machines which are locked/tagged out when serviced, maintained, or set-up.

Other- Employees whose work operations are or may be in an area where energy control procedures may be utilized (they are neither affected nor authorized employees).

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Lockout definitionLockout is the process of preventing

the flow of energy from a power source to a piece of equipment.◦Accomplished when an authorized

employee installs a lock, block, or chain on the machine’s disconnect switch or other electrical control switch, valve or lever that will keep it in the off position.

◦Authorized employees are the only employees who can apply/remove lock.

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Tagout definitionTagout is the process of placing a tag on the

power source.◦ Tag acts as a warning not to restore energy-it is

not a physical restraint.◦ Tag must clearly state “Do Not Operate”◦ Tag should only be used when the machine won’t

accept a lock.◦ Tag must be applied/removed by an authorized

employee.

If a tag is used on an energy isolating device that is capable of being locked out, the tag must be attached at the same location that the lock would have been attached.

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Hazardous Energy SourcesElectricalMechanicalPneumatic (involving gases,

especially air)Hydraulic (involving fluids)ChemicalThermalWater under pressure (steam)GravityPotential energy (stored energy)

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Energy Control ProgramIs required by OSHA for

controlling hazardous energy.Energy Control Program consists

of:◦Energy control procedures◦Employee training◦Periodic inspections

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Energy Control ProgramAn energy control procedure includes the

following:◦ Intended use of the procedure;◦ Specific steps for shutting down, isolating, blocking,

and securing machines or equipment to control hazardous energy;

◦ Specific steps for the placement, removal, and transfer of lockout or tagout devices, as well as the responsibility for them;

◦ Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures.

It is important to understand that each type of machine or equipment needs its own lockout/tagout procedure.

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Work activities that would be considered servicing or maintaining equipment:

ConstructingInstallingSetting UpAdjustingInspectingModifyingRepairingCleaning Equipment

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Prepare for Shutdown6 steps to be done in sequence

in preparing for shutdown :1. Prepare for shutdown2. Shutdown3. Isolate equipment from energy

sources4. Apply lockout or tagout device5. Release stored energy, and6. Verify isolation

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Prepare for Shutdown

Step One:The authorized employee must

know:The type and magnitude of its

energyThe hazards of energy that must

be controlledThe methods or means to control

it

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Shutdown

Step Two:Turn off or shut down the

machinery or equipment using the machine’s normal operating controls.

Use orderly shutdown to avoid any additional or increased hazards as a result of equipment stoppage.

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Isolate Equipment

Step Three:Each energy isolating device-

such as a disconnect switch, circuit breaker, valve, etc- must be placed in the “off ” position.

A lock must be secured to each energy isolating device to hold it in the “safe” or “off” position

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Apply devicesStep four:Notify affected employees that the

lockout/tagout procedure is starting.Attach lockout/tagout devices to each

energy isolating device.Only authorized employees can attach

or remove lockout and tagout devices.Devices must be durable.OSHA mandates that lockout and tagout

devices must identify the person who applied them.

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Release Stored Energy

Step five:Relieve all potentially hazardous

stored or residual energy.◦Relieve pressure in compressed air

linesVerify machine isolation from

energy

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Verify Isolation

Step Six:Verify machine is deenergized Verify machine is isolated

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Lockout DevicesEmployer must provide each authorized

employee with his or her own lockout/tagout devices.◦ The use of someone else’s lockout device is

prohibited.Device must be used to control energy only.Devices could be:

◦ Locks◦ Tags◦ Chains◦ Wedges◦ Key blocks◦ Adapter pins◦ Self-locking fasteners

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Lockout DevicesDevices must have the following qualities:Be durable, which means they must be

capable of withstanding weather conditions, corrosive environments, etc. for the maximum period of time that exposure is expected.

Be standardized within the facility in color, shape or size.

Be substantial enough to prevent removal without the use of excessive force or unusual techniques, such as the use of bolt cutters or other metal cutting tools.

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TagsTags must have the following qualities:Be durable in construction and printed so that

exposure to weather conditions or corrosive environments will not cause them to deteriorate.

Be standardized within the facility both in print and format.

Be substantial enough in design and attachment to prevent inadvertent or accidental removal.

Be one-piece, all environment tolerant nylon cable tie.

Include warning statements such as Do Not Start, Do Not Open, Do Not Close, Do Not Energize or Do Not Operate.

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Group LockoutsEach authorized employee must

affix a personal lockout or tagout device when he or she begins work.

Each authorized employee must remove the device when he or she stops work on the machine.

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Shift ChangesLockout/tagout protection must

be continuous.Lockout/tagout protection must

have an orderly transfer between employees.◦This means that the first employee’s

lock remains in place until the next shift’s employee applies his or her lock.

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Device RemovalLockout or tagout device must be

removed by the authorized employee who applied it.

Device may be removed under direction of employer if authorized employee is unavailable.

Steps employers must take before removing a lock or tag:◦Verify the authorized employee who applied

lock is not at the facility.◦Take all reasonable efforts to contact the

authorized employee.

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Restoring EnergyThe work area must be inspected to ensure

that items, such as tools are removed from around the equipment and that all parts of the equipment are replaced including guards and safety devices.

All employees have been removed or safely positioned from the area.

Affected employees are notified that the lockout or tagout devices have been removed.

****Affected employees must not attempt to restart or reenergize machines or equipment that are locked/tagged out.****