1. Control of Hazardous Energy – Lockout/Tagout 29 CFR 1910.147
National Precast Concrete Association
Safety Program of the Quarter - Spring 2008
Control of Hazardous Energy – Lockout/Tagout 29 CFR
Compliance Training Presentation
NPCA Safety, Health and Environmental Committee
Lockout/Tagout

2. Disclaimer
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 requirements.

3. Purpose
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, etc.
When present this energy could cause a circuit to energize, or a machine / machine part to move or fall, causing injury to an employee.

4. Definitions
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 energy.

5. 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.

6. Definitions
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 device.
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 removed.

7. Exemptions 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.

8. 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.

9. 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.

10. 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

11. 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

12. 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

13. Generic Procedure for LOTO
Place lockout and tagout devices on the power source
Test the equipment for potential energy
Return all controls to the neutral of off position
Maintenance or servicing can now be performed

14. 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

15. Removal of LOTO Personnel must be clear of the equipment
Each authorized person shall remove only his or her own lockout and/or tagout device
Return to energy isolating device to its on position

16. Additional Instructions
When the authorized employee is not available, the following actions may be taken:
Make a reasonable attempt to contact the authorized employee.
Remove all tools and material from the equipment area.
Make sure all affected employees are clear of the area.

17. 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 device.

18. Training Authorized Employees:
Instructed in the recognition of applicable hazardous energy sources.
Instructed in the procedures for lockout / tagout
Instructed in the proper procedures for de-energizing an energy control device.
Instructed in the use of the locks and tags.
Instructed in the procedures for restoring energy.

19. National Precast Concrete Association
Safety Program of the Quarter - Spring 2008
Training
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
Lockout/Tagout

20. Training 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

21. Training 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

22. 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.

23. Failing to enforce
these procedures
could lead to disaster!

24. 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 performed.
A lockout / tagout inspection checklist will be used to document this inspection
Procedures will be updated as necessary
Employees re-trained as necessary

25. 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.

26. Additional Resources
29 CFR Control of Hazardous Energy (Lockout/Tagout)
29 CFR Selection and Use of Electrical Work Practices
The NPCA Safety Manual

27. National Precast Concrete Association
Safety Program of the Quarter - Spring 2008
Disclaimer
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.
Lockout/Tagout