LOCKOUT AND TAGOUT. PART 1: INTRODUCTION

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1 LOCKOUT AND TAGOUT PART 1: INTRODUCTION Applicability of This Module Use the following General Applicability Checklist to determine whether a rulebook and its sections apply to your operation If you answer YES to the rulebook question, the rulebook applies to you unless you answer YES for a rulebook exemption Once you determine that the rulebook does apply to your operation, you must answer the section questions If a section question does not exist, then that section applies if the rulebook applies If you answer YES to a section question, that section applies to you unless you answer YES for an exemption from that section If you answer YES to a rulebook or section exemption, then the rulebook or section does not apply GENERAL APPLICABILITY CHECKLIST Rulebook J2: Lockout and Tagout RULEBOOK: Does your facility have any situations where the control of energy (LOTO) is needed during the: servicing and/or maintenance of machines and equipment; normal production operations when an employee is required to move or bypass a guard or other safety device; or normal operations if the employee is required to place any part of the body into an area on a machine or piece of equipment where the work is actually performed on the material being processed (point of operation) or where an associated danger zone exists during a machine operating cycle RULEBOOK Exemption: Do you qualify for any of the following exceptions? Are you in construction, agriculture, and maritime employment? Do you work only in installations under the exclusive control of electric utilities for the purpose of power generation, transmission and distribution (including related equipment for communication or metering)? Is your exposure to electrical hazards from work on, near, or with conductors or equipment in electric utilization installations? Do you conduct only oil and gas well drilling and servicing? Applies Y q N q Exempt Y q N q LT/Part 1-1

2 Lockout and Tagout Introduction Regulatory Summary Regulations in this module require employers to establish a program and utilize procedures for attaching appropriate lockout or tagout devices to energy-isolating devices, and to otherwise disable machines or equipment to prevent unexpected energization, startup, or release of stored energy in order to prevent injury to employees The federal regulations that apply to the control of energy during servicing and/or maintenance of machines and equipment are found in 29 CFR In addition, many state and local governments have requirements for the control of energy during servicing and/or maintenance of machines and equipment The Occupational Safety and Health Administration (OSHA) is authorized to administer and enforce the lockout/tagout regulations Therefore, the regulated community must follow both federal and applicable state law, and any local requirements In 2004, OSHA recognized the national consensus standard ANSI/ASSE Z Control of Hazardous Energy Lockout/Tagout and Alternative Methods The ANSI Z standard offers useful guidance for employers and employees attempting to control hazardous energy However, OSHA has not determined that, in all cases, compliance with specific provisions of the ANSI Z standard and its annexes, would constitute compliance with relevant OSHA requirements Still, this document may be a good resource during an audit OSHA maintains numerous Directives on the topic of Lockout/Tagout (LOTO) All Directives may be viewed on the OSHA website ( wwwoshagov), by clicking on the letter D (for Directives) in the site Index In the Directives page, search for The most relevant and current Directive that may be useful in specific compliance issues is the following: CPL , The Control of Hazardous Energy Enforcement Policy and Inspection Procedures LT/Part 1-2

3 Lockout and Tagout Introduction Key Compliance Definitions The definitions listed below are derived from 29 CFR Affected employee An employee whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed NOTE: OSHA interprets the role of an affected employee becoming an authorized employee when the affected employee s duties are enlarged to include performing servicing or maintenance on a machine or piece of equipment which must be locked or tagged out Before performing service or maintenance, that employee must receive the training detailed in (c)(7)(i)(A) (OSHA Compliance Letter, ) Authorized employee A person who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment An affected employee becomes an authorized employee when that employee s duties include performing servicing or maintenance covered under 29 CFR NOTE: OSHA interprets the definition of an authorized employee if they either: 1) lock out or tag out machinery/equipment in order to perform servicing or maintenance, or 2) implement a lockout and/or tagout system procedural element on machines or equipment (in order to permit servicing or maintenance) Employees implement a lockout/tagout procedural element if they: a) perform energy source isolation; b) implement lockout and/or tagout on machines or equipment; c) dissipate potential (stored) energy; d) verify energy isolation; e) implement actions to release LOTO; or f) test or position machinery or equipment (OSHA Compliance Letter, ) Capable of being locked out An energy-isolating device is capable of being locked out if it has a hasp or other means of attachment to which, or through which, a lock can be attached, or it has a locking mechanism built into it Other energy-isolating devices are capable of being locked out if lockout can be achieved without the need to dismantle, rebuild, or replace the energy-isolating device, or permanently alter its energy control capability 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, including, but not limited to, the following: a manually-operated electrical circuit breaker; a disconnect switch; a manually-operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors and, where no pole can be operated independently; a line valve; a block; and any similar device used to block or isolate energy Push buttons, selector switches, and other control-circuit type devices are not energy-isolating devices Energy source Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy LT/Part 1-3

4 Lockout and Tagout Introduction Hot tap A procedure used in the repair, maintenance, and service activities that involves welding on a piece of equipment (pipelines, vessels, or tanks) under pressure, in order to install connections or appurtenances It is commonly used to replace or add sections of pipeline without the interruption of service for air, gas, water, steam, and petrochemical distribution systems Lockout The placement of a lockout device on an energy-isolating device, in accordance with an established procedure, ensuring that the energy-isolating device and the equipment being controlled cannot be operated until the lockout device is removed Lockout device A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy-isolating device in the safe position and prevent the energizing of a machine or equipment Included are blank flanges and bolted slip blinds Normal production operations The utilization of a machine or equipment to perform its intended production function Servicing and/or maintenance Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment These activities include lubrication, cleaning, or unjamming of machines or equipment, and making adjustments or tool changes, where the employee may be exposed to the unexpected energization or startup of the equipment, or release of hazardous energy Setting up Any work performed to prepare a machine or equipment to perform its normal production operation Tagout The placement of a tagout device on an energy-isolating device, in accordance with an established procedure, to indicate that the energy-isolating device and the equipment being controlled may not be operated until the tagout device is removed Tagout device A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy-isolating device in accordance with an established procedure, to indicate that the energy-isolating device and the equipment being controlled may not be operated until the tagout device is removed LT/Part 1-4

5 LOCKOUT AND TAGOUT PART 2: PRE AUDIT PREPARATION Items to consider getting in advance: Written lockout/tagout program Policies and procedures related to lockout/tagout Equipment and machine energy control procedures Equipment and machine specifications, if available ANSI/ASSE Z Control of Hazardous Energy Lockout/Tagout and Alternative Methods 29 CFR , the Control of Hazardous Energy (Lockout/Tagout) Inspection Procedures and Interpretive Guidance STD [STD 1-73], (1990, September 11) OSHA Letters of Interpretation Items to have facility personnel prepare or gather in advance: Training records and materials related to lockout/tagout Inspection records related to lockout/tagout Injury and accident reports Locks and/or tags used in the lockout/tagout program LT/Part 2-1

6 Lockout and Tagout Pre audit Preparation Acronyms and Abbreviations Used in This Module ANSI ASSE CFR American National Standards Institute American Society of Safety Engineers Code of Federal Regulations OSHA lb LOTO Occupational Safety and Health Administration pound Lockout/Tagout LT/Part 2-2

7 LOCKOUT AND TAGOUT PART 3: RULEBOOK 1 General Requirements The Lockout/Tagout Standard does not apply to the following (29 CFR (a)(2)(iii)(A)): work on cord and plug connected electric equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the energy source with the plug under the exclusive control of the employee performing the servicing or maintenance; hot tap operations involving transmission and distribution systems for substances such as gas, steam, water, or petroleum products when they are performed on pressurized pipelines, provided that the employer demonstrates that continuity of service is essential; shutdown of the system is impractical; documented procedures are followed; and special equipment is used which will provide proven effective protection for employees; or minor tool changes and adjustments and other minor servicing activities which take place during normal production operations if they are routine, repetitive, and integral to the use of the equipment for production, if the work is performed using alternative measures which provide effective protection Minor servicing includes constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment It also includes lubrication, cleaning, or un-jamming of machines or equipment NOTE 1: When taking advantage of the exception for minor tool changes and adjustments, special care must be taken to ensure that the alternative measures that are used instead of lockout/tagout truly provide effective protection It cannot be assumed that a guard that provides adequate protection during normal operation of the equipment can be relied on to provide effective protection during minor servicing OSHA has incorporated ANSI B Machine Tools - Performance Criteria for Safeguarding in CPL as a reference that gives several alternative means of safeguarding the hazardous portions of machines and equipment When such means are properly applied they may be used as alternative measures to lockout/tagout that provide effective protection CPL should be consulted as part of a thorough evaluation of whether employees are adequately protected during minor servicing activities In addition, the manufacturer s manual for many recently manufactured interlocks, e-stops, etc, discuss whether the equipment is designed in accordance with ANSI B and whether it is appropriate for use during minor servicing operations or not NOTE 2: The Electrical Safety Standard requires that conductors and parts of electric equipment that have been deenergized but have not been locked out or tagged must be treated as energized parts, and the requirements that only qualified persons wearing appropriate PPE may work on or near them apply (29 CFR (b)(1)) When taking advantage of the minor servicing exemption, it is important to verify whether electrical conductors and parts are completely deengergized while servicing operations are performed LT/Part 3-1

8 Lockout and Tagout Rulebook 11 A program consisting of energy-control procedures, employee training, and periodic inspections must be established (29 CFR (c)(1) (c)(2)) Determine if the employer has established a program consisting of energy-control procedures, employee training, and periodic inspections The program must set in place requirements to ensure that, before any employee performs any servicing or maintenance on a machine or equipment where unexpected energizing, startup, or release of stored energy could occur and cause injury, the machine or equipment is isolated from the energy source and rendered inoperative (29 CFR (c)(1)) Verify that the following practices are included in the program (29 CFR (c)(2)): If an energy-isolating device is capable of being locked out, the employer s energy control program must utilize lockout, unless the employer can demonstrate that utilization of a tagout system will provide full employee protection If an energy-isolating device is not capable of being locked out, the employer s energy control program must utilize a tagout system Whenever major replacement or major repair, renovation, or modification of a machine or equipment is performed, and whenever new machines or equipment are installed, energy-isolating devices for such machines or equipment must be designed to accept a lockout device NOTE: This requirement only applies to equipment and machines manufactured after January 2, 1990; however, when alterations to older machines are made, they must be designed to accept a lockout device 12 Procedures must be developed, documented, and used to control potentially hazardous energy when employees are engaged in the activities covered by the lockout/tagout standard (29 CFR (c)(4)) Verify that the procedures clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be used to control hazardous energy and the means to enforce compliance including, but not limited to, the following (29 CFR (c)(4)(ii)): a specific statement of the intended use; the specific procedural steps to shut down, isolate, block, and secure machines or equipment to control hazardous energy; specific procedural steps for the placement, removal, and transfer of lockout or tagout devices, and the responsibility for taking these actions; and specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures If a procedure is unavailable for a particular piece of equipment or machine, determine that the following elements exist (29 CFR (c)(4)(i)): the equipment or machine has no potential for stored or residual energy or re-accumulation of stored energy after shut down; the equipment or machine has a single energy source which can be readily identified and isolated; the isolation and locking out of that energy source will completely de-energize and de-activate the equipment or machine; the equipment or machine is isolated from that energy source and locked out during maintenance or servicing; a single lockout device will achieve a locked-out condition; the lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; the maintenance and servicing does not create hazards for other employees; and the employer has had no accidents involving unexpected activation or re-energization of the equipment or machine during maintenance or servicing LT/Part 3-2

9 Lockout and Tagout Rulebook 13 When a tagout device is used on an energy-isolating device that is not capable of being locked out, the tagout device must be attached at the same location the lockout device would have been attached (29 CFR (c)(3)(i)) Verify that a tagout device is attached in the same location as a lockout device would have been (29 CFR (c)(3)(i)) Verify that this requirement is included in the employer s standard operating procedures (GMP) 14 The level of safety achieved in the tagout program must be equivalent to the level of safety obtained by using a lockout program (29 CFR (c)(3)(ii)) Determine if the employer has demonstrated that the level of safety achieved in the tagout program is equivalent to the level of safety obtained by using a lockout program (29 CFR (c)(3)(i) (c)(3)(ii)) Determine if the employer has implemented additional means, if necessary, to ensure full employee protection by reducing the likelihood of an inadvertent energization, including the following where applicable (29 CFR (c)(3)(ii)): removing an isolating circuit element; blocking a controlling switch; opening an extra disconnecting device; or removing a valve handle 15 Protective materials and hardware must be provided (29 CFR (c)(5)(i) (c)(5)(ii)) Verify that the employer meets the following requirements: locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware are provided by the employer for isolating, securing, or blocking of machines or equipment from energy sources (29 CFR (c)(5)(i)); and lockout devices and tagout devices are singularly identified as the only devices(s) used to control energy and are not used for any other purpose (29 CFR (c)(5)(ii)) 16 Lockout/tagout devices must be durable and meet certain requirements (29 CFR (c)(5)(ii) (c)(5)(iii)) Verify that the devices used in the lockout/tagout program are appropriately designed and constructed, and are provided where and when needed (29 CFR (c)(5)(ii) Verify that lockout and tagout devices are capable of withstanding the environment to which they are exposed for the maximum period of time that exposure is expected (29 CFR (c)(5)(ii)((A)(1)) Verify that tagout devices are constructed and printed so that exposure to weather conditions or wet and damp locations will not cause the tag to deteriorate or the message on the tag to become illegible (29 CFR (c)(5)(ii)(A)(2)) Verify that tags will not deteriorate when used in corrosive environments such as areas where acid and alkali chemicals are handled and stored (29 CFR (c)(5)(ii)(A)(3)) Verify that lockout and tagout devices are standardized within the facility in at least one of the following criteria: color; shape; or size; and, in the case of tagout devices, print and format (29 CFR (c)(5)(ii)(B)) Verify that lockout devices are substantial enough to prevent removal except by use of excessive force or unusual techniques, such as by bolt cutters or other metal-cutting tools (29 CFR (c)(5)(ii)(C)(1)) Verify that tagout devices, including their means of attachment, are substantial enough to prevent inadvertent or accidental removal (29 CFR (c)(5)(ii)(C)(2)) Verify that tagout device attachment means are non-reusable, attachable by hand, self-locking, and nonreleasable with a minimum unlocking strength of no less than 50 lb and having the general design and basic characteristics of being at least equivalent to a one-piece, all-environment-tolerant nylon cable tie (29 CFR (c)(5)(ii)(C)(2)) Verify that lockout devices and tagout devices indicate the identity of the employee applying the device(s) (29 CFR (c)(5)(ii)(D)) LT/Part 3-3

10 Lockout and Tagout Rulebook Verify that tagout devices warn against hazardous conditions if the machine or equipment is energized and include a legend such as the following: Do Not Start, Do Not Open, Do Not Close, Do Not Energize, Do Not Operate (29 CFR (c)(5)(iii)) 17 Periodic inspections must be conducted at least annually to ensure that requirements are being followed (29 CFR (c)(6)(i) (c)(6)(ii)) NOTE: OSHA provides detailed guidance on how to set up a periodic inspection program, including when and how energy control procedures can be grouped for the purpose of inspection, inspection of energy control procedures that are performed less frequently than every 12 months, and the methods that can be used to accomplish periodic inspections When evaluating this paragraph, refer to CPL Chapter XVII Verify that periodic inspections are being conducted at least annually as follows (29 CFR (c)(6)(i)): Periodic inspections must be performed by an authorized employee other than the one(s) utilizing the energy control procedure being inspected Periodic inspections must be conducted to correct any deviations or inadequacies identified Where lockout is used for energy control, periodic inspections must include a review between the inspector and each authorized employee of that employee s responsibilities under the energy control procedure being inspected as well as the training elements in paragraph 18 Where tagout is used for energy control, periodic inspections must include a review between the inspector and each authorized and affected employee of that employee s responsibilities under the energy control procedure being inspected and of the limitations of tags Verify that the employer certifies that periodic inspections have been performed and that certification includes the following (29 CFR (c)(6)(ii)): the equipment or machines on which the energy control procedure was being utilized; the date of the inspection; the employees included in the inspection; and the person performing the inspection 18 Training must be provided to ensure that employees understand the purpose and functions of the energy control program and that they acquire the knowledge and skills required for the safe application, usage, and removal of energy controls (29 CFR (c)(7)(i) (c)(7)(ii) and (c)(7)(iv)) Determine whether each authorized employee has received initial training in recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control (29 CFR (c)(7)(i)) Verify that there are certified records that (29 CFR (c)(7)(iv)): show that employee training has been accomplished and is kept up to date; and contain each employee s name and dates of training Determine whether each affected employee has been instructed in the purpose and use of the energy-control procedure (29 CFR (c)(7)(i)) Determine whether all other employees whose work operations are or may be in an area where energy-control procedures may be utilized, are instructed about the procedure and about the prohibition relating to attempts to restart or re-energize machines or equipment that are locked out or tagged out (29 CFR (c)(7)(i)) When tagout systems are used, determine whether employees are also trained in the following limitations of tags (29 CFR (c)(7)(ii)): Tags are essentially warning devices attached to energy-isolating devices, and do not provide the physical restraint on those devices that is provided by a lock When a tag is attached to an energy-isolating means, it is not removed without authorization of the authorized person responsible for it, and it is never bypassed, ignored, or otherwise defeated In order to be effective, tags must be legible and understandable by all authorized employees, affected employees, and all other employees whose work operations are or may be in the area Tags and their means of attachment must be made of materials that will withstand the environmental conditions encountered in the workplace NOTE: Where tags are potentially attached with a fastener which might be inappropriate for the workplace, interview employees to determine if they know which fastener to use LT/Part 3-4

11 Lockout and Tagout Rulebook Tags and their meaning must be understood as part of the overall energy control program and should not evoke a false sense of security Tags must be securely attached to energy-isolating devices, so that they cannot be inadvertently or accidentally detached during use 19 All authorized and affected employees must be retrained whenever their job assignments change, whenever there is a change in equipment, machines, or processes which presents a new hazard, or whenever there is a change in the energy-control procedures (29 CFR (c)(7)(iii)) Verify that additional retraining is conducted as required: whenever a periodic inspection reveals, or whenever the employer has reason to believe, that there are deviations from or inadequacies in the employee s knowledge or use of the energy-control procedures (29 CFR (c)(7)(iii)(A) (c)(7)(iii)(b)); and to re-establish employee proficiency, and introduce new or revised control methods and procedures as necessary (29 CFR (c)(7)(iii)(C)) NOTE: OSHA expects retraining to be provided for all authorized and affected employees whenever there is a change in their job assignments, a change in machines, equipment or processes that present a new hazard, or when there is a change in the energy control procedure (CPL ) 110 Lockout or tagout procedures must be performed only by the authorized employees who are performing the servicing or maintenance (29 CFR (c)(8)) Verify that only authorized, trained individuals perform lockout/tagout operations (29 CFR (c)(8)) 111 Affected employees must be notified by the employer or authorized employee of the application and removal of lockout devices or tagout devices (29 CFR (c)(9)) Verify that all affected employees are to be notified regarding lockout/tagout devices and determine if notification is to be given before the controls are applied and after they are removed from the machine or equipment (see also section 2) (29 CFR (c)(9)) Verify that employees are notified before and after lockout/tagout devices are either placed or removed from equipment and machines (29 CFR (c)(9)) 112 Procedures must be followed whenever lockout or tagout devices must be temporarily removed from the energy-isolating device, and the machine or equipment is energized to test or position the machine, equipment, or component thereof (29 CFR (f)(1)) Verify that sequential steps are taken as follows (29 CFR (f)(1)): clear the equipment or machine of tools and materials; remove employees from the machine or equipment area; remove the lockout or tagout devices; proceed with testing or positioning; and de-energize all systems and reapply energy control measures to continue the servicing and maintenance 113 When outside personnel are engaged in lockout/tagout procedures, the on-site employer and the outside employer must inform each other of their respective lockout or tagout procedures (29 CFR (f)(2)) Verify that the onsite employer and the offsite employer informs each other of their respective lockout or tagout procedures (29 CFR (f)(2)(i)) Verify that the onsite employer ensures that his/her employees understand and comply with the restrictions and prohibitions of the offsite employer s energy control program (29 CFR (f)(2)(ii)) LT/Part 3-5

12 Lockout and Tagout Rulebook 114 When lockout/tagout procedures are performed by a crew, craft, department, or other group, they must utilize a procedure which affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device (29 CFR (f)(3)) Verify that when servicing and/or maintenance is performed by a crew, craft, department, or other group, they utilize a procedure that affords the employees a level of protection equivalent to that provided by implementation of a personal lockout or tagout device (29 CFR (f)(3)(i)) Verify the lockout/tagout procedures include, but are not limited to, the following specific requirements (29 CFR (f)(3)(ii)): Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device (such as an operations lock) Provision made for the authorized employee to ascertain the exposure status of individual group members with regard to the lockout or tagout of the equipment or machine When more than one crew, craft, or department is involved, assignment of overall job-associated lockout or tagout control responsibility is given to an authorized employee designated to coordinate affected work forces and ensure continuity of protection Each authorized employee must attach a personal lockout or tagout device to the group lockout device, group lockbox, or comparable mechanism when he or she begins work, and must remove those devices when he or she stops working on the machine or equipment being serviced or maintained 115 Procedures must be utilized during shift or personnel changes to ensure the continuity of lockout or tagout protection (29 CFR (f)(4)) Verify that the procedures which address continuity of lockout or tagout protection include a provision for the orderly transfer of lockout or tagout device protection between off-going and oncoming employees to minimize exposure to hazards from the unexpected energization or startup of the machine or equipment, or release of stored energy (29 CFR (f)(4)) 2 Application and Release of Energy Controls 21 Procedures must be established to apply energy controls (29 CFR (d)) Verify that procedures to apply energy controls (the lockout or tagout procedures) cover the following elements, and that the actions and are done sequentially: Prepare for shutdown Before an authorized or affected employee turns off a machine or equipment, the authorized employee must have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy (29 CFR (d)(1)) Shutdown machine or equipment The machine or equipment must be turned off or shut down using the procedures established for that machine or equipment An orderly shutdown must be utilized to avoid any additional or increased hazard(s) to employees as a result of the equipment stoppage (29 CFR (d)(2)) Isolate machine or equipment All energy-isolating devices needed to control energy to the machine or equipment must be located and operated to isolate the machine or equipment from the energy source(s) (29 CFR (d)(3)) Apply lockout or tagout device (29 CFR (d)(4)) 1) Lockout or tagout devices must be affixed to each energy-isolating device by authorized employees 2) Lockout devices, where used, must be affixed in a manner that will hold the energy-isolating devices in a safe or off position 3) Tagout devices, where used, must be affixed in a manner that will clearly indicate that the operation or movement of energy-isolating devices from the safe or off position is prohibited NOTE 1: Where tagout devices are used with energy-isolating devices designed with the capability of being locked, the tag attachment must be fastened at the same point at which the lock would have been attached LT/Part 3-6

13 Lockout and Tagout Rulebook NOTE 2: Where a tag cannot be affixed directly to the energy-isolating device, the tag must be located as close as safely possible in a position that will be immediately obvious to anyone attempting to operate the device Isolate stored energy All potentially hazardous stored or residual energy must be relieved, disconnected, restrained, and otherwise rendered safe NOTE: If there is a possibility of re-accumulation of stored energy to a hazardous level, verification of isolation must be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists (29 CFR (d)(5)) Verify isolation Prior to starting work on machines or equipment that have been locked out or tagged out, the authorized employee must verify that isolation and de-energization of the machine or equipment have been accomplished (29 CFR (d)(6)) 22 Before lockout or tagout devices are removed and energy is restored to the equipment and machine, appropriate procedures must be followed and actions taken by the authorized employee(s) (29 CFR (e)) Review procedures and interview employees to verify that the authorized employee is taking appropriate actions consistent with the lockout/tagout procedures as follows: the work area is inspected to ensure that nonessential items have been removed (29 CFR (e)(1)); the area is checked to ensure that equipment or machine components are operationally intact (29 CFR (e)(1)); the work area is checked to ensure that all employees have been safely positioned or removed (29 CFR (e)(2)(i)); affected employees are notified before lockout or tagout devices are to be removed and before the equipment or machine is started (29 CFR (e)(2)(ii)); and affected employees are notified after the lockout or tagout devices have been removed and the equipment or machine has re-started (29 CFR (e)(2)(ii)) Review procedures and interview employees to verify that lockout or tagout devices are removed from each energy-isolating device by the employee who applied the device (29 CFR (e)(3)) Review procedures and interview employees to verify that, if the authorized employee who applied the lockout or tagout device is not available to remove it, specific procedures and training for removal of lockout or tagout devices have been established (29 CFR (e)(3)) These procedures and training must include at least the following elements: verification by the employer that the authorized employee who applied the device is not at the facility; a method to make all reasonable efforts to contact the authorized employee to inform him/her that their lockout or tagout device has been removed; and a method to ensure that the authorized employee has this knowledge before he/she resumes work at that facility NOTE: OSHA has determined that the lockout or tagout device may be removed by either destructive force (bolt cutters, etc) or by non-destructive means (master key) as long as the corresponding procedures and training provide the level of safety required by the standard (OSHA Interpretation Letter, 2/28/00) LT/Part 3-7

14 LOCKOUT AND TAGOUT PART 4: SCORESHEET SITE: DATE: 1 General Requirements N/A Complies Does not comply 11 A program consisting of energy-control procedures, employee training, and periodic inspections must be established (29 CFR (c)(1) (c)(2)) 12 Procedures must be developed, documented, and used to control potentially hazardous energy when employees are engaged in the activities covered by the lockout/tagout standard (29 CFR (c)(4)) 13 When a tagout device is used on an energy-isolating device that is not capable of being locked out, the tagout device must be attached at the same location the lockout device would have been attached (29 CFR (c)(3)(i)) 14 The level of safety achieved in the tagout program must be equivalent to the level of safety obtained by using a lockout program (29 CFR (c)(3)(ii)) 15 Protective materials and hardware must be provided (29 CFR (c)(5)(i) (c)(5)(ii)) 16 Lockout/tagout devices must be durable and meet certain requirements (29 CFR (c)(5)(ii) (c)(5)(iii)) 17 Periodic inspections must be conducted at least annually to ensure that requirements are being followed (29 CFR (c)(6)(i) (c)(6)(ii)) 18 Training must be provided to ensure that employees understand the purpose and functions of the energy control program and that they acquire the knowledge and skills required for the safe application, usage, and removal of energy controls (29 CFR (c)(7)(i) (c)(7)(ii) and (c)(7)(iv)) 19 All authorized and affected employees must be retrained whenever their job assignments change, whenever there is a change in equipment, machines, or processes which presents a new hazard, or whenever there is a change in the energycontrol procedures (29 CFR (c)(7)(iii)) 110 Lockout or tagout procedures must be performed only by the authorized employees who are performing the servicing or maintenance (29 CFR (c)(8)) 111 Affected employees must be notified by the employer or authorized employee of the application and removal of lockout devices or tagout devices (29 CFR (c)(9)) 112 Procedures must be followed whenever lockout or tagout devices must be temporarily removed from the energy-isolating device, and the machine or equipment is energized to test or position the machine, equipment, or component thereof (29 CFR (f)(1)) 113 When outside personnel are engaged in lockout/tagout procedures, the on-site employer and the outside employer must inform each other of their respective lockout or tagout procedures (29 CFR (f)(2)) 114 When lockout/tagout procedures are performed by a crew, craft, department, or other group, they must utilize a procedure which affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device (29 CFR (f)(3)) 115 Procedures must be utilized during shift or personnel changes to ensure the continuity of lockout or tagout protection (29 CFR (f)(4)) LT/Part 4-1

15 Lockout and Tagout Scoresheet 2 Application and Release of Energy Controls N/A Complies Does not comply 21 Procedures must be established to apply energy controls (29 CFR (d)) 22 Before lockout or tagout devices are removed and energy is restored to the equipment and machine, appropriate procedures must be followed and actions taken by the authorized employee(s) (29 CFR (e)) END OF SCORESHEET LT/Part 4-2