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Control of Hazardous Energy (Lockout/Tagout)

Workers performing service or maintenance on machinery and equipment are exposed to injuries from the unexpected energization, startup of the machinery or equipment, or release of stored energy in the equipment.

Develop a Lockout/Tagout program to shut down equipment, isolate it from its energy source(s), and prevent the release of potentially hazardous energy while maintenance and servicing activities are being performed.

When using Lockout tags, in addition to normal training required for all employees, employees must be trained in the following limitations of tags:

Lockout Tags are essentially warning devices and do not provide the physical restraint of a lock.
Lockout Tags must be legible and understandable by all employees.
When a tag is attached to an isolating means, it is not to be removed except by the person who applied it, and it is never to be bypassed, or ignored.
Tags and their attachments must be made of materials that will withstand the environmental conditions encountered in the workplace.
Tags may evoke a false sense of security. They are only one part of an overall energy control program.
Tags must be securely attached to the energy-isolating devices so that they cannot be detached accidentally during use.

A 26 year old, male recycling packer died after being crushed in a paper recycling bin by a recycling ram (crushing device) that exerts 118 tons of force. The company had no effective lockout/tagout procedures.

Lock Out Tag

Lockout & Electrical Products

Create an energy compliant lockout/tagout program. Everything you need to equip employees and identify energy control panels.

  Heavy Duty Lockout Tags
  2-Part Lockout Key Tags
  Lockout Tags
  Padlocks
  Caution Labels
  Padlock Labels
  Lockout Labels and Arrows
  Lockout Labels
  Circuit Breaker Lockouts

  Universal Ball Valve Lockouts
  Gate-Valve Lockouts
  Lockout Hasps
  Metal Lock Box
  Lockout Stations
  Lockout Tool Box with Componenets
  Universal Plug Lockouts

Danger & Warning Tags

"Tagout" means placing a warning tag or sign — a tagout device — on an energy-isolating device. Tagout devices must control hazardous energy at least as effectively as lockout devices. But, because tagout devices don’t provide the same physical barrier to hazardous energy as lockout devices, it may be difficult to demonstrate that they are equally effective. Opening an extra disconnect or removing a valve handle are examples of ways to protect workers from hazardous energy when they service or maintain tagged-out equipment. The tag must be securely fastened to the energy-isolating device and must state that the equipment being serviced or maintained can’t be operated until the tag is removed.

  Do Not Operate Tag
  This Tag and Lock Tag
  Equipment Lock Out Tag
  Danger-Do Not Operate Tag
  Do Not Start Tag

Danger & Warning Tags

Sample Lockout/Tagout Written Program

A Lockout/Tagout written program has many purposes:

1. To establish a safe and positive means of shutting down machinery, equipment and systems.
2. To prohibit unauthorized personnel or remote control systems from starting machinery or equipment while it is being serviced.
3. To provide a secondary control system (tagout) when it is impossible to positively lockout the machinery or equipment.
4. To establish responsibility for implementing and controlling lockout/tagout procedures.
5. To ensure that only approved locks, standardized tags and fastening devices provided by the company will be utilized in the lockout/tagout procedures.

Lockout/Tagout Written Program

Sample Training Programs

If an employee's duties include performing work covered by the Lockout / Tagout program, they must be trained as an authorized employee.

Employees who perform the following types of work must be trained:

Lock Out Station
Servicing or maintenance of machines or equipment where the unexpected start-up, activation or release of stored energy could cause injury.
Operations where an employee is required to remove or bypass a guard or other safety device.
Operations where an employee is required to place any part of his or her body into an area of the machine where work is actually performed upon the material being processed, or where a similar danger zone exists during the machine operating cycle.
Work on equipment where an energy source itself poses a hazard to the employee (e.g., electrical systems) that must be controlled for the work to be performed safely.
Entry into confined spaces, such as vats or tanks, where the supply lines for chemicals, gases or other materials into the space must be blocked and locked out to prevent the introduction of these materials into the space while employees are performing work.

Compliance Digest

Compliance Forms

Lockout/Tagout Energy Control Procedures

Compliance Checklist

Lockout/Tagout Checklists

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