OSHA Lockout Tagout Guide

OSHA Standards can be useful for workplace and employee safety. Here, we are going to publish OSHA 29 CFR 1910.147 standards in detail. Follow us to get more information about OSHA Lockout Tagout Standards.

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OSHA Standard 29 CFR 1910.147 - Capable of being locked out

Adhering to OSHA regulations is essential when implementing Lockout Tagout procedures during machine maintenance or servicing. In previous blogs, we have explored various OSHA guidelines in depth. In this blog, the focus shifts to a critical concept within those standards - “capable of being locked out” - and its implications for equipment safety and compliance An energy-isolating device is considered CAPABLE OF BEING LOCKED out if:

·  It is designed with a hasp or other means of attachment.

·  It has a locking mechanism.

· If a lockout can be achieved without the need to dismantle, rebuild, or replace the energy isolating device.

Energized: A machine is said to be energized if it is connected to an energy source. Or if it contains any stored energy- chemicals, gases, liquids; Energy from the movement of springs; Pressurized and moving gases, etc.

Check OSHA Guidelines in detail -  https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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OSHA 29 CFR 1910.147 Standard: Scope (a)(1)

The main aim of this Standard 1910.147(a)(1) is to protect the employees from hazardous energy sources on machines during maintenance from: Unexpected energization or startup of the machines and equipment: Employees servicing or maintaining machines may be exposed to serious physical harm or death if hazardous energy is not properly controlled. Unexpected energization includes- sudden, accidental, unintentional or careless startup or release of hazardous energies that pose a serious threat to employees. Release of Stored Energy that can cause injury to employees: Any energy can become hazardous if stored energy builds to a dangerous level or is suddenly released. Turning the power off or removing the energy source doesn’t guarantee that the equipment is safe. If workers service or perform maintenance without relieving chemicals, gases, liquids and vapors or remove springs, wheels or elevated parts, Batteries and capacitors, Pressurized or moving gases, then their sudden release could cause serious injury to personnel. The Standard establishes minimum performance requirements for the control of hazardous energy sources. Check OSHA Guidelines in detail -  https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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OSHA Lockout Tagout Standard 1910.147(f)(3)(ii) - Group Lockout or Tagout

Group lockout or tagout devices shall be used in accordance with the procedures required by paragraph (c)(4) of this section including, but not necessarily limited to, the following specific requirements:

(f)(3)(ii)(A) Primary responsibility is in the hands of the authorized employee for the employees working under the protection of a group lockout or tagout device.

(f)(3)(ii)(B) The authorized employee has to ascertain the exposure status of individual group members with regard to the lockout tagout of the equipment

(f)(3)(ii)(C) When more than one crew, craft, or department is involved, assignment of overall job responsibility is on an authorized employee, designated to coordinate affected work forces and ensure continuity of protection

(f)(3)(ii)(D) Each authorized employee shall affix a personal lockout or tagout device to the group lockout device, group lock box, or comparable mechanism when he or she begins work, and shall remove those devices when he or she stops working on the machine.

Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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OSHA Lockout Tagout Standard 1910.147(f)(2) - Outside Personnel (Contractors, etc.)

OSHA Lockout Tagout Standard 1910.147(f)(2) - Outside Personnel (Contractors, etc.)

The requirements mentioned under section (f)(2) of the OSHA Lockout Tagout standard provides guidance to employers beyond the mutual informing of both parties regarding their respective Lockout Tagout procedures. In the standard preamble, OSHA states that the proper utilization of these provisions, when they are understood and agreed upon, is a way to prevent misunderstandings by either the plant employees or the outside service personnel regarding the use of Lockout Tagout procedures both in general and for specific application. Whenever outside servicing personnel/contractor are to be engaged in the servicing or maintenance activities, both, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures to avoid any conflicts later. Moreover, it becomes the responsibility of the onsite employer to ensure that his employees understand and comply with the restrictions and prohibitions of the outside employer's energy control program Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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OSHA Lockout Tagout Standard 1910.147(f) - Additional Requirements

In general, equipment and machines are customarily shut down following the normal LOTO procedures, and any residual / stored energy is safely released. However, under certain circumstances, for example, testing with the power on, is often necessary to ensure the proper assembly and functioning of the components. It may not be possible to apply Lockout Tagout during the test being performed.

In such cases, OSHA permits the removal of Lockout Tagout devices and the re-energization of equipment only during the time necessary for the testing or positioning of the machine, equipment, or component, and only when re-energization is essential to accomplish the servicing task.

However, appropriate measures should be taken to protect people and minimize the risk in such special cases.

Temporary removal of locks or tags and re-energization of the machinery or equipment is permitted to allow testing or repositioning, provided that specific procedures control the sequence of actions to be taken. The procedures must provide maximum safety coverage for employees when the equipment or machinery must be energized during the course of servicing. Employee exposure to hazards is high during these transition periods.

When this occurs, re-energization also requires that the authorized employee:

1. Clear the machines or equipment of tools and materials.

2. Remove employees from the immediate area.

3. Remove the LOTO devices as specified in your company plan.

4. Energize and proceed with testing or positioning.

5. De-energize all systems, isolate the machine or equipment from the energy source, and reapply lockout or tagout devices as specified.

Therefore, the energy control procedure for the equipment being serviced must reflect the required sequence of actions to be taken, and employees should be thoroughly trained in the use of procedures.

Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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Lockout Tagout Stations - Organise and Protect Your Workplace

Discover the diverse range of Lockout Tagout Stations available at E-Square Alliance. We offer Standard LOTO Stations in yellow and red, featuring a secure key-locking mechanism for enhanced safety. These stations are available in both metallic and non-metallic materials, ensuring durability and adaptability to various workplace environments.

Designed for convenience and accessibility, our LOTO stations can be wall-mounted near isolation points or used as portable units for flexible safety management. Additionally, we provide customization options to meet specific customer requirements. Explore our extensive selection today and enhance workplace safety with tailored solutions.

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OSHA Lockout Tagout Standard 1910.147(e) - Lockout or Tagout Devices Removal

Each lockout or tagout device shall be removed from each energy isolating device by the employee who applied the device. But as per the Exception to paragraph (e)(3): If the employee who applied the LOTO device is not available to remove it, that device may be removed under the direction of the employer, provided that specific procedures and training for such removal have been developed, documented and incorporated into the employer's energy control program. The specific procedure shall include at least the following elements: (e)(3)(i) Verification by the employer that the authorized employee who applied the device is not at the facility: (e)(3)(ii) Making all reasonable efforts to contact the authorized employee to inform him/her that his/her lockout or tagout device has been removed; and (e)(3)(iii) Ensuring that the authorized employee has this knowledge before he/she resumes work at that facility. However, the removal of personal Lockout Tagout device by another employee is not possible for the sake of convenience or simply because the authorized person is not available. Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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OSHA Lockout Tagout Standard 1910.147(e) - Release from Lockout or Tagout

After the maintenance task is complete, the machines are supposed to be reenergized and restored to normal production operation. But, before that reenergization takes place, OSHA’s Lockout Tagout standard requires that, standardized procedures should be followed, to ensure that employees are not subject to an increased potential for injury. Section (e)(1) requires that when the maintenance task is complete, the work area should be examined and thoroughly checked to ensure that all the nonessential items, including guards, left-behind tools, parts, and materials, have been removed, and that the equipment is operationally intact to avoid any mishap. Section (e)(2) requires a check of the work area to ensure that all employees are safely positioned, and the affected employees are notified that the Lockout Tagout devices have been removed, and the machine is safely reenergized. Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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OSHA Lockout Tagout Standard: Application of Control 1910.147(d)(4)

The next element of the sequence is:

Lockout Tagout application: The isolating device must be locked and tagged out by the authorized employee using individual Locks and Tags. These Locks & Tags must be affixed to each energy isolating device to hold it in a safe or off position and physically prevent its operation. Tagout devices must be affixed in a manner that it indicates the movement of the isolating device from the safe or off position is prohibited. Moreover, when the Tagout device is used along with the Lockout device, capable of being locked out, the tag so attached must be fastened at the same point at which the lock would have been attached. Although the Tag is supposed to be attached to the equipment along with the isolating device, in cases where the tag cannot be directly attached to the energy isolating device, it shall be located as close as safely possible to the device. Making sure that it is easily visible to the employee working on the machine, or around the machine, to avoid any inadvertent energization. Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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LOTOTO - Lockout Tagout Tryout Procedure Steps and Training

One of the most critical safety protocols for energy control is Lockout Tagout (LOTO) and its enhanced version, Lockout Tagout Tryout (LOTOTO). Checkout what is LOTOTO, common mistakes to avoid, LOTOTO procedure steps and training.

LOTOTO is not just about locking and tagging, it is a methodical, verified process that ensures worker safety through every stage of equipment maintenance. Let’s take a look at the steps involved in a successful LOTOTO process: https://www.safetylock.net/blog/mastering-lototo-the-ultimate-guide-to-lockout-tagout-tryout-for-workplace-safety/

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OSHA Lockout Tagout Standard: Application of Control 1910.147(d) (5) (6)

Stored Energy: After applying the Lockout Locks and tags, check for the stored or residual energies. Any residual energy ignored by any chance can be a potential danger, leading to accidents and fatalities. Therefore, it shall be relieved, disconnected, controlled, and otherwise rendered safe. Although the hazardous energy has been isolated in the previous step, stored, residual or potential energy may still be retained in the machine. To control potentially hazardous stored energy, the spring should be brought to a relaxed or neutral position. Verification of isolation shall be continued until the maintenance work is completed, or until the possibility of such accumulation no longer exists. The authorized employee is responsible to check, and verify that isolation and de-energization of the machine or equipment have been accomplished. Machines must be tried-tested-verified by visual inspection, to make sure that the energy isolation has been accomplished.

Some companies perform LOTOTO - Lockout Tagout Tryout, to confirm that the machine has been rendered safe.

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Unlocking Workplace Safety: Essential LOTO Kits for Every Industry

Workplace safety is a top priority for industries that deal with hazardous energy sources. Lockout Tagout procedures are designed to protect employees from unexpected machinery start-ups and energy releases during maintenance or servicing. Without proper LOTO measures, workers are at risk of serious injuries, which can lead to operational disruptions and legal consequences for businesses.

LOTO kits provide a comprehensive solution for energy isolation, ensuring that workers can perform maintenance tasks safely. These kits contain essential lockout devices, padlocks, tags, and other tools necessary for implementing an effective lockout program. This article explores the importance of LOTO kits, their components, and the best options for different industries.

The Importance of LOTO Kits in Workplace Safety

LOTO kits are not just a regulatory requirement; they are a crucial investment in workplace safety. Here’s why they are essential:

Prevents Accidents & Injuries - Proper lockout procedures help eliminate risks associated with the release of hazardous energy.

Ensures Compliance - LOTO kits help industries comply with safety regulations such as OSHA (Occupational Safety and Health Administration) and ANSI (American National Standards Institute).

Enhances Productivity - A well-organized LOTO system minimizes downtime by providing quick and easy access to necessary tools.

Improves Accountability - Lockout kits ensure that only authorized personnel can restore energy, preventing unauthorized machine startups.

LOTO Kits for Different Industries

Each industry has unique safety requirements, and LOTO kits are designed to cater to these specific needs. Here’s a look at essential LOTO kits for various industries:

1. Manufacturing Industry

Comprehensive LOTO kits with circuit breaker lockouts, valve lockouts, and padlocks.

Ensures safe maintenance of heavy machinery and conveyor systems.

2. Oil & Gas Industry

Specialized valve lockout devices for handling hazardous liquids and gases.

Weather-resistant lockout padlocks and durable lockout tags.

3. Electrical & Power Plants

Electrical lockout kits with plug lockouts, breaker lockouts, and insulated padlocks.

Protects workers from electrical hazards during repairs.

4. Food & Beverage Industry

Corrosion-resistant LOTO devices to comply with food safety standards.

Ensures safe handling of processing machinery.

5. Construction Industry

Portable lockout kits with durable hasps and padlocks for on-site work.

Helps ensure the safety of electrical and mechanical equipment in temporary work locations.

Key Components of a LOTO Kit

A complete LOTO kit contains various lockout tagout devices that cater to different energy sources. Some of the essential components include:

1. Lockout Padlocks

Used to secure lockout devices in place, ensuring they cannot be removed accidentally.

Available in different materials like steel, aluminum, and non-conductive plastic for electrical applications.

2. Lockout Hasps

Allow multiple workers to apply their own padlocks to a single lockout point.

Ensures group lockout procedures are followed during multi-person maintenance work.

3. Electrical Lockout Devices

Circuit Breaker Lockouts: Prevent accidental re-energization of circuit breakers.

Plug Lockouts: Secure electrical plugs to stop unauthorized access.

Switch Lockouts: Lock out toggle switches, buttons, or control panels.

4. Valve Lockout Devices

Used to lock out various types of valves, including ball valves, gate valves, and butterfly valves.

Prevents hazardous liquids or gases from being released during maintenance.

5. Lockout Tags

Clearly indicate why equipment is locked out and who is responsible for the lockout.

Help communicate safety measures to all workers.

6. Lockout Stations & Storage Boxes

Organized storage solutions for LOTO devices.

Help keep all necessary equipment in one place for easy access.

How to Choose the Right LOTO Kit for Your Workplace

When selecting a LOTO kit, consider the following factors:

Industry-Specific Requirements: Choose a kit designed for the hazards present in your industry.

Durability: Select high-quality materials that can withstand harsh working conditions.

Compliance: Ensure the LOTO kit meets OSHA and other safety regulations.

Storage & Organization: Opt for kits with lockout stations or carrying cases for easy access and organization.

Conclusion

LOTO kits are an essential part of workplace safety, protecting workers from hazardous energy while ensuring compliance with safety regulations. By investing in the right Lockout Tagout kit for your industry, you can create a safer work environment, reduce risks, and improve overall efficiency. Prioritizing workplace safety is not just a legal requirement - it’s a responsibility that safeguards lives and enhances productivity.

Would you like to learn more about choosing the best LOTO kit for your industry? Start exploring your options today and take a proactive step toward safety!

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OSHA Lockout Tagout Standard: Application of Control 1910.147(d)

The established procedures for the application of energy control (the lockout or tagout procedures) covers the following elements and actions as mentioned above. Preparation of Shutdown: Before an authorized employee turns off the machine, he must have knowledge regarding the types, magnitude, hazards, and the means to control the energy. The first step is intended to notify all the affected employees regarding the Lockout and allow the employees to get ready for the shutdown, and plan ahead to perform safely.

In complex or group Lockout Tagout situations, all involved personnel should be made aware of their respective roles and assignments. Machine or Equipment shutdown: To place the machine in a state that it will let employees work on it safely, it must be turned off or shutdown using established procedures. An orderly shutdown must be used to avoid any increased or additional hazards to employees as result of shut down. Machine isolation: All the isolating devices such as isolators, valves, etc. that are needed to control the energy of the machines, must be physically located and operated so that the machine is isolated from its energy sources. Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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OSHA Lockout Tagout Standard: Application of Control

Under section (a)(3)(i) of the Lockout Tagout standard 1910.147, the employers are required to establish a program and utilize procedures for affixing appropriate lockout devices or tagout devices to Energy Isolating Devices, and to otherwise disable machines or equipment to prevent unexpected energization, start up or release of stored energy in order to prevent injury to employees.

This section (d) of the Lockout Tagout standard, highlights the elements of the application of control of the established procedures.

The procedure shall cover the following elements and actions and it shall be done in the sequence mentioned below:

• 1910.147(d)(1): Preparation for shutdown.

• 1910.147(d)(2): Machine or equipment shutdown.

• 1910.147(d)(3): Machine or equipment isolation.

• 1910.147(d)(4): Lockout or tagout device application.

• 1910.147(d)(5): Stored energy.

• 1910.147(d)(6): Verification of isolation.

Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-documentation/

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Lockout Tagout - Energy Isolation and Notification of Employee

Section (c) states that the process of Lockout Tagout shall be performed only by the authorized employees who are servicing. This is so because, an authorised employee is especially trained for the particular isolation, which any other employee might not be able to perform efficiently.

Lockout Tagout requires technical understanding, which cannot be done by any unskilled professional. Therefore, an authorised employee is assigned by the supervisor.

Notification of Affected Employees.

Lack of information regarding the status of equipment could endanger the employees who re-energize, operate or work around the machines. Whenever LOTO control might directly affect another employee’s work activities, paragraph (c) (9) requires the employer or authorized employee to notify the affected employees prior to applying, and after removing the Lockout Tagout device.

Such notification informs affected employees of the impending interruption of the normal production operation and reinforces the importance of the restrictions imposed.

After removing a LOTO device, notifying employees, alerts them that the equipment is capable of being started-up. Else, employees might mistakenly believe that a system is safe to continue working around the machine, leading to heinous accidents.

Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-29-cfr-1910-147-standard/

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OSHA Lockout Tagout Standard 1910.147(c) - Employee Retraining

While the employer is required to provide effective training for all employees covered by the LOTO standard, under section (c)(7)(iii) Retraining must be provided to all the authorized as well as affected employees depending upon the circumstances mentioned above.

There are three types of employees which must receive Training & Retraining: authorized, affected, and other. The amount and type of training/retraining that each employee receives is based upon the relationship of that employee's job to the machine and upon the degree of knowledge relevant to hazardous energies.

In addition, retraining must be conducted if an inspection reveals a lack of understanding of LOTO procedures by the employees. This is called Additional Retraining.

Whenever a periodic inspection discloses any deviations or inadequacies in the employees' understanding, additional retraining becomes mandatory.

Under section (c)(7)(iv) Employers are required to certify that effective training and retraining has been provided to all employees covered by the standard. The certification must contain each employee's name and dates of training.

Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-29-cfr-1910-147-standard/

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𝐋𝐨𝐜𝐤𝐨𝐮𝐭 𝐓𝐚𝐠𝐨𝐮𝐭 - 𝐓𝐫𝐚𝐢𝐧𝐢𝐧𝐠 𝐚𝐧𝐝 𝐂𝐨𝐦𝐦𝐮𝐧𝐢𝐜𝐚𝐭𝐢𝐨𝐧 (Part D, E and F)

𝐏𝐚𝐫𝐭 𝐃 specifies,

Tags must be made of materials capable enough of withstanding the environment to which they are exposed for the maximum period of time.

This also means that, exposure to weather conditions or wet and damp locations should not cause the tag to deteriorate.

𝐏𝐚𝐫𝐭 𝐄 further elaborates -

These Lockout Tags although play a very important part in providing safety to the worker applying the safety device, but they might induce false sense of security to the plant worker, if used alone.

Incidences occur where, due to bad environmental condition or physical dismantling, LOTO Tag got removed during servicing, lead to mishaps.

Therefore, Lockout tags must always be used along with LOTO Locks if the machine or equipment in use is capable of being Locked out.

𝐏𝐚𝐫𝐭 𝐅 says,

It is necessary that these Tags must be securely attached to the energy isolating devices so that they cannot be inadvertently detached.

They are non-reusable, self-locking, and non-releasable with a minimum unlocking strength of no less than 50 pounds.

Workers on the site must be specified and trained about these limitations of Tags.

Check OSHA Guidelines - https://www.safetylock.net/learn-lockout-tagout/osha-29-cfr-1910-147-standard/