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Lockout/Tagout Program to Control Hazardous Energy

This checklist policy is used for protecting employees who must do service or maintenance on machines or equipment and who could be injured by an unexpected start-up or release of hazardous energy. This policy will ensure that machinery or equipment is stopped, isolated from all hazardous energy sources, and properly locked or tagged out.

MaintainX

07/26/2022

Lockout/Tagout Program to Control Hazardous Energy

Key requirements laid out by OSHA include the following:

Written Procedures

The lockout tagout program must include a written energy-control procedure that covers how and when a machine should be disconnected from each energy source, how lockout and/or tagout devices should be placed to prevent the possibility of re-energization, and information on how to prevent the risk from stored and/or re-accumulated energy.

Training

Employees must be given training about the program. This should include how to use and remove energy control devices.

Evaluation

The facility is required to perform an annual evaluation of the lockout tagout program to ensure it is effective. During this evaluation the facility must identify any changes to machines that would require an update to the program. This evaluation should also look at whether employees are properly following the program. If they are not, additional training or enforcement may be necessary.

These are just the minimum requirements of an energy control program. OSHA fully expects each facility to properly evaluate its unique situation and create a program that addresses the specific hazards present.

The following are the most common types of power that could present a danger to people working on or near a machine:

Electricity

This is the most common source of energy. It typically comes from a main electrical cable that goes into a machine. Other sources of traditional electricity could be a gas or diesel generator or battery backup systems.

Hydraulic Pressure

Hydraulic pressure is commonly used in presses, lifts, and other similar machines. If there is hydraulic pressure in a line, it should be discharged prior to work beginning.

Hydraulic Accumulation

Hydraulic accumulation is a similar type of energy, but is found in a pump rather than in the lines. Disconnecting a hydraulic pump and making sure any stored energy is discharged is essential.

Pneumatic Energy

Using compressed air is common in certain types of machinery. Compressed air can be stored in lines, pipes, tanks, or other locations. Identify any potential areas where compressed air could be present and ensure the program accounts for it.

Gas

Gas is a common source of energy. While not commonly used in modern machinery that requires a lockout tagout program, it does need to be considered.

Steam

Steam is still a very effective source of energy and is used in a variety of industries. Identifying steam energy sources in a machine is critical for the success of any lockout tagout system.

Thermal

Thermal energy comes from heat. Most machines create heat, and even if it is not intended to activate a machine, this should be considered. Looking at all the possibilities is essential for an effective program.

Gravity

When power is removed from a system, it is often going to be more susceptible to gravitational energy. As electrical brakes release, this energy can make machines move, which is why it is so critical that it is a part of a lockout tagout program.

Kinetic

Tension from springs or other sources needs to be accounted for to keep the maintenance teams safe.

Requirements Prior to Work Starting

The following are the general lockout/tagout steps required prior to starting any work. Using these as a starting point, each facility should create specific instructions for each machine:

Preparing for Shutdown

Machine operators should prepare the machine for proper shutdown. Many machines have shutdown sequences that need to be followed to ensure all the energy is dissipated.

Actual Shutdown

Complete the actual shutdown of the machine.

Disconnecting Power

Disconnect a machine from its main power source and all other energy sources.

Locking Out the Power

Apply a lockout or tagout device to the energy sources of the machine.

Secure Machine

Take steps to release any stored energy or residual energy, and then secure any parts that need to be secured.

Verification

Take whatever steps are necessary to verify that the machine has been completely de-energized.

Preparing for Re-Energizing of Machines

Some key steps for preparing to re-energize a machine are:

Inspect the Machine

Inspect the machine to ensure no tools, parts, or other items have been left by the maintenance team.

Maintenance Checklist

Make sure each item on the checklist created for the maintenance performed has been done. Missing a task will require the lockout tagout procedure to be implemented again, which introduces additional risk.

Check All Tags

Make sure all tagout tags have been properly removed by the individuals who applied them.

Confirm Employees Are Clear

Take one last walk around the machine (but not into dangerous areas since the tags have been removed) to ensure everyone is positioned where they are supposed to be.

Initiate Power Up Procedures

Going through the standard power-up procedures for a given machine is important. Most machines have specific tasks that need to be done in a specific order. Having experienced machine operators perform the power-up process can help improve the safety of the machine.

Source: MaintainX (Community Member)

Please note that any procedure, checklist, or other document available in the MaintainX Global Procedure Library is provided for general education and information only and does not constitute legal, medical, or financial advice. MaintainX makes the materials available AS IS and AS PROVIDED, without warranties of any kind. By downloading or using any such materials, you assume the risk that they may not be appropriate for your specific situation and agree that you are solely responsible for any such use, including compliance with applicable law and with meeting any conditions of product warranties.

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