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HazardousEnergyOregon OSHA’sguide tocontrollinghazardousenergy

Safe jobs are smart businessOne serious injury can stop thegrowth of your business in its tracks.We offer no-cost safety & health consultations,training, and education workshops.Contact us at: 800-922-2689www.orosha.orgAbout this documentA guide to controlling hazardous energy is a publication of theOregon OSHA Standards and Technical Resources Section.Thanks to Peggy Munsell, Mike Lulay, and Ron Haverkost.Thanks to the following individuals for crafting the final document:n Patricia Young: Oregon OSHA, design and layoutn Mark Peterson: DCBS Communications, editing and proofingQuestions or comments? We’d like to hear from you.Contact Ellis Brasch: 503-947-7399, ellis.k.brasch@state.or.us.

CONTENTSIntroduction. 1What you’ll learn from this guide.1Understanding hazardous energy.2Energy and motion.2Forms of energy.3How energy becomes hazardous.4Hazardous energy in the workplace: a recent accident.4Controlling hazardous energy.6Identifying energy sources.6De-energizing equipment.6Dissipating potential (stored) energy that can’t be isolated.7Locking out or tagging out energy-isolating devices.7Lock out or tag out? How to decide.9Understanding energy-control procedures.10Developing written energy-control procedures.10Training employees.13Traditional lockout vs. group lockout.14Evaluating written energy-control procedures.16Working by the rules.18Division 1 rules — all workplaces.18Division 2 rules — general industries.19Division 3 rules — construction.21Division 4 rules — agriculture.22Division 7 rules — forest activities.22Definitions.23Orergon OSHA services.26Oregon OSHA’s guide to controlling hazardous energy

Oregon OSHA’s guide to controlling hazardous energy

IntroductionYou can’t hear it. You can’t see it. Hazardousenergy stays silent and invisible until it’s toolate. Hazardous energy threatens if you do thefollowing:n Service or maintain equipment that couldstart or move unexpectedly.n Work near equipment when it’s being serviced.n Supervise employees who service equipment or who work near equipmentwhile it’s being serviced.This guide is based on the requirements in Oregon OSHA’s standard forhazardous energy control — Subdivision 2/J, 1910.147, which protectsemployees who could be injured as a result of the unexpected release ofhazardous energy. The requirements apply when an employee doing serviceor maintenance work on a machine or equipment could be injured by theunexpected start-up or release of hazardous energy. Lockout and tagout arethe primary methods of controlling hazardous energy.Service or maintenance includes erecting, installing, constructing, repairing,adjusting, inspecting, unjamming, setting up, trouble-shooting, testing,cleaning, and dismantling machines, equipment, or processes. In this guide,equipment means equipment and machines.What you’ll learn from this guiden Why you should be concerned about hazardous energy.n Safe practices for controlling hazardous energy.n Key requirements of OR-OSHA’s hazardous-energy-control standard— Subdivision 2/J, 1910.147.n Other Oregon OSHA standards that have hazardous-energy-controlrequirements.Remember: This guide will help you understand how to control hazardousenergy and meet the requirements of 1910.147 — but it doesn’t take the placeof 1910.147.Oregon OSHA’s guide to controlling hazardous energy1

Understanding hazardous energyEnergy and motionEnergy is the power for doing work. Energy exists in different forms (see thetable on Page 3) but all forms are associated with motion. Tensioned objectssuch as suspended loads have potential energy — energy that has the potentialfor motion. Releasing the load converts potential energy to kinetic energy andcauses the load to drop.Tensioned objects have potential energy.Moving objects have kinetic energy.Illustration: Patricia Young, Oregon OSHA.This forklift truck, raised for repair work, has potential energy.2Oregon OSHA’s guide to controlling hazardous energy

Forms of energyPotentialStored energy that can be drawn upon to do work.Suspended loads, compressed springs, and pressurizedhydraulic systems are examples. Potential energy can beconverted to kinetic energy and many of the other energyforms described below.KineticEnergy resulting from moving objects such as releasedloads and uncoiling springs. When these objects arereleased, their potential energy is converted to kineticenergy.FlammableEnergy converted from the combustion of gasses, liquids,solid chemicals, and vapors.ChemicalThe capacity of a substance to do work or produce heatthrough a change in its composition. Chemical energy canbe converted from gasses, liquids, solid chemicals, andvapors.ElectricalEnergy generated through the conversion of other formssuch as mechanical, thermal, or chemical energy. Energystored between plates of a charged capacitor is an exampleof potential electrical energy. Typical electrical energysources include open busbars, motors, and generators.ThermalEnergy transferred from one body to another as the result ofa difference in temperature. Heat flows from the hotter tothe cooler body. Sources include mechanical work,radiation, chemical reactions, and electrical resistance.Oregon OSHA’s guide to controlling hazardous energy3

How energy becomes hazardousEnergy in any form becomes hazardous when it builds to a dangerous level oris released in a quantity that could injure a worker. Hazardous energy is neverfar from those who need to service or maintain powered equipment. Simplyturning the power off doesn’t make the equipment safe! It’s critical that thosewho service or repair equipment know how hazardous energy could harmthem and how to control it.Hazardous energy in the workplace: a recent accidentThe son of the owner of a commercial drywallconstruction company, who was also an employeeof the company, was preparing an aerial lift for ajob and had replaced two battery terminals. He hadraised the aerial boom and was reaching toward thebattery compartment across the metal enclosurethat houses the lift’s toggle controls when the boomdropped and pinned him to the control panel. Hisfather discovered him and summoned emergencyresponders but he died at the site.Investigation findingsn The lift’s emergency valve, hydraulic hosesand fittings, and electrical wiring were inspected after the accidentand were not defective; however, the on/off key switch had beenbypassed so that the operator could use the toggle switches withoutusing the key.n The battery charging system was missing a fuse that would stop thesystem from charging and the spring-loaded toggle switches thatcontrolled the boom did not have guards to prevent accidental contact.n The employee did not use lockout procedures while he was working onthe lift and did not block the boom to prevent it from dropping.n The owner had not reviewed the lift’s instruction manual with thevictim or other company employees.4Oregon OSHA’s guide to controlling hazardous energy

n Although the company had more than 10 employees, it did not have asafety committee.The accident resulted in the following violations:437-001-0760 — The employer failed to ensure that employees did notremove or tamper with required safety devices.1910.147(c)(4) — The employer did not develop, document, and requireemployees to use lockout procedures to control hazardous energy duringmaintenance work.437-001-0765 — The employer had more than 10 employees but did nothave a safety committee.n Employers must establish a safety committee or hold safety meetings.Oregon OSHA’s guide to controlling hazardous energy5

Controlling hazardous energyTo control hazardous energy, you have to prevent it from being transmittedfrom its source to the equipment that it powers. You can accomplish that bydoing the following:n Identify energy sources.n De-energize equipment by isolating or blocking the energy sources.n Dissipate potential (stored) energy that could affect the equipment.n Lock out the equipment’s energy-isolating device.n Tag out the energy-isolating device only if you can’t lock it out.Identifying energy sourcesIdentify equipment in your workplace that needs service or maintenance.Determine the form of energy that powers the equipment, including potentialenergy that may remain when the energy source is disconnected. Label the energysources so that workers will know what equipment is powered by each energysource.De-energizing equipmentDe-energizing equipment means isolating it from its energy sourceand controlling potential energy so that no energy can flow to the equipment.The method you use to de-energize equipment depends on the form of energyand the means available to control it. Safe practices for de-energizingequipment:n Disconnect motors from the equipment.n Isolate electrical circuits.n Disconnect equipment from energy sources.n Block the fluid flow in hydraulic, pneumatic, or steam systems withcontrol valves or by capping or blanking the lines.n Block equipment parts that could be moved by gravity.6Oregon OSHA’s guide to controlling hazardous energy

Dissipating potential (stored) energy that can’t be isolatedStored energy must be released after equipment has been de-energized.Capacitors, coiled springs, elevated machine members, rotating flywheels, and air,gas, steam, chemical, and water systems are sources of stored energy. If the energycould return to a hazardous level, make sure that it remains isolated from theequipment until all service work is finished. Safe practices for dissipating potentialenergy:n Vent pressurized fluids until internal pressure levels reach atmosphericlevels.n Discharge capacitors by grounding them.n Release or block tensioned springs.n Ensure that all moving parts have stopped completely.Locking out or tagging out energy-isolating devicesEnergy-isolating devices prevent energy from being transmitted from anenergy source to equipment. Energy-isolating devices are the primary meansfor protecting those who service equipment. Examples (shown below) aremanually operated electrical circuit breakers, main disconnect switches, andline valves and blocks.Examples of locked out and tagged out energy-isolating devicesMain disconnect switchLine valveCircuit breakerOregon OSHA’s guide to controlling hazardous energy7

An energy-isolating device is effective only whenno one can accidentally restart the equipment.Locking out is a procedure for securing an energyisolating device in an off, closed, or neutralposition. When an energy-isolating device islocked out, a worker can safely service hazardousequipment. A lockout device — typically a lockwith a unique key or combination — secures theenergy-isolating device in a safe position. Whenan energy-isolating device is locked out, theequipment it controls will not work until thelockout device is removed.Similarly, tagging out is a procedure for placing awarning tag or sign — a tagout device — on anenergy-isolating device. Tagout devices mustcontrol hazardous energy at least as effectively aslockout devices. But tagout devices don’t providethe same physical barrier to hazardous energy aslockout devices, so it’s harder to ensure that theyare equally effective. A tagout device must besecurely fastened to the energy-isolating deviceand must state that the equipment being servicedcan’t be operated until it is removed.Lockout and tagout devices must meet thefollowing criteria to ensure that they’re effectiveand not removed inadvertently:Durable. Lockout devices must work under theenvironmental conditions in which they are used.Warnings on tagout devices must be legible evenin wet, damp, or corrosive conditions.Standardized. Lockout and tagout devices mustbe designated by color, shape, or size. Tagoutdevices must have a standardized print andwarning format.8Oregon OSHA’s guide to controlling hazardous energy

Substantial. Lockout devices and tagout devices must be strong enough that theycan’t be removed inadvertently. Tagout devices must be attached with a single-use,self-locking material such as a nylon cable tie.Identifiable. Any employee who sees a lockout or tagout device mustrecognize who attached it and understand its purpose. Each lock must have aunique key or combination; this means that only the employee who uses thelock has the key or the combination to that lock.If you’re an employer, you must provide lockout and tagout devices toemployees who need to shut down equipment to service or maintain it.When you replace, renovate, or modify equipment, ensure that the energyisolating devices will accept lockout devices. New or renovated equipment(modified after Jan. 2, 1990) must be capable of being locked out.Lockout or tagout? How to decideIf you can lock out an energy-isolating device, then you must lock it out beforeyou service the equipment that it controls. If you can’t lock out an energyisolating device, then you must tag it out. Remember that you must ensure thatthe hazardous energy is controlled just as effectively with the tagout device asit would be with a lockout device.Oregon OSHA’s guide to controlling hazardous energy9

Understanding energy-control proceduresYou need to accomplish three critical activities to ensure employees’ safetywhen they’re servicing or working near equipment that could expose them tohazardous energy:n Develop written procedures for controlling hazardous energy.n Train employees in the procedures.n Conduct inspections of the procedures at least annually.Developing written energy-control proceduresYou must document energy-control procedures for use by authorizedemployees who lock out or tag out equipment to perform service andmaintenance. The procedures for equipment with one or more hazardousenergy sources must include the following:n The intended use of the procedure.n Steps for shutting down, isolating, blocking, and securing equipment.n Steps for the placement, removal, and transfer of lockout devices.n Equipment-testing requirements to verify the effectiveness of the energycontrol procedures.When written procedures are not requiredYou do not need to document the procedures if accidents that involveunexpected activation or re-energizing of equipment have not occurred andthe following conditions exist:n A single source of energy can be readily identified and isolated.n Locking out the energy source completely de-energizes and deactivatesthe equipment.n The lockout device is under the exclusive control of the employeeperforming the service or maintenance.10Oregon OSHA’s guide to controlling hazardous energy

n There is no potential stored or residual energy that could harm employeesafter shutdown.n The service or maintenance work does not create hazards for otheremployees.When re-energizing equipment is necessary — when power is needed to testor position the equipment, for example — temporary removal of lockout ortagout devices is allowed. This applies only for the time required to performthe task and the procedure must be documented.Employees must do the following before they begin service ormaintenance work:1. Inform all affected employees of equipment shutdown.2. Shut down equipment.3. Isolate or block hazardous energy.4. Remove any potential (stored) energy.5. Lock out or tag out the energy sources.6. Verify the equipment is isolated from hazardous energy andde-energized.Employees must do the following before they remove lockout or tagoutdevices and re-energize equipment:1. Remove tools and replace equipment components.2. Inform co-workers about energy-control device removal.3. Ensure all workers are clear of the work area.4. Verify power controls are off or in a neutral position.5. Remove the lockout or tagout device.6. Re-energize equipment.Oregon OSHA’s guide to controlling hazardous energy11

Common questionsWhat happens if I attach a lockout or tagout device but I’m not available toremove it? Your employer can authorize another employee to remove thedevice if that employee is trained to do so and follows a documented energycontrol procedure. The procedure must ensure that you’re not available toremove the device, that someone has tried to contact and inform you thatanother employee has removed the device, and that you know the device hasbeen removed before you return to work.How do I deal with locked-out or tagged-out equipment when work shiftschange? You can adapt your energy-control procedures to shift changes as long asthe procedures ensure that employees on all shifts are protected.How do I deal with locked-out or tagged-out equipment after long-termshutdowns? You should also have an additional energy-control procedure toprotect employees if they must restart equipment after long-term shutdowns.Determine who will be responsible for monitoring any lockout and tagoutdevices that control energy to the equipment. Include steps in the procedure forprotecting employees if they need to remove or change parts while theequipment is shut down. Do not restart equipment until you are absolutelycertain that it is working properly.What if I contract service or maintenance on my equipment? You and thecontractor must understand one another’s lockout and tagout procedures.Review your contractor’s energy-control program before the contractor doesany on-site work. Your employees must also understand and comply with thecontractor’s energy-control program.Do I need a lockout/tagout program when working on motor vehicles? Youmust ensure that vehicles, machinery, and equipment you are servicing areisolated from their energy source and made inoperable before doing anymaintenance or repair work.12Oregon OSHA’s guide to controlling hazardous energy

Training employeesAll employees must be trained to know basic hazardous-energy concepts andthe purpose of the devices used to control hazardous energy. They should alsoknow what tasks might expose them to hazardous energy and how hazardousenergy can be controlled.Some employees need to know more about hazardous energy than others.What they need to know depends on whether they service the equipment orjust work near the equipment while it’s being serviced. Oregon OSHA uses theterms authorized employees for those who service equipment and affectedemployees for those who work in areas where the equipment is serviced.Authorized employees lock out or tag out equipment and service or maintainthe equipment. Required training:n How to find and recognize hazardous energy sources.n The types and magnitudes of energy used in the workplace.n How to isolate energy sources.Affected employees use equipment serviced under lockout or tagout proceduresor work in an area affected by the procedures. An affected employee becomesan authorized employee when the employee performs service or maintenancework on the equipment. Required training:n The purpose of energy-control procedures.n How energy-control procedures are applied.n How energy-control procedures will protect them.Keep training records. Keep current training records for each authorized andaffected employee. Document the employee’s name and the training date.Retrain employees when work conditions change. Authorized and affectedemployees must be retrained whenever their job assignments change, energycontrol procedures change, equipment or work processes present new hazards, orwhen they don’t follow energy-control procedures.Oregon OSHA’s guide to controlling hazardous energy13

Traditional lockout vs. group lockoutTraditional lockoutRecall that lockout means securing an energy-isolating device in an off, closed,or neutral position. Under traditional lockout, each authorized employee secureseach energy-isolating device — typically with a lock as shown below. (Anauthorized employee is one who locks out or tags out the energy-isolating deviceand services the equipment.)Traditional lockout with two energy-isolating devicesLocked out energy-isolating devicesEach authorized employee places his personal lock oneach energy-isolating device before beginning servicework, then removes that lock after the work has been done.Service work involving many employees and many energyisolating devices can make traditional lockout complicated.Group lockoutIn many workplaces, however, a group of authorized employees may need toservice equipment that has several energy sources and several energy-isolatingdevices.Under group lockout, just one designated person in the group assumesresponsibility for securing each energy-isolating device. There are a number ofvariations of group lockout; the group lockbox variation (see the illustrationon Page 15) reduces the number of locks and makes it easier for employees tocoordinate their activities.14Oregon OSHA’s guide to controlling hazardous energy

Group lockout with multiple energy-isolating devicesThis designated person locks out each of these energy-isolating devices and puts the keyinto a group lockbox with a multi-lock hasp.These authorized employees place their locks on thegroup lockbox before they begin work. After eachworker finishes, the worker removes his lock from thebox.Group lockout: fewer lockout devices requiredFor complicated energy-control systems, group lockoutcan reduce the number of lockout devices that employees must use.Here’s an example: Ten employees do maintenance on a machine that has fiveenergy sources that need to be isolated.n Traditional lockout requires 50 locks. (Each employee places a lock oneach energy-isolating device.)n Group lockout requires 15 locks. (A designated person in the group placesa lock on each energy-isolating device. Each authorized employee places alock on the group lockbox.)Group lockout can also reduce the risk of injury for service and maintenanceemployees, contractors, and other affected employees who don’t regularlywork with complicated energy-control systems.Oregon OSHA’s guide to controlling hazardous energy15

Example of a group lockout procedure — the group lockbox variationStep 1A designated, authorized employee in the group secures eachenergy-isolating device with a personal lock.Step 2The same authorized employee places the key that fits each lock ina group lockbox with a multilock hasp.Step 3The other authorized employees in the group secure the lockbox— they attach their personal locks to the box — before beginningtheir service work.Step 4After each employee finishes service work on the equipment, thatemployee removes his personal lock from the lockbox.Step 5After all the employees have finished their service work andremoved their personal locks from the lockbox, the authorizedemployee who placed the key in the box removes it.Step 6The authorized employee uses the key to remove the lock on eachenergy-isolating device.Evaluating written energy-control proceduresAn evaluation is an inspection of all written energy-control procedures by anauthorized employee. The purpose of the inspection is to determine thatemployees are following the written procedure and that the procedure is correct.Either the employer or the inspector must document each inspection with thefollowing information:n The equipment on which the procedure is used.n The date of the inspection.n The employees included in the inspection.n The person who did the inspection.If an inspector finds that employees are not following an energy-controlprocedure or that the procedure is not protecting them, those employees must beretrained and the procedure’s deficiencies corrected.16Oregon OSHA’s guide to controlling hazardous energy

The authorized employee who does the inspection must understand theprocedure and must not be among those following the procedure at the time ofthe inspection. Each procedure must be verified for its accuracy, completeness,and effectiveness in energy control.Reviewing a lockout procedure. If the inspection covers a procedure forequipment with an energy-isolating device that can be locked out, theinspector must review the procedure with the employees who use it to servicethe equipment. The inspector can review the procedure with the employeesindividually or in a group.Reviewing a tagout procedure. If the inspection covers a procedure forequipment with an energy-isolating device that can only be tagged out, theinspector must review the procedure with the authorized employees who servicethe equipment and with affected employees who may work in the area when theequipment is serviced. The inspector can review the procedure with theemployees individually or in a group.Oregon OSHA’s guide to controlling hazardous energy17

Working by the rulesThis section helps you determine which OR-OSHA rules you should follow tocontrol hazardous energy at your workplace. Keep in mind the following:n If you service equipment that could start or move unexpectedly, follow therequirements in 1910.147, The control of hazardous energy (lockout/tagout).n You may also need to comply with one or more of the other listed rules,depending on the nature of your work. For example, if you do repair work ina permit-required confined space, see 1910.146, Permit-required confinedspaces. If you do maintenance on a forging machine, see 1910.218, Forgingmachines.n If electricity is your primary hazard — for example, if you work on ornear parts of fixed electrical equipment or circuits — follow therequirements in 1910.333, Work on or near energized circuits.Division 1 rules — all workplacesRules for all workplaces 437-001-0760The employer must ensure that employees are properly instructed andsupervised in the safe operation of the machines, tools, equipment, and workprocesses that they are authorized to use.Employees must stop machines or moving parts and properly tag out or lock outthe starting control before oiling, adjusting, or repairing, except when theequipment has a means for oiling or adjusting that will prevent contact withmoving parts.18Oregon OSHA’s guide to controlling hazardous energy

Division 2 rules — general industriesThe control of hazardous energy (lockout/tagout) 1910.147Employees who service equipment that could start or move unexpectedly dueto uncontrolled hazardous energy. Develop written hazardous energy-controlprocedures. Train employees about hazardous energy concepts andprocedures. Conduct periodic (at least annual) inspections of the procedures.Permit-required confined spaces 1910.146Employees who enter permit-required confined spaces. Before employeesenter, the space must be protected from hazards caused by the release ofenergy or material.Vehicles for highway and road operation characteristicsand maintenance 437-002-0223Employees who inspect, maintain, or repair vehicles with dump bodies. Thedump body must have a permanently attached support device that can belocked in position to prevent accidental lowering. The employee doing servicework must use the device to support the dump body when it is raised.Forging machines 1910.218Employees who change dyes or do maintenance work on hydraulic forgingpresses. The hydraulic pumps and power apparatus must be locked out. Theram must be blocked so that it meets the criteria stated in this rule.Stationary compactors, self-contained compactors,and balers 437-002-0256Employees who service equipment for refuse collection and compaction.Use a lockout device that will ensure hazardous energy is isolated fromthe equipment. Division 2, Subdivision J 1910.147 applies.Bakery equipment 1910.263Employees who do service work on cooling towers. Cooling towers that extendtwo or more floors must have a lockout switch on each floor so employees canlock the mechanism and prevent it from starting.Employees who do service work on or inside ovens. The equipment must have amain disconnect switch or circuit breaker that employees can reach quickly andsafely. The main switch or circuit breaker must be locked in the open positionwhen an employee works on or inside an oven.Oregon OSHA’s guide to controlling hazardous energy19

Electric power generation, transmission, and distribution 1910.269Employees who service equipment that could start or move unexpectedly.Develop hazardous-energy-control procedures. Train employees abouthazardous-energy concepts and procedures. Conduct peri

Potential Stored energy that can be drawn upon to do work. Suspended loads, compressed springs, and pressurized hydraulic systems are examples. Potential energy can be converted to kinetic energy and many of the other energy forms described below. Kinetic Energy resulting from mov

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