**Proper Lock-Out/Tag-Out Procedure**

**P \....** PROCESS SHUTDOWN

**R \....** RECOGNIZE ENERGY TYPE

**O \....** OFF - SHUT OFF ISOLATING DEVICES

**P \....** PLACE LOCK AND TAG

**E \....** ENERGY RELEASE STORED ENERGY (0 ENERGY STATE)

**R \....** RECHECK CONTROLS AND RETURN TO PROPER SETTING

**ENERGY TYPES**

Recognize The Types of Energy To Shut Down

1\. Electrical Energy

2\. Hydraulic and/or Pneumatic Energy

3\. Fluids and Gases

4\. Mechanical Energy

**ACCIDENT SITUATIONS**

Accident Start Up Equipment can accidentally be turned on and your hands
may be in the point of operation or while you are inside.

Electrical Shock You can be accidentally electrocuted if the power is
still on or if it is accidentally turned on.

Hazardous Materials If released can go into confined areas or the work
area.

> Stored Energy You could be caught in equipment that can move due to
> stored energy, even with the power off.

**The Solution Is Quite Simple: Use The PROPER Lock-Out Procedures.**

**LOCK RULES**

1\. Use an appropriate "Lock-Out Device", such as Lock Tongs, or a Lock
Tag. Each person must attach his or her own lock to the Lock-Out Device.

2\. Identify Locks Each lock will be identified by a number or a name. A
lock without a tag is not good enough. Additional information that
identifies the person / persons doing the work must be on the tag. Also
the type of work that is being performed should be on the tag.

3\. Sign The Tag In some instances one tag is enough, however, the tag
must be signed by each worker. In some circumstances a supervisor will
also need to sign the tag.

4\. One Key Per Lock

5\. Never give your key to anyone else.

**Recheck controls and return to proper setting**

**Process Shut Down**

Open disconnect before pulling the plug. Shut down

> process or equipment.

**Recognize Energy Type**

> Recognize the correct power source.

**Shut Off all Power Controls**

> Shut off machine and electrical energy at both machine and main power
> switch. There may be more than one source of power and all must be
> shut off. If necessary, electrical drawings and a supervisor may need
> to be involved.

**Place Lock-Out Device, Lock and Tag**

> Each person working on equipment needs to put his or her lock on the
> switches and sign the tag.

**Energy - Release Stored Energy**

> Bleed electrical capacitors if any.

**Recheck Controls and Return To "OFF" Setting**

> Recheck the start button and properly test that you have zero energy
> state.

**HYDRAULIC AND/OR PNUEMATIC LOCK-OUT P Process Shut Down**

**Recognize Energy Type**

> Recognize all sources of energy -- the electric that
>
> powers the pumps or compressors, and the air or

hydraulic valves themselves.

**Shut Off all Power Controls**

> Shut off each energy type.

**Place Lock-Out Device, Lock and Tag**

> The shape or location on some valves may be difficult to lock out. If
> there is not a specific lock out tag out procedure in place you should
> ask your supervisor.

**Energy - Release Stored Energy**

> Bleed the stored energy by bleeding the air line and draining the
> compressor, or by using other prescribed methods. Keep in mind that
> when bleeding stored energy it could cause some parts of the equipment
> to move, as it is being held by the stored energy.

**Recheck Controls and Return To "OFF" Setting**

> Return controls to proper settings.

**PROPER FLUIDS AND GASES LOCK-OUT P Process Shut Down**

Shut down process using recommended procedures.

**Recognize Energy Type**

> Recognize the material and its hazards. If material is
>
> hazardous, use the proper protective equipment. Even

water can become a hazardous fluid under high

pressure.

**Off! -Shut Off all Isolating Valves**

If a job requires breaking in to a line close off isolating

> device, blanking if necessary. Some valves may be

difficult to lock out. A locking bar or chains may be

needed. Check with supervisor.

**Place Lock-Out Device, Lock and Tag**

Sign tag.

**Energy - Release Stored Energy**

> Release pressure and drain to achieve zero energy state.

**Recheck Controls and Return "OFF" Setting**

> Recheck line and test properly and make sure you have
>
> zero energy state.

**P-R-O-P-E-R MECHANICAL ENERGY LOCK-OUT**

**Mechanical Energy** may be released at the point of operation, or
where two or more points of operation come together. This is where you
might get caught. In most cases blocking mechanical energy is done in
addition to shutting off the primary source, such as electrical,
hydraulic and pneumatic. Some examples include inserting restraining
pins or bars in the point of operation or block under a lift.

In cases where these blocks to mechanical energy are not locked in
place, they should not be the primary means of shutting off energy.
Mechanical energy can also be stored.

**1 Gravity -**

Things that are up can fall of their own weight. Pins or

blocking may be required.

**2 Springs**

> BOING! can spell DEATH. Release tension or compressed springs by using
> methods prescribed by the equipment manufacturer.

**3 Tension**

> Things under tension can spring in. Release tension by
>
> using prescribed method by equipment manufacturer.
>
> **P Process Shut Down**
>
> Shut down the process.
>
> **R Recognize Energy Type**
>
> Recognize all forms of energy -- Need to be shut off, such as
> electrical and mechanical. Mechanical is usually a secondary energy
> source closest to point of operation.
>
> **O Off! -Shut Off all Power Controls**
>
> Such as switches, valves and other isolating devices.
>
> **P Place Lock-Out Device, Lock and Tag**
>
> Place lock on the isolating device and sign tag.
>
> **E Energy - Release Stored Energy**
>
> Release, spring or tension to achieve, zero energy state
>
> **Recheck Controls and Return To "OFF" Setting**

**ZERO ENERGY START UP**

Zero Energy State to Start-up to Operating State

Starting the equipment is just as important as Lock-Out//Tag-Out in
terms of safety.

**Start-up**

• Inspection

• Clean up

• Replace guards

• Check controls

• Remove locks

• Visual checks

**Inspect**

When work is finished the equipment must be inspected for proper
adjustment before starting equipment. **Clean Up**

All materials and debris must be cleaned up. Any combustible materials
and old parts used during repairs must be cleaned up. **Replace Guards**

Replace all guards to the equipment. If adjustments can not be made with
the guard on after start-up, leave off only the ones to be adjusted
after start-up. **Check Controls**

Make sure all switches are in the off position. In some cases the
machine can start automatically when energy is restored. **Remove
Locks**

Each person must remove his or her own lock or tag. This will ensure you
are in a safe place when the equipment is started. **Visual Checks**

If the equipment is too large to see all around it, station personnel
around the area and sound the personnel alarm before starting the
equipment.

If your operation is more complex, having many pieces of equipment and a
lot of people, a comprehensive Lock-Out/ Tag-Out procedure may involve
additional steps.

Lock-0ut/Tag-Out may use a gang box or other system to ensure that locks
are secure and not removed without authorization.

American Concrete Pipe Association • 222 W. Las Colinas Blvd., Suite 641
• Irving, TX 75039-5423 • 972-506-7216 Fax 972-506-7682 •
www.concrete-pipe.org