Temporary removal of lockout or tagout device

Temporary removal of lockout or tagout device

Exceptions where a zero-energy state cannot be achieved due to the task at hand are covered under OSHA 1910.147(f)(1).[2] When lockout or tagout devices must be temporarily removed from the energy isolating device and the equipment energized to test or position the equipment, the following lockout tagout steps shall be followed:

Clear the machine or equipment of tools and materials in accordance with paragraph (f)(1)(i) of this section
Remove employees from the machine or equipment area in accordance with paragraph (f)(1)(ii) of this section
Remove the lockout or tagout devices as specified in paragraph (f)(1)(iii) of this section
Energize and proceed with testing or positioning (f)(1)(iv)
De-energize all systems and reapply energy control measures in accordance with paragraph (f)(1)(v) of this section to continue the servicing and/or maintenance

Lockout device calculator
Estimate the number of devices needed on a per-facility basis
The total number of lockout devices needed for your lockout tagout system will vary by organization. Here’s one way to determine a good estimate for your organization:

Decide how many stations or departments need a lockout device cabinet or board.
Discuss with authorized employees where the cabinet or board should be located based on the location of equipment, with high-volume equipment areas being the key factor for lockout tagout station placement.
Look at the high-hazard equipment areas (boiler, chiller, generators and facilities equipment rooms) and production departments. Count the total number of devices required for all the written machine-specific procedures in the desired area and order 10% of the total number of devices. If the boiler room has 50 pieces of equipment and 100 ball valve devices, the boiler lockout station should have 10 ball valve devices. The need to lock out all equipment at your facility should never happen, but placing an initial order of 10% will be a good starting point.
Monitor lockout station devices with an inventory list to see if more devices need to be ordered after the initial order.