Chapter 4

Lockout/Tagout
Section 1 Presentation
Section 2 Narrative

1
 29 CFR 1910.147
the Control of
Hazardous
Energy Sources
(lockout/tagout)

Note that this standard concerns the control of all hazardous energy
sources and not just electricity. Many people seem to consider electrical
hazards only when there are many other potential hazardous energy
sources.

2
 Scope & Application

zServicing and/or
Maintenance
ªNon-production

This standard is intended to apply to non-production operations of

equipment. When the widget-maker is making widgets, this standard
generally does not apply. However, when you are performing
maintenance on the widget maker, the standard applies.

3
 Scope & Application
zNormal Production if
»remove or bypass a
guard
»exposed to danger
zone (point of operation)

The exception is that it does apply during normal production if you

remove or bypass a guard, or if an employee is exposed to a danger
zone (point of operation).

4
 Scope & Application
zUnexpected
Energization or Start Up
zAccidental Release of
Stored Energy

The purpose of the standard is to avoid the unexpected energization or

start up of equipment and to avoid any accidental release of stored
energy.

5
 ENERGY TYPES
zDirect
vs. Stored
zExamples

Examples of direct energy would be the direct electrical supply that

operates the equipment, moving water that turns a wheel or other
device, or flowing natural gas that powers equipment.

Examples of stored energy would be a compressed spring, a battery,

gravity, a capacitor, or pressurized pipe.

6
 Lockout/Tagout
Lockout/Tagout
Does not apply to:
zconstruction
zagriculture
zmaritime
zelectric utilities
zoil and gas wells

For most businesses and industry not covered by the LOTO standard
there are other standards that apply.

7
 Lockout/Tagout
does not cover operations:
zminor tool changes
adjustments
zcord and plug connected
equipment
zlimited hot tap operations

The LOTO standard does not cover minor tool changes or adjustments.
Changes consider "minor" are those that can be performed on a machine
designed to have them done while still being in operation. An example
might be oiling a part of the equipment.

Cord and plug connected equipment is not covered as long as the plug
remains under the control of the employee performing the
maintenance.

Hot tap operations could include tapping into an operating natural gas
line. It is allowed when shutting the line down would result in extreme
expense. The operation must be done by those well-qualified.

8
 LOTO
zLocks
–when equip. lockable
zTags
–when equipment not
lockable
–Replacement, Repair,
Renovation
»make lockable

LOTO locks must be distinctive from any other locks in the facility.
They may be color-coded or they may be distinctive in some other way.
LOTO locks may not be used on lockers, toolboxes etc.

A LOTO log must be used when the equipment is lockable. If the

equipment is not lockable, the use of a tag only is acceptable. Lockable
does not just mean that the equipment is designed to take a lot. There
are many LOTO devices manufactured to make various equipment
lockable. If one of these devices will work in your situation, you must
use it.

If equipment is not lockable, it must be modified and made lockable the

first time you perform any major repair or renovation to the equipment.

9
 Energy Control Program
zEnergy Control Procedures
zTraining Program
zPeriodic Inspections
zMeans to Enforce
Compliance

A written energy control program is required. It consists of the

individual step-by-step procedures written for each piece of
equipment, explanation of your training program, requirements for
periodic inspections to ensure LOTO is being properly applied in your
facility, and a means to enforce compliance.

Your means to enforce compliance may be a graduated system of steps.

10
 Machine Specific Procedures
1910.147(c)(4)(ii) The procedures shall
clearly & specifically outline:
z Specific procedural steps for shutting
down, isolating, blocking & securing
machines or equip. to control
hazardous energy;
z Specific procedural steps for the
placement, removal & transfer of
lockout devices or tagout devices
z 1910.147(c)(4)(i) "Exception:" The
employer need not document the
required procedure for a particular
machine or equipment, when all of the
following elements exist:.......

I have seen many LOTO programs that contain one generic set of
procedures that say something like "locate and turn off all energy
sources." That is not an energy control program or even a procedure.
You must have written step-by-step procedures for every piece of
equipment that has more than one energy source. That energy source
and how to turn it off must be obvious.

11
 Machine Specific Procedures
1910.147(c)(4)(ii) The procedures shall
clearly & specifically outline:
z Specific procedural steps for shutting
down, isolating, blocking & securing
machines or equip. to control
hazardous energy;
z Specific procedural steps for the
placement, removal & transfer of
lockout devices or tagout devices

Specific procedural steps means the steps required for that particular
piece of equipment.

12
 Devices
zEnergy Isolation Devices
–Switches
–Valves
zLOTO Devices
–Tags
–Locks
–Devices that make EIDs lockable

Energy isolation devices are the switches, valves and other controls that
turn off the energy used by the piece of equipment.

LOTO devices include tags and locks as well as the many special
devices available that make other wise unlockable energy isolation
devices lockable. An example is a circuit breaker cover. Most circuit
breakers are not lockable but you still must lock them because you can
purchase a device that makes them lockable.

13
 LOTO Procedures
zpreparation for shut down
zshut down
zisolate
–including type and magnitude of energy
zblock
zrelease stored energy
out
Lock t
zverification Tago
u

zre-energization

Each individual LOTO procedure (procedure for a single piece of equipment) must include each
of these seven steps:

Preparation for shut down would include things like notifying all affected parties, a list of the
LOTO devices needed, a copy of the proper procedure - preferably in the form of a check-off
sheet.

Shut down would be the manner in which you normally turn the piece of equipment off.

Isolation would be the physical act of turning off the switch, valves etc. This procedure
must explain the type and magnitude of energy been isolated.

Blocking is the use of a physical block to stop something from moving. For example, using the
post to block open a doorway that opens vertically.

Release of stored energy includes specific instructions on how to release all potential stored
energy in the piece of equipment.

The verification step is required (where possible) for each isolation and blocking step. For
example, verifying the isolation of electrical energy may include turning on a switch to ensure
nothing happens. The final verification step would be to turn on the piece of equipment in the
normal fashion and make sure it doesn’t come on. There once was a man who failed to do that
and was killed by electrical energy. He had LOTOed the wrong piece of equipment. There were
several identical pieces of equipment in a row and he LOTOed the wrong one.

Re-energization is a step-by-step procedure explaining how to re-energize the equipment.

14
 Machine Specific Procedures

Example

Following is an example of a LOTO procedure. Yours does not have to

be exactly like this, but it should serve the same functions as this one.

15
 13.3 FIELD CHECKLIST - Cropper

Department: Work Area: Equipment/Machine:

Process:
Research Laboratory West Clean Room MOCVD Research
Reactor

ENERGY

Type Stored or Magnitude Initial Shutdown

Direct
A Electrical Direct 12,000 VDC On/Off switch at Ion Gauge
Controller Panel

B Electrical Direct 208 VAC Quick Disconnect power connector

at Cryo-Pump
-8
C Vacuum Stored 10

D Chemical Direct House On/Off switch at Helium compressor

(Helium) Supply in basement support area
E Thermal Direct Heat Flexible electric heating tape

Step Isolation Energy LOTO Device Comments Verification

Device Type &
Device
Location
1 On/Off switch Disconnect Attach exhaust Devices in Operate
at Ion Gauge pump power hose to the "Off" Start Button
Contoller connector pressure relief Position on Panel
Panel valve

Page 1 of 3 Initial

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Step Isolation Energy LOTO Device Comments Verification
Device Type &
Device
Location
2 Hydraulic Direct - None: Pumps Operate
Valves CRV1-5 on Insure Isolated by Valves
CRV1,CRV2, USL System Automatic Electrical CRV1 thru 6
CRV3,CRV4, and CRV6 Bleed Down of Disconnect
CRV5, CRV6 on Cutter Line Pressure
Blade
Assembly

3 Pneumatic Direct - Lock, Tag, Apply Operate

Gate Valve Air Line to Gate Valve ver LOTO Start Button
CAS1 Cropper and Devices in on Panel
USL on Wall "Off"
Load End of Position
Cropper and Bleed
Line

4 Pneumatic Direct - Lock, Tag, 1/4 Apply Operate

CAS2 Air Line to Turn Valve LOTO Start Button
Graphite Cover Devices in on Panel
Supply "Off"
Pump on Position &
Side of Tub Bleed Line
Loader

Page 2 of 3 Initial

17
 Step Isolation Energy LOTO Device Comments Verification
Device Type &
Device
Location
5. Cooling Direct - 2 Locks, 2 Apply Bleed Line
Water - Gate Water Line Tags, 2 Gate LOTO
Valves to Cropper Valve Covers Devices in
CHWR1 and "Off"
CHWR2 Position &
Bleed Line

6 None Stored - None Release of Remove

USL System Hydraulic Bars From
Pressure USL
Could Allow
Pins
Holding
Bars to
Release
I certify that I have followed all procedures in the Energy Control Program and have
investigated the potential of any other hazardous energy or hazardous movement that
may occur during this operation.

Authorized Employee

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 "Authorized employees"
z An employee who performs
servicing or maintenance on
machines and equipment. LOTO is
used by these employees for their
own protection.
z Those who are charged with the
responsibility for implementing the
energy control procedures and
performing the service and
maintenance.

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 "Affected Employees"
zCould interfere with
Energy Isolation

Anyone who could interfere with the LOTO procedure is considered an

affected employee. That includes everyone who may be in the vicinity.

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Performance & Notification
Notification of Employees
z"Affected Employees"
notified of application
and removal
zbefore controls applied
zafter they are removed

21
 Exception to Written
Procedures
zNo Potential for Stored or
Residual Energy
zSingle Energy Source
–that will deenergize and
deactivate cont

No potential for stored or residual energy includes things like static

electricity and gravity that might not be obvious to you.

A single energy source that is the only source of energy, stored or

direct, for that piece of equipment. A grinder would be a good example.

22
 Exceptions
zlocked out by a single
device
–exclusive control of the
employee
–does not create hazards
for other employees
zNo Accidents have
occurred
This single energy source must be lockable by a single device. Single is
not intended to mean you cannot use a LOTO device and a lock.

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 Group LOTO
zTwo Types
–group devices
–group box

Group LOTO is a very often misunderstood. Group LOTO must provide the same
level of protection to each individual as if each individual had locked out and tagged
every energy source and released all stored energy. The supervisor cannot go out on
his own, lock out a piece of equipment, and then send maintenance employees to
work on the piece of equipment. Because the maintenance employees have not had
the opportunity to take a copy of the procedures and check for themselves that the
LOTO is correct they do not have the same level of protection as if they had done it
themselves. One answer is to take the group around each with their own set of
procedures and show them each LOTO, blocking, or energy release point.

There are two basic types of group LOTO. One involves the use of a LOTO devices
which locks the energy isolation device and has multiple holes for multiple locks. It
must be designed so that it cannot be opened until every single lock is removed. With
this type of group LOTO each individual working on the piece of equipment places
their own personal lock on these devices at every LOTO .

The second type of group LOTO involves the placing of only one lock and each LOTO
point, then taking the only keys for these locks and placing them in a lockable box.
Every employee working on the piece of equipment in places they are locked on the
lockable box. This keeps anyone from retrieving the keys to unlock any of the locks
until every employee has removed their lock from the LOTO box. Again each
employee would have the right to take a set of the procedures and ensure the LOTO
was done correctly.

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 Lock Removal
zwhen and how may
you cut off a
worker’s lock

There is a very specific procedure that must be in your energy control plan in the
event you must cut off a workers lock. For example, a worker forgets to remove a lock
when he is finished working on the piece of equipment. He finishes his shift and
leaves. When you find that he is gone you can’t just go and cut off his lock.

First you must try to contact him. Call him at home, on a cell phone if possible, or
anyplace you think he might be. If you get hold of him you can ask him if he
intended to leave the lock on or not. He may not have finished his maintenance work
and is planning on finishing it on the next shift. You should have two people perform
this function, one of which should be a supervisor. That gives you a witness who can say
that you tried to contact him.

If you cannot contact him first to be sure he is not still in the building. Then check the
piece of equipment and be sure that he is not inside. If he is still not found have an
authorized employee check the piece of equipment to be sure it is in working order.
The employee may have left his lock on the equipment on purpose because he hasn’t
finished his work. Then you may cut off the lock.

When the employee returns to work, there are two things that must be done. One is
discipline according to your disciplinary procedure. The second is retraining, because
he has demonstrated a lack of knowledge that he is required to have. This does not
mean he has to go through the whole course again. It means someone must go over
the procedures that he violated and be sure he understands them.

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 LOTO Training
–affected
employees
»over view of
procedures
»prohibition to
restart
Affected employee training is relatively simple. You are primarily
teaching them not to interfere with a LOTO procedure.

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 Training Required
zRecognitionof Hazardous
Energy Sources
zTypes and Magnitude of
Energy
zLOTO Methods & Means

Training authorized employees is much more involved than training

affected employees. Authorized employee training has to be site-
specific. Train them on the specific pieces of equipment that they will
be working on.

Train them on all of the different sources of hazardous energy they may
encounter in their workplace, including types and magnitude.
Thoroughly review all procedures with them.

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 Training Required
zLimitations of Tags
zRetraining Required
–change job assignments
–change in processes
–change in procedures
–inadequacies in employee's
knowledge

If you have any situations where tags can be used without a lock, explain these to
them.

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Control of Hazardous Energy (Lockout/Tagout)
29 CFR 1910.147
Overview

Workers performing service or maintenance on machinery and equipment may be

exposed to injuries from the unexpected energization, startup of the machinery or
equipment, or release of stored energy in the equipment.

The Lockout/Tagout standard requires the adoption and implementation of practices and
procedures to shut down equipment, isolate it from its energy source(s), and prevent the
release of potentially hazardous energy while maintenance and servicing activities are
being performed. It contains minimum performance requirements, and definitive criteria
for establishing an effective program for the control of hazardous energy. However,
employers have the flexibility to develop lockout/tagout programs that are suitable for
their respective facilities.

This tutorial summarizes for you the key components of the standard in a
question/answer format. This tutorial is intended to guide the user in understanding
aspects of the Lockout/Tagout standard. It is not to substitute for compliance with the
plain terms of the standard. Nothing in this tutorial is intended to diminish or otherwise
affect OSHA's authority to enforce the requirements of 29 CFR 1910.147 or of the OSH
Act, nor is it intended to create any legally enforceable right or benefit in any person.

Scope and Application

Who does this standard apply to?

ƒ General Industry workers performing servicing and/or maintenance on machines

or equipment and who are exposed to the unexpected energization, startup, or
release of hazardous energy. (a)(1)(i) Under the standard, the term
"unexpected" also covers situations in which the servicing and/or maintenance is
performed during ongoing normal production operations if:
ƒ An employee is required to remove or bypass machine guards or other
safety devices (a)(2)(ii)(A) or
ƒ An employee is required to place any part of his or her body into a point of
operation or into an area on a machine or piece of equipment where work
is performed, or into the danger zone associated with the machine's
operation. (a)(2)(ii)(B)

What activities or operations are covered?

ƒ Any servicing and/or maintenance of machines or equipment when the source of

energy to the machines or equipment is electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, or other energy.
(b) Definition of energy source

ƒ Constructing, installing, setting up, adjusting, inspecting, modifying, maintaining

and/or servicing machines or equipment, including lubrication, cleaning or
unjamming of machines or equipment, and making adjustments or tool changes,
where employees could be exposed to the unexpected energization or startup of
the equipment or release of hazardous energy.
(b) Definition of servicing and /or maintenance
Who does this standard not apply to?

ƒ General Industry workers performing servicing and maintenance on machines or

equipment who are NOT exposed to the unexpected energization or startup of the
machines or equipment, or the release of hazardous energy.

What activities and operations are not covered?

ƒ Servicing and/or maintenance of equipment performed during normal production

operations if:
ƒ The safeguarding provisions of Subpart O, and other applicable general
industry standards are effective in preventing worker exposure to hazards
created by the unexpected energization or startup of machines or
equipment, or the release of energy.
(a)(2)(ii)

ƒ Minor tool changes and adjustments, and other minor servicing activities that take
place during normal production operations which are routine, repetitive, and
integral to the use of that production equipment, as long as workers are
effectively protected by alternative measures which provide effective machine
safeguarding protection. (a)(2)(ii)(B) (NOTE:)

ƒ Construction, agriculture, and maritime employment. (a)(1)(ii)(A)

ƒ Installations under the exclusive control of electric utilities for power generation,
transmission, and distribution. (a)(1)(ii)(B)

ƒ Exposure to electrical hazards from work on, near, or with conductors or

equipment in electric utilization installations. (a)(1)(ii)(C)

ƒ Oil and gas well drilling and servicing. (a)(1)(ii)(D)

ƒ Work on cord and plug connected electrical equipment, if:

ƒ The equipment is unplugged from the energy source and the authorized
employee has exclusive control of the plug.
(a)(2)(iii)(A)

ƒ Hot tap operations that involve transmission and distribution systems for gas,
steam, water, or petroleum products on pressurized pipelines, if:
ƒ Continuity of service is essential, shutdown of the system is impractical,
documented procedures are followed, and employees are effectively
protected by special equipment. (a)(2)(iii)(B)

Purpose

What is the purpose of the standard?

ƒ To prevent injury to servicing and/or maintenance employees due to the

unexpected energization or startup of machines and equipment, or release of
stored energy. (a)(3)(i)

How is this accomplished?

 ƒ Employers must establish an energy control program, consisting of energy control
procedures, employee training, and periodic inspections to ensure that before
service and maintenance is performed, machines and equipment that could
unexpectedly startup, become energized, or release stored energy, are isolated
from their energy source(s) and rendered safe.
(a)(3)(i); (c)(1)-Energy Control Program

Definitions

What definitions are useful to understand how the lockout tagout standard will
be applied? (b)

ƒ Authorized employee: An employee who locks or tags machines or equipment

in order to perform servicing or maintenance.
ƒ Affected employee: An employee who is required to use machines or equipment
on which servicing is performed under the Lockout/Tagout standard or who
performs other job responsibilities in an area where such servicing is performed.
ƒ Other employees: All employees who are or may be in an area where energy
control procedures may be utilized.
ƒ Capable of being locked out: An energy-isolating device is considered capable
of being locked out if it:
ƒ Is designed with a hasp or other means of attachment to which a lock can
be affixed.
ƒ Has a locking mechanism built into it.
ƒ Can be locked without dismantling, rebuilding, or replacing the energy-
isolating device or permanently altering its energy control capability.
ƒ Energized: Machines and equipment are energized when they are connected to
an energy source or they contain residual or stored energy.
ƒ Energy-isolating device: A mechanical device that physically prevents the
transmission or release of energy, including but not limited to the following: A
manually operated electrical circuit breaker; a disconnect switch; a manually
operated switch by which the conductors of a circuit can be disconnected from all
ungrounded supply conductors and, in addition, no pole can be operated
independently; a line valve; a block; and any similar device used to block or
isolate energy. Push buttons, selector switches and other control circuit type
devices are not energy isolating devices.
ƒ Energy source: Any source of electrical, mechanical, hydraulic, pneumatic,
chemical, thermal, or other energy.
ƒ Lockout: The placement of a lockout device on an energy-isolating device, in
accordance with an established procedure, ensuring that the energy-isolating
device and the equipment being controlled cannot be operated until the lockout
device is removed.
ƒ Lockout device: Any device that uses positive means, such as a lock, blank
flanges and bolted slip blinds, to hold an energy-isolating device in a safe
position, thereby preventing the energizing of machinery or equipment.
ƒ Normal production operations: Utilization of a machine or equipment to
perform its intended production function.
ƒ Servicing and/or maintenance: Workplace activities such as constructing,
installing, setting up, adjusting, inspecting, modifying, maintaining and/or
servicing machines or equipment, including lubrication, cleaning or unjamming of
machines or equipment, and making adjustments or tool changes, where
employees could be exposed to the unexpected energization or startup of the
equipment or release of hazardous energy.
ƒ Tagout: The placement of a tagout device on an energy-isolating device, in
accordance with an established procedure, to indicate that the energy-isolating
 device and the equipment being controlled may not be operated until the tagout
device is removed.
ƒ Tagout device: Any prominent warning device, such as a tag and a means of
attachment, that can be securely fastened to an energy-isolating device to
indicate that the machine or equipment to which it is attached may not be
operated until the tagout device is removed.

Energy Control Program

What are the core components of the energy control program?

The energy control program has three core components: energy control procedures,
employee training, and periodic inspections.

ƒ Energy control procedures detail and document the specific information that an
authorized employee must know to accomplish lockout/tagout, namely, the scope,
purpose, authorization rules and techniques to be utilized for the control of
hazardous energy. (c)(1); (c)(4)(i); (c)(4)(ii)

ƒ Periodic inspections of the energy control procedures ensure that the procedures
and the requirements of the standard are being followed. (c)(1)

ƒ Employee training and retraining, along with additional training under a tagout
system, ensures that the purpose and function of the energy control programs are
understood by the employer. (c)(1); (c)(7)(ii)

What is the intent of the energy control program?

ƒ To ensure that before any employee services equipment where the

potential exists for unexpected energization or start-up of equipment or
the release of stored energy, the machine or equipment is isolated from
the energy source and rendered inoperative. (c)(1)

Does the employer have the flexibility to develop his/her own program?

Yes. Employers are expected to develop programs and procedures, training and
inspections, that meet the needs of their particular workplace and the particular types of
machines and equipment they use and service as long as they meet the requirements of
the standard.

Energy Control Procedures - Documentation

What is the employer's obligation in establishing energy control procedures?

Employers must develop, document, and use specific procedures to control potentially
hazardous energy when employees are servicing equipment or machinery.
(c)(4)(i)

Under what limited situations is documentation of the procedures not

required?(c)(4)(i) (NOTE:)(Exception:)
 ƒ The machine or equipment has no potential for stored or residual energy, or for
reaccumulation of stored energy after shut down, which could endanger
employees.

ƒ The machine or equipment has a single energy source that can be readily
identified and isolated and the isolation and locking out of that energy source will
completely deenergize and deactivate the machine or equipment.

ƒ The machine or equipment is isolated from that energy source and locked out
during servicing or maintenance.

ƒ A single lockout device will achieve a locked-out condition.

ƒ The lockout device is under the exclusive control of the authorized employee
performing the servicing or maintenance.

ƒ The servicing or maintenance does not create hazards for other employees.

ƒ The employer has had no accidents involving the unexpected activation or

reenergization of machines or equipment during servicing or maintenance.

Energy Control Procedures - Required Content

What specific elements must be documented in the employer's energy control

procedures?

ƒ The procedures must outline the scope, purpose, authorization, rules and
techniques that the employer will use to control hazardous energy.
(c)(4)(ii)

ƒ The procedures must state the means to be used to enforce compliance.

(c)(4)(ii)

At a minimum, the procedures must include:

ƒ A specific statement of the intended use of the procedure.

(c)(4)(ii)(A)

ƒ Specific procedural steps for shutting down, isolating, blocking, and securing
machines or equipment to control hazardous energy. (c)(4)(ii)(B)

ƒ Specific procedural steps for the placement, removal, and transfer of lockout
devices or tagout devices, and a description of who has responsibility for them.
(c)(4)(ii)(C)

ƒ Specific requirements for testing a machine or piece of equipment to determine

and verify the effectiveness of lockout devices, tagout devices, and other energy
control measures. (c)(4)(ii)(D)

Periodic Inspection
What is the intent of the requirement for the employer to conduct periodic
inspections?

To ensure that the energy control procedures continue to be implemented properly, that
the employees are familiar with their responsibilities, and that any deviations or
procedural inadequacies that are observed are corrected. (c)(6)(i); (c)(6)(i)(B)

How often must the inspection take place?

At least annually. (c)(6)(i)

Who performs the periodic inspection?

An authorized employee not involved in the energy control procedure being inspected.
(c)(6)(i)(A)

What does the periodic inspection entail?

ƒ The employer must identify any deficiencies or deviations and correct them.
(c)(6)(i)(B)

ƒ Where lockout is used, the inspector must review each authorized employee's
responsibilities under the procedure with that employee (group meetings are
acceptable). (c)(6)(i)(C)

ƒ Where tagout is used, the inspector must review both the authorized and affected
employee's responsibilities with those employees for the energy control procedure
being inspected, and the additional training responsibilities of 1910.147(c)(7)(ii).
(c)(6)(i)(D)

ƒ The employer must certify that the periodic inspections have been performed.
(c)(6)(ii)

What must the certification identify?

ƒ Identify machine on which the procedure was utilized. (c)(6)(ii)

ƒ Date of inspection. (c)(6)(ii)

ƒ Identify the employees included in inspection. (c)(6)(ii)

ƒ Identify person who performed the inspection. (c)(6)(ii)

Employee Training and Communication

Why must employees be trained?

ƒ So that they understand the purpose and function of the energy control program.
(c)(7)(i)
 ƒ So that employees acquire the knowledge and skills necessary for the safe
application, usage and removal of the energy controls. (c)(7)(i)

The standard requires different levels of training for the three categories of
employees; what are the differences in the training required for the three
categories?

ƒ Authorized employees must receive training on the recognition of applicable

hazardous energy sources, the type and magnitude of the energy available in the
workplace, and the methods and means necessary for energy isolation and
control. (c)(7)(i)(A)

ƒ Affected employees must receive training on the purpose and use of the energy
control procedure. (c)(7)(i)(B)

ƒ Other employees (those whose work activities are or may be in an area where
energy control procedures may be utilized) must be instructed about the
procedure and about the prohibition relating to attempts to restart or reenergize
machines or equipment that are locked out or tagged out. (c)(7)(i)(C)

What additional training is required when tagout systems are used?

Employers must train employees in the following limitations of tags

(c)(7)(ii):

ƒ Tags are essentially warning devices affixed to energy isolating devices and do
not provide the physical restraint on those devices that is provided by a lock.
(c)(7)(ii)(A)

ƒ When a tag is attached to an energy isolating means, it is not to be removed

without authorization and it is never to be bypassed, ignored, or otherwise
defeated. (c)(7)(ii)(B)

ƒ Tags must be legible and understandable by all employees.

(c)(7)(ii)(C)

ƒ Tags and their means of attachment must be made of materials which will
withstand the environmental conditions encountered in the workplace.
(c)(7)(ii)(D)

ƒ Tags may evoke a false sense of security and their meaning needs to be
understood as part of the overall energy control program.
(c)(7)(ii)(E)

ƒ Tags must be securely attached to energy isolating devices so that they cannot be
inadvertently or accidentally detached during use.
(c)(7)(ii)(F)

Employee Retraining

Who must be retrained?

All affected and authorized employees must be retrained under certain conditions listed
below. (c)(7)(iii)(A)

Is training required annually?

No.

What triggers the retraining requirements?

ƒ A change in job assignments. (c)(7)(iii)(A)

ƒ A change in machines, equipment, or processes that present a new hazard.

(c)(7)(iii)(A)

ƒ A change in the energy control procedures. (c)(7)(iii)(A)

ƒ Periodic inspections reveal that there are deviations in the energy control
procedure. (c)(7)(iii)(B)

ƒ The employer believes that there are deviations from, or inadequacies in, the
employee's knowledge or use of the energy control procedures. (c)(7)(iii)(B)

What is the object of the retraining?

ƒ To introduce new or revised control methods and procedures as necessary.

(c)(7)(iii)(C)

ƒ To reestablish employee proficiency. (c)(7)(iii)(C)

Does training require certification?

Yes. Employer must certify that training or retraining took place and that the employee is
kept up to date. (c)(7)(iv)

What information must appear on the certificate?

ƒ Each employee's name. (c)(7)(iv)

ƒ The dates of training and /or retraining. (c)(7)(iv)

Lockout/Tagout

If an energy isolating device is not capable of being locked out, can the
employer use a tagout system?

Yes, if an energy isolating device is not capable of being locked out, the employer's
energy control program must use a tagout system. (c)(2)(i)

If an energy isolating device is capable of being locked out, must the employer
use a lock out system?
Yes. Unless the employer can demonstrate that the tagout system will provide full
employee protection, as described in paragraph (c)(3) of the standard.
(c)(2)(ii) (The employer may choose to use a tagout system as long as the
requirements for additional training and periodic inspections are met. )

New or Modified Equipment

What is the date after which all new machines and equipment, or all machines
and equipment that undergo major repair, renovations or modification, must be
equipped with energy-isolating devices capable of accepting a lockout device?

January 2, 1990. (c)(2)(iii)

Full Employee Protection

What are the requirements for the use of tagout devices when lockout devices
are capable of being used?

ƒ The tags are attached where the lockout devices would be. (c)(3)(i)

ƒ The employer demonstrates that the tagout will provide protection at least as
effective as locks and will assure full employee protection.
(c)(3)(i)

How does an employer demonstrate that the protection achieved using the
tagout program is equivalent to the level of safety obtained by using a lockout
program?

The employer must comply with all tagout-related provisions and also use additional
safety measures that provide a level of safety equivalent to that obtained by using
lockout. This might include removing and isolating a circuit element, blocking a
controlling switch, opening an extra disconnecting device, or removing a valve handle to
reduce the potential for any inadvertent energization while the tags are attached.
(c)(3)(ii)

Materials and Hardware

What protective materials and hardware must be provided by the employer for
isolating, securing or blocking machines or equipment from their energy
sources?

ƒ Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or
other hardware. (c)(5)(i)

What are the requirements for the lockout and tagout devices?

ƒ Must be durable, so that they are capable of withstanding the environment to

which they are exposed for the maximum period of time that exposure is
expected. (c)(5)(ii)(A)(1)

ƒ Must be singularly identified. (c)(5)(ii)

 ƒ Must be the only devices used for controlling energy. (c)(5)(ii)

ƒ Must not be used for other purposes. (c)(5)(ii)

ƒ Must be standardized within the facility in at least one of the following criteria:
color, shape, or size. Additionally, tagout devices must be standardized as to print
and format. (c)(5)(ii)(B)

ƒ Must be identifiable, in that it indicates the identity of the employee applying the
devices. (c)(5)(ii)(D)

In addition to the above, what other hardware requirements are specific to

lockout?

ƒ Must be substantial enough to prevent removal without the use of excessive force
or unusual techniques such as with the use of bolt cutters or other metal cutting
tools. (c)(5)(ii)(C)(1)

In addition to the above, what other hardware requirements are specific to

tagout?

ƒ Must be constructed and printed so that exposure to weather conditions or wet

and damp locations will not cause the tag to deteriorate or the message on the
tag to become illegible. (c)(5)(ii)(A)(2)

ƒ Must not deteriorate when used in corrosive environments such as areas where
acid and alkali chemicals are handled and stored. (c)(5)(ii)(A)(3)

ƒ Must be standardized in print and format. (c)(5)(ii)(B)

ƒ Must be substantial to prevent inadvertent or accidental removal.

(c)(5)(ii)(C)(2)

ƒ Must have an attachment means of a non-reusable type, attachable by hand, self-

locking, and non-releasable with a minimum unlocking strength of no less than 50
pounds and having the general design and basic characteristics of being at least
equivalent to a one-piece all-environment-tolerant nylon cable tie.
(c)(5)(ii)(C)(2)

ƒ Must warn against hazardous conditions if the machine or equipment is energized.

(c)(5)(iii)

ƒ Must include a legend such as: Do Not Start, Do Not Open, Do Not Close, Do Not
Energize, Do Not Operate. (c)(5)(iii)

Application of Energy Control

To safely apply energy control to machines or equipment (using either lockout

or tagout devices), authorized employees must perform certain procedures, in a
specific order. What are the sequential procedures?
 ƒ Preparation for shutdown: Before an authorized or affected employee turns off
a machine or equipment, the authorized employee must have knowledge of the
type and magnitude of the energy, the hazards of the energy to be controlled,
and the method or means to control the energy. (d)(1)

ƒ Machine or equipment shutdown: The machine or equipment must be turned

off or shut down using the procedures established for it to avoid any additional or
increased hazards to employees as a result of the machine or equipment
stoppage. (d)(2)

ƒ Machine or equipment isolation: All energy-isolating devices that are needed

to control the machine's energy source must be located. These devices must then
be used to isolate the machine or equipment from its energy source(s).
(d)(3)

ƒ Lockout or tagout device application: Lockout or tagout devices must be

affixed to each energy-isolating device by authorized employees. Lockout devices
where used, must be affixed in a manner that will hold the energy isolating
devices in a "safe" or "off" position. Where tagout devices are used, it must be
affixed in a manner that will clearly indicate that the operation or movement of
energy isolating devices from the "safe" or "off" position is prohibited. If the tag
can not be affixed directly to the energy isolating device, the tag must be located
as close as safely possible to the device, in a position that will be immediately
obvious to anyone attempting to operate the device. (d)(4)(i)-(d)(4)(iii)(B)

ƒ Stored energy: After the energy-isolating device has been locked out or tagged
out, all potentially hazardous stored or residual energy must be relieved,
disconnected, restrained, and otherwise rendered safe. (d)(5)(i)

ƒ Verification of isolation: Before any work begins on machines or equipment

that have been locked out or tagged out, an authorized employee must verify that
the machine or equipment has been properly isolated and deenergized.
(d)(6)

Release from Lockout/Tagout

The Lockout/Tagout standard includes requirements for releasing machines or

equipment that have been locked out or tagged out prior to restoring energy to
the equipment and using it. Before lockout or tagout devices are removed, and
energy restored, what procedures must the authorized employee follow?

ƒ Machine/equipment inspection: The work area must be inspected to ensure

that nonessential items (e.g., tools, spare parts) have been removed and that all
of the machine or equipment components are operationally intact. (e)(1)

ƒ Positioning of employees: The work area must be checked to ensure that all
employees have been safely positioned or have cleared the area. In addition, all
affected employees must be notified that the lockout or tagout devices have been
removed before the equipment is started. (e)(2)(i)-(e)(2)(ii)

ƒ Lockout or tagout device removal: Each lockout or tagout device must be

removed from the energy-isolating device by the employee who applied the
device. (e)(3)
What is the unique circumstance that allows an employee other than the one
who applied the lockout/tagout device to remove the device?

When the authorized employee who applied the lockout or tagout 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. (e)(3)
Exception

What steps must the employer take if an employee, other than the one who applied the
lockout/tagout device, removes the device?

ƒ The employer must verify that the authorized employee who applied the device is
not at the facility. (e)(3)(i)

ƒ The employer must make all reasonable efforts to contact the authorized
employee to inform him/her that his/her lockout or tagout device has been
removed. (e)(3)(ii)

ƒ The employer must ensure that the authorized employee knows that the lockout
device has been removed before he/she resumes work at the facility.
(e)(3)(iii)

Testing of Machines

When may lockout or tagout devices be removed temporarily?

In some circumstances, employees need to temporarily restore energy to a machine or

piece of equipment during servicing or maintenance to test and /or reposition the
machine or piece of equipment. Lockout or tagout devices may be removed temporarily
in order to perform these tasks. (f)(1)

What sequence of action must occur in the temporary removal of the

lockout/tagout devices?

1. The machine or equipment must be cleared of tools and materials. (f)(1)(i)

2. Employees must be removed from the machine or equipment area. (f)(1)(ii)
3. All lockout or tagout devices may then be removed. (f)(1)(iii)
4. Authorized employees may then proceed to energize and test or position the
equipment or machinery. (f)(1)(iv)
5. Following testing or positioning, all systems must be deenergized and energy
control measures reapplied to continue the servicing and /or maintenance.
(f)(1)(v)

Outside Personnel (Contractors)

What are the obligations of the outside contractor and the on-site employer?

ƒ Whenever contractors and other outside servicing personnel

perform tasks covered by the Lockout/Tagout standard, they
must adhere to all the standard's requirements. (a)(1); (a)(2);
(a)(3)(i); (f)(2)(i)
 ƒ The contractor or outside employer and the on-site employer must inform each
other of their respective lockout or tagout proecedures. (f)(2)(i)

ƒ The on-site employer must ensure that his/her employees understand and comply
with the restrictions and prohibitions of the outside employer's energy control
program. (f)(2)(ii)

Group Lockout/Tagout Requirements

Can servicing or maintenance be performed by a crew, department, or other

group under this standard?

Yes. If they have been properly trained and the energy control program is followed.
(f)(3)(i); (c)(7)

What procedures must be followed that, when a group is performing servicing

and/or maintenance, will offer group employees the same protection that the
standard provides to individual employees?

ƒ Protection must be utilized which affords the employees a level of protection

equivalent to that provided by the implementation of a personal lockout or tagout
device. (f)(3)(i)

ƒ Primary responsibility for a set number of employees working under the

protection of a group lockout or tagout device must be vested in a single
authorized employee. (f)(3)(ii)(A)

ƒ The single authorized employee must determine the exposure status of individual
group members. (f)(3)(ii)(B)

ƒ If there will be more than one crew, department, or group involved in the activity,
a single authorized employee must be designated to coordinate affected
workforces and to ensure continuity of protection. (f)(3)(ii)(C)

ƒ Each authorized employee must affix a personal lockout or tagout device as

required in the standard when work begins and remove it when work is
completed. (f)(3)(ii)(D)

Shift and Personnel Changes

How is the continuity of lockout or tagout protection maintained during shift or

personnel changes?

ƒ Employers must ensure the continuity of employee protection by providing for the
orderly transfer of lockout or tagout device protection between off-going and
incoming employees. This will help to minimize exposure to hazards from the
unexpected energization or start-up of the machine or equipment or the release
of stored energy. (f)(4)

(The Appendix to 1910.147 offers non-mandatory guidelines to help employers and

employees in complying with the requirements of this section, as well as to provide other
helpful information.)