CONTROL OF

HAZARDOUS ENERGY
Bureau of Workers Comp
PA Training for Health & Safety
(PATHS)

OSHA 29 CFR 1910.147

LOCK OUT -
TAG OUT

(LOTO)

PPT-026-01 1
 LOTO Mishaps are Severe!

Average lost work

days for failure to
LOTO is 24 days per
injury.

120 annual
workplace fatalities
are related to failure
to LOTO.

PPT-026-01 2
Tag Center

Centralized
point to keep
appropriate
tags

PPT-026-01 3
Purpose of the LOTO Standard

If a risk exists to any

person upon unexpected
start up or sudden
release of stored energy,
all protective measures
must be taken to isolate
all sources of hazardous
energy.

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 Authorization

Any employee who

may be involved in
the service or
maintenance of any
machine or
equipment that has
potential for release
of hazardous energy
is authorized to lock-
out/tag-out if he or
she is trained.

PPT-026-01 5
 What Should be Done?

Determine which
machines/equipment need to
be locked/tagged out (e.g., by
JHA/inspection/knowledge).

Appoint a program
administrator.

Purchase appropriate locks

and tags.

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What Should be Done?

Develop program

Determine status of employees

(authorized, affected, etc.)

Provide training

Implement program

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 Program Responsibility

Responsibility should be given to a

program administrator for:
lock acquisition
safe work procedures
training coordination
contractor coordination
assisting supervisors in implementation
and enforcement of disciplinary actions
for non-compliance

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Program Responsibility

Conducting periodic inspections

Documenting changes in control

program as result of inspections

Assisting in development of specific

procedures

Maintaining program availability for

employees and interested persons

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 When to Apply LOTO

Application of lock-out/tag-out is required . . .

When servicing and/or maintaining
machines or equipment,

When its necessary to remove a guard or

bypass safety device or interlock, or

If an employee has the potential to be

exposed to material being processed (point
of operation) or the machine operating
cycle.

PPT-026-01 10
 OSHA Exception on LOTO

Minor tool changes, adjustments or other

minor servicing activities which take place
during normal production operations, if they
are routine, repetitive and integral to the use
of the equipment for production provided
alternative measures are used that offer
effective protection!

Could changing a
Yes, provided above
drill bit qualify as
criteria is met
an exception?

PPT-026-01 11
 Exclusions

The LOTO standard does not apply to:

Cord and Plug Electrical Equipment

Plug has to be under the exclusive control of the
employee performing servicing or maintenance

Hot tap operations = welding on transmission and

distribution systems (water, gas, steam or petroleum
products) when performed on pressurized pipelines,
provided the employer demonstrates that:
Continuity of service is essential
Shutdown of system is impractical
Documented procedures are followed
Special equipment is used to provide proven
effective protection for employees
PPT-026-01 12
 Authorized Devices

Shall be capable of
withstanding the environment
to which they are exposed for
the maximum period of time
that exposure is expected.

Tag-out devices must be

constructed and printed so
that exposure to weather will
not cause deterioration or the
message to become illegible.

Shall indicate the identity of

the person applying the
device.

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 Documented Procedure for
Every Machine

Not necessary if everything listed below exists:

Machine/equipment has no potential for stored or

residual energy or re-accumulation of stored energy
after shut down, which could injure employees
Machine/equipment has single energy source readily
identified and isolated
Isolation and LOTO of that energy source will
completely de-energize and deactivate
machine/equipment
Machine/equipment is isolated from that energy
source and locked out during servicing/maintenance

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 Documented Procedure
for Every Machine

Not necessary if all exist:

Single LOTO device will achieve a locked-out

condition
LOTO device is under the exclusive control of
the authorized employee performing
servicing/maintenance
Servicing/maintenance does not create hazards
for others
The employer has had no accidents involving
unexpected activation/re-energization of
machine/equipment being serviced/maintained.
PPT-026-01 15
 Authorized Employee

Person who locks or

tags-out machine.

Recommendation: The
appendix of your LOTO
program should contain
a list of authorized
employees for the
particular area/facility.

PPT-026-01 16
 Affected Employee

Employees whose job

requires them to
operate the machine or
process on which
maintenance or service
is being performed

Need to be notified
upon shut down and
start up

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Affected Work Station

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 Individual Lock-Out

Shut down machine; power control off; lock-out

Stored energy dissipated and then isolated

Engage controls for machine operation,

verify OFF

Work may proceed

If shift changes, individual LOTO repeated

by next shift

PPT-026-01 19
 Restoring Equipment
to Service

Replace all guards and safety devices

Inspect work area to ensure all

nonessential items have been removed
and machine/equipment components are
operationally intact

Vents and bleeders closed, blinds removed,

blocks and tags removed

Employees notified and moved to safe area

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 Restoring Equipment
to Service

Each employee removes his or her lock

Machine is restarted to ensure it is working

properly/safely

Affected employees are notified that

machine/equipment is back in service

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 Group Lock-Out

Same as individual lock-out, except:

Primary responsibility vested in authorized
employee for set number of employees
involved
Provision for authorized employee to ascertain
exposure status of individual group members
When more than one crew, craft, department,
etc., is involved, LOTO responsibility given to
one authorized employee for coordination
Each authorized employee affixes personal
LOTO device to group LOTO device/lockbox
when they begin work

PPT-026-01 22
 Group Restoration
to Service

Each trade - replace all guards and safety

devices

Vents and bleeders closed, blinds removed,

blocks and tags removed

Each employee removes his or her lock

PPT-026-01 23
 Group Restoration
to Service

Employees are notified and removed to a

safe distance

Group authorized person ensures machine

device is operating properly/safely

Group authorized person notifies all

personnel/affected employees that
machine/equipment is back in service

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 Long Term Safety Lockout

Extended period of
time - machines use
discontinued or is no
longer part of
operation

Long-term locks
available for use by
the responsible
person

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 Unauthorized Removal

Consequences of unauthorized removal of LOTO

devices should be in the program (let all
personnel know what actions occur if somebody
removes or damages LOTO devices without
authorization)

Example: Only an authorized person can remove

personal locks (list names and departments of
authorized persons). If a LOTO device is
removed, damaged or disabled, the responsible
employee will receive disciplinary action pursuant
to .
PPT-026-01 26
 Subject to
Disciplinary Action

All involved parties for failure to

implement LOTO (including supervisors)

Misuse of LOTO equipment

Contractors who fail to adhere

PPT-026-01 27
 Tags

Tags are used if energy-

isolating device not capable of
being locked out.

Tags should not be removed

without authorization of the
authorized person responsible
for it.

Tags must be legible and

understandable by all
employees.

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 Tags

Tags and their means of attachment must

be made of materials that can withstand
environmental conditions

Tags must be securely attached to energy-

isolating devices

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 Training

1910.147 (c)(7)(i) = The employer shall

provide training to ensure that the purpose
and function of the energy control program
are understood by employees and that the
knowledge and skills required for the safe
application, usage and removal of the energy
controls are acquired by employees.

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 Training
All Employees

Training should include:

Purpose of LOTO program

Use of the energy-control program

LOTO devices and plant specifics

Rules and consequences of unauthorized

removal of LOTO devices

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 Training Authorized Employees
List & Identify all Sources of Energy

Electrical
Hydraulic
Pneumatic
Thermal
Chemical
Mechanical
Cord & Plug Equip.
Other Types

PPT-026-01 32
Training Authorized Persons

In addition to basic LOTO training given to all

employees, training for authorized persons
should also include:
When to implement LOTO

Recognition of hazardous energy sources

Type and magnitude of energy in workplace

Returning equipment to service

If questions on applicationspecific actions

to be taken
PPT-026-01 33
 Retraining
Authorized & Affected Persons

Required when:

New equipment is
brought into the
workplace
Change in job
assignment
Changes in LOTO
equipment
Periodic audit
identifies need
PPT-026-01 34
 Periodic Inspection

Periodic inspection should be

performed at least annually by
an authorized employee other
than the one(s) using the energy
control procedure being
inspected.

Periodic inspections are

conducted to correct deviations
or inadequacies.

Certify inspections done:

- identify machine or equipment
- date of inspection
- person performing inspection
- employees included

PPT-026-01 35
Testing/Positioning of Machines,
Equipment, Components

In situations where LOTO devices must be

temporarily removed from the energy- isolating
device and the machine/equipment has to be
energized to test or position:
Clear the machine or equipment of tools and
materials
Remove employees from the machine or
equipment area
Remove the LOTO devices
Energize and proceed with testing/positioning
De-energize all systems and reapply energy-
control measures to continue
servicing/maintaining
PPT-026-01 36
 Contractors

Exchange of LOTO
procedures

Agreement of
procedures before work
begins

Discipline of contractor
and/or contractor
employees for failure to
use LOTO

PPT-026-01 37
Appropriate Posting

PPT-026-01 38
 End Result

Due to OSHA and as a best practice, facilities

should have a LOTO program in place where
appropriate.

Employees should receive LOTO training as

appropriate, and training should be documented.

Employees need to understand that when LOTO

is in use, they should not attempt to remove or
otherwise re-energize the machine.

PPT-026-01 39
Any Questions

PPT-026-01 40