The document outlines the Energy Control Procedures for Lockout/Tagout as specified by OSHA regulations, particularly 29 CFR 1910.147. It emphasizes the importance of a written program that includes procedures for energy isolation, employee training, and periodic inspections, detailing steps for effective lockout/tagout practices. Additionally, it provides exceptions, definitions, and procedures for maintaining safety during servicing and maintenance operations in various industrial settings.

1. Energy Control
Procedures
Lockout/Tagout
29 CFR 1910.147
Georgia Tech Research Institute

2. 2
Most Frequently Cited Serious
Violations in General Industry
FY 2006
1418
1155
733
689
645
589
572
564
556
522
212(a)(1) - O
1200(e)(1) - Z
212(a)(3)(ii) - O
23(c)(1) - D
1200(h)(1) - Z
151(c) - K
147(c)(1) - J
215(b)(9) - O
147(c)(4)(i) - J
305(b)(1) - S
Standard
&
Subpart:
1910.
Machine Guards - General
Eye & Body Flushing Facilities
Point of Operation
Open-Sided Floors
Conductors Entering Cabinets/Boxes/Fittings Protected from Abrasion
Lockout/Tagout - Program
Grinders-Tongue Guards
Hazard Communication – Information & Training
Note: There were also 1222 Section 5(a)(1) General Duty Clause violations cited for all inspections
during this period.
Lockout/Tagout - Procedures
Hazard Communication – Written Program

3. 3
Subpart J - General Environmental
Controls (1910.141 - 147)
572
556
448
342
188
147(c)(1)
147(c)(4)(i)
147(c)(7)(i)
147(c)(6)(i)
147(c)(4)(ii)
Lockout/Tagout - Program
Lockout/Tagout - Training
Lockout/Tagout - Procedures
Lockout/Tagout - Content of energy control procedures
Standard:
1910.
Lockout/Tagout procedure - Periodic inspection

4. What is covered?
 Servicing and maintenance
 Normal production operations where:
 Employees by-pass guard(s)
 Employees place any part of their body in a
hazardous area
When you are training it is important to cover the
relationship between Subpart O-Machine Guarding
and Lockout Tagout!!

5. What is not covered?
 Construction, agriculture, and maritime
 Normal production operations (subpart O)
 Cord-and-plug under the control of
employee (written procedure still required)
 Exposure to electrical conductors (subpart
S and electrical safety-related work
practices)

6. Locked Out?????????

7. Energy types
 Electrical
 Mechanical
 Hydraulic
 Pneumatic
 Chemical
 Thermal
 Other

8. Lockout vs. Tagout
 If capable of being locked out:
Prefer lockout
Tags allowed, if employer can demonstrate
FULL EMPLOYEE PROTECTION
 Machine Modifications
If you alter a machine you must make the
machine capable of accepting a lock.

9. Full employee protection?
 Tags attached at the same location as
locks
 Full compliance with all tagout provisions
in 29 CFR 1910.147
 Additional means when necessary (e.g.
removal of a valve handle)

10. Definitions
 Affected employee
 Authorized employee
 Capable of being locked out
 Energy isolating device
 Servicing and/or maintenance

11. Servicing and maintenance
includes:
 Setting up
 Adjusting
 Inspecting
 Modifying
 Installing

12. Lockout/tagout requirements
 Written program which includes specific
written procedures
 Training of employees (not just
maintenance!)
 Periodic review of procedures

13. Written lockout/tagout
procedure
(Equipment Specific Procedures)
 Clearly and specifically outline
Scope
Purpose
Authorization
Rules, techniques for control of energy

14. Lockout procedure (cont.)
 Clearly and specifically outline:
Means to enforce compliance including:
 Intended use of procedure
 Specific procedural steps
 Specific testing requirements

15. Documentation exceptions:
 Machine has no potential for stored energy
 Machine has a single energy source
 Isolation of that source will completely de-
energize
 Machine is isolated and locked out during
maintenance

16. Documentation exceptions
(cont.)
 A single lockout device will achieve
locked-out condition
 Lockout device under exclusive control of
employee
 Maintenance does not create hazard to
others
 No previous accidents involving
unexpected energization on this
equipment

17. Energy control procedure
 Notification of employees
 Preparation for shutdown
 Machine or equipment shutdown
 Machine or equipment isolation
 Lockout/tagout device application
 Stored energy
 Verification of isolation
 Release from lockout/tagout

18. Equipment Specific Procedures

19. Lockout procedure – Step 1
 NOTIFICATION OF EMPLOYEES
Before controls are applied, and before they
are removed

20. Lockout procedure – Step 2
 PREPARATION FOR SHUTDOWN
Knowledge of the type and magnitude of
energy and methods to control energy

21. Lockout procedure – Step 3
 MACHINE OR EQUIPMENT SHUTDOWN
Orderly shutdown to avoid increased hazard

22. Lockout procedure – Step 4
 MACHINE OR EQUIPMENT ISOLATION
All energy isolation devices located and
operated to isolate machine

23. Line breaking:
Means the intentional opening of a pipe,
line, or duct that is or has been carrying
flammable, corrosive, or toxic material, an
inert gas, or any fluid at a volume,
pressure, or temperature capable of
causing injury

24. Line blanking or blinding:
Means the absolute closure of a pipe, line,
or duct by fastening of a solid plate that
completely covers the bore and that is
capable of withstanding the maximum
pressure of the pipe, line, or duct with no
leakage beyond the plate.

25. Double block and bleed:
Means the closure of a line, duct, or pipe by
closing and locking or tagging two in-line
valves and by opening and locking or
tagging a drain or vent valve in the line
between the two closed valves.

26. Lockout procedure – Step 5
 LOCKOUT OR TAGOUT DEVICE
APPLICATION
Affixed by authorized employee holding
energy isolating device in the safe or off
position

28. Lockout procedure – Step 6
 STORED ENERGY
Relieve all stored energy and continue to
verify if there is a chance of re-accumulation

29. Stored energy examples
 Batteries and capacitors
 Pressure differential
Hydraulic
Pneumatic
Vacuum
 Springs
 Gravity

30. Lockout procedure – Step 7
 VERIFICATION OF ISOLATION
Prior to servicing or maintenance, authorized
employee must verify machine has been de-
energized

31. Lockout procedure – Step 8
 RELEASE FROM LOCKOUT OR TAGOUT
 Inspect work area to ensure removal of non-
essentials
 Employees safely positioned and notified
 Lockout/tagout removal (by employee who applied)

32. Lock/tag removal if authorized
employee is not available?
 Verify that authorized employee is not at facility
 Make reasonable efforts to inform him or her
 Ensure that he/she knows of removal upon re-
entering
MUST INCLUDE THIS PROCEDURE IN
WRITTEN PROGRAM

33. Hardware requirements
 Durable
 Standardized
 Substantial
 Identifiable

34. Hardware must be:
 Provided by the employer
 Singularly identified
 Only devices used for control
 Not used for other purposes

35. Hardware must be (cont.):
 Durable – be able to withstand
environment
 Standardized – color, size, etc.
Tags : print and format
 Substantial – no accidental removal
Tag attachment means:
 Withstand at least 50 pounds of force
 Not re-usable
 Self locking
 Attachable by hand

36. Durable…

37. Hardware must be (cont.):
 Identifiable – identify the employee who
applied
Tags must include legend such as DO NOT
START

38. Locked Out Tagged Out of
Service

40. Hmmm?

41. Allows for
identification
Disconnect

44. Periodic Inspection
 Performed at least annually
 Lockout – include review with authorized
employees
 Tagout – include review with authorized and
affected employees
 Certification record kept:
 Identify machine or equipment
 Date of inspection
 Employees performing and included in inspection

45. Training and re-training
 Authorized employees
Recognition of hazardous energy
Type and magnitude of hazardous energy
Methods of isolating energy
How to verify isolation
 Affected – Purpose and use of procedure
 Other – Procedure and Prohibition from
tampering
 Tagout provisions

46. Re-training is required when:
 Change in job assignment
 Change in machine or process
 Change in lockout/tagout procedure
 Inadequacies revealed in periodic review

47. Training certification
 Certify that the training has been
conducted and kept up to date:
Employee names
Date(s) of training

48. Other requirements
 Contractors?
 Personnel or shift changes?

49. Testing or positioning machines
 Clear the machine of tools and materials
 Remove employees from the area
 Remove lockout/tagout devices
 Energize and proceed with
testing/positioning
 De-energize and re-apply energy control
measures

50. Group lockout
 Personal lock or tag (usually)
 Lockbox or master tag system with
principal authorized employee
“Shall utilize a procedure which affords a
level of protection equivalent to that
provided by the implementation of a
personal lockout or tagout device”

51. Group Lockout
Each exposed employee must be provided the same level of
protection…Each person must be protected by their own lock!

52. TRAINING
 General
Operation
Steps to:
 Change
 Set up
 Clean
 Second Nature
 Feedback from Employees

53. Training (cont.)
 Inspections
Hazard Assessment (Training of Operators)
Incorrect Procedures (Training of Supervisors)
 Documentation
Training
Retraining

54. Minor Servicing Exemption
 Activities which are routine, repetitive, and
integral to the use of the equipment for
production are not covered by this standard if
alternative measures provide effective protection.
 Activity must be conducted during normal
production operations
 Activity must be routine (regular course of
procedure in accordance with established
practices), repetitive (regularly repeated as part
of production), and integral (essential to the
production process).

58. Lockout/ Tagout Tech Guide
available @
www.oshainfo.gatech.edu

59. SUMMARY
 Written program including written
procedures for each machine
 Training of employees
 Periodic review of program
 ENFORCEMENT