Lockout/tagout was the most frequently cited standard in 2006. It requires employers to have a written program including energy control procedures for each machine or piece of equipment. Employers must provide training to employees and periodically review the program. The standard aims to prevent injuries by ensuring that hazardous energy is isolated and controlled before employees perform service or maintenance on machines.

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

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

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

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 deenergize
 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 deenergized

31. Lockout procedure – Step 8

RELEASE FROM LOCKOUT OR TAGOUT
 Inspect
work area to ensure removal of nonessentials
 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 reentering
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. Disconnect
Allows for
identification

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
