MODULE 20
Lockout/Tagout
1910.147(a)(1) Scope
 Covers servicing and maintenance of
machines and equipment in which
 Unexpected energization or start up or
 Release of stored energy could cause
 Injury to employees
 Normal operation is
covered in 1910
Subpart O
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1910.147(a)(1)(ii) Exemptions
 Construction, agriculture and maritime
employment;
 Electrical Utilities;
 Electrical equipment (covered by
Subpart S)
 Oil and gas well drilling and servicing
 So why comply?
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Control of Hazardous Energy
 Why use lockout/tagout?
 Protects maintenance personnel from
power being reapplied by mistake
 Recommended by API RP 54 for
electrical systems in drilling and
servicing operations
 Recognized hazard
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1910.147(a)(2) Application
 Service and maintenance:
 Employee required to remove or bypass a
guard or safety device
 Employee required to place part of body
into area that would be a danger zone
during machine operation cycle
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1910.147(a)(2) Application
 Exception: Minor adjustments and
servicing activities during normal
production if
 Routine
 Repetitive
 Integral to production
 Provided that alternative measures
provide effective protection
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1910.147(a)(2) Application
 Does not apply to cord and plug
connected equipment for which
 Exposure to hazard is controlled by
unplugging and
 Plug under exclusive control of employee
performing service or maintenance
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1910.147(a)(2) Application
 Does not apply to hot tap operations in
transmission and distribution operations
in pressurized pipelines provided that:
 Continuity of service is essential,
 Shutdown of system is impractical, and
 Documented procedures and special
equipment provide proven effective
protection for employees
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1910.147(a)(3) Purpose
 Establish a program and utilize
procedures for affixing appropriate
lockout devices or tagout devices to
energy isolating devices
 Prevent unexpected energization, start
up or release of stored energy in order
to prevent injury to employees
 Training and procedural requirements
for other sections’ LO/TO requirements
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1910.147(b)
Definitions
Affected employee
 Job requires employee to
 operate or use a machine or equipment
on which servicing or maintenance is being
performed under lockout or tagout, or
 work in an area in which such servicing or
maintenance is being performed
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Authorized employee
 Locks out or tags out machines or
equipment in order to perform servicing
or maintenance on that machine or
equipment
 Affected employee whose duties include
servicing or maintenance under this
section
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Energized
 Connected to an energy source OR
 Containing residual or stored energy
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Energy isolating device
 A mechanical device that physically
prevents the transmission or release or
energy
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Circuit breakers included
NOT push buttons
NOT selector switches
NOT control circuits
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Energy source
 Any source of:
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Electrical,
Mechanical,
Hydraulic,
Pneumatic,
Chemical,
Thermal, or
Other energy
What kind of energy
did the rock have?
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Lockout
 Placement of a lockout device on an
energy isolating device, in accordance
with an established procedure,
ensuring that energy isolating device
and equipment being controlled cannot
be operated until lockout device is
removed
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Lockout device
 Device that uses a positive
means such as a lock,
either key or combination
type, to hold an energy
isolating device in the safe
position and prevent the
energizing of a machine or
equipment
 Blank flanges and bolted
slip blinds included
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Servicing and/or maintenance
 Workplace activities such as:
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Constructing,
Installing,
Setting up,
Adjusting,
Inspecting,
Modifying, and
Maintaining and/or servicing machines or
equipment
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Tagout
 Placement of tagout device
 on an energy isolating device,
 in accordance with an established
procedure,
 to indicate that energy
isolating device and
equipment being controlled
may not be operated until
tagout device is removed
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1910.147(c)
General Requirements
Energy control program
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Energy control procedures
Employee training
Periodic inspections
Any employee who services/maintains
any equipment where unexpected
energizing or stored energy release
could cause injury isolates and renders
it inoperative first.
©2006 TEEX
1910.147(c)(ii) General
Requirements
 If an energy isolating device
is capable of being locked
out, the employer's energy
control program shall utilize
lockout, unless the employer
can demonstrate that the
utilization of a tagout system
will provide full employee
protection
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1910.147(c)(iii) General
Requirements
 Energy isolating devices designed to
accept lockout devices whenever:
 Replacement or major repair, renovation or
modification of equipment is performed or
 New machines or equipment are installed
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1910.147(c)(3) Full employee
protection
 When tagout device used on energy
isolation device capable of being locked
out:
 Same location as potential lockout device
 Demonstrably equivalent program
 May require additional safety elements
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1910.147(c)(4) Energy control
procedure
 Procedures shall be developed,
documented and utilized for the
control of potentially hazardous energy
when employees are engaged in the
activities covered by this section.
 Exception with all 8 elements listed in
standard
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1910.147(c)(4) Energy control
procedure
 Outline scope, purpose, authorization, rules,
techniques for control of hazardous energy,
including:
 Specific intended use of the procedure;
 Specific steps for shutting down, isolating,
blocking and securing equipment
 Specific steps for placement, removal, transfer of
lockout/tagout devices and responsibility for them
 Specific requirements for testing equipment to
verify effectiveness of lockout devices, tagout
devices, and other energy control measures
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1910.147(c)(5) Protective
materials and hardware
 Locks, tags, chains, wedges, key
blocks, adapter pins, self-locking
fasteners, or other hardware shall be
provided by the employer for isolating,
securing or blocking of equipment from
energy sources
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1910.147(c)(5) Protective
materials and hardware
 Lockout and tagout devices must be:
 Singularly identified
 The only device(s) used for controlling
energy
 Not used for other purposes
 And shall meet the following
requirements:
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1910.147(c)(5) Protective
materials and hardware
 Capable of withstanding environment
for maximum time period
 Moisture or corrosives must not make
tag deteriorate
 Standardized:
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Color
Shape
Size
Print/Format
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1910.147(c)(5) Protective
materials and hardware
 Lockout devices:
 Substantial enough to prevent removal without
excessive force or unusual techniques such as
bolt cutters
 Tagout devices:
 Substantial enough to prevent inadvertent or
accidental removal
 Non-reusable attachment means
 Attachable by hand, self-lockable
 At least equivalent to nylon cable tie
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1910.147(c)(5) Protective
materials and hardware
 Lockout and tagout devices indicate
identity of employee applying devices
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1910.147(c)(6) Periodic
Inspection
 Energy control procedure inspected at
least annually:
 By authorized employee not using the
procedure being inspected
 Correct any deviations
 Review employee responsibilities with:
 each authorized employee – lockout
 each affected or authorized employee –
tagout
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1910.147 (c)(7) Training and
communication
 Ensure employees understand
purpose and function of energy
control program
 Ensure employees acquire skills
required for safe application, usage,
removal of energy controls
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Employee Training
Requirements
 Authorized employee:
 Recognition of hazardous energy sources
 Type and amount of energy in workplace
 Methods and means for energy isolation
 Affected employee:
 Purpose and use of procedure
 Other employees in area:
 Procedure and prohibition on restarting
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Employee Training
Requirements for Tagout
 Train on limitations of tags:
 Warning devices do not provide physical
restraint that a lock would
 Tag not to be removed without owner’s
authorization, bypassed, ignored, defeated
 Must be legible / understandable to work
 Must withstand environmental conditions
 False sense of security
 Attach securely: avoid accidental removal
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Employee Retraining
 For all authorized or affected employees
when:
 Job assignment changes
 Equipment or processes present new
hazard
 Energy control procedure changes
 Knowledge / use of program is inadequate
 Certify employee training up to date
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1910.147(c)(8) Energy Isolation
 Only the authorized employees
performing the servicing or maintenance
may apply lockout/tagout
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1910.147(c)(9) Notification of
Employees
 Affected employees must be notified
 By employer or authorized employee
 Of application and removal of lockout and
tagout devices
 Before controls are applied
 After controls are removed
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1910.147(d)
Application of Control
Order of Operation for
Application of Control
1.
2.
3.
4.
5.
Preparation for shutdown
Equipment shutdown – orderly
Equipment isolation
Lockout or tagout device application
Stored energy relieved; continue while
reaccumulating
6. Verification of isolation
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Test and return to “off” position
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1910.147(e)
Release from Lockout/Tagout
1910.147(e) Release from
Lockout
 Before lockout or tagout devices
removed and energy restored, ensure:
 Machine or equipment:
 Inspect area; remove nonessential items
 Ensure equipment components intact
 Employees:
 Ensure all employees safe or removed
 Before restart, notify affected employees of
removal
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1910.147(e) Release from
Lockout
 Each lockout/tagout device removed by
employee who applied the device
 If not available, removed under employer
direction
 Specific procedures and training from
energy control program must be in use!
 Verify that applying employee is not at facility
 Make all reasonable efforts to contact/notify
 Ensure authorized employee knows of removal
before resuming work at facility
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1910.147(f)
Additional Requirements
1910.147(f)(1) Testing or
Positioning
 Temporary removal of lockout/tagout
devices for testing/positioning:
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Clear tools and materials
Remove employees from equipment area
Remove lockout/tagout devices (as in (e))
Energize and test or position
Deenergize systems and reapply energy
control measures to continue servicing
©2006 TEEX
1910.147(f)(2) Outside Personnel
 Contractors and other outside
personnel:
 On-site employer and outside employer
inform each other of lockout/tagout
procedures
 On-site employer complies with outside
employer’s energy control program
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1910.147(f)(3) Group Lockout or
Tagout
 Procedure must provide protection
equivalent to personal lockout/tagout
device
 Primary responsibility is vested in an
authorized employee for a set number
of employees working under the
protection of a group lockout or tagout
device (such as an operations lock);
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1910.147(f)(3) Group Lockout or
Tagout
 When more than one crew, craft,
department, etc. is involved:
 Designated authorized employee takes
lockout/tagout control responsibility
 Coordinates affected work forces
 Ensures continuity of protection
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1910.147(f)(3) Group Lockout or
Tagout
 Each authorized employee affixes
personal lockout/tagout device to group
lockout device when beginning work
 Each removes personal device when
stopping work on this equipment
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1910.147(f)(4) Shift or Personnel
Changes
 Specific procedures in energy control
plan
 Ensure continuity of lockout/tagout
protection
 Orderly transfer of lockout/tagout device
protection between shifts
 Minimize exposure to hazards from
unexpected energization or release
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