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?

2006 TEEX

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.
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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 owners
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
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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
employers 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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