[Audio] Control of Hazardous Energy
Control of Hazardous Energy
Lockout/Tagout
Lockout/Tagout. 

Scene 1

Control of'Hazardous Energy
Lockout/Tagout
Wo place

Control of Hazardous Energy
Control of Hazardous Energy

[Audio] INTRODUCTION
A Hazardous Energy Control Program, also known as a Lockout/Tagout ( LOTO) Program, is designed to prevent injuries caused by the unexpected start-up, energization, or release of stored energy in machinery when it is set up, serviced, or repaired. The specific practices and safety procedures used to make sure machines are properly shut off and not able to start while work on the equipment is performed is known as LOTO. The LOTO process, outlined in the Occupational Safety and Health Administration ( OSHA) 29 Code of Federal Regulations ( CFR) 1910.147, requires that hazardous energy sources that power machines are "isolated and rendered inoperative" (prevented from working) before service or repair are started on the equipment. Hazardous Energy Hazardous energy sources include electrical, chemical, radiation, pneumatic, hydraulic, mechanical, thermal, and gravitational energy sources. Each of these energy sources must be dissipated (used up) and isolated (turned off with a circuit breaker, switch, valve, flange, or other energy-restraining or energy-releasing device) before maintenance or repairs can start.
Stored Energy All equipment can store energy even after the power source is isolated. To control the stored energy and prevent it from suddenly releasing and injuring or killing an employee, physical controls – literally locks and tags – are used in a LOTO Program to prevent the machine's parts from unexpectedly moving or releasing energy.
General Requirements This publication outlines OSHA's general requirements for controlling hazardous energy and carrying out a LOTO Program. It contains helpful information and the basic elements for a written plan, but it does not supersede OSHA requirements. Employers should review the OSHA standard for each specific worksite and customize the program accordingly. Since OSHA regulations set minimum requirements, you are encouraged to add additional information to your site-specific program.. 

Scene 2

A Hazardous Energy Control Program, 
also known as a Lockout/Tagout (LOTO) 
Program, is designed to prevent injuries 
caused by the unexpected start-up, 
energization, or release of stored energy 
in machinery when it is set up, serviced, or 
repaired. The specific practices and safety 
procedures used to make sure machines are 
properly shut off and not able to start while 
work on the equipment is performed is known 
as LOTO. The LOTO process, outlined in the 
Occupational Safety and Health Administration 
(OSHA) 29 Code of Federal Regulations (CFR) 
1910.147, requires that hazardous energy 
sources that power machines are “isolated 
and rendered inoperative” (prevented from 
working) before service or repair are started on 
the equipment.

Hazardous Energy 
Hazardous energy sources include electrical, 
chemical, radiation, pneumatic, hydraulic, 
mechanical, thermal, and gravitational energy 
sources. Each of these energy sources must be 
dissipated (used up) and isolated (turned off 
with a circuit breaker, switch, valve, flange, or

other energy-restraining or energy-releasing 
device) before maintenance or repairs can 
start.

Stored Energy 
All equipment can store energy even after 
the power source is isolated. To control the 
stored energy and prevent it from suddenly 
releasing and injuring or killing an employee, 
physical controls – literally locks and tags – 
are used in a LOTO Program to prevent the 
machine’s parts from unexpectedly moving or 
releasing energy.

General Requirements 
This publication outlines OSHA’s general 
requirements for controlling hazardous energy 
and carrying out a LOTO Program. It contains 
helpful information and the basic elements 
for a written plan, but it does not supersede 
OSHA requirements. Employers should review 
the OSHA standard for each specific worksite 
and customize the program accordingly. Since 
OSHA regulations set minimum requirements, 
you are encouraged to add additional 
information to your site-specific program.

[Audio] TABLE OF CONTENTS Control of Hazardous Energy ( Lockout/Tagout) Workplace Program
INTRODUCTION ................................................................................................................ 2 LOCKOUT / TAGOUT REQUIREMENTS............................................................................. 4
Create a Written Lockout/Tagout Statement.................................................... 4 Make the Procedures Easy to Access .................................................................. 5 Employees' Roles and Responsibilities ............................................................... 5 Lockout/Tagout Employee Training .................................................................... 6
Regular Review and Inspection............................................................................ 7 Proper Recordkeeping........................................................................................... 7 LOCKOUT / TAGOUT PROCEDURES ................................................................................. 8
RESTORING EQUIPMENT TO NORMAL OPERATIONS.................................................. 9
Procedures Involving More Than One Person.................................................. 10
Procedures Involving Vendors or Contractors ................................................ 11 COMPLIANCE TO OSHA CFR 1910.147 .......................................................................... 12 APPENDICES .................................................................................................................... 13
A. Definitions ........................................................................................................ 14 B. Energy Control ( Lockout/Tagout) Program Flowchart ............................... 15 C. Energy Control ( Lockout/Tagout) Procedure Form..................................... 16 D. Equipment Detail List for Lockout/Tagout Procedures Form ................... 17
E. Lockout/Tagout Activity Log Compliance Sheet ......................................... 18 F. Lockout/Tagout Training Attendance List Form ......................................... 19
G. Lockout/Tagout Quiz....................................................................................... 20
4
4. 

Scene 3

TABLE OF CONTENTS 
Control of Hazardous Energy (Lockout/Tagout) Workplace Program

INTRODUCTION ................................................................................................................ 2  
 
 
LOCKOUT / TAGOUT REQUIREMENTS............................................................................. 4

Create a Written Lockout/Tagout Statement.................................................... 4  
 
 
 Make the Procedures Easy to Access .................................................................. 5  
     
 
Employees’ Roles and Responsibilities ............................................................... 5 
 
 
 Lockout/Tagout Employee Training .................................................................... 6

Regular Review and Inspection............................................................................ 7  
     
 
Proper Recordkeeping........................................................................................... 7  
 
 
LOCKOUT / TAGOUT PROCEDURES ................................................................................. 8

RESTORING EQUIPMENT TO NORMAL OPERATIONS.................................................. 9

Procedures Involving More Than One Person.................................................. 10

Procedures Involving Vendors or Contractors ................................................ 11

COMPLIANCE TO OSHA CFR 1910.147 .......................................................................... 12

APPENDICES .................................................................................................................... 13

A. Definitions  ........................................................................................................ 14

B.
 
 Energy Control (Lockout/Tagout) Program Flowchart ............................... 15

C.
 
 Energy Control (Lockout/Tagout) Procedure Form..................................... 16

D.
 
 Equipment Detail List for Lockout/Tagout Procedures Form ................... 17

E.
 
 Lockout/Tagout Activity Log Compliance Sheet ......................................... 18

F.
 
 Lockout/Tagout Training Attendance List Form ......................................... 19

G.
 
 Lockout/Tagout Quiz....................................................................................... 20

[Audio] Lockout/Tagout Requirements
A LOTO Program is vital to a strong workplace safety program. OSHA estimates that 120 deaths and 50,000 on-the-job injuries are prevented each year by proper LOTO procedures.1 However, controlling hazardous energy through effective LOTO steps remains in OSHA's Top 10 list for the most-cited violations.2
To meet the requirements of OSHA's Control of Hazardous Energy Standard, 29 CFR 1910.147, employers are responsible for establishing these LOTO procedures: 1. Create a formal, written statement on how to use LOTO procedures. 2. Make procedures easy to access. 3. Define employees' roles and responsibilities for the LOTO
Program. 4. Train employees on the LOTO
Program.
5. Review and inspect the LOTO
Program regularly. 6. Keep proper records.
Create a Written LOTO Statement RPM LOTO Program must be in writing and include, at minimum, the following:
• the name and location of the equipment that must be locked out;
• a list of equipmentspecific steps controlling hazardous energy when shutting down each machine and starting it again;
• information on any secondary energy sources such as heat, fumes, tension, or other hazards that must be moved or tied down;
• the name of the OSHA-approved device needed to lock out the energy
(such as a padlock, blank flange, or bolted slip blind) for each machine or piece of equipment;
• the location of stored lockout devices;
• the process to verify that the LOTO device is locked;
• the process for placing a tag on the lock and identifying the worker who put the tag on it; and
• the steps for bringing the machine or equipment back online after maintenance or service is completed. 5. 

Scene 4

A LOTO Program is vital to a strong workplace 
safety program. OSHA estimates that 120 
deaths and 50,000 on-the-job injuries 
are prevented each year by proper LOTO 
procedures.1 However, controlling hazardous 
energy through effective LOTO steps remains 
in OSHA’s Top 10 list for the most-cited 
violations.2

To meet the requirements of OSHA’s Control of 
Hazardous Energy Standard, 29 CFR 1910.147, 
employers are responsible for establishing 
these LOTO procedures:

1. Create a formal, written statement
on how to use LOTO procedures.

3. Define employees’ roles and
responsibilities for the LOTO
Program.

5. Review and inspect the LOTO
Program regularly.

RPM LOTO Program must be in writing and 
include, at minimum, the following:

•
the name and
location of the
equipment
that must be
locked out;

•
a list of
equipment-
specific steps
controlling
hazardous
energy when
shutting down
each machine and starting it again;

•
information on any secondary energy
sources such as heat, fumes, tension,
or other hazards that must be moved
or tied down;

•
the name of the OSHA-approved
device needed to lock out the energy
(such as a padlock, blank flange, or
bolted slip blind) for 
each machine or piece 
of equipment;

•
the location of stored
lockout devices;

•
the process to verify
that the LOTO device
is locked;

•
the process for
placing a tag on the
lock and identifying
the worker who put
the tag on it; and

•
the steps for bringing the machine
or equipment back online after
maintenance or service is completed.

[Audio] Make the Procedures Easy to Access LOTO procedures should be readily available to employees and management. Employers may choose to use binders or a dedicated software system in a location that is easily accessible to all employees. Employees' Roles and Responsibilities
Employers are tasked with making sure all workers are notified and aware of their role during LOTO procedures. Responsible persons include, but are not limited to, the following:
• Program Administrator
The Program Administrator is often a management staff member assigned by the employer to enforce the LOTO Program. This individual is responsible for ensuring that hazardous energy is controlled according to LOTO procedures at all times.
•
Affected Employee
Affected employees are the workers who operate or use the machines or equipment that are being serviced or maintained. The OSHA standard requires that affected employees are informed of a shutdown even if they are not involved in the service or the maintenance of the machinery or equipment.
•
Authorized Employee
An authorized employee is the person who will perform the LOTO procedure before maintenance or repairs to the machinery or equipment begins. Specifically, a machine operator or maintenance mechanic may be designated as the authorized employee responsible to make sure all precautions and needed lockouts are in place before starting repair work. An authorized employee and an affected employee may be the same person if the affected employee's duties also include performing service or repairs on the equipment.
•
LOTO Team
All employees are responsible for complying with the LOTO Program and using the proper devices.
Since the process of creating, overseeing, and maintaining an effective
LOTO Program is often daunting, employers can delegate the responsibility to a LOTO Team rather than one person. A LOTO Team should be comprised of qualified, knowledgeable individuals who come from various workgroups directly affected by the LOTO standard.
These individuals may include, but are not limited to the: օ program administrator; օ maintenance supervisor; օ maintenance mechanics; 6. 

Scene 5

LOTO procedures should be readily available 
to employees and management. Employers 
may choose to use binders or a dedicated 
software system in a location that is easily 
accessible to all employees.

Employers are tasked with making sure all 
workers are notified and aware of their role 
during LOTO procedures. Responsible persons 
include, but are not limited to, the following:

•
Program Administrator
The Program Administrator is
often a management staff member
assigned by the employer to enforce
the LOTO Program. This individual
is responsible for ensuring that
hazardous energy is controlled
according to LOTO procedures at all
times.

•
Affected Employee
Affected employees are the workers
who operate or use the machines or
equipment that are being serviced
or maintained. The OSHA standard

requires that affected employees are 
informed of a shutdown even if they 
are not involved in the service or the 
maintenance of the machinery or 
equipment.

•
Authorized Employee
An authorized employee is the
person who will perform the LOTO
procedure before maintenance
or repairs to the machinery or
equipment begins. Specifically, a
machine operator or maintenance
mechanic may be designated as the
authorized employee responsible
to make sure all precautions and
needed lockouts are in place before
starting repair work. An authorized
employee and an affected employee
may be the same person if the
affected employee’s duties also
include performing service or repairs
on the equipment.

•
LOTO Team
All employees are responsible for
complying with the LOTO Program
and using the proper devices.
Since the process of creating, over-
seeing, and maintaining an effective
LOTO Program is often daunting,
employers can delegate the
responsibility to a LOTO Team rather
than one person. A LOTO Team
should be comprised of qualified,
knowledgeable individuals who come
from various workgroups directly
affected by the LOTO standard.
These individuals may include, but
are not limited to the:

[Audio] օ line supervisors;
օ immediate work area supervisors; օ machine operators or production workers; օ safety committee members; օ safety manager; and
օ training manager.
Often, LOTO Team responsibilities may be divided as follows: օ The immediate supervisor of the work area and the mechanical maintenance supervisor share joint responsibility to make sure machine operators and maintenance mechanics follow and comply with LOTO procedures.
օ Since line supervisors or the maintenance supervisor(s) usually decide whether the equipment should be locked out, these individuals often take on the duties of keeping records for the procedures.
օ The safety manager is most often responsible for assuring overall compliance, coordinating team activities, and conducting the training.
օ The safety committee, the safety manager, the maintenance manager, or the line supervisors often conduct regular inspections as required by OSHA.
օ The maintenance mechanics and the machine operators are often tasked with collecting the equipment inventory and data used to create LOTO procedures. Lockout/Tagout Employee Training
A LOTO program is only as good as the training used to teach it. All employees should receive basic LOTO awareness training that includes:
• the importance of respecting locked and tagged machinery;
• the understanding that voiding a lock or tag and attempting to start the equipment can cause loss of life or limb to another employee;
• the safe application, use, and removal of energy controls; and
• the disciplinary measures for tampering with locked or tagged equipment.
In addition, all supervisors should receive authorized employee training since they will be responsible for making sure proper LOTO procedures and practices are observed. Authorized employee training should include:
• instructions on lockout procedures;
• the use and limitations of tags;
• recognizing hazardous energy sources; and
• methods and means for isolating and controlling energy. Training should be conducted by a designated qualified person, such as the maintenance supervisor, and another designated individual, such as the safety manager, should keep training or retraining records. Texas Department of Insurance, Division of Workers' Compensation www.txsafetyatwork.com HS96- 100F ( 09- 21) 7. 

Scene 6

օ machine operators or
production workers;

Often, LOTO Team responsibilities 
may be divided as follows:

օ The immediate supervisor of the
work area and the mechanical 
maintenance supervisor 
share joint responsibility to 
make sure machine operators 
and maintenance mechanics 
follow and comply with LOTO 
procedures.

maintenance supervisor(s) 
usually decide whether the 
equipment should be locked out, 
these individuals often take on 
the duties of keeping records for 
the procedures.

օ The safety manager is most
often responsible for assuring 
overall compliance, coordinating 
team activities, and conducting 
the training.

օ The safety committee, the safety
manager, the maintenance 
manager, or the line supervisors 
often conduct regular 
inspections as required by OSHA.

օ The maintenance mechanics
and the machine operators are 
often tasked with collecting the 
equipment inventory and data 
used to create LOTO procedures.

A LOTO program is only as good as the training 
used to teach it. All employees should receive 
basic LOTO awareness training that includes:

• the importance of
respecting locked and
tagged machinery;

• the understanding
that voiding a lock or
tag and attempting
to start the
equipment can cause
loss of life or limb to
another employee;

• the safe application, use, and removal
of energy controls; and

• the disciplinary measures for
tampering with locked or tagged
equipment.

In addition, all supervisors should receive 
authorized employee training since they will 
be responsible for making sure proper LOTO 
procedures and practices are observed. 
Authorized employee training should 
include:

• recognizing hazardous energy
sources; and

• methods and means for isolating and
controlling energy.

Training should be conducted by a designated 
qualified person, such as the maintenance 
supervisor, and another designated individual, 
such as the safety manager, should keep 
training or retraining records.

Texas Department of Insurance, Division of Workers’ Compensation 
www.txsafetyatwork.com 
HS96-100F (09-21) 
7

[Audio] Regular Review and Inspection
A LOTO Program is not something management can set and forget. Regular inspections help monitor the effectiveness of the LOTO Program and verify that procedures are kept up-to-date to keep workers safe. It is best to set a specific time when the annual review and inspection of the preceding year's LOTO activities can be conducted.
It is the Program Administrator's task to ensure that changes to equipment and the lockout devices and methods used are reflected in the updated LOTO Program. A designated individual, such as the safety manager, should maintain these records and make them available for OSHA inspection. Proper Recordkeeping
LOTO-related recordkeeping must include, but is not limited to, the following:
• Training Records
Training records should include the attendees' names, dates, topics, trainer's name, sample training materials or a syllabus, the trainer's credentials, and the employees' completed quiz results.
• Lock and Key Issue Records
Keep a record of when locks and keys were issued, why, and to whom.
• LOTO Activity Log
The activity log needs to include who, what, when, where, and why a lockout was performed. Smaller facilities may use one centrallylocated log, usually maintained by Set of safety caution labels and tags for lockout/tagout maintenance safety procedures. the supervisor. In larger facilities, each department or workgroup should maintain area-specific logs that are collected annually and stored in a central archive. In department-specific cases, the area supervisors maintain the LOTO Activity Log for their area, while the maintenance supervisor or the safety manager usually maintain the archived Activity Logs.
• Inventory List
An inventory list of all LOTO devices and their stored location should be maintained.
• Procedures List
A master binder or document management system listing all machine-specific LOTO procedures should be available in an accessible location for all employees. Texas Department of Insurance, Division of Workers' Compensation www.txsafetyatwork.com HS96- 100F ( 09- 21) 8. 

Scene 7

A LOTO Program is not something 
management can set and forget. Regular 
inspections help monitor the effectiveness of 
the LOTO Program and verify that procedures 
are kept up-to-date to keep workers safe. It 
is best to set a specific time when the annual 
review and inspection of the preceding year’s 
LOTO activities can be conducted.

It is the Program Administrator’s task to ensure 
that changes to equipment and the lockout 
devices and methods used are reflected in 
the updated LOTO Program. A designated 
individual, such as the safety manager, should 
maintain these records and make them 
available for OSHA inspection.

LOTO-related recordkeeping must include, but 
is not limited to, the following:

•
Training Records
Training records should include the
attendees’ names, dates, topics,
trainer’s name, sample training
materials or a syllabus, the trainer’s
credentials, and the employees’
completed quiz results.

•
Lock and Key Issue Records
Keep a record of when locks and
keys were issued, why, and to whom.

•
LOTO Activity Log
The activity log needs to include
who, what, when, where, and why
a lockout was performed. Smaller
facilities may use one centrally-
located log, usually maintained by

Set of safety caution labels and tags for 
lockout/tagout maintenance safety procedures.

the supervisor. In larger facilities, 
each department or workgroup 
should maintain area-specific 
logs that are collected annually 
and stored in a central archive. In 
department-specific cases, the area 
supervisors maintain the LOTO 
Activity Log for their area, while 
the maintenance supervisor or the 
safety manager usually maintain the 
archived Activity Logs.

•
Inventory List
An inventory list of all LOTO devices
and their stored location should be
maintained.

•
Procedures List
A master binder or document
management system listing all
machine-specific LOTO procedures
should be available in an accessible
location for all employees.

Texas Department of Insurance, Division of Workers’ Compensation 
www.txsafetyatwork.com 
HS96-100F (09-21)
8

[Audio] Lockout/Tagout Procedures
A designated authorized employee should perform the following six LOTO procedures to prevent the unexpected release of energy during equipment maintenance, repair, and set-up: Prepare for Shutdown The authorized employee must:
• investigate and identify all forms of hazardous energy and know how to control it;
• obtain a copy of the machine-specific energy control procedure for use during equipment shutdown; and
• notify all affected employees that a lockout or tagout system is going to be used and the reason why. Equipment Shutdown If the machine or equipment is operating, shut it down using the manufacturer's or employer's normal stopping procedures. Inform all affected employees about the shutdown, even if they are not involved in the service or maintenance. Energy Isolation Isolate the equipment from any energy source. Isolation may mean many things, such as turning off the power at a breaker or shutting a valve. However, among other safety concerns, remember that:
• electrical equipment can store energy in capacitors;
• machines running on hydraulic or pneumatic energy can keep pressure in areas between the energy-isolating device and the moving parts;
• equipment running on chemical energy can have fuel in the lines;
• springs and tension belts can contain stored mechanical energy; and
• pistons suspended in mid-motion can store energy from gravity.
Apply LOTO Devices Apply the assigned lockout device, such as a padlock, blank flanges, or bolted slip blinds to keep the equipment in a safe ( energyisolating) position. Then, if tags are used, place a tag on the device in the same manner as the lock. Fill tags out completely and correctly using the authorized employee's name who is performing the lockout and any other vital information. Pulling a fuse or flipping a circuit breaker is no substitute for locking out!. 

Scene 8

A designated authorized 
employee should perform the 
following six LOTO procedures 
to prevent the unexpected 
release of energy during 
equipment maintenance, repair, 
and set-up:

Prepare for Shutdown 
The authorized employee must:

•
investigate and identify
all forms of hazardous
energy and know how
to control it;

•
obtain a copy of the machine-specific
energy control procedure for use
during equipment shutdown; and

•
notify all affected employees that a
lockout or tagout system is going to
be used and the reason why.

Equipment Shutdown 
If the machine or equipment is operating, 
shut it down using the manufacturer’s or 
employer’s normal stopping procedures. 
Inform all affected employees about the 
shutdown, even if they are not involved in the 
service or maintenance.

Energy Isolation 
Isolate the equipment from any energy 
source. Isolation may mean many things, 
such as turning off the power at a breaker or 
shutting a valve. However, among other safety 
concerns, remember that:

•
electrical equipment can store
energy in capacitors;

•
machines running on hydraulic or
pneumatic energy can keep pressure
in areas between the energy-isolating
device and the moving parts;

•
equipment running on chemical
energy can have fuel in the lines;

•
springs and tension belts can contain
stored mechanical energy; and

•
pistons suspended in mid-motion
can store energy from gravity.

Apply LOTO Devices 
Apply the assigned lockout device, such as a 
padlock, blank flanges, or bolted slip blinds 
to keep the equipment in a safe (energy-
isolating) position. Then, if tags are used, place 
a tag on the device in the same manner as 
the lock. Fill tags out completely and correctly 
using the authorized employee's name who 
is performing the lockout and any other vital 
information. Pulling a fuse or flipping a circuit 
breaker is no substitute for locking out!

[Audio] Check for Stored Energy Even after the energy source has been disconnected and the machine has been locked out, hazardous energy may remain in the machine. Make sure all parts have stopped moving and dissipate (use up the energy), restrain, or make non-hazardous in some way all stored energy before maintenance or service begins. Ways to release stored energy may include:
• grounding the equipment;
• releasing tension on springs;
• blocking the movement of springdriven or hydraulic and pneumatic parts;
• placing braces or blocks on parts that could fall because of gravity;
• bleeding or depressurizing lines;
• venting open valves; or
• repositioning the equipment. Verify Isolation of Equipment Clear all personnel from dangerous areas and check again to make sure the equipment is isolated correctly and de-energized before repair or maintenance begins.
•
Verify that the main disconnect switch or circuit breaker cannot be moved to the ON position.
•
Press all operating controls to ensure there is no power.
•
Return all power switches to the OFF or NEUTRAL position.
•
Informing employees in the area that the work is about to begin.
Restoring Equipment to Normal Operations
When the servicing or maintenance is completed and the machine or equipment is ready to return to its normal operating condition, the following LOTO procedures should be used:
•
Check to make sure that all nonessential items have been removed.
Look around the machinery and the immediate area to ensure all tools have been accounted for and have not been left in or on the equipment. Replace all system components, safety mechanisms, covers, and guards. Return all parts, spare parts, accessories, and damaged components to the appropriate locations or inventories.
•
Confirm that all employees have been safely positioned or removed from the area. Workers completing any project with LOTO are required to make sure that there are no people inside, around, or near the equipment to be restarted. Texas Department of Insurance, Division of Workers' Compensation www.txsafetyatwork.com HS96- 100F ( 09- 21) 10. 

Scene 9

Check for Stored Energy 
Even after the energy source has been 
disconnected and the machine has been 
locked out, hazardous energy may remain in 
the machine. Make sure all parts have stopped 
moving and dissipate (use up the energy), 
restrain, or make non-hazardous in some 
way all stored energy before maintenance or 
service begins. Ways to release stored energy 
may include:

•
blocking the movement of spring-
driven or hydraulic and pneumatic
parts;

•
placing braces or blocks on parts that
could fall because of gravity;

Verify Isolation of Equipment 
Clear all personnel from dangerous areas and 
check again to make sure the equipment is 
isolated correctly and de-energized before 
repair or maintenance begins.

•
Verify that the main disconnect
switch or circuit breaker cannot be
moved to the ON position.

•
Press all operating controls to ensure
there is no power.

•
Return all power switches to the OFF
or NEUTRAL position.

•
Informing employees in the area that
the work is about to begin.

When the servicing or maintenance is completed and the 
machine or equipment is ready to return to its normal operating 
condition, the following LOTO procedures should be used:

•
Check to make sure that all nonessential items
have been removed.
Look around the machinery and the immediate area
to ensure all tools have been accounted for and have
not been left in or on the equipment. Replace all
system components, safety mechanisms, covers, and
guards. Return all parts, spare parts, accessories, and
damaged components to the appropriate locations or
inventories.

•
Confirm that all employees have been safely
positioned or removed from the area.
Workers completing any project with LOTO are
required to make sure that there are no people
inside, around, or near the equipment to be restarted.

Texas Department of Insurance, Division of Workers’ Compensation 
www.txsafetyatwork.com 
HS96-100F (09-21)
10

[Audio] Before removing any LOTO device, inspect the work and account for all personnel including equipment operators, maintenance personnel, contractors, cleaning staff, inspectors, or workers returning from a break or shift change.
•
Verify that the controls are in NEUTRAL, set to OFF, or in a readystate.
•
Remove the lockout devices and reenergize the machine or equipment.
To make sure LOTO removal is performed safely, each lock and tag should be removed from each energy-isolating device by the employee who applied them. In some situations, the original worker who placed the LOTO device may not be available due to a shift or employment change, illness, or another emergency. When the authorized employee who applied the LOTO device is not available to remove it, training and procedures should be developed that include:
օ verifying that the authorized employee who applied the device is not at the facility;
օ making all reasonable efforts to contact the authorized employee to inform them that their LOTO device is getting removed; and օ ensuring that the authorized employee has this knowledge of the LOTO device removal before he or she resumes work at that location.
•
Notify affected employees that the servicing or maintenance is completed, and the machine or equipment is ready for use. Procedures Involving More Than One Person If more than one individual is required to LOTO equipment, the following procedures should be used:
•
Both individuals must place their names on the LOTO device.
•
If an energy-isolating device cannot accept multiple locks or tags, a multiple LOTO device ( hasp) may be used.
•
If lockout is used, a single lock may be used to lock out the machine or equipment with the key being placed in a lockout box or cabinet that allows the use of multiple locks to secure it. Each employee must then use his or her lock to secure the box or cabinet.
•
If servicing of equipment lasts more than one work shift, LOTO protection must not be interrupted. Employees completing their shift and preparing to leave the facility must not remove their lock until the next employee to service the equipment is ready to lockout.
•
When an employee who applied a lock is not there to remove it, a twoperson rule will apply, allowing the lock to be cut only in the presence of the work area supervisor, who must report the emergency procedure in detail to the safety manager within 24 hours. The report must include the name of the employee who placed the lock on the equipment and the names of the employee and supervisor who removed the lock.. 

Scene 10

Before removing any LOTO device, 
inspect the work and account for all 
personnel including equipment operators, 
maintenance personnel, contractors, 
cleaning staff, inspectors, or workers 
returning from a break or shift change.

•
Verify that the controls are in
NEUTRAL, set to OFF, or in a ready-
state.

•
Remove the lockout devices and re-
energize the machine or equipment.
To make sure LOTO removal is performed
safely, each lock and tag should be
removed from each energy-isolating
device by the employee who applied
them. In some situations, the original
worker who placed the LOTO device
may not be available due to a shift or
employment change, illness, or another
emergency. When the authorized
employee who applied the LOTO device
is not available to remove it, training and
procedures should be developed that
include:

օ verifying that the authorized
employee who applied the device is 
not at the facility;

օ making all reasonable efforts to
contact the authorized employee to 
inform them that their LOTO device is 
getting removed; and

օ ensuring that the authorized
employee has this knowledge of the 
LOTO device removal before he or 
she resumes work at that location.

•
Notify affected employees that
the servicing or maintenance is
completed, and the machine or
equipment is ready for use.

Procedures Involving More 
Than One Person  
If more than one individual is required 
to LOTO equipment, the following 
procedures should be used:

•
Both individuals must place their
names on the LOTO device.

•
If an energy-isolating device cannot
accept multiple locks or tags, a
multiple LOTO device (hasp) may
be used.

•
If lockout is used, a single lock may
be used to lock out the machine
or equipment with the key being
placed in a lockout box or cabinet
that allows the use of multiple
locks to secure it. Each employee
must then use his or her lock to
secure the box or cabinet.

•
If servicing of equipment lasts
more than one work shift, LOTO
protection must not be interrupted.
Employees completing their shift
and preparing to leave the facility
must not remove their lock until
the next employee to service the
equipment is ready to lockout.

•
When an employee who applied a
lock is not there to remove it, a two-
person rule will apply, allowing the
lock to be cut only in the presence
of the work area supervisor,
who must report the emergency
procedure in detail to the safety
manager within 24 hours. The
report must include the name of
the employee who placed the lock
on the equipment and the names
of the employee and supervisor
who removed the lock.

[Audio] Procedures Involving Vendors or Contractors Whenever outside service personnel, contractors, or vendors are engaged in activities covered by OSHA's Control of Hazardous Energy Standard, they must adhere to the host employer's LOTO Program. The contractor must receive Contractor Safety Orientation Training and comply with the host employer's LOTO Program. The host employer's maintenance personnel and the contractor must perform a multiple-person LOTO in all systems, equipment, and machines that the contractor is servicing. In some instances, the contractor may be required to sign a waiver, relieving the company of any liabilities while on site. Compliance to OSHA CFR 1910.147
If your company has employees who service or maintain machines that could cause an injury, then most likely the LOTO regulations apply to you. Any time someone must construct, install, set up, adjust, inspect, modify, maintain, or service a machine or piece of equipment you must have a procedure in place to do it safely. Even tasks like lubricating, cleaning, unjamming, or changing the attachments must follow the proper lockout procedure. If your employees work in or on machines that could smash, cut, shock, trap, burn, electrocute, or injure a worker you are better off having a LOTO Program in place. Examples of when LOTO procedures are required include, but are not limited to:
•
Engine-Driven Equipment
This includes repairs, adjustments, and maintenance on conveyors, agitators, vehicles, presses, mills, lathes, exhaust fan blowers, printshop equipment, and similar manufacturing or office equipment.
• Exposure to Electricity
This includes work on powerlines, electrical panel boxes, disconnecting switches, and machinery and equipment hook up.
•
Exposure to Hazardous Materials
This includes repairs and maintenance on pumps, boilers, pipelines, or tanks containing flammable liquids, acids, caustics, steam, or other harmful liquids and gases.
There are a few cases during normal production operations when this standard does not apply. Servicing and maintenance of the machine during normal operations is covered only when an employee is required to:
• remove or bypass a guard or other safety device;
• place any part of their body into an area on a machine or piece of equipment where work is performed on the material being processed; or
• place any part of their body into an area on a machine or piece of equipment where a danger zone exists during a machine's operating cycle.
Minor tool changes and adjustments, and other minor servicing activities that take. 

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Procedures Involving Vendors or Contractors 
Whenever outside service personnel, contractors, or vendors are engaged in activities 
covered by OSHA’s Control of Hazardous Energy Standard, they must adhere to the host 
employer’s LOTO Program. The contractor must receive Contractor Safety Orientation 
Training and comply with the host employer’s LOTO Program. The host employer’s 
maintenance personnel and the contractor must perform a multiple-person LOTO in all 
systems, equipment, and machines that the contractor is servicing. In some instances, the 
contractor may be required to sign a waiver, relieving the company of any liabilities while on 
site.

If your company has employees who service or 
maintain machines that could cause an injury, 
then most likely the LOTO regulations apply to 
you. Any time someone must construct, install, 
set up, adjust, inspect, modify, maintain, or 
service a machine or piece of equipment 
you must have a procedure in place to do it 
safely. Even tasks like lubricating, cleaning, 
unjamming, or changing the attachments must 
follow the proper lockout procedure. If your 
employees work in or on machines that could 
smash, cut, shock, trap, burn, electrocute, or 
injure a worker you are better off having a 
LOTO Program in place. Examples of when 
LOTO procedures are required include, but are 
not limited to:

•
Engine-Driven Equipment
This includes repairs, adjustments,
and maintenance on conveyors,
agitators, vehicles, presses, mills,
lathes, exhaust fan blowers,
printshop equipment, and similar
manufacturing or office equipment.

•
Exposure to Electricity
This includes work on powerlines,
electrical panel boxes, disconnecting
switches, and machinery and
equipment hook up.

•
Exposure to Hazardous Materials
This includes repairs and
maintenance on pumps, boilers,
pipelines, or tanks containing
flammable liquids, acids, caustics,
steam, or other harmful liquids and
gases.

There are a few cases during normal 
production operations when this standard 
does not apply. Servicing and maintenance 
of the machine during normal operations is 
covered only when an employee is required to:

•
remove or bypass a guard or other
safety device;

•
place any part of their body into
an area on a machine or piece of
equipment where work is performed
on the material being processed; or

•
place any part of their body into
an area on a machine or piece of
equipment where a danger zone
exists during a machine’s operating
cycle.

Minor tool changes and adjustments, and 
other minor servicing activities that take

[Audio] place during normal production operations, are not covered by this standard if they are routine, repetitive, and integral to the use of the equipment for production. However, these activities must be performed using other safety measures to ensure employees are protected. CFR 1910.147 does not apply to agriculture, construction, maritime, and oil-and-gas well drilling and servicing, which have separate standards for the control of hazardous energy specific to these industries. Also, it does not apply to electrical hazards covered by 29 CFR Part 1910 Subpart S or specific LOTO steps for electrical shock and burn hazards covered by 29 CFR Part 1910.333. In addition, it does not apply to the control of hazardous energy in power generation, transmission, and distribution plants, covered by 29 CFR 1910.269.. 

Scene 12

place during normal production operations, 
are not covered by this standard if they are 
routine, repetitive, and integral to the use 
of the equipment for production. However, 
these activities must be performed using other 
safety measures to ensure employees are 
protected.

CFR 1910.147 does not apply to agriculture, 
construction, maritime, and oil-and-gas well 
drilling and servicing, which have separate 
standards for the control of hazardous energy 
specific to these industries. Also, it does not 
apply to electrical hazards covered by 29 
CFR Part 1910 Subpart S or specific LOTO 
steps for electrical shock and burn hazards 
covered by 29 CFR Part 1910.333. In addition, 
it does not apply to the control of hazardous 
energy in power generation, transmission, 
and distribution plants, covered by 29 CFR 
1910.269.

[Audio] Appendix A: Definitions
Affected Employee - an employee whose job requires him or her to operate or use a machine or equipment on which servicing or maintenance is being performed under LOTO, or whose job requires him or her to work in an area in which such servicing or maintenance is being performed.
Authorized Employee - A person who locks or implements a tagout system procedure on machines or equipment to perform the servicing or maintenance on that machine or equipment. An authorized employee and an affected employee may be the same person when the affected employee's duties also include performing maintenance or service on a machine or equipment, which must be locked, or a tagout system implemented.
Capable of Being Locked Out - an energy-isolating device is considered capable of being locked out if it is designed with a hasp or other attachment or integral part to which a lock can be affixed or if it has a locking mechanism built into it. Other energy-isolating devices are also considered capable of being locked out if lockout can be achieved without the need to dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy control capability.
Energized - connected to an energy source or containing residual or stored energy.
Energy-Isolating Device - a mechanical device that physically prevents the transmission or release of energy including but not limited to the following: A manually operated electrical circuit breaker; a disconnect switch; a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors and, in addition, no pole can be operated independently; a slide gate; a slip blind; a line valve; a block; and any similar device used to block or isolate energy. The term does not include pushbuttons, selector switches, and other control circuit-type devices. Energy Source - any source of kinetic or potential energy, including but not limited to electrical, mechanical, hydraulic, pneumatic, chemical, and/or thermal energy. Hot Tap - a procedure used in the repair, maintenance, and services activities that involves welding on a piece of equipment ( pipelines, vessels, or tanks) under pressure, to install connections or appurtenances (an attachment that becomes part of the property such as a furnace or air-conditioning unit). It is commonly used to replace or add sections of a pipeline without the interruption of service for air, gas, water, steam, and petrochemical distribution systems.
Lockout- the placement of a lockout device on an energy-isolating device, according to an established procedure, ensuring that the energy-isolating device and the equipment being controlled cannot be operated until the lockout device is removed. 14. 

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Affected Employee - an employee whose job requires him or her to operate or use a machine 
or equipment on which servicing or maintenance is being performed under LOTO, or whose 
job requires him or her to work in an area in which such servicing or maintenance is being 
performed.

Authorized Employee - A person who locks or implements a tagout system procedure on 
machines or equipment to perform the servicing or maintenance on that machine or equipment. 
An authorized employee and an affected employee may be the same person when the affected 
employee’s duties also include performing maintenance or service on a machine or equipment, 
which must be locked, or a tagout system implemented.

Capable of Being Locked Out - an energy-isolating device is considered capable of being 
locked out if it is designed with a hasp or other attachment or integral part to which a lock 
can be affixed or if it has a locking mechanism built into it. Other energy-isolating devices are 
also considered capable of being locked out if lockout can be achieved without the need to 
dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy control 
capability.

Energized - connected to an energy source or containing residual or stored energy.

Energy-Isolating Device - a mechanical device that physically prevents the transmission or 
release of energy including but not limited to the following: A manually operated electrical circuit 
breaker; a disconnect switch; a manually operated switch by which the conductors of a circuit 
can be disconnected from all ungrounded supply conductors and, in addition, no pole can be 
operated independently; a slide gate; a slip blind; a line valve; a block; and any similar device 
used to block or isolate energy. The term does not include pushbuttons, selector switches, and 
other control circuit-type devices.

Energy Source - any source of kinetic or potential energy, including but not limited to electrical, 
mechanical, hydraulic, pneumatic, chemical, and/or thermal energy.

Hot Tap - a procedure used in the repair, maintenance, and services activities that involves 
welding on a piece of equipment (pipelines, vessels, or tanks) under pressure, to install 
connections or appurtenances (an attachment that becomes part of the property such as a 
furnace or air-conditioning unit). It is commonly used to replace or add sections of a pipeline 
without the interruption of service for air, gas, water, steam, and petrochemical distribution 
systems.

Lockout- the placement of a lockout device on an energy-isolating device, according to an 
established procedure, ensuring that the energy-isolating device and the equipment being 
controlled cannot be operated until the lockout device is removed.

[Audio] Lockout Device - a device that utilizes a positive means such as a lock, either key or combination type, to hold an energy-isolating device in a safe position and to prevent the energizing of a machine or equipment. Normal Production Operation - the utilization of a machine or equipment to perform its intended production function. Servicing or Maintenance - workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, maintaining, or servicing machines or equipment. These activities include lubrication, cleaning or un-jamming of machines or equipment, adjusting, or tool changes, where the employee may be exposed to the unexpected energization or start-up of the equipment or release of hazardous energy.
Setting Up - Any work performed to prepare a machine or equipment to perform its normal production operation.
Tagout - the placement of a tagout device on an energy-isolating device using an established procedure to indicate that the energy-isolating device and the equipment being controlled may not be operated until the tagout device is removed. Tagout Device - a prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy-isolating device according to an established procedure, to indicate that the energy-isolating device and the equipment being controlled may not be operated until the tagout device is removed.. 

Scene 14

Lockout Device - a device that utilizes a positive means such as a lock, either key or 
combination type, to hold an energy-isolating device in a safe position and to prevent the 
energizing of a machine or equipment.

Normal Production Operation - the utilization of a machine or equipment to perform its 
intended production function.

Servicing or Maintenance - workplace activities such as constructing, installing, setting up, 
adjusting, inspecting, modifying, maintaining, or servicing machines or equipment. These 
activities include lubrication, cleaning or un-jamming of machines or equipment, adjusting, or 
tool changes, where the employee may be exposed to the unexpected energization or start-up 
of the equipment or release of hazardous energy.

Setting Up - Any work performed to prepare a machine or equipment to perform its normal 
production operation.

Tagout - the placement of a tagout device on an energy-isolating device using an established 
procedure to indicate that the energy-isolating device and the equipment being controlled may 
not be operated until the tagout device is removed.

Tagout Device - a prominent warning device, such as a tag and a means of attachment, which 
can be securely fastened to an energy-isolating device according to an established procedure, 
to indicate that the energy-isolating device and the equipment being controlled may not be 
operated until the tagout device is removed.

[Audio] Appendix B: Energy Control Program Flowchart
Classify LOTO data into equipment requiring procedures
Develop a general LOTO SOP for equipment with only one source of energy
Identify equipment that meets LOTO exemptions, 1910.147 (c)(4)(i)
Develop specific LOTO procedures for equipment with multiple power sources
Test the general and specific LOTO procedures to make sure they work
Update the general & specific LOTO procedures if needed
Assemble a master log that contains all the general, specific, & exempted equipment LOTO procedures
Develop & distribute area-specific LOTO binders to identified work areas
Conduct periodic inspections to ensure LOTO procedures are working & update if required
*Required Conditions for Lockout Tagout
Procedure Exemption - 1910.147(c)(4)(i).
An energy control procedure is not required if all of the following conditions exist:* 1.
The machine or equipment has no potential stored or residual energy, and energy may not reaccumulate after shutdown. 2.
There is a single energy source that can easily be identified and isolated. 3.
The lockout will completely deenergize the equipment. 4.
The equipment is isolated and locked out from the energy source during maintenance. 5.
A single lockout device will achieve the required isolation. 6.
The lockout device is under the exclusive control of the authorized employee performing the work. 7.
The work does not create hazards for other employees. 8.
Previous use of this exemption has not caused accidents involving unexpected re-energization or startup.
Collect LOTO data for all equipment. 

Scene 15

Appendix B: 
Energy Control Program Flowchart

Classify LOTO 
data into 
equipment 
requiring 
procedures

Develop a general 
LOTO SOP for 
equipment with 
only one source of 
energy

Identify 
equipment that 
meets LOTO 
exemptions, 
1910.147 (c)(4)(i)

Develop specific 
LOTO procedures 
for equipment 
with multiple 
power sources

Test the general 
and specific LOTO 
procedures to 
make sure they 
work

Update the 
general & specific 
LOTO procedures 
if needed

Assemble a master log 
that contains all the 
general, specific, & 
exempted equipment 
LOTO procedures

Develop & distribute 
area-specific LOTO 
binders to identified 
work areas

Conduct periodic 
inspections to ensure 
LOTO procedures are 
working & update if 
required

*Required Conditions for Lockout Tagout
Procedure Exemption - 1910.147(c)(4)(i).

An energy control procedure is not required 
if all of the following conditions exist:* 
1.
The machine or equipment has no potential
stored or residual energy, and energy may not re-
accumulate after shutdown.
2.
There is a single energy source that can easily be
identified and isolated.
3.
The lockout will completely deenergize the
equipment.
4.
The equipment is isolated and locked out from the
energy source during maintenance.
5.
A single lockout device will achieve the required
isolation.
6.
The lockout device is under the exclusive control
of the authorized employee performing the work.
7.
The work does not create hazards for other
employees.
8.
Previous use of this exemption has not caused
accidents involving unexpected re-energization or
startup.

[Audio] Appendix C: Energy Control Procedure Form Instructions: The Authorized Employee and the Program Administrator will complete this digital, fillable form for each piece of equipment separately. This form should inventory all energy sources and LOTO points for each piece of equipment. When finished, group equipment according to common procedures or common functions. The master copy of these forms shall be kept in one or more central location(s), including but not limited to the Safety Office, the Maintenance Supervisor's office, or the Production Manager's office. There must be 24/7 access to the facility's master LOTO binder or dedicated software system. Use additional forms as new equipment is acquired. Procedure Description
Equipment Description: Serial Number: Location of Equipment: Area or Department: Number of Lockout Points: Lockout Device(s) Needed: Lockout Procedure:
Procedure to Verify Lockout is Complete:
Release and Start Up Procedure:
Date Written: Procedure Written By: Date Revised: eview
Date R ed: Reviewing Personnel:
Date Approved: Approvals:. 

Scene 16

Instructions: The Authorized Employee and the Program Administrator will complete this digital, fillable form for 
each piece of equipment separately. This form should inventory all energy sources and LOTO points for each piece 
of equipment. When finished, group equipment according to common procedures or common functions. The master 
copy of these forms shall be kept in one or more central location(s), including but not limited to the Safety Office, the 
Maintenance Supervisor’s office, or the Production Manager’s office. There must be 24/7 access to the facility’s master 
LOTO binder or dedicated software system. Use additional forms as new equipment is acquired.

Serial Number: 
Location of Equipment: 
Area or Department:

Number of Lockout Points: 
Lockout Device(s) Needed:

Date Written:  
Procedure Written By: 
Date Revised:

[Audio] Appendix D: Equipment Detail List For LOTO Procedures
Instructions: This digital, fillable form is made from the procedures in Appendix C. A list is needed for each type of procedure. Corresponding LOTO numbers can be given to lists of procedures, then the LOTO number can be put on the equipment so no mistake is made on which procedure is used. Equipment Description Serial # Company ID # Location. 

Scene 17

Appendix D: 
Equipment Detail List For LOTO Procedures

Instructions: This digital, fillable form is made from the procedures in Appendix C. A list is needed for 
each type of procedure. Corresponding LOTO numbers can be given to lists of procedures, then the 
LOTO number can be put on the equipment so no mistake is made on which procedure is used.

Equipment 
Description 
Serial # 
Company ID # 
Location

[Audio] Appendix E: LOTO Activity Log Compliance Sheet
LOTO Activity Log Compliance Sheet
Issue Date:
Revision Date:
Revision #: Shift Supervisor: LOTO Shift (check one):
Day Swing Graveyard
Project: Master Control Log #: Lockbox Location: Job #:
Employee
Lock #
Authorized Employee Lock Installed
Date/ Time
Equipment Identification and Location
Lock Removed
Date/Time
Release Reason. 

Scene 18

Appendix E: 
LOTO Activity Log Compliance Sheet

Shift Supervisor: 
LOTO Shift (check one):

Master Control Log #: 
Lockbox Location: 
Job #:

[Audio] Appendix F: LOTO Training Attendance List
This digital, fillable form is a list of people who attended training on the Lockout/Tagout Program on . Name Signature Padlock # 20. 

Scene 19

Appendix F: 
LOTO Training Attendance List

This digital, fillable form is a list of people who attended training on the Lockout/Tagout Program on 
.

[Audio] Appendix G: Lockout/Tagout Quiz
Name: Date:
Department: Badge or ID #: 1. What is the primary purpose of locking and tagging out a machine? a. to comply with OSHA Regulations; b. to keep someone from using the equipment; c. to isolate the equipment from its energy sources (make sure it cannot be turned on); or d. none of the above. 2. Which is not a situation where we would need to lock out a machine? a. repairing equipment; b. cleaning, lubricating, or general maintenance; c. clearing jammed mechanisms; or d. none of the above 3. Which of the following is not a type of energy requiring lockout/tagout procedures? a. electrical; b. kinetic; c. hydraulic; or d. pneumatic. 4. Which devices can be used for the purpose of lockout? a. padlocks and chains; b. valve clamps and wedges; c. key blocks and pins; or d. all of the above. 5. If you do not have a lock, you can use a tag in its place to lockout a machine. a. True b. False 6. Any employee can lock out a machine. a. True b. False 7. Who can remove the installed lock or tag on a locked-out machine? a. anyone who gets the key; b. only the maintenance supervisor; c. only maintenance personnel; or d. the employee who installed the lock. 8.
If a machine, already under lockout procedures, will be restarted, first follow the normal release and start up procedure. Afterwards, reinstate original locks and tags. a. True b. False 9.
Once affected personnel have been notified that the proper lockout procedure has been followed and the machinery has been verified as properly locked out, all of the requirements in this program have been fulfilled. a. True b. False. 

Scene 20

Department:  
 
 
 
 
 
 
 
Badge or ID #:

Lockout/Tagout Workplace Program