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Lockout-Tagout Interactive Training Program

Lets focus on three components:

  • Standards
  • Hot Topics/Major Issues
  • Simulated LOTO inspections


Workers performing service or maintenance on machinery and equipment may be exposed to injuries from the unexpected energization, startup of the machinery/equipment, or release of stored energy in the equipment.

The LOTO standard requires the adoption and implementation of practices and procedures to shut down the machines/equipment, isolate it from its energy source(s), and prevent the release of potentially hazardous energy while maintenance and servicing activities are being performed. (see 29 CFR 1910.147 for LOTO standards)

  • Who does this standard apply to?
    • General Industry workers performing servicing and/or maintenance on machines or equipment and who are exposed to the energization, startup, or release of hazard energy.
  • What activities or operations are covered?
    • Any servicing and/or maintenance of machines or equipment when the source of energy to the machines or equipment (including lubrication, cleaning or unjamming of machines or equipment, and making adjustments or tool changes, where employees could be exposed to the unexpected energization or startup of the equipment or release of hazardous energy).

Hot Topics:

1) Relationship of 1910.147, The Control of Hazardous Energy (LOTO) Standard, to Subpart O, Machinery and Machine Guarding Standards:

This topic addresses the relationship between the Control of Hazardous Energy (LOTO) standard and the Machinery and Machine Guarding Standards (Subpart O). It also presents information concerning minor servicing and unexpected energization. Want to read more? Checkout this link.

2) Energy Control Program

Covered employers must implement a comprehensive energy control program consisting of:

3) Group LOTO

In some cases, servicing or maintenance work is performed using a group or groups of employees. The LOTO standard has specific requirements for lockout or tagout operations involving more than one employee:

4) Multiple Energy Sources/Multiple Items of Equipment

The LOTO standard is intended to protect employees from the unexpected energization, start-up, or release of hazardous energy during the performance of servicing and maintenance operations. 

5) Relationship of 1910.147, The Control of Hazardous Energy (Lockout/Tagout) Standard, to 1910.269, Electric Power Generation, Transmission, and Distribution Standard, and 1910.333, Selection and Use of Electrical Work Practices Standard

Case Studies:

Printing Press Roll Cleaning

A printing press produces printed materials as its normal production function. The printing press's rollers have to be cleaned periodically during the work shift to ensure quality control. Read more on this scenario here!

Automotive Component Lubrication Robotics

At an employer's automotive component manufacturing facility, manufacturing operations make extensive use of robots located within fenced cages. Read more on this scenario here!

Replacement of Nitrogen Pressure Vessel Seals

A group of employees is assigned to replace the head seals on twelve large nitrogen pressure vessels (accumulator bottles) at a manufacturing facility. Read more on this scenario here!

Multiple Energy Control Procedures

A manufacturing facility has 130 separate lockout procedures. Many of these procedures are unique and apply to specific pieces of equipment. Some of these procedures, however, are duplicates and address pieces of equipment that are essentially identical to another piece of equipment. Read more on this scenario here!

Sour Water Pipeline Repairs

At a chemical plant, there are two lines carrying "sour water" (water contaminated with hydrocarbons, hydrogen sulfide, or other chemicals). The lines run between the facility's sour water stripping unit and its tank farm where the processed sour water is stored. Read more on this scenario here!

Steel Mill Teeming Car Repairs

An employee is assigned to adjust part of the drive mechanism on a teeming car in a steel mill. The teeming car is isolated from its energy sources and locked out, and the employee crawls underneath the car to start the maintenance job. Read more on this scenario here!

Overhead Crane Servicing and Maintenance

A millwright is assigned to a servicing and maintenance task on an overhead crane. The employee initiates the prescribed energy control procedure by turning "off" the crane's electrical disconnect switch and placing his lock onto this energy isolating device. Read more on this scenario here!


Keep your team safe and hard at work with this training guide.

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