Energy Control Procedures

The best way to create a machine-specific procedure is to create a step-by-step checklist that everyone who works on the machine can follow. Checklists are a reliable way to ensure everything is done correctly and in the proper order-- both of which are critical for safety.

Procedures should be written specifically for each piece of equipment and cover:

• Shut down.
• Isolation from energy source(s).
• Blocking from residual energy source(s).
• Securing equipment for work.

If the lockout/tagout process is the same for the various machines used at a workplace, then a single energy-control procedure may be sufficient. For example, similar machines (those using the same type and magnitude of energy) that have the same or similar types of control measures can be covered by a single procedure. Otherwise, employers must develop separate energy-control procedures for each piece of equipment.

(To read more, see section on Exceptions that are not covered under a LO/TO program.)
A limited exception to the documentation of energy control procedures for a piece of equipment is given in 29 CFR 1910.147(c)(4)(i). If an employer can demonstrate the existence of EACH of the eight elements listed below, documentation of the procedures for the equipment is not required. The exception terminates if circumstances change and ANY of the eight elements no longer exist.

• The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees.
• The machine or equipment has a single energy source which can be readily identified and isolated.
• The isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment.
• The machine or equipment is isolated from that energy source and locked out during servicing or maintenance.
• A single lockout device will achieve a locked-out condition.
• The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance.
• The servicing or maintenance does not create hazards for other employees.
• The employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance.

The LO/TO standard also applies to operations where there is interconnected or nearby equipment.

Interconnected Equipment: If an authorized employee is exposed to hazardous energy from interconnected machines or equipment, the energy control procedures for all interconnected machines or pieces of equipment must be implemented.

• Example: A snapped belt on a motor needs changed but the motor is located directly over an interconnected conveyor. The authorized employee must stand on the conveyor to replace the belt. If the conveyor were unexpectedly started, the authorized employee could be severely injured. Since the conveyor is interconnected and exposes the authorized employee to the potential for injury from unexpected startup, the energy control procedures for the motor must also require that energy control procedures for the conveyor be implemented.

Nearby Equipment: If an authorized employee, in performing service and maintenance work on a machine or piece of equipment, is exposed to hazardous energy from nearby machines or equipment, the employer is required to provide the employee with protection from these hazardous energy sources.

• Example: A snapped belt on a motor needs changed but there is a nearby production process where a robot arm is operating. When the robot arm operates, it could strike the authorized employee replacing the belt. The employer must provide protection by effectively guarding the nearby robot arm to protect the authorized employee. If that is not possible, the robot arm must be locked and tagged out.