ANSI/ASSE Z244.

1 – 2003 (R2014)

AmericAn n AtionAl S tAndArd

ANSI/ASSE Z244. 1 – 2003 (R2014)
Control of Hazardous Energy
Lockout/Tagout and Alternative Methods
ANSI/ASSE Z244.1 – 2003 (R2014)

AmericAn S ociety of
S Afety e ngineerS
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The information and materials contained in this publication have been developed from sources believed
to be reliable. However, the American Society of Safety Engineers (ASSE) as secretariat of the ANSI
accredited Z244 Committee or individual committee members accept no legal responsibility for the
correctness or completeness of this material or its application to specific factual situations. By publication
of this standard, ASSE or the Z244 Committee does not ensure that adherence to these
recommendations will protect the safety or health of any persons, or preserve property.
 ANSI®
ANSI/ASSE Z244.1 – 2003 (R201 4)

American National Standard

Control of Hazardous Energy

Lockout/Tagout and Alternative Methods

Secretariat

American Society of Safety Engineers

1 800 East Oakton Street
Des Plaines, Illinois 6001 8-21 87

Approved September 9, 201 4

American National Standards Institute, Inc.
American Approval of an American National Standard requires verification by ANSI that the
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interpretation should be addressed to the secretariat or sponsor whose name
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Caution Notice: This American National Standard may be revised or withdrawn
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Published October 201 4 by

American Society of Safety Engineers

1 800 East Oakton Street
Des Plaines, Illinois 6001 8-21 87
(847) 699-2929 • www.asse.org
Copyright ©201 4 by American Society of Safety Engineers
All Rights Reserved.
No part of this publication may be reproduced
in any form, in an electronic retrieval system or
otherwise, without the prior written permission
of the publisher.
Printed in the United States of America
Foreword (This Foreword is not a part of American National Standard Z244.1 -2003 (R201 4).)

History
In March 1 973, the Accredited Standards Committee Z244 held its first organizational
meeting in New York to develop a standard on lockout/tagout. The National Safety
Council functioned as the initial secretariat and provided a draft document "Guidelines for
a Lockout Program" dated November 1 971 that was used as a reference for the
committee’s deliberations. By the end of 1 975, the standard development work was
complete and public review and balloting was finished. However, various administrative
and procedural problems precluded the standard from being officially released. In March
1 982, American National Standard for Personnel Protection - Lockout/Tagout of Energy
Sources - Minimum Safety Requirements Z244.1 was finally approved and published.
In 1 987, the standard was re-affirmed without any changes in content. In April 1 988, the
Occupational Safety and Health Administration (OSHA) released a proposed rule "The
Control of Hazardous Energy Sources (Lockout/Tagout)” 29 CFR 1 91 0.1 47 which used
ANSI Z244.1 as a principal reference source. The committee believed no consequential
action should be taken on the Z244.1 standard while federal rulemaking was underway.
In September 1 989, OSHA promulgated its final rule 29 CFR 1 91 0.1 47, “The Control of
Hazardous Energy Sources (lockout/tagout).” Again in 1 992, the ANSI standard was re-
affirmed without change. The American Society of Safety Engineers became the
secretariat of the Z244 Lockout/Tagout Committee in 2003. The standard was
significantly revised in 2003 and was reaffirmed without technical change in 2008 and
again in 201 4.
Need for a Standard
A wealth of casualty data exists in the private, public and governmental sectors related to
the unexpected release of hazardous energy. In fact, the issue is of global concern since
all of the major industrialized countries of the world are actively addressing the problem in
various ways. The U.S. Occupational Safety and Health Administration provided
persuasive injury data in its justification for a lockout/tagout standard for general industry.
In spite of substantial efforts by employers, unions, trade associations and government
during the past 35 years, the annual toll of injury and death related to hazardous energy
release incidents remains unacceptable. We now know that all forms of energy must be
addressed; that operational personnel are injured as often as maintenance workers; that
often thermal and gravitational forces and trapped materials under pressure are
overlooked; that complex equipment and processes frequently demand unique
approaches to energy isolation or control; and that employers need to commit resources
and substantial effort in planning, training, procedure development and infrastructure
before lockout/tagout application ever occurs.
The rapid growth of technology continues to require different methods and techniques for
safeguarding workers from the unexpected release of hazardous energy. Every business
sector is actively changing the way traditional work is done, which then requires
employers to develop new equally effective responses for hazardous energy control.
Protective standards need to be continually improved to provide guidance for current
conditions as well as evolving technical developments.
Standard Perspective
The content of this standard was approached from a business and industry perspective.
However, the principles, methods and guidance are applicable to a variety of other
settings and circumstances where unexpected release of hazardous energy can occur. It
is recommended that the procedures, techniques, methods and design guidance detailed
 herein will be utilized by all those whose activities fall within the scope and purpose of
this standard.
The standards committee and the secretariat have made a concerted effort to produce a
standard that represents the best practice regarding the control of hazardous energy. All
circumstances or situations where personnel are exposed to unexpected energy release
may not have been anticipated and adequately addressed with respect to the standard's
content. New developments are to be expected, and revisions of the standard will be
necessary as the state of the art progresses and further experience is gained. However,
uniform requirements are needed and the standard in its present form provides
performance requirements that are necessary when developing and implementing a
system for protecting personnel from hazardous energy.
Current Status
During 1 997, the committee was reconstituted and voted to revise the existing standard
after over 20 years without change. Consequential meetings began in 1 998 and the
revision process began with writing task groups being formed and continued through
2003 when this document was produced. The title of the standard was modified to
recognize the broader universe of hazardous energy control. The standard now more
effectively addresses the need for greater flexibility through the use of alternative
methods based on risk assessment and application of the hazard control hierarchy. In
addition, the standard emphasizes management’s responsibility for protection of
personnel against the release of hazardous energy.
The standard was processed and approved for submittal to ANSI by the Accredited
Standards Committee (Z244) on Control of Hazardous Energy-Lockout/Tagout and
Alternative Methods for Personnel Protection. The standard was approved by ANSI on
July 29, 2003 with a publication day of April 1 4, 2004.
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The standard was then reaffirmed without technical change by the committee and
approved by ANSI on November 1 1 , 2008 and again on September 9, 201 4.
Conformance language in the standard consists of the words “shall” and “should”. In this
standard, the word “shall” is intended to be prescriptive, specifying mandatory
requirements for compliance with the standard. The word “should” specifies non-
mandatory recommendations and good practices that have been found to be helpful.
Suggestions for improvements of this standard are welcome. They should be sent to:
American Society of Safety Engineers (ASSE), 1 800 East Oakton Street, Des Plaines, IL
6001 8 c/o Z244 Secretariat, Practices and Standards.
Revisions : The Z244 Committee welcomes proposals for revisions to this standard.
Revisions are made to the standard periodically (usually five years from the date of the
standard) to incorporate changes that appear necessary or desirable, as demonstrated
by experience gained from the application of the standard. Proposals should be as
specific as possible, citing the relevant paragraph number(s), the proposed wording and
the reason for the proposal. Pertinent documentation would enable the Z244 Committee
to process the changes in a more-timely manner.
Interpretations : Upon a request in writing to the Secretariat, the Z244 Committee will
render an interpretation of any requirement of the standard. The request for interpretation
should be clear, citing the relevant paragraph number(s) and phrased as a request for a
clarification of a specific requirement. Oral interpretations are not provided.
No one but the Z244 Committee (through the Z244 Secretariat) is authorized to provide
any interpretation of this standard.
Approval: Neither the Z244 Committee nor American National Standards Institute (ANSI)
"approves," "certifies," "rates" or "endorses" any item, construction, proprietary device or
activity.
Appendices : Appendices are included in most standards to provide the user with
additional information related to the subject of the standard. Appendices are not part of
the approved standard.
Committee Meetings : The Z244 Committee meets twice a year. Persons wishing to
attend a meeting should contact the Secretariat for information.
Standard Approval: This standard was processed and approved for submittal to ANSI by
the American National Standards Committee on Control of Hazardous Energy, Z244.
Approval of the standard does not necessarily imply (nor is it required) that all committee
members voted for its approval. At the time this standard was reaffirmed, the Z244
Committee had the following members:
Edward V. Grund, CSP, P.E., Chair
Jeff Fryman, Vice Chair
Timothy R. Fisher, CSP, CHMM, ARM, CPEA, Secretary
Jennie Dalesandro, Administrative Technical Support

Organization Represented Name of Representative

Aluminum Association Mark Eliopulos
American Chemistry Council Paul Dobrowsky
American Petroleum Institute Kendall C. Crawford, P.E., CSP
American Society of Safety Engineers David Dodge, CSP, P.E.
George Karosas, CSP, P.E.
B1 1 Standards, Inc. Sam Boytor
Bayer MaterialScience, LLC Terry L. Ketchum
BNSF Railway Jim Weber, MS, CSP
Kevin Wilde
Castell Interlocks Ashan Bogollagama
Pierre Balson
Edison Electric Institute Charles J. Kelly
Goodyear Tire & Rubber Co. James W. Lane
Dan Pyanowski
Grund Consulting Edward V. Grund, CSP, P.E.
Richard Bouchard
Honda of America Manufacturing, Inc. Jason Stover, CSP
Institute of Electrical & Electronics Engineers James H. Beall
Sue Vogel
International Brotherhood of Electrical Workers David Mullen
International Union, UAW Andrew Comai, MS
JDF Consulting Enterprises Ltd. Jeff Fryman
Johnson & Johnson Guy C. Rechtoris, MS, CSP
Ronny Briers
NPES: The Association for Suppliers of Printing, Debbie Orf
Publishing & Converting Technologies
Omron Scientific Technologies, Inc. Joseph Doran, P.E.
Christopher Soranno
Precision Metalforming Association William Gaskin
James Barrett, Jr.
 Premier Factory Safety Ernie Eisenbach
Robotic Industries Association Pat Davison
Ross Controls Dan Henman
Eric Cummings
Sauer-Danfoss, Inc. Ken Foltz
Society of Plastics Industry Dale Bartholomew
David Felinski
Toyota Motor Manufacturing NA, Inc. Troy Uahinui
U.S. Department of Labor – OSHA Ken Stevanus

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Contents SECTION ........................................... ................................................... .. PAGE

Introduction ...................................... ................................................... ........ 1 0

1 . Scope, Purpose, and Application ................................................... ...... 1 0

1 .1 Scope ............................................. .............................................. 1 0
1 .2 Purpose ................................................... .................................... 1 0
1 .3 Application ................................................... ................................ 1 1

2. Definitions ....................................... ................................................... ... 1 1

3. Responsibilities .................................. ................................................... 1 3

3.1 Manufacturers, Integrators, Modifiers and Remanufacturers....... 1 3
3.2 Users ................................................... ........................................ 1 3
3.3 Authorized Individuals ....................................... ........................... 1 3

4. Design ................................................... ............................................... 1 3

4.1 Manufacturer, Integrator, Modifier and Remanufacturer
Responsibilities .................................. ....................................... 1 3
4.2 Energy Isolating Devices ................................................... .......... 1 3
4.3 Special Tools or Devices ................................................... .......... 1 4
4.4 Warnings and Special Instructions .............................................. 1 4
4.5 Component Isolation ......................................... ........................... 1 4
4.6 Documentation Requirements ................................................... .. 1 4
4.7 Stored and Residual Energy ............................................ ............ 1 5
4.8 Control Integration ................................................... .................... 1 5
4.9 Physical Safeguards ........................................ ............................ 1 5

5. Hazardous Energy Control Program ................................................... . 1 5

5.1 User Responsibilities ................................................... ................ 1 5
5.2 Methods of Control ................................................... ................... 1 6
5.3 Lockout/Tagout Program ................................................... .......... 1 6
5.4 Alternative Methods ........................................... .......................... 24
5.5 Communication and Training .......................................... ............. 28
5.6 Program Review ................................................... ....................... 29

Annexes:
A - Risk Assessment and Risk Reduction ................................................ 31
B (1 ) - Sample Lockout/Tagout Program and Policy .............................. 36
B (2) - General Lockout/Tagout Procedure ............................................ 41
C - Sample of an Energy Control Procedure ............................................ 43
D - Sample of a Lockout/Tagout Placard ........................................... ....... 46
 E - Group Lockout/Tagout ................................................... ..................... 48
F - Alternative Method for Freeze Plug Applications ................................ 54
G - Remote Low Voltage Lockout System ................................................ 55
H - Alternative Method for the Printing Industry ........................................ 56
I - Alternative Method for the Plastics Industry ........................................ 57
J - Alternative Method for Robotic Applications ....................................... 59
K- Alternative Methods Involving Trapped Key Interlock Systems .......... 60
L - Sample of a Lockout/Tagout Application Inspection Form .................. 62
M - Bibliography ................................................... ..................................... 64

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
AMERICAN NATIONAL STANDARD Z244.1
CONTROL OF HAZARDOUS ENERGY
LOCKOUT/TAGOUT AND ALTERNATIVE METHODS
INTRODUCTION
This standard provides guidance regarding:
 responsibilities of the principal
parties involved in hazardous
energy control (Section 3);
 design issues that influence
the effective application of con-
trol methodology (Section 4);
 hazardous energy control
program elements necessary
for employee protection (5.3);
 alternative methods develop-
ment for tasks that are routine,
repetitive, and integral to the
production process, or where
traditional lockout/tagout pro-
hibits the completion of those
tasks (5.4);
 special applications where
traditional methods of hazard-
ous energy control are
inappropriate or impractical
(5.3.1 0);
 communication and training
requirements for involved
personnel (5.5); and
 management review of the
total hazardous energy control
process to ensure its function-
ing effectiveness (5.6).
The standard provides for decision-making
flexibility regarding hazardous energy
control methodology. Alternative methods,
when used, are based upon risk
assessment and application of the classic
hazard control hierarchy (5.4.2). However,
10
lockout/tagout continues to be emphasized
as the primary hazardous energy control
approach.
1. SCOPE, PURPOSE, AND APPLI-
CATION
1 .1 Scope. This standard establishes
requirements for the control of hazardous
energy associated with machines, equip-
ment or processes that could cause injury to
personnel.
1 .2 Purpose. The purpose of this
standard is to establish requirements and
performance objectives for procedures,
techniques, designs and methods that
protect personnel where injury can occur as
a result of the unexpected release of
hazardous energy. Unexpected release of
hazardous energy can include any
unintended motion, energization, start up or
release of stored energy, deliberate or
otherwise, from the perspective of the
person(s) at risk.
Lockout/tagout is the primary method of
hazardous energy control. When the tasks
specified in 1 .3 are routine, repetitive and
integral to the production process, or
traditional lockout/tagout prohibits the
completion of those tasks, alternative
methods of control that are based on risk
assessment (5.4.1 ) and that provide
effective personal protection shall be used.
NOTE: Tasks that are routine, repetitive and
integral to production generally exhibit most
of the following characteristics:
 Short in duration
 Relatively minor in nature
 Occur frequently during the
shift, day or week
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

 Usually performed by oper- erecting, installing, constructing, repairing,

ators, set-up, service or adjusting, inspecting, unjamming, setting
maintenance personnel up, trouble-shooting, testing, cleaning,
 Do not involve extensive dismantling, servicing and maintaining
disassembly machines, equipment or processes.
 Represent predetermined
cyclical activities This standard does not apply to work on
 Expected to occur regularly cord and plug connected electrical equip-
 Minimally interrupt the pro- ment for which exposure to the hazards of
duction process unexpected energization or start up of the
 Exist even when optimal equipment is controlled by the unplugging of
operating levels are achieved the equipment from the energy source and
 Require task specific per- by the plug being under the exclusive
sonnel training control of the individual performing the
servicing or maintenance.
The reason for intervention (i.e.
perform the task) is to sustain the This standard does not apply to hot tap
machine, equipment or process operations involving transmission and
continuity within the nominal distribution systems for substances such as
performance range and output gas, steam, water or petroleum products
quality. This usually occurs when when they are performed on pressurized
the machine, equipment or pipelines, provided the user demonstrates
process is operating normally and that (1 ) continuity of service is essential; (2)
the need for periodic service or shutdown of the system is impractical; and
adjustment is predictable based on (3) documented procedures are followed
operating
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Each user should inventory and
examine all tasks deemed to be 2. DEFINITIONS
"routine, repetitive and integral to
production" and determine if they 2.1 Alarm. An audible or visual means
possess the above characteristics used to alert personnel to an impending
before proceeding in the develop- hazard, (e.g. start up, motion or a failure or
ment of alternative methods based malfunction of a machine, equipment or
on risk assessment. If the tasks do process).
not substantially conform, then
lockout /tagout should be used. 2.2 Authorized Individual. A person
who is assigned to perform hazardous
This document is a performance standard energy control.
and, as such, is not intended to limit or
restrict the use of other existing specific 2.3 Control Circuit. The means of
standards and procedures that meet the initiating or interrupting energy to a
performance objectives defined in this machine, equipment or process. Also the
standard and provide an equivalent level of circuit of a control apparatus or system that
personal protection from exposure to directs the performance of machine,
hazardous energy. equipment or process, but does not directly
interrupt the flow of energy. Control circuits
1 .3 Application . This standard applies may be hydraulic, pneumatic, electric or
to, but is not limited to, activities such as, electromechanical.

11
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

2.4 Control Reliability. The capability mechanism allows, or prevents, the

of a device or system to stop or prevent
initiation of hazardous motion in the event of
a single component failure within the device
or system.
2.5 Control System. Sensors, manual
input and mode selection elements,
interlocking and decision making circuitry
and output elements provided to the
operating devices or mechanisms of the
machine, equipment or process.
2.6 De-Energized. Disconnected from
all energy sources and not containing
residual or stored energy.
2.7 Energized. Connected to an
energy supply or containing residual or
stored energy.
2.8 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 line valve;
a block and any similar device used to block
or isolate energy.
2.9 Guard. A physical barrier that
prevents access to areas of the machine,
equipment or process where a hazard
exists.
2.1 0 Hazardous Energy. Any electri-
cal, mechanical, hydraulic, pneumatic,
chemical, nuclear, thermal, gravity or other
energy that could cause injury to personnel.
2.1 1 Integrator. An entity that is
responsible for assembling a group of
interrelated or interacting machine,
equipment or process components.
2.1 2 Interlock. A device or system
whereby the status of one control or
operation of another.
2.1 3 Lockout Device. A positive
means such as a lock that secures an
energy isolating device in a position that
prevents the energizing of a machine,
equipment or process.
2.1 4 Lockout/Tagout. The placement
of a lock/tag on the energy isolating device
in accordance with an established
procedure, indicating that the energy
isolating device shall not be operated until
removal of the lock/tag in accordance with
an established procedure. (The term
“lockout/tagout” allows the use of a lockout
device, a tagout device or a combination of
both.)
2.1 5 Manufacturer. An entity that
designs, fabricates, assembles or supplies
machines, equipment or processes.
2.1 6 Modifier. An entity that changes or
alters an existing machine, equipment or
process.
2.1 7 Remanufacturer. Any entity
whose business is the redesign or
reconstruction of a machine or equipment.
2.1 8 Risk Assessment. A compre-
hensive evaluation of the probability and the
degree of the possible injury or damage to
health in a hazardous situation in order to
select appropriate safeguarding (see 5.4.1
and Annex A).
2.1 9 Safety Signs. A visual alerting
device in the form of a sign, label, decal,
placard or other marking that advises the
observer of the nature and degree of the
potential hazard(s) that can cause injury or
death.
2.20 Tagout Device. A prominent
warning means, such as a tag and a means
of attachment, which can be securely
fastened to an energy isolating device to
indicate that the energy isolating device and

12
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
the equipment being controlled may not be
operated until the tagout device is removed.
2.21 User. An entity that utilizes
machines, equipment or processes covered
by this standard, and is responsible for the
personnel associated with hazardous
energy control.
3. RESPONSIBILITIES
3.1 Manufacturers, Integrators, Modi-
fiers and Remanufacturers. Manufacturers,
integrators, modifiers and remanufacturers
shall be responsible for designing,
integrating, installing and building machines,
equipment or processes so that the user can
effectively control hazardous energy during
activities outlined in 1 .3.
3.2 Users. Users shall be responsible
for complying with the applicable provisions
of this standard by establishing an effective
program for the protection of individuals
from hazardous energy during activities
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NOTE: A user may become an integrator,
modifier or a remanufacturer if the user
performs work within the definition of those
entities (see Definitions).
3.3 Authorized Individuals. Author-
ized individuals shall be responsible for
performing hazardous energy control in
compliance with the program, procedures
and training provided to them by the user.
4. DESIGN
4.1 Manufacturer, Integrator, Modi-
fier and Remanufacturer Responsibil-
ities. Machines, equipment and processes
shall be designed, manufactured, supplied
and installed so the user can comply with the
control methodologies of this standard.
Modifications affecting energy isolation shall
comply with this standard. A risk assessment
shall be performed during the engineering
design stage of development to determine
the need for, and design sufficiency of,
13
appropriate energy isolating devices and
systems (see Annex A).
4.1 .1 Exposure Minimization. Manu-
facturers, integrators, modifiers and
remanufacturers shall design machines,
equipment and processes to be reliable,
therefore requiring a low level of
intervention. The machine, equipment or
process should be designed so that
personnel are not exposed to hazardous
energy during routine and repetitive
servicing and maintenance activities.
NOTE: This can be accomplished by
positioning controls outside hazardous
areas, adding controls at appropriate
locations, providing external lubrication
points or providing guarding.
4.1 .2 Partial Energization. For those
functions when partial energization is
necessary, the manufacturer, integrator,
modifier or remanufacturer shall perform a
risk assessment similar to that outlined in
Annex A toGroup
Sharing determine the chats
and our safest method of
machine, equipment or process access.
When it is necessary for machines,
equipment or processes to remain partially
energized (e.g. in order to hold parts, save
information, retain heat or provide local
lighting), alternative control methodologies
shall be provided for personnel safety.
4.2 Energy Isolating Devices.
Machines, equipment and processes shall
be designed, manufactured, supplied and
installed with energy isolating devices to
enable compliance with the requirements in
5.3. Consideration shall be given to the
intended use of the machine, equipment or
process. Devices shall be capable of
controlling or dissipating hazardous energy,
or both. The devices should be an integral
part of the machine, equipment or process.
When these devices are not integral to the
machine, equipment or process, the
manufacturer shall include in the installation
instructions recommendations for type and
location of energy isolating devices.
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
4.2.1 Location. Energy isolating devices
shall be accessible and, when practical, be
conveniently located to facilitate the
application of lockout devices during service
and maintenance.
NOTE: Energy isolating devices are best
located outside any hazardous areas at a
convenient manipulating height from an
adjacent walking area (i.e. not overhead, on
ladders or under machinery).
4.2.2 Identification. All energy isolating
devices shall be adequately labeled or
marked unless they are located and
arranged so that their purpose is clearly
evident. The identification shall include the
following:
a) machine, equipment or
process supplied;
b) energy type and magnitude.
NOTE: The potential for error will be
reduced if personnel are not expected to
rely on memory or experience as to which
isolating devices apply to which machines,
equipment or processes. When machine,
equipment or process placarding or posting
contains the required energy isolating
device identification, individual devices may
be marked or coded and their identity
referenced on the placard or posting
information.
Where conditions such as security are
warranted, coded identification is accept-
able.
Examples of labeling or marking (e.g. tags,
embossing, engraving, stenciling, etc.)
language are as follows: Main Power Press
3 (480V); Natural Gas-Process Line 2;
Hydraulic Pump Discharge (800 psi); Bay A
Compressed Air (1 00 psi).
4.2.3 Capability. Energy isolating
devices shall be capable of either being
14
locked or otherwise secured in an effective
isolating position.
NOTE: Examples of effective isolating
devices may include, but are not limited to,
levers with aligning lock tabs (holes),
ballcocks with aligning lock tabs, locking
covers which only work when the switch is
in the safe position, wheels with locking tabs
(and position indicators), physical blocks
with locking aligning tabs.
4.2.4 Suitability. Each energy isolating
device shall be evaluated to determine its
suitability for its intended application.
4.3 Special Tools or Devices. If
special tools or devices are necessary for
servicing or maintaining the machine,
equipment or process or their component
parts, they shall be provided with the
machine, equipment or process.
4.4 Warnings and Special Instruc-
tions. The manufacturer shall determine if
warnings and special instructions are
necessary for servicing or maintaining the
machine, equipment or process. Appro-
priate information shall be provided by the
manufacturer, integrator, modifier or
remanufacturer in a written manual. In
addition, where the manufacturer deter-
mines that warnings or special instructions
are to be located in the area of the hazard
on a label, placard or sign, the manufacturer
shall so affix or provide appropriate placard
material to the user for later installation.
4.5 Component Isolation. Machine,
equipment or process installation shall
provide for the local isolation of component
parts or component systems if they are to
be serviced or maintained separately. The
number and location of energy isolation
devices shall be determined by the
configuration of the machine, equipment or
process and its intended application.
NOTE: Examples of local component
isolation may include machines having
heating systems and other auxiliary systems
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
that have separate sources of hazardous
energy that must be controlled.
4.6 Documentation Requirements.
The manufacturers, systems integrators,
modifiers and remanufacturers shall provide
a written manual (documentation) detailing:
a) the specific location and
procedures for use of energy
isolating devices provided (see
5.3.1 .2);
b) step-by-step procedures for
servicing or maintenance on any
machine, equipment or process
that must be performed under
partial energization based on the
results of a risk assessment;
c) specific instructions for safely
addressing such conditions as
malfunctioning, jamming, misfeed-
ing or other interruptions of the
operation; and
Get more FREE standards from Standard Sharing
d) installation instructions inten-
ded for the installer of the
machine, equipment or process
that identifies the location of
necessary energy isolating
devices.
4.7 Stored and Residual Energy.
When stored or residual energy has been
determined to be a hazard, a means for
non-hazardous dissipation or safe restraint
of the stored or residual energy shall be
incorporated into the machine, equipment or
process. Devices used for the dissipation of
stored energy shall be designed with a
means or method of verifying their position
and state.
When machinery run-down or coasting is
determined to be a hazard, guarding shall
be installed that protects against the hazard
or prevents access until the motion has
ceased.
15
NOTE: In the case of stored or residual
thermal energy, warnings and/or instruc-
tions may be provided instead of a device to
dissipate or restrain the energy, if such a
device is not practical. Warnings and
instructions may also be omitted if the
existence and location of hazardous thermal
energy is readily apparent due to the
function of the machine, equipment or
process.
4.8 Control Integration. When alter-
native methods are used during setup,
troubleshooting or other tasks requiring
energization or partial de-energization,
protective systems shall be used to ensure
that a device or system will stop or prevent
initiation of hazardous motion or release of
hazardous energy in the event of a single
component failure within the device or
system.
NOTE: Typical methods of accomplishing
this task are:
a)Group
a hardware based, control-
and our chats
reliable safety interlock system; or
b) safety-rated multiple-channel
Programmable Logic Controllers
(PLCs), when manufactured speci-
fically for safety applications,
applied per manufacturer’s instruc-
tions.
4.9 Physical Safeguards. Physical
safeguards (e.g., pins, blanks, blocks,
restraints, chains or blinds) shall be
designed to withstand, with an appropriate
safety factor, all forces to which they will be
subjected and comply with applicable
standards when one exists for the device.
5. HAZARDOUS ENERGY CON-
TROL PROGRAM
5.1 User Responsibilities.
5.1 .1 Equipment. The user shall obtain
machines, equipment and processes that
comply with Section 4 (Design) of this
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
standard. If, after one year from the
approval date of this standard, the user
obtains noncompliant equipment, the user
shall upgrade the equipment to be
compliant with Section 4 of this standard.
NOTE: Equipment that may require upgrade
includes newly purchased used equipment,
items designed to different standards and
existing equipment that is moved within or
between locations.
If the user purchases components, parts of
machines or assembles a number of
machines into an integrated production line,
the user assumes the role of integrator and
must fulfill the requirements of Section 4.
The user shall obtain equipment with
isolation devices that allow authorized
individuals to execute the hazardous energy
control program outlined in 5.3.
NOTE: A single energy isolating device that
supplies multiple operations or machines,
while satisfying requirements, may create
situations that encourage personnel to
deviate from fulfilling the intent of this
standard. Additional isolation devices or the
implementation of alternate methods may
be necessary to eliminate these situations.
5. 1 . 2 Prog ram . The user shall establish
a written program for hazardous energy
control detailing the requirements in
Sections 5.3 and 5.4. The purpose of the
program is to ensure that risk of exposure to
hazards will be eliminated or minimized
before any authorized individual performs
any activity listed in Section 1 .3 on a
machine, equipment or process where the
unexpected energizing, start up or release
of stored energy could occur and cause
injury (see Figure 1 ).
NOTE: Users’ evaluations should consider
the warnings and special instructions
provided by the manufacturer.
5. 2 M eth od s of Con trol . The method
of hazardous energy control selected
depends on whether the task can be
16
performed with or without energized
conditions. In all cases, the primary method
of control shall be lockout/tagout as
specified in 5.3. When lockout/tagout is not
used for tasks specified in 1 .3 that are
routine, repetitive and integral to the
production process, or traditional lockout/
tagout prohibits the completion of those
tasks, then other alternative control
methodologies, procedures or combinations
thereof, as specified in 5.4, shall be used to
protect personnel while performing these
tasks. However, before adopting alternative
methods of control, the user shall conduct a
risk assessment that demonstrates the
adequacy of the evaluation and the
effectiveness of the protective measures
(see 5.4).
5. 3 Lockou t/Tag ou t Prog ram . Lock-
out/tagout is a systematic program that shall
consist of the following elements to provide
effective protection of personnel:
a) a survey of all hazardous
energy;
b) identification of energy isola-
ting devices;
c) the selection and procure-
ment of protective materials and
hardware;
d) the assignment of duties and
responsibilities;
e) the determination of shut-
down, de-energization, energiza-
tion and start-up sequences;
f) written procedures for ma-
chines, equipment and processes;
g) training of personnel; and
h) auditing of program ele-
ments.
NOTE: A sample lockout/tagout program
and policy is shown in Annex B.1 .
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Figure 1
Decision Matrix for Safeguarding
Hazardous Energy

Task requiring access to machine,

equipment or process

Routine, repetitive action?

NO or YES
Lockout prohibits task
completion?

Exposed to hazard? Exposed to hazard?

or or
Guards removed? Guards removed?
or NO NO or
Interlocks bypassed? Interlocks bypassed?

YES Perform YES

Task
more FREE standards from Standard Sharing Group and Perform
Perform
Get Risk
our chats
Lockout/Tagout Assessment
Procedure

Apply YES Alternative

Alternative method
method possible?
NO

5.3.1 General Requirements for isolating device or permanently alter its

Lockout/Tagout. If an energy isolating
device is capable of being locked out,
lockout shall be used unless the user can
demonstrate that the use of a tagout
program will provide effective protection for
personnel. An energy isolating device is
capable of being locked out if it has a hasp
or other means of attachment to which, or
through which, a lock can be affixed, it has
a locking mechanism built into it or if lockout
can be achieved without the need to
dismantle, rebuild or replace the energy
energy control capability.
If an energy isolating device is not capable
of being locked out, a tagout program shall
be used.
When a tagout device is used on an energy
isolating device, which is capable of being
locked out, the tagout device shall be
attached at the same location that the
lockout device would have been attached,
and the user shall demonstrate that the

17
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
tagout program will provide an effective
level of safety.
In demonstrating that an effective level of
safety is achieved in the tagout program,
the user shall demonstrate full compliance
with all tagout-related provisions of this
standard. Additional protective means shall
include, but are not limited to, the removal
of an isolating circuit element, blocking of a
controlling switch, opening of an extra
disconnecting device or the removal of a
valve handle to reduce the likelihood of
inadvertent energization.
5.3.1 .1 Hazardous Energy Control
Procedures. An important element of the
overall hazardous energy control program is
the development of procedures. Each
unique piece of equipment, system or
process shall have detailed procedures
developed and documented for the control
of hazardous energy during servicing or
maintenance activities. These procedures
shall be posted or otherwise readily
available for authorized individuals to review
and use.
NOTE: An example of a comprehensive
specific machine, equipment or process
energy control procedure is shown in
Annex C. In addition, an example of a
placard (graphic style procedure) is shown
in Annex D.
Where a plant or facility has more than one
piece of similar equipment or more than one
identical system or process line, a single
procedure may be applied to all.
NOTE: For example, a printing company
with six identical four-color sheet-fed
printing presses may have one procedure
covering these six presses. Similarly, a
bottling company with two identical bottling
lines may have one procedure covering
these two lines.
Where a machine, system or process has a
single energy supply that is readily identified
18
and isolated, written procedures shall not be
required.
5.3.1 .2 Procedure Elements. The proce-
dures shall clearly and specifically outline
the requirements for effective isolation of
the machine, equipment or process. The
procedures shall include all of the following:
a) identification of the machine,
equipment or process;
b) listing of all required energy
isolating devices and location;
c) specific procedural steps for
shutting down, isolating, blocking,
securing and relieving stored or
residual energy;
d) specific procedural steps for
the placement and removal of
lockout/tagout devices; and
e) specific requirements for
verifying that isolation and de-
energization has been accom-
plished.
5.3.1 .3 Procedure Management. The
user shall develop a plan for the ongoing
need for developing or revising procedures
to address new machine, equipment or
process acquisition, changes to existing
machines, equipment or process; correction
of identified hazardous energy control
deficiencies and addition of any hazardous
energy control improvements that may be
generated.
The user shall establish responsibilities for
ensuring that procedures accurately reflect
the current requirements and are effective in
controlling machine, equipment or process
hazardous energy.
Procedures shall be readily accessible to
authorized individuals and may be
maintained via print or electronic media or
available in placard style at the machine,
equipment or process.
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
NOTE: Procedures may be supplemented
by checklists where machine, equipment or
process isolation or de-energization
sequence complexity or criticality warrants.
5.3.1 .3.1 Format. The user should establish
guidelines for consistent formatting of
procedures.
5.3.1 .3.2 Validation. Each procedure shall
be verified for its accuracy, completeness
and energy control effectiveness by a
knowledgeable person.
5.3.1 .3.3 Approval. Each procedure shall
be approved by the user’s designee before
implementation.
5.3.1 .3.4 Document Maintenance. Periodic
review of the procedures shall be conducted
by the user to ensure they are current. The
date of creation, revision and update of
each procedure shall be maintained.
5.3.1 .4 Protective
Get moreMaterials and Hard-
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ware. All applicable protective materials and
hardware required to effect isolation of
energy shall be provided by the user.
Each lockout device and tagout device shall
be uniquely identified; shall be the only
device(s) used for controlling hazardous
energy; shall not be used for other purposes
and shall meet the following requirements:
a) Lockout and tagout devices,
including their means of attach-
ment, shall be capable of
withstanding the environment to
which they are exposed and shall
remain legible for the maximum
period of time that exposure is
expected;
b) Lockout and tagout devices
shall be standardized within the
facility in at least one of the
following criteria: color, shape, size
or specific markings and addition-
ally, in the case of tagout devices,
19
print and format shall be
standardized;
c) Lockout and tagout devices,
including their means of attach-
ment, shall be substantial enough
to prevent inadvertent or acci-
dental removal without the use of
excessive force or destructive
techniques;
d) Lockout and tagout devices
shall indicate the identity of the
authorized individual applying the
device(s);
e) Where exposed to adverse
conditions (weather conditions,
wet and damp locations or
corrosive environments), tagout
devices shall be constructed and
printed so that exposure will not
cause the tag to deteriorate or the
message on the tag to become
illegible; and
f) Tagout devices shall warn
against hazardous conditions if the
machine or equipment is ener-
gized and shall include a danger
warning and legend such as one of
the following: "Do Not Start. Do
Not Open. Do Not Close. Do Not
Energize. Do Not Operate."
5.3.1 .5 Energy Isolating Device Identi-
fication. All energy isolation devices shall
be adequately labeled or marked to indicate
their function, unless they are located and
arranged so their purpose is evident. The
identification shall include the following:
1 ) machine, equipment or process supplied
and 2) energy type and magnitude. The
marking shall be of sufficient durability to
withstand the anticipated environment.
NOTE: The potential for accidents can be
reduced if employees are not expected to
rely on memory as to which isolating
devices apply particularly in complex
equipment. There is a greater potential for
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
error when energy isolating devices are
unlabeled or inadequately identified. Where
conditions such as complexity or security
are warranted, coded identification is
acceptable.
Examples of marking and labeling include
attached or embossed markings and signs
such as “Main Breaker (480 V) Press 3”,
“Natural Gas Shutoff Process Line 2”, “Drive
Power Isolation Axis X Only”, “High
Pressure (600 psi) Return Line".
Electrical boxes can be labeled directly on
the box. Valves can be labeled on the valve
body or with a suspended sign or tag.
5.3.1 .6 Energy Isolation. Lockout or
tagout shall be performed only by
authorized individuals.
5.3.2 Elements of Energy Control.
Elements of energy control shall include the
following actions and should be done in the
following sequence:
5.3.2.1 Preparation for Shutdown.
Authorized individuals shall understand the
applicable procedures, acquire the neces-
sary protective materials and hardware,
identify the notification requirements,
determine related issues and assess the
consequences of the shutdown.
5.3.2.2 Notification of Personnel.
Personnel who could be affected by the
shutdown of the machine, equipment or
process shall be notified prior to the
application and after the removal of lockout
devices or tagout devices.
5.3.2.3 Machine, Equipment or Process
Shutdown. The machine, equipment or
process shall be de-energized or shut down
using the specific established hazardous
energy control procedures.
NOTE: A specific sequence of shutdown
may be necessary to avoid any additional or
increased hazard(s) to individuals as a
20
result of the machine, equipment or process
stoppage.
5.3.2.4 Machine, Equipment or Process
Isolation. All energy isolating devices that
are needed to control the energy to the
machine, equipment or process to accom-
plish the required task(s) shall be
determined and operated in such a manner
as to isolate the machine equipment or
process from the energy supply.
On complex machinery, equipment and
processes where it is necessary to isolate
power or motion for a specific component
while maintaining power to control systems,
support utilities and other devices and
components, sectional (localized) lockable
energy isolating devices shall be used.
NOTE: Hazardous energy may exist in
adjacent machinery, equipment and
processes to that being worked on.
Appropriate energy isolation or other safety
related steps may be required.
5.3.2.5 Lockout or Tagout Device
Application. Lockout or tagout devices
shall be affixed to each energy isolating
device by authorized individuals.
Lockout devices, where used, shall be
affixed in a manner that will ensure that
energy isolating device(s) remain in a “safe”
or “off” position.
Tagout devices, where used, shall be
affixed in such a manner as will clearly
indicate that the operation or movement of
energy isolating devices from the "safe" or
"off" position is prohibited.
Where tagout devices are used with energy
isolating devices designed with the
capability of being locked, the tag attach-
ment shall be fastened at the same point at
which the lock would have been attached.
Where a tag cannot be affixed directly to the
energy isolating device, the tag shall be
located as close as safely possible to the
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
device in a position that will be immediately
obvious to anyone attempting to operate the
machine, equipment or process. In addition,
a tag shall be placed at the operator’s
control position to alert personnel that the
machine, equipment or process is de-
energized.
5.3.2.6 Partial De-Energization. Through
the addition of secondary energy isolating
devices downstream of the primary energy
isolating devices, energy may be seg-
mented to various components, devices,
sections or operating entities if necessary
from an operation’s or safety standpoint.
The user may protect sectionalized areas as
required for operational and maintenance
tasks while allowing partial operation,
cycling or indexing as required. The user
shall install these devices according to
appropriate national standards (e.g. NFPA
79, Electrical Standard for Industrial
Machinery).
5.3.2.7 Controlling Stored Energy. All
potentially hazardous stored, residual or removed
Get more FREE standards from Standard Sharingfrom the and
potential energy shall be relieved, discon-
nected, restrained or otherwise controlled.
NOTE: Additional measures may be
necessary to prevent re-accumulation of
energy to protect individuals.
5.3.2.8 Verification of Isolation. Prior to
starting work on machines, equipment or
processes that have been locked out or
tagged out, the authorized individual shall
verify that isolation and de-energization has
been accomplished.
NOTE: Verification may be accomplished by
testing circuitry, cycling, visually inspecting
position, manually trying; monitoring
movement or discharge; observing bleeds,
gauges, indicators, etc. or other available
means. Use of the technique(s) with the
best degree of isolation assurance is
preferred.
5.3.2.9 Return to Service. The work area
shall be inspected to ensure that
nonessential items have been removed, that
the machine, equipment or process is
operationally intact and all personnel are in
a safe location.
Personnel who could be affected by a return
to service action shall be alerted before
energy is restored to the machine,
equipment or process.
Each lockout or tagout device shall be
removed from each energy isolating device
by the authorized individual who applied the
device or by compliance with 5.3.4.
After lockout or tagout devices have been
removed and before a machine, equipment
or process is started, personnel who could
be affected by such action shall be notified
that the lockout or tagout device(s) have
been removed.
5.3.3 Provisions for Energy Control
Interruption. In situations in which lockout
or tagout devices must be temporarily
Group energy
our isolating
chats device(s)
and the machine, equipment or process
must be either fully or partially energized to
test, troubleshoot or position the machine,
equipment, process or a component thereof,
the sequence of actions detailed in 5.3.2.9
shall be followed.
When the energy is no longer needed,
reapply lockout/tagout according to the
appropriate sequence found in 5.3.2.
5.3.4 Procedures for User-Directed
Lockout/Tagout Device Removal. When
the authorized individual who applied the
lockout or tagout device is not available to
remove it, that device may be removed
under the direction of the user, provided that
specific procedures and training for such
removal have been developed, documented
and incorporated into the user's energy
control program. The user’s specific
procedure shall incorporate the require-
ments in 5.3.2.9 in addition to the following
elements:
21
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
a) verification by the appro-
priate supervisory personnel of the
status and condition of the
machine, equipment or process
and that the authorized individual
who applied the device is not
reasonably available or not at the
facility; and
b) ensuring that the authorized
individual has been informed
before they resume work at that
facility that their lockout or tagout
device has been removed.
5.3.5 Outside Service or Contractor
Personnel. The host-user and outside
service or contractor personnel shall each
designate a representative responsible for
determining their relationship, responsibil-
ities and obligations regarding hazardous
energy control prior to the outside service or
contractor starting work or providing
services.
5.3.5.1 Apprising of Hazard. The host-
user shall inform the outside service or
contractor designated representative of any
known special or unique hazards that are
related to the machinery, equipment or
process to which the outside service or
contractor employees could be exposed.
5.3.5.2 Program Coordination. All out-
side service organizations’ or contractors’
programs shall be coordinated with the
host-user’s hazardous energy control
program when there is integration of job
tasks. Protection for all individuals who
could be exposed to hazardous energy
within the facility shall be mutually
understood, communicated and agreed
upon between the parties.
NOTE: The contractor's program may be
similar and yet different in the form they
take (i.e. practice or hardware). In order to
eliminate confusion or to clearly differentiate
and standardize on contractor-controlled
lockouts, the host-user site may provide
locks and tags that are coordinated with the
22
site lock and tag system. Communication is
a key element of a hazardous energy
control program and a clear tag/lock identity
with assigned responsibility is important.
5.3.5.3 Communications. Prior to and
during the course of the work, both the host-
user and outside service or contractors shall
keep each other informed of any activities or
conditions that may adversely affect the
application of hazardous energy control or
impact the normal operation of machines,
equipment or processes.
NOTE: Examples of activities or conditions
that could warrant communication between
the parties include interruption of energy
supply, disabling a fire protection/security
system, emergency alarm systems,
hazardous area ventilation and special
equipment that is needed for energy
isolation.
5.3.5.4 Temporary Personnel. Directly
supervised temporary personnel required to
perform lockout functions shall be trained,
issued locks and tags and, depending on
their specific job responsibilities, require site
authorization and possess certain qualifi-
cations to perform specific work covered by
this lockout/tagout standard.
5.3.6 Group Lockout/Tagout. When
multiple energy isolating devices protecting
the affected work activity are secured by
lockout/tagout but are not applied directly by
each authorized individual, a designated
individual shall be responsible for lockout/
tagout of each energy isolating device and
providing a single location or device that
allows each member of the group to apply
their individually-controlled lock or tag.
Verification shall take place to determine the
effectiveness of the energy isolation.
5.3.7 Complex Group Lockout/
Tagout. When all energy isolating devices
protecting the affected work activity are
secured by lockout/tagout but are not
controlled directly by each authorized
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
individual, and more than one of the
following conditions applies:
a) a significant number of
energy isolating devices or author-
ized individuals are involved;
b) the period of energy isolation
is extended;
c) the energy isolating device(s)
is relatively inaccessible; or
d) there is interdependence and
interrelationship of the system
components;
then management shall designate
authorized individuals responsible for
ensuring an equivalent level of personal
protection for each member of the group
utilizing individual continuous accountability
methods such as work permits, control
boards, etc. Verification shall take place to
determine the effectiveness of the energy
isolation. SeeGetAnnex
more EFREE
for additional
standardsgroup
from Standard
lockout/tagout guidance.
NOTE: In the servicing and maintenance of
sophisticated and complex process equip-
ment utilized in the petroleum, utility,
metals, paper, food and chemical industries,
adaptation and modification of normal group
lockout/tagout procedures may be
necessary to ensure the safety of the
employees performing the servicing and
maintenance.
5.3.8 Shift or Personnel Changes.
Specific procedures shall be utilized during
shift or personnel changes to ensure the
continuity of lockout or tagout protection,
including a provision for the orderly transfer
of lockout or tagout device protection
between off-going and oncoming authorized
individuals, to minimize exposure to hazards
from the unexpected energization or start-
up of the machine, equipment or process or
the release of stored energy.
23
NOTE: An example of shift or personnel
changes is as follows: a service lock is
applied to each energy isolating device
when the authorized employee or contractor
has completed their shift but the work is not
completed or when the employee or
contractor must leave the building for any
reason (example: pick up parts, move to
another machine, etc.). When their personal
lock is removed, a service/transition lock is
applied. All maintenance personnel have
keys to the service locks, which allow them
to remove these locks and attach their
personal locks to continue repair of the
machine/equipment. A service lock is not
intended to replace a personal lock. The
sole purpose is to maintain the integrity of
the lockout between employees or
contractors. When a service lock is removed
and replaced by a personal lock, the
employee is required to verify that all energy
sources remain isolated or controlled.
5.3.9 Remote or Noncontiguous Loca-
tions. Where isolation devices are in a
remote
or Group
Sharing noncontiguous location, written
and our chats
procedures shall be used in conjunction with
written authorizations to ensure that
authorized individuals performing the work
verify the isolation and de-energization or
re-energization through direct communi-
cation with personnel designated in the
procedure.
NOTE: Examples of remote or non-
contiguous locations include:
a) Pipeline operations with
widely spaced pump stations,
including those connecting off-
shore oil and gas production to
onshore terminals and gas
transmission and distribution
systems, including underground
gas storage systems, gas wells
and compressor stations.
b) Electric power transmission
and distribution systems.
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
5.3.1 0 Special Applications. Experience
has identified some types of equipment or
process systems where the design inhibits
the use of established lockout/tagout
procedures contained in 5.3. In these cases,
alternative methods of hazardous energy
control per 5.4 shall be used to prevent the
unexpected movement or motion of
equipment, or minimize the risk of a
hazardous condition or event. The user
should obtain the recognized standard(s) for
their machines, equipment and processes to
determine if specific alternate methods are
necessary.
5.3.1 0.1 Freeze Plug Technology. The
application of freeze plug technology for
isolation of piping systems shall provide the
same degree of protection for exposed
personnel and essentially follow the same
practices required in 5.2 for the lockout/
tagout of hazardous energy sources. See
Annex F for detailed requirements.
5.3.1 0.2 Remote Low Voltage Lockout
System. Remotely activated electro-
mechanical lockout systems are an accept-
able alternative to be used in selected
applications such as long machines and
inaccessible or inconvenient locations of
primary isolation devices. The user shall
install and operate such systems in accord-
ance with the manufacturer’s directions.
See Annex G for further details.
5.4 Alternative Methods. When
lockout/tagout is not used for tasks specified
in 1 .3 that are routine, repetitive and integral
to the production process (see 1 .2), or
traditional lockout/tagout prohibits the
completion of those tasks, then an
alternative method of control shall be used.
Control options such as those specified in
5.4.3 through 5.4.6 shall be used following
the hierarchy in 5.4.2 to ensure effective
protection.
Selection of an alternative control method
by the user shall be based on a risk
assessment of the machine, equipment or
process as specified in 5.4.1 . The risk
24
assessment shall take into consideration
that existing safeguards provided with the
machine, equipment or process may need
to be removed or modified to perform a
given task.
The alternative method selected shall have
detailed procedures developed and docu-
mented for the control of hazardous energy.
NOTE: Activities that might be performed
using alternative methods include die
changing, jam clearing, make-ready,
lubrication, tool changes, roll polishing,
minor cleaning, adjustments and set-up.
NOTE: It is important that the correct
devices are selected for the application. An
engineering review will ensure that proper
safety devices such as those listed in
Sections 5.4.3 through 5.4.6 are utilized. If
the engineering review identifies an applica-
tion where special engineered devices such
as blocks, racks, supports, pins, etc. are
required, these devices shall be designed
and built using appropriate safety factors.
Examples of alternative methods of hazard-
ous energy control are contained in the
annexes. Annex H applies to the printing
industry; Annex I applies to machinery used
in the plastics industry; Annex J applies to
robotic applications. In any of these
examples, all provisions of this standard
apply in the development of alternative
methods.
5.4.1 Risk Assessment. For purposes
of this standard, risk assessment is
intended to be a qualitative estimation and
does not require quantitative probabilistic
analysis and shall include the following
elements:
a) identification of the tasks
(including foreseeable misuse) and
related hazards;
b) qualitative estimation of ex-
posure and severity to determine
the level of risk;
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
c) assessment and evaluation
of the risk;
d) identification of potential
control actions considered to
reduce the risk of each hazard;
e) identification of control
actions selected as the best
protective alternative;
f) verification of the effective-
ness of the selected alternative;
and
g) documentation of the risk
assessment process.
NOTE: This standard does not require a
specific methodology, but includes Annex A
as an example to illustrate the analytical
concept that may be necessary to ensure
that any alternative method(s) selected
provides an acceptable level of risk to the
exposed individuals.
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5.4.2 Hierarchy of Alternative Control
Implementation. A hierarchical process
shall be employed in the selection of
alternative control methodologies in the
following order of preference:
a) Eliminate the hazard through
design;
b) Use engineered safeguards
as specified in 5.4.3;
c) Use warning and alerting
techniques as specified in 5.4.4;
d) Use administrative controls
(such as safe work procedures,
practices and training) as specified
in 5.4.5 and 5.4.6, respectively;
and
e) Use personal protective
equipment as specified in 5.4.7.
When the alternative methodology has been
determined using b) through e) above,
appropriate communication and training of
individuals shall be developed and provided.
NOTE: The objective of this process is to
select the highest level of feasible
control(s). In many cases, application of any
single control methodology is not adequate
to provide an effective level of protection for
personnel. It may be necessary to use a
combination of the methodologies sug-
gested in Sections 5.4.3 to 5.4.6 to provide
individuals with protection equivalent to
lockout/tagout.
NOTE: Annexes H, I and J provide illustra-
tive examples of how various industries
have employed alternative control method-
ologies to provide individuals with effective
alternative protection.
5.4.3 Engineered Safeguards. When
using any engineered safeguard as an
element of an alternative control method,
the user shall
useand
Group robust industrial quality
our chats
components; incorporate control reliable
safety control circuits; consider the
effectiveness and failure modes of the
device(s); assess the possible residual risks
and the possibility that the safeguard may
be defeated/bypassed. These systems must
provide an equivalent level of protection to
prevent the unexpected energization of
equipment being serviced.
5.4.3.1 Exclusive Personal Control. The
user shall provide a means of exclusive
personal control to prevent exposure to the
hazardous energy. Examples include locks,
pendants, blocks, pins and the location and
proximity to control devices.
5.4.3.2 Control Circuit Integrity. When
control circuits are used as part of the
safeguarding system intended for use
during setup, troubleshooting or other tasks
requiring energization or partial de-energi-
zation, the level of risk must be determined.
The level of risk is determined by identifying
the involved tasks, hazards, potential
25
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
severity of injury and exposure. The greater
the severity potential for injury, the more
frequent the access, and the more direct the
contact with the hazard, then the greater the
risk. The control system selected must be of
sufficient integrity to provide protection for
the established level of risk.
NOTE: Typical methods in increasing order
of integrity are:
a) Negligible Risk Potential –
Infrequent exposure and low injury
severity. A single channel circuit of
industrial rated components that
mechanically or electromechan-
ically isolates the incoming power
from the motor, solenoid or other
actuating device that produces
hazardous motion.
b) Low Risk Potential – individual shall have exclusive personal
Frequent exposure and low injury
severity. A dual channel circuit of
industrial rated components that
mechanically or electromechani-
cally isolates the power and is
inspected as part of normal
operations to ensure integrity of
the system.
c) Medium Risk Potential – Any
exposure to serious injury. A dual
channel circuit (one of which is
hardwired) of industrial rated
components that is self-checking
or monitored through the use of a
safety relay or safety (multiple
channel) PLCs to ensure integ rity
and performance of the control
circuits. These systems typically
have redundant interlock switch
safety contacts, redundant iso-
lation through positively guided
electromechanical relays, and are
monitored or self-checking through
use of a safety relay or safety PLC
that is designed and installed to a
high level of integrity through the
selection of robust components.
26
NOTE: Single channel general
purpose PLCs do not satisfy this
requirement.
d) High Risk Potential – Any
exposure to a catastrophic injury.
A control reliable dual channel
hardwired circuit of industrially-
rated components that satisfies the
design features as specified in
ANSI B1 1 .1 9 (with redundant door
interlock switches etc.), using a
safety relay or safety PLC to
ensure integrity and performance
of the safeguarding system. This
system shall be designed to
ensure protection equivalent to a
mechanical disconnect switch or
master shut-off valve.
NOTE: Under all circumstances, the
control over the means to maintain the state
of the control circuit in a protective mode.
Examples include personnel safety keys or
other locking devices.
5.4.3.3 Area Scanners. These devices
detect objects or persons entering the
sensing field (hazardous area). Their
application is typically indicated for covering
large or irregularly shaped areas.
5.4.3.4 Guards. For the purpose of this
standard there are two types of guards,
fixed and movable. Guards that do not have
to be opened frequently are fixed in such a
way that their removal necessitates the use
of tools. Movable guards shall be inter-
locked.
Guards shall not create any additional
hazards to personnel.
5.4.3.5 Hold-to-Run Devices. These
devices require the individual to use a hand
or hands to apply direct pressure to one or
more buttons or switches. If the button or
switch is released, a signal is sent to the
control circuit. These devices only protect
the individual using the device.
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
NOTE: Three position (center enable)
devices offer additional protection to the
holder by sending an “off” signal to the
control if the device is released or fully
compressed.
5.4.3.6 Light Curtains. These devices
create a sensing plane. The sensing plane
is comprised of one or more transmitting
elements and one or more receiving
elements. When an object or person
interrupts one or more beams, the device
sends a signal to the control circuit.
5.4.3.7 Pressure Mats. Pressure mats
are used to detect the presence of a person
or object on a walking surface. When
downward pressure is applied to the mat, a
signal is sent to the control circuit.
5.4.3.8 Safety-Rated Switches. These
are devices that are tamper resistant and
mechanically actuated with positively driven
multiple contacts. Magnetic switches may
comply if Get theymore
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coded and have
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monitored contacts.
5.4.3.9 Stop Devices. These devices are
usually push buttons, cables, position or
edge sensors that activate a switch. When
the device is activated, a signal is sent to
the control circuit.
5.4.3.1 0 Trapped Key Devices. These
devices are mechanically attached to power
circuits, switches, valves and access points,
and require operators to follow a predeter-
mined sequence of actions. Keys are
captive or free in electromechanical and
mechanical interlocks depending on the
condition of the equipment or process.
Examples of trapped key use are contained
in Annex K.
5.4.4 Warning and Alerting Tech-
niques. Where risk assessment indicates
their use or where engineered safeguards
alone do not provide an acceptable level of
protection, warning or alerting techniques
shall be implemented. Techniques to be
27
considered include, but are not limited to,
the following:
5.4.4.1 Attendant. An attendant may be
used to warn exposed personnel or monitor
the effectiveness of the applied safeguard.
5.4.4.2 Automated Warning Systems.
Audible or visual devices are used individ-
ually or in combination to warn personnel of
potentially hazardous conditions.
5.4.4.3 Barricades. Barricades are used
to prevent access to a hazardous area, and
may be used in conjunction with warning
signs.
5.4.4.4 Warning Signs and Tags. Warn-
ing signs, symbols or tags are used to warn
personnel where hazards exist.
5.4.5 Administrative Controls (Safe
Work Procedures and Practices). Where
the risk assessment indicates their use or
where engineered safeguards, warning and
alerting
techniques
Sharing Group andor aour
combination
chats thereof
do not provide an acceptable level of
protection, administrative controls such as
safe work procedures and practices shall be
developed and implemented.
The following elements shall be considered
when developing safe procedures and
practices to provide effective alternative
protection.
5.4.5.1 Apparel. Loose or other inappro-
priate clothing, long hair or other items that
may contact moving machinery should not
be allowed. Exposed conductive articles of
jewelry and clothing, including metalized
aprons, cloth with conductive thread or
metal headgear, should not be worn where
they present an electrical contact hazard.
5.4.5.2 Illumination. Adequate illumina-
tion shall be available for the task to be
performed.
5.4.5.3 Preparation for Work. All author-
ized individuals involved with the task or
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
activity, prior to starting the work, shall
review existing hazards, written practices,
documented alternative method(s) and
control measures to be used.
5.4.6 Training. Training on the use of
alternative methodologies shall be con-
ducted in accordance with 5.5.2.
5.4.7 Personal Protective Equipment.
Where the risk assessment indicates their
use or where engineered safeguards,
warning/alerting techniques, safe work
procedures and practices, or a combination
thereof, do not provide an acceptable level
of protection, authorized individuals shall be
protected from injury by appropriate
personal protective equipment.
5.5 Communication and Training.
5.5.1 Communication. Users shall be
responsible for informing all personnel
regarding the provisions of the hazardous
energy control program to an appropriate
level. Users shall also be responsible for
apprising appropriate authorized individuals
of aspects of the hazardous energy control
program such as changes in the program,
incident experience, progress against the
plan, performance data, auditing results and
other pertinent details.
5.5.2 Training. The user shall provide
initial training that will ensure that all
authorized individuals understand the
purpose and function of the energy control
program. Training shall be such that all
authorized individuals have an under-
standing that is appropriate for the level of
hazard exposure they may encounter. The
following elements are to be included in a
training program:
a) Individual training shall be
carried out prior to authorized
individuals performing service and
maintenance tasks or being
potentially exposed to hazardous
energy.
28
b) Training shall be specific to
the user’s written program.
c) The training program shall be
developed using applicable manu-
facturer’s documentation, industry
best practices, regulatory require-
ments and input from the
authorized individuals.
d) Each authorized individual
shall receive training in the type
and magnitude of the energy
available in the workplace.
e) Each authorized individual
shall receive training in the type of
energy that might be encountered
during servicing or maintenance
and methods or means to control
and isolate that energy.
f) Training shall include
samples of machine specific
procedures and enable personnel
to interpret and implement proce-
dures developed in 5.3.1 .2.
g) The user shall document that
all initial and additional training has
been conducted. The documenta-
tion shall contain each individual's
name, dates of training and the
training topic.
NOTE: The user should avoid exclusive use
of generic training programs to ensure that
authorized individuals adequately under-
stand the user’s specific program.
Documentation of the information covered
during training should be maintained.
Training methods may include, but are not
limited to, formal instruction (direct instructor
contact), computer-based or interactive
training, simulation and practical demon-
strated application.
Every effort should be made to structure
training to make it understandable to all
authorized individuals regardless of their
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
level of education, primary language or
disabilities. Annual refresher training should
be conducted to maintain an appropriate
level of awareness.
Additional information on developing
effective training programs can be found in
ANSI/ASSE Z490.1 ; Accepted Practices in
Safety, Health and Environmental Training .
5.5.3 Additional Training. Retraining
shall be provided for all authorized
individuals whenever there is a change in
their job assignments, a change in
machines, equipment or processes that
present a new hazard or when there is a
change in the energy control procedures.
Additional retraining shall also be conducted
whenever an audit reveals, or whenever the
user has other reason to believe, that the
authorized individual’s knowledge or use of
the energy control procedures is inadequate
or inconsistent with the requirements.
5.5.4 Assessment of Training. The
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user shall conduct an assessment of the
effectiveness of the training that is
conducted.
The assessment shall be done in such a
way to ensure that authorized individuals
demonstrate:
a) knowledge of the program;
b) recognition and understand-
ing of hazardous energy types;
and
c) use of appropriate hazardous
energy control procedures.
Authorized Individuals who do not demon-
strate an adequate level of knowledge or
use of appropriate hazardous energy control
procedures shall be retrained.
5.6 Program Review. The user shall
periodically assess the condition and
effectiveness of each of the elements of the
hazardous energy control program (see
5.2). The assessment shall include, as a
minimum, the written program, specific
machine, equipment, process procedures,
lockout/tagout hardware, energy isolating
devices, alternative methods and communi-
cation and training.
5.6.1 Program Monitoring and
Measurement. The user shall determine
the frequency of monitoring and measuring
of each of the hazardous energy control
program elements.
NOTE: Various methods may be utilized to
determine that the program has appropriate
content, describes current conditions and is
properly executed.
Monitoring, measuring and assessing
components should be included in the
program review process. A measurement
system that is capable of providing
qualitative and quantitative feedback on
hazardous energy control performance
should be established.
chats should be
placed on both operational and mainte-
nance personnel who are directly involved
in hazardous energy control application.
Criteria should be established that provides
the basis for repetitive measurement.
Management should compare results and
determine if there is a positive or negative
change in any program element. A
summary should include trends, variances,
rates of compliance, key findings and
observations and recommendations for
program improvement.
5.6.2 Application of Specific Proce-
dures. Compliance with specific hazardous
energy control procedures (machine,
equipment or process) is critical. Therefore,
the user shall establish a continual auditing
plan that will provide current information
regarding maintenance of application
effectiveness. The user is responsible for
executing the auditing plan to verify that
complete compliance is occurring. Auditing
shall be conducted at least annually and
29
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

documentation shall be maintained for a

minimum of three years.
NOTE: The user should determine the
frequency of monitoring (e.g. monthly) and
an appropriate specific hazardous energy
control procedure application sample size.
The application effectiveness audits should
be random and address all shifts, days of
operation, groups, non-standard work
situations and individual personnel.
Knowledgeable personnel should conduct
visual observations of authorized individuals
performing specific procedure application to
include feedback and documentation. See
Annex L for a sample application inspection
form.
5. 6. 3 P erform an ce The user
F eed back.

shall establish a system for providing both

positive and negative feedback to
appropriate individuals and supervisors
regarding the hazardous energy control
program. Where deficiencies are found,
corrective action shall be taken and
appropriate individuals informed of the
required improvements.

30
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

ANNEX A – INFORMATIONAL
Annexes are included to provide the user with additional information related to the subject
of the standard. Annexes are not part of the approved standard.

Risk Assessment and Risk Reduction

A.1 Risk Assessment

Risk assessm en t i s an an al yti cal tool con sistin g of a n u mber of di screte steps in ten d ed to
in su re th at h azard s are properl y id en tified , th at associated risks are eval u ated and th at
appropriate measu res are taken to red u ce th ose risks to an acceptabl e l evel . Typical el emen ts
of a risk assessmen t process in cl u d e th e fol l owin g steps.
N OTE – Ad d i ti on al d etai l s on speci fi c ri sk assessm en t m eth od ol og i es are fou n d i n th e
fol l owi n g d ocu m en ts: I SO 1 41 21 /EN 1 050, AN SI B1 1 -TR3, AN SI /RI A R1 5. 06 an d
M I L STD-882D (see An n ex M )

A.1 .1 Identify all Tasks

Al l tasks an d acti vities sh ou l d be con sid ered . Exampl es of activi ties for wh ich tasks sh ou l d be
id en tified in cl u d e set u p, in stal l ation , rem oval , main ten an ce, operatin g, ad j u stin g , cl ean in g ,
trou bl esh ootin g an d programmin g.
A.1 .2 Identify Hazards
H azard s, su ch as mech an ical , el ectrical , th ermal , pn eu matic, h yd rau l ic, radiation , resid u al or
stored en ergy, motion , fu el s an d h um an factors associated with each task, shou l d be
con sid ered . Get
Associated hazard
more FREE s for a particu
standards l ar task Sharing
from Standard n ot related to hand
Group azard ouchats
our s en ergy rel ease
may al so n eed to be reviewed .
Con sid eration sh ou l d in cl u d e h u m an error, m an agemen t system d eficien cies an d foreseeabl e
improper u se of eq u ipm en t.
A.1 .3 Assess the Potential Consequences
Assess th e severity of in j u ri es to al l person s th at cou l d be h armed by th e h azard s. Th is
incl u d es other person s wh o may be affected by th e task. Th e maxim u m severity of the possibl e
in j u ry sh ou l d be con si d ered for each task.
A.1 .4 Assess the Potential Exposure to the Hazards
Assess th e poten tial exposu re of al l person s to th e id en tified h azard s. Th i s assessmen t sh ou l d
con si der th e natu re, d uration an d freq u ency of exposu re to th e h azards. Consid erati on sh ou l d
al so be g iven to th e nu mber of person s su bj ected to th e exposu re.
A.1 .5 Assess the Probability of Occurrence
Determ in e th e probabi l ity of occu rren ce of th e h azard ou s event by assessin g th e fol l owin g
factors:
a) safegu ard s, safety d evices an d safety systems ei th er in u se or to be u sed ;
b) rel iabi l ity h istory an d fail u re m od e;
c) operation al or main ten an ce d eman d s of th e task;
d ) possibil ity of d efeat or fai l u re of safegu ard s;
e) accid en t h istory rel atin g to th e particu l ar task, acti vity, mach in e, eq u ipment or process;

31
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

f) th e com peten ce of al l person s performin g th e task;

g) th e workin g en viron m en t.

A.1 .6 Evaluate the Risk

Th e in form ation in A. 1 . 1 th rough A. 1 . 5 sh ou l d be eval u ated for each id en tifi ed h azard an d task
to determin e the l evel of risk. Based on th is process, a determin ation of th e acceptabil ity of th e
risk l evel can be mad e. Th e determi n ation m ay in vol ve risk comparison s, con sen su s appraisal s
or in formed val u e j u dgm en ts.
A.2 Acceptable Level of Risk
I f th e eval u ation in A. 1 . 6 d etermin es th e risk to be acceptabl e, th en th e process i s com pl eted
u n ti l a revi ew i s req u ired (see A. 5). I f th e risk(s) are determ ined to be u n acceptabl e, th en th e
risk red u ction process i n A. 3 sh ou l d be im pl em en ted .
A.3 Risk Reduction (Implementation)
Ri sk red u ction is a h ierarchical process em ployed to red u ce or con trol risk by: el im in ation
throu gh d esign , u se of en gin eered safegu ard s, awareness mean s in cl u d in g warn in g an d
al ertin g tech ni q ues, ad min istrati ve con trol s in cl u d in g safe work proced u res an d train i n g, u se of
person al protective eq u ipment an d train in g. Often , for an y particu l ar machin e, eq u ipm en t or
process, th e sol u tion may in cl ud e aspects of each of th ese el emen ts. Th e risk red u ction
process sh ou l d i n vol ve th e appropriate person n el , sh ou l d be d ocu men ted an d sh ou l d ad here to
the process ou tl i n ed bel ow and il l u strated in Fig u re A. 2.
N OTE – Th e fol l owi n g q u esti on s sh ou l d be asked to d eterm i n e th e ad eq u acy of th e
ri sk red u cti on process:
a) I s th e safety l evel ad eq u ate? Can th e task be performed wi th ou t cau si n g i n j u ry
or d am ag e to h eal th ?
b) H ave appropri ate safety m easu res been taken for al l tasks or acti vi ti es? Are th e
measu res taken com pati bl e wi th each oth er?
c) Do th e safety m easu res g en erate an y n ew, u n expected h azard s or probl em s?

A.3.1 Risk Reduction by Design

Risk red u ction shou l d first attem pt to el imin ate th e h azard th rou gh design . Th e primary
obj ecti ve in impl emen tin g d esign featu res is to el i min ate h azard s or red u ce th ei r risk by
substitu tion .
A.3.2 Risk Reduction by Use of Engineered Safeguards
Safegu ard s or safety d evices sh ou l d be u sed to protect person n el from h azard s th at can n ot be
reasonabl y el imin ated or su ffi ci en tl y red u ced by d esi gn .
Safegu ard s or safety d evi ces an d th e safety con trol system (el ectrical , pn eum atic, h yd rau l ic,
etc. ) sh ou l d be of a su itabl e rel iabil ity for th e risk red ucti on that i s req u ired .
N OTE – Exam pl es of en g i n eered safeg u ard s i n cl u d e g u ard s (both fi xed an d
i n terl ocked ), trapped key d evi ces, tri p d evi ces (l i g h t cu rtai n s, l aser scan n ers,
pressu re m ats, safety rated swi tch es, etc. ). Safety d evi ces i n cl u d e for exam pl e,
em erg en cy stop bu tton s, en abl i n g or h ol d to ru n d evi ces, etc.

A.3.3 Risk Reduction by Use of Warning and Alerting Techniques

Warn in g an d al ertin g techn iq u es shou l d be u sed to protect person nel from h azard s th at can n ot
be reason abl y el im in ated or su ffici en tl y redu ced by d esign , en gin eered safegu ard s or a
combin ation of th ese el emen ts.

32
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)
N OTE – Exam pl es of warn i n g an d al erti n g tech n i q u es i n cl u d e atten d an ts, au d i bl e an d
vi su al si g n al s, barri cad es, si g n s an d tag s.

A.3.4 Risk Reduction by Use of Administrative Controls

Ad d iti on al risk red u ction is ach ieved by th e u se of ad m in istrative con trol s in cl u d in g safe work
proced u res, stan d ard practices an d ch eckl ists an d train i ng . Th ese sh ou l d be u sed to con trol
risk th at can n ot be reason abl y el imin ated or sufficien tl y red u ced by the u se of d esign ,
en gin eered safegu ard s, warn in g an d al erti n g tech n iq u es or a combin ation of th ese el em en ts.
Train in g sh ou l d be u sed as a compl emen t to al l th e risk red u ction meth od s d escri bed h ere.
N OTE – Exam pl es of safe work proced u res, practi ces an d trai n i n g i n cl u d e stan d ard
operati n g i n stru cti on s, i l l u m i n ati on , pre-j ob revi ew an d establ i sh i n g safe d i stan ces
from a h azard . Exam pl es of types of trai n i n g th at can be u sed to d evel op profi ci en cy
of au th ori zed i n d i vi d u al s m ay i n cl u d e com pu ter based , si m u l ati on , d ri l l s, cl assroom or
exerci ses.

A.3.5 Risk Reduction by Use of Personal Protective Equipment

Add ition al risk red u ction is ach ieved by effective u se of prescribed person al protective
eq u ipment (PPE). Stron g ad min istrati ve procedu res mu st be in pl ace for the PPE to be an
effecti ve safegu ard .
N OTE – Person al protecti ve eq u i pm en t can i n cl u d e safety eyewear or sh i el d s,
footwear, protecti ve g l oves (i n su l ati n g or cu t resi stan t) an d protecti ve h ead g ear.

A.4 Repeat the Risk Assessment Process

Wh en th e risk red u ction h as been compl eted , th e ri sk assessmen t process sh ou l d be repeated
(see A. 1 an d A. 2). Con si deration sh ou l d in cl ud e th e risk red u ction m eth od s ch osen (in cl u d i n g
factors stated in A. 1 . 5), any new tasks gen erated an d an y n ew h azard s gen erated .
Get more FREE standards from Standard Sharing Group and our chats
I f th e risks have been d eemed to be acceptabl e, th en th e iterative process is compl ete u n til a
review is req u ired (see A. 5). I f th e risks are not yet d eemed to be acceptabl e, th en th e risk
red u ction process sh ou l d be repeated (see A. 3), fol l owed by a repetition of the risk
assessmen t as d escribed in th i s section .
A.5 Review the Risk Assessment and Risk Reduction
Th e risk assessmen t an d ri sk red u ction sh ou l d be reviewed :
a) fol l owin g its i mpl emen tation to ensu re sol u tion s are effective an d in place;
b) fol l owin g an in ci den t or n ear miss;
c) wh en ever n ew tasks or acti vi ties are req u ired ;
d ) wh en ever th ere are mod ifi cation s to th e m ach in e, eq u ipmen t or process;
e) on a period i c basi s.

33
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Figure A.1
The Risk Assessment and Risk Reduction Process

Risk Assessment

Identify Identify Assess Assess the Assess the Evaluate

all Hazards the potential probability of the
tasks (A.1 .2) potential exposure occurrence risk
(A.1 .1 ) consequence to the (A.1 .5) (A.1 .6)
(A.1 .3) hazards
(A.1 .4)

Review the Risk

risk assessment
Acceptable
assessment and risk Yes level of
and risk reduction
reduction completed risk?
(when (A.2)
Repeat the appropriate)
risk (A.5)
assessment
process
(A.4) No

Risk reduction Risk reduction Risk reduction Risk reduction Risk reduction
by use of by use of by use of by use of by design
personal administrative warning and engineered (A.3.1 )
protective controls alerting safeguards
equipment (A.3.4) techniques (A.3.2)
(A.3.5) (A.3.3)

Risk Reduction
(Implementation)

34
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Figure A.2
(Informative)
Sample Risk Assessment for Alternative Methods
(Severity and probability estimation based on machine with no safeguards in place.)
(All risks initially determined to be intolerable without additional safeguarding.)
Department : 26 Operation: Block Machining
Task : Tool change – mill cutter at station 1 2 left.
Severity/
Exposure Risk
Task Hazards
Severity:
Catastrophic, Serious,
Level Protective Measures
Moderate, Minor High
Moderate
(Alternative Methods)
Exposure: Low
Frequent, Periodic,
Infrequent
Identify replacement tool CutsGet
frommore
sharp tooling Moderate/Periodic Moderate Gloves and procedures
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Inspect tool Cuts from sharp tooling Moderate/Periodic Moderate Gloves and procedures
Remove old cutter - Crushing from transfer bar Catastrophic/ High Interlocked guard with trapped key
movement Periodic
- Crushing, entanglement, cuts
from mill cutter movement if Serious/Periodic High Interlocked guard with trapped key
energized
- Cuts from sharp tooling Moderate/Periodic Moderate Gloves and tool assist
- Coolant in eyes Moderate/Periodic Moderate Chemical goggle
- Burn from hot cutter Moderate/Periodic Moderate Procedures and gloves
Install new cutter - Crushing from transfer bar Catastrophic/ High Interlocked guard with trapped key
movement Periodic
- Crushing, entanglement, cuts Serious/Periodic High Interlocked guard with trapped key
from mill cutter movement if
energized
- Cuts from sharp tooling Moderate/Periodic Moderate Gloves and tool assist

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex B (1 )
(Informative)
Sample Lockout/Tagout Program and Policy
I. Purpose
To establish a control system and utilize procedures to prevent the unexpected release or transmission of
machine equipment/process energy.
II. Objectives
A. Prevent inadvertent operation or energization of the machine equipment/process in order to
protect personnel.
B. Establish methods for achieving zero energy state.
C. Comply with applicable regulatory standards.
III. Scope
A. This policy applies to activities such as, but not limited to: erecting, installing, constructing,
repairing, adjusting, inspecting, cleaning, operating or maintaining the equipment/process.
B. This policy applies to energy sources such as, but not limited to: electrical, mechanical,
hydraulic, pneumatic, chemical, radiation, thermal, compressed air, energy stored in springs and
potential energy from suspended parts (gravity).
C. International facilities will comply with the substance of this policy or the prevailing national
requirements whichever is more stringent.
D. Installation design requirement. After January 1 , 1 990, whenever replacement or major repair,
renovation or modification of a machine or equipment is performed, and whenever new
machines or equipment are installed, energy isolating devices shall be designed to accept a
lockout device (29 CFR 1 91 0.1 47).
IV. Definitions
A. 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 line valve; a block and any similar device used to block or isolate
energy. The term does not include pushbutton, selector switch and other control circuit type
devices.
B. Lockout. The placement of a lockout device on an energy isolating device, in accordance with an
established procedure, ensuring that the energy isolating device and the equipment being
controlled cannot be operated until the lockout device is removed.
C. Lockout Device. A device that utilizes a positive means such as a lock, to hold an energy
isolating device in a safe position and prevent the energizing of a machine or equipment.
D. “Capable of Being Locked Out.” An energy isolating device that is designed with a hasp or other
means of attachment to which, or through which a lock can be affixed, or if it has a locking
mechanism built into it. Other energy isolating devices will also be considered to be capable of
being locked out, if lock out can be achieved without the need to dismantle, rebuild or replace
the energy isolating device or permanently alter its energy control capability.
E. Tagout. The placement of a tagout device on an energy isolating device, in accordance with
established procedure, to indicate that the energy isolating device and equipment being
controlled may not be operated until the tagout device is removed.
F. Tagout Device. A prominent warning device such as a tag and means of attachment which can
be securely fastened to an energy isolating device in accordance with 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.
G. Caution Tag. A warning device such as a tag and means of attachment used to warn employees
of an existing or potential hazard. Its legend cautions personnel of the hazard(s) and identifies
the applier.

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

H. Affected Employee. An employee whose job requires them to operate or use a machine or
equipment on which servicing or maintenance is being performed under lockout or tagout.
I. Authorized Employee. A person who locks out or tags out machines or equipment to perform the
servicing or maintenance on that machine.
J. Other Employee. An employee whose job requires them to work in an area in which
machine/equipment servicing or maintaining is being performed.
K. Servicing/Maintenance. Workplace activities such as constructing, installing, setting up,
adjusting, inspecting, modifying and maintaining and/or servicing machines or equipment. These
activities include lubrication, cleaning or unjamming of machines or equipment and making
adjustments to tool changes where the employee may be exposed to the unexpected
energization or start up of the equipment or release of hazardous energy.
V. Procedure
A. Lockout/Tagout System. Each facility shall develop a written lockout/tagout policy, which
incorporates the following elements:
1 . Principles
a. All personnel (hourly and salary) shall comply with the provision of the lockout/tagout
system. Supervision must enforce the use of personnel locks/tags to insure protection
when personnel performing tasks where exposure to unexpected energization may
occur.
b. The locks/tags shall be standardized throughout the facility and the only authorized
method used of the lockout/tagout of energy sources. Locks and employee tags shall
not be used for any purpose other than personal protection.
c. Individual locks/tags shall be applied and removed by each person exposed to the
potential for unexpected release of energy, other than in those special situations where
specific facility procedures have been developed.
d. Where equipment is lockable, use of a lock is required by all exposed personnel.
e. Where equipment is not lockable, tagout application or special lockout/tagout
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be utilized.
f. When locks are used in the lockout/tagout application, they shall always be
accompanied by tags.
(1 ) Locks used for personnel protection shall be accompanied by employee tags.
(2) Locks used to protect against hazards shall be accompanied by caution tags.
g. Energy isolating devices shall be clearly labeled or identified to indicate their function
unless located and arranged so their purpose is evident. Such identification is
necessary to reduce possible errors in applying the lockout/tagout.
h. The lockout/tagout of electrical energy sources shall occur at the circuit disconnect
switch. (Note: Facilities shall identify any situations where the circuit cannot be
positively interrupted and develop procedures providing equivalent protection.
Feasibility of effective circuit isolation shall be considered in future engineering
improvements.)
i. The use of electrical control circuitry to accomplish lockout/tagout is normally
prohibited since it does not offer positive personnel protection. Examples:
(1 ) Electrical shorts. (Water in lines and some types of dust can create a path to
complete the control circuit.)
(2) Vibration or switch component failure.
(3) Remote or interlocked switches not affected by control circuitry.
2. Protective Appliances
a. Locks. Shall be purchased specifically for lockout applications. They shall be of such
design and durability that removal by other than abnormal means would require
excessive force or unusual techniques. In addition, they shall possess individual
keying/combination capability.
b. Tags. Appliances that are used to provide warning or information.
(1 ) Employee Tag (mandatory). Used only for personnel protection; clearly
distinguishable from caution tags and shall include a legend such as D O N OT

37
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

S TART ; D O N OT O PERATE , or a similar directive that informs employees working in

the area not to start up the equipment.
(2) Caution Tag (mandatory). Provides a warning of hazards. It does not indicate that
the applier is currently exposed to the unexpected release or transmission of
energy. The use of a caution tag is provided to preserve the integrity of the
employee tag.
c. Lockout Fixture. An appliance that accommodates one or more locks to secure an
energy isolating device.
d. Additional Protecting Appliances. Some exposures may require additional protective
techniques or mechanical safeguards.
3. Application and Exposure Survey
a. Each facility shall conduct an application survey to determine if the equipment/process
can be safely isolated.
(1 ) The survey should determine if energy isolating devices are available, adequate
and practically located for positive protection.
(2) A plan shall be developed to correct the surveyed deficiencies or provide interim
alternative protection in order to make the lockout/tagout system effective.
b. Each facility shall conduct an exposure survey to determine what tasks are being
done, i.e., cleaning rolls, removing jams, etc., with equipment energized. Each
situation shall be evaluated to determine if the task can be accomplished with the
power off or alternatively what method must be used to reduce employee risk.
4. Responsibilities
a. Management is responsible for the development, implementation and administration of
an effective lockout/tagout system.
b. All employees are responsible for complying with the provisions of the facility
lockout/tagout system.
c. Affected employees shall be aware of lockout/tagout procedures used to guard against
unexpected startups.
d. Only authorized individuals shall operate energy isolating devices and place locks/tags
on controls to prevent unexpected startups.
e. Other employees who work in the area where lockout/tagout procedures are used shall
be instructed about their purpose and prohibited from attempting to restart machines or
equipment that are locked or tagged out.
B. System Utilization
1 . Preparation for Lockout/Tagout
a. All personnel affected by the intended lockout/tagout shall be notified by the supervisor
or authorized employee before commencing any work.
b. A method shall be established to permit access to the equipment/process. This method
should involve acknowledgement and release by the individual(s) responsible for the
equipment/process.
c. A pre-job plan shall be developed to insure appropriate lockout/tagout when the
equipment/process complexity or nature and scope of work warrants (i.e., job
objectives and involved equipment/process; estimated job duration; crafts involved;
type, number and location of energy isolating devices, start-up provisions, etc.).
2. Application of Lockout/Tagout
a. Use appropriate equipment/process shutdown procedure(s) to deactivate operating
controls or return them to the neutral mode.
b. All involved energy isolating devices shall be operated/positioned in such a manner as
to isolate the equipment/process from the energy source(s).
c. Locks and employee tags shall be applied to each energy isolating device by
authorized individuals.
(1 ) Lockout fixtures and locks shall be attached in such a manner as to hold the
energy isolating device(s) in a safe position.
(2) Employee tags shall be completed by the applier and attached to the energy
isolating device(s)
d. After lockout/tagout application and prior to commencement of work, one or more of

38
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

the following actions shall be taken:

(1 ) Operate the equipment/process controls (push buttons, switches, etc.) to verify
that energy isolation has been accomplished. Controls must be deactivated or
returned to the neutral mode after test.
(2) Check the equipment/process by use of test instruments and/or visual inspection
to verify that energy isolation has been accomplished.
e. The equipment/process shall be examined to detect any residual energy. If detected,
action must be taken to relieve or restrain the stored energy.
3. Release from Lockout/Tagout
a. Each lock/tag shall be removed by the authorized individual who applied it prior to
leaving the job.
(1 ) A procedure shall be developed to deal with instances where employees have left
the jobsite without clearing their personal lock/tag.
b. The individual responsible for the equipment/process (affected employee) shall be
notified when the work is complete and the overall lockout/tagout has been cleared.
(1 ) Before equipment/process energization, visual inspection of the work area should
be made to insure that all personnel are in the clear and that all nonessential
items have been removed and components are operationally intact.
4. Specific Procedures
Each facility will develop specific energy isolation procedures for major machines/
equipment/process components/utilities, etc. A “Lockout/Tagout Checklist for Energy
Isolation or Job Safety Analysis” is suitable for this requirement.
C. Special Lockout/Tagout Situations
1 . Lockout/Tagout Interruption (Energized Testing)
In situations where the energy isolating device(s) is locked/tagged and there is a need for
testing or positioning of the equipment/process, the following sequence shall apply:
a. Clear equipment/process of tools and materials.
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c. Clear the energy isolating device(s) of locks/tags according to established procedure.
d. Proceed with test.
e. De-energize and relock/tag energy isolating device(s) to continue the work.
f. Operate controls, etc., to verify energy isolation.
2. Exposure of Non-Company Personnel
a. Company and outside employers (contractors, etc.) shall inform each other of their
respective lockout/tagout procedures.
b. Each facility shall insure that its employees understand and comply with the
requirements of the outside employer’s or mutually agreed upon energy control
procedures.
3. Multiple Personnel Protection
For major process/equipment overhaul, rebuilds, etc., which require crew, craft, department
or other group lockout/tagout, a system is required that affords employees a level of
protection equivalent to that provided by personal lockout/tagout.
4. High Voltage Work
Special written procedures shall be developed to describe the lockout/tagout measures
necessary when employees are required to work on high voltage circuits or equipment
(above 600 volts).
5. Shift Change
Facilities shall develop specific written procedures to accommodate those situations where
it is necessary to continue the current lockout/tagout of the equipment/process into
subsequent shifts.
VI. Exception
Unique requirements for equipment/process service such as jogging, threading coil/stock, etc. may
necessitate employee activity under energized conditions. Each such task must be evaluated to
provide safeguarding techniques to protect employees from equipment/process exposures (see

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

V.A.3.b.).
VII. Education and Training
A. Training shall be provided prior to assignment to insure that employees understand the purpose
and function of the plant lockout/tagout program and that the knowledge and skills required for
the safe application, use and removal of energy controls are acquired. The training shall include
the essential elements of §1 91 0.1 47 and the following:
1 . Each affected employee shall be instructed in the purpose and use of the energy control
procedure.
2. Each authorized employee shall receive training in the recognition of applicable hazardous
energy sources, the type and magnitude of the energy available in the work place, the
methods and means necessary for energy isolation and control and the means of
verification of control.
3. Other employees whose work operations are or may be in an area where energy control
procedures may be utilized shall be instructed about the procedure and about the
prohibition relating to attempts to restart or reenergize machines or equipment which are
locked out or tagged out.
B. Retraining shall be provided annually to reestablish employee proficiency with control methods
and procedures.
1 . Retraining shall also be provided for all affected and authorized employees whenever there
is a change in job assignments, a change in machines, equipment or processes that
present a new hazard or when there is a change in the energy control procedures or
revision of control methods.
2. Additional retraining shall also be conducted whenever periodic audits (see VIII,
Management Controls) reveal or whenever supervisory observations give reason to believe
that there are deviations from or inadequacies in the employee’s knowledge or use of
energy control procedures.
C. Plant documentation shall certify that employee training has been accomplished and is being
kept up-to-date. The certification shall contain each employees name, clock number and dates of
training.
VIII. Management Controls
A. Each facility shall develop and document a formal compliance audit of the lockout/tagout energy
control procedure semiannually to insure that employees are knowledgeable and utilize the
designated procedures. The documentation shall identify the machine or equipment on which the
energy control procedure was being utilized, the date of the inspection, the employees included
in the inspection and the person performing the inspection.
1 . An authorized management employee shall perform annual audits.
2. The amount of lockout/tagout auditing should adequately represent the size of the plant and
number of authorized employees.
3. The audits shall be designed to correct any deviations or inadequacies observed.
4. Where lockout is used for energy control, the audit shall include a review, between the
inspector and each authorized employee, of that employee’s responsibilities under the
energy control procedure being audited.
5. Where tagout is used for energy control, the audit shall include a review, between the
inspector and each authorized and affected employee, of that employee’s responsibilities
under the energy control procedure being audited to insure that employees understand the
limitations of a tagout system and their purpose in the energy control program.
6. Where tagout procedures are used, other employees whose work operations are or may be
in the area shall be contacted by the inspector to insure that they are aware of and
understand the purpose of the procedures.

N OTE - I f com pl i an ce wi th an y el em en t of th i s proced u re i s n ot possi bl e, eq u i val en t

protecti on m u st be provi d ed by an al tern ate system approved by th e safety/h eal th
d epartm en t.

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex B (2)
(Informative)
General Lockout/Tagout Procedure
Purpose and Scope
The purpose of this procedure is to prevent injury to employees from unexpected start-up,
energization or release of stored energy from machinery or processing during servicing or maintenance
of equipment. This standard specifies the minimum locking, tagging, clearing and trying procedure
necessary to prevent injury from an inadvertent start-up, or release of energy or material.
Steps to Follow:
Step 1 . Preparation For Shutdown – Employees authorized to lockout/tagout equipment shall identify
the type and magnitude of the energy to be controlled, all hazards (including stored energy)
and the method or means of controlling the energy. They shall also notify all affected persons
in the area that the equipment will be locked/tagged out.
Step 2. Equipment Shutdown – The equipment shall be shut down by following established shutdown
procedures.
Step 3. Equipment Isolation – Use of disconnect switches, line valves, blocks, blinds, removal of
spools and capping of lines, etc., shall be used.
Step 4. Application of Lockout/Tagout Devices – Locks/tags shall be applied to the isolation device.
Each employee working on the equipment shall be responsible for attaching their personal
locks without exception.
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Step 5. Stored Energy – After applying locks/tags to the energy isolation devices, all potentially
hazardous stored or residual energy must be relieved, blocked, bled, restrained or rendered
safe.
Step 6. Verification of Isolation – Prior to starting work, after isolation and locking/tagging energy
sources, turn on (try) all start buttons and other activating controls on the equipment to make
sure the equipment has been de-energized. Be sure to return all controls to the off or neutral
position after trying to start.
Step 7. Release From Lockout/Tagout Control – Prior to restoring energy to the equipment, remove all
tools, ensure all affected employees are clear and informed that energy to the equipment will
be restored and guards are in place. Then all locks/tags can be removed and energy restored.
Special Considerations:
1 . No changes, adjustments or repairs that require shutting down the equipment will be made
without permission of the operator or operating supervisor in charge. The equipment involved
must have been turned over to repair crews before the work begins.
2. If more than one employee works on the same equipment, each person must attach their lock
and tag.
3. When an employee is reassigned from a job, which is incomplete, and the equipment must of
necessity remain locked out, the employee involved will notify their supervisor before removing
their lock/tag. The supervisor will then lockout/tagout the equipment or arrange for such lockout
and tagging prior to the first employee removing their lock and tag.

41
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

4. No attempt shall be made by anyone to operate a control device to which a lock or tag is
attached.
5. When a job is to be extended from one shift to another, the relieving employee or the supervisor
shall attach their lock/tag to the lockout device before the employee going off shift removes their
lock/tag. If the supervisor places their lock/tag on the device instead of the oncoming employee,
the oncoming employee shall place their lock/tag on the device before starting work.
6. In the event an employee leaves a lock/tag or equipment and cannot be found, the supervisor
may have the lock/tag removed only after following the procedures outlined.
7. When requested by operating personnel, maintenance personnel shall perform electrical
disconnects. The employees performing the work must go with the person making the disconnect
and attach their lockout/tagout device to the control device.
8. When locking out electrical disconnects, push buttons shall be tried to make sure the correct
switch has been opened.
9. In no case shall anyone be assigned to remove another employee’s lockout/tagout device except
the supervisor as authorized in item no. 6, above.
1 0. Locks and danger tags issued for use in making lockouts will not be used for any purpose other
than as outlined.
1 1 . A supervisor shall lockout/tagout equipment when the equipment is to be out of service for an
extended period of time, (over eight hours).
1 2. Outside contractors shall be informed of the lockout/tagout procedures and required to follow it.

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Procedure Annex C
(Informative)
Sample of an Energy Control Procedure
Equipment Description - VacuBlast Cabinet w/Dust Extractor – BLS1004, DEX1035

DEPARTMENT:
Unit 3
Heat Treat

VERSION #:
2002

REFERENCE #:
157

POINT OF
CONTACT:
Supervisor
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Hazardous Energy
Type Magnitude
P Electrical 415 volts
Pneumatic 100 psi

Required Safety Equipment

Tagout Tag(s) (2)
E Interlocking Hasp(s) (2)
Padlock(s) (2)
Ball Valve Lockout(s) (1)

Reference #: 157
Machine: VacuBlast Cabinet w/Dust Extractor – BLS1004, DEX1035

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

I. Shut Down Procedures:

(a) Notify all affected employees that a lockout or tagout system is going to be
utilized and the reason for. The authorized employee shall know the type and magnitude of
energy that the machine or equipment utilizes and shall understand the associated hazards.

(b) Electrical:
Press the "STOP" button to completely de-energize the machine.

II. Isolation Procedures:

(a) Electrical: Located between the two machines.
Turn the main service isolator to "OFF" to isolate the electrical POWER.

(b) Pneumatics: Located on the right side of the machine.

Rotate the main air valve to the “CLOSED” position to block the air service.

III. Lockout Procedures:

(a) Electrical:
Lockout the main isolator using an interlocking hasp and padlock.

(b) Pneumatics:
Lockout the air service valve using a ball valve lockout, interlocking hasp,
and padlock.

IV. Verification Procedures:

(a) Electrical:
Try the machine start controls (e. g. by switching the "ON/OFF" switch to the
“ON” or “START” position and observing that the machine does not operate)
after lockout/tagout to make sure the correct isolation device has been secured and
Switch the "ON/OFF" or
that the device is in the open or safe position.
“START” switch to the “OFF” position. IF electrically qualified and authorized
to do so, verify blade openings visually on electrical conductors or energized
parts. Test for no voltage on phase-to-phase and phase-to-ground before
beginning work.

(b) Pneumatics:
Verify isolation and dissipation of the air service by observing that the flow of
air ceases.

V. Returning to Service:
(a) Check the machine and the immediate area around the machine to ensure that
nonessential items have been removed and that the machine components are
operationally intact.

(b) Check the work area to ensure that all employees have been safely positioned or
removed from the work area.

44
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

(c) Electrical:
Remove the padlock and interlocking hasp from the main isolator and turn the
isolator to the "ON" position.

(d) Pneumatics:
Remove the ball valve lockout, interlocking hasp and padlock from the air
service line and rotate the main air service valve to the “OPEN” position.

(e) Notify affected employees that the maintenance is completed and the machine is
ready for production.

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AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex D
(Informative)
Sample of a Lockout/Tagout Placard

46
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex D
(Informative)
Sample of a Lockout/Tagout Placard

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex E
(Informative)
Group Lockout/Tagout
E.1 Group Procedural Structure
In Appendix C, Instruction Standard 1 -7.3, OSHA outlines a procedural structure that could be used under
group lockout/tagout circumstances:

 A primary authorized employee would be designated to exercise primary responsibility for

implementation and coordination of the lockout/tagout of hazardous energy sources.
 The primary authorized employee would coordinate with equipment operators before and after
completion of servicing and maintenance operations, which require lockout/ tagout.
 A verification system would be implemented to insure the continued isolation and de-energization
of hazardous energy sources.
 Each authorized employee would be assured of their right to verify individually that the hazardous
energy has been isolated and/or de-energized.
 When more than one crew, craft, department and so on is involved, each separate group of
servicing/maintenance personnel would be accounted for by a principal authorized employee
from each group. Each principal employee is responsible to the primary authorized employee for
maintaining accountability of each worker in that specific group in conformance with the company
procedure. No person may sign on or off for another person or attach or remove another person’s
lockout/tagout device unless the provisions of the exception to 29 CFR 1 91 0.1 47(e)(3) are met.

E.2 Group Lockout/Tagout (Lockbox Procedures)

 Group lockout/tagout using lockbox techniques usually involve:
1 .) pyramiding control methods
2.) company or general locks/tags for isolating devices
3.) multilevel boxes or cabinets
4.) master/job locks/tags
5.) personal cards, tabs, etc.
6.) multiple lockout devices
In Figures E.1 and E.2, lockout boards (complete setups for complex isolation) are shown that
incorporate these elements.

 Pyramiding control methods are often used in complex isolation situations. The approach can be
used with locks, tags or a combination of the two. Personnel security is managed by establishing
a hierarchy of control in which no single individual has the authority or ability to move/remove any
energy isolation device without appropriate procedural approval. Figure E.3 illustrates a scheme
for establishing such a control structure. The following explanation applies:
General: Three groups of employees are involved in the energy isolation activity in order
to perform service/maintenance. A total of 1 0 employees (A-J) will be involved. Eighteen
energy isolating devices (1 -1 8) will need to be locked/tagged by the employees.
Step 1 : Employees (A-C) in Group I will operate energy isolating devices (1 -6) and
lock/tag using company/equipment type locks/tags.

48
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Step 2: Keys/tag stubs are placed in Group I lockbox from company/equipment type
lock/tags. Employees (A-C) place personal locks/tags on multiple lockout devices on
lockbox. Principal authorized employee (A) collects personal keys/stubs from employees
(A-C).
Step 3: Principal authorized employee (A) takes personal keys/stubs from employees (A-
C) and deposits them in master job lock-box.
Step 4: Groups II and III follow the same pattern in steps 1 through 3 above.

Step 5: All keys/stubs securing group’s lockboxes and representing employees (A-J) are
now deposited in the master job lockbox.
Step 6: Each principal authorized employee (A, D and H) for each group places a group
lock/tag on the master lockbox and retains the key/stubs.
Step 7: The primary authorized employee places a job lock/tag on the multiple lockout
device on the master lockbox and retains the key/stub. Outcome: All keys/stubs for
energy isolating devices are secured in-group lockboxes. All employee personal
keys/stubs are secured in master lockbox. Keys/stubs for master lockbox are in
possession of three principal authorized and one primary authorized employee(s).

N OTE: A n u m ber of vari ati on s are possi bl e i n th i s type of con trol pyram i d to ach i eve
th e en d resu l t, th at i s, person al secu ri ty for al l poten ti al l y exposed person n el .

 OSHA Instruction Standard 1 -7.3, Appendix C describes various methods of lockout/tagout where
lockboxes are used as the controlling technique. Three variations are presented as follows:
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is placed upon each
energy isolation device after de-energization. The key(s) and removed tab(s) are then
placed into a lockbox. Each authorized employee assigned to the job then affixes their
personal lock or tag to the lockbox. As a member of a group, each assigned authorized
employee verifies that all hazardous energy has been rendered safe. The lockout/tagout
devices cannot be removed or the energy isolating device turned on until the appropriate
key or tag is matched to its lock or tag.
Type C. After each energy isolating device is locked/tagged out and the keys/tabs placed
into a master lockbox, each servicing/maintenance group principal authorized employee
places their personal lock or tag upon the master lockbox. Then each principal authorized
employee inserts their key into a satellite lockbox to which each authorized employee in
that specific group affixes their personal lock or tag. As a member of a group, each
assigned authorized employee verifies that all hazardous energy has been rendered
safe. Only after the servicing/maintenance functions of the specific subgroup have been
concluded and the personal locks or tags of the respective employees have been
removed from the satellite lockbox, can the principal authorized employee remove their
lock from the master lockbox.
Type D. During operations to be conducted over one shift (or even many days or weeks)
a system such as described here might be used. Single locks/tags are affixed upon a
lockbox by each authorized employee as described at Type B or Type C above. The
master lockbox is first secured with a job-lock before subsequent locks by the principal
authorized employees are put in place on the master lockbox. The job-lock may have
multiple keys if they are in the sole possession of the various primary authorized
employees (one on each shift). As a member of a group, each assigned authorized
employee verifies that all hazardous energy has been rendered safe. In this manner, the

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

security provisions of the energy control system are maintained across shift changes
while permitting re-energization of the equipment at any appropriate time or shift.

E.3 Group Lockout/Tagout (Permit Systems)

OSHA Instruction Standard 1 -7.3 (1 990) Appendix C offers guidance and examples of compliance
regarding energy isolation where machine, equipment and process complexity demand more exhaustive
control methods.

 Petroleum, chemical, steel and industrial gas production, among others, involve operations in
which adaptation and modification of normal group lockout/tagout procedures is needed in order
to insure the safety of employees performing service and maintenance activities. To provide
greater worker safety through implementation of a more feasible system and to accommodate the
special constraints of the standard’s requirement for ensuring employees a level of protection
equivalent to that provided by the use of a personal lockout or tagout device, an alternative
procedure may be implemented if company documentation justifies it. Lockout/tagout, blanking,
blocking and similar practices are often supplemented in these situations by the use of work
permits and a system of continuous worker accountability. In evaluating whether the equipment
being serviced or maintained is so complex as to necessitate a departure from the normal group
lockout/tagout procedures to the use of an alternative procedure, the following factors (which
often occur simultaneously) are among those that must be evaluated: the physical size and extent
of the equipment being serviced/maintained; the relative inaccessibility of the energy isolating
devices; the number of employees performing the servicing/maintenance; the number of energy
isolating devices to be locked/tagged out and the interdependence and interrelationship of the
components in the system or between different systems.

 After the machinery, equipment or process is shut down and the involved hazardous energy has
been controlled, maintenance, servicing and operating personnel must verify that the isolation of
the equipment is effective. The workers shall walk through the affected work area to verify
isolation. If there is a potential for the release or reaccumulation of hazardous energy, verification
of isolation must be continued. The servicing/maintenance workers may further verify the
effectiveness of the isolation by attempting procedures that are used in the work (for example,
using a bleeder valve to verify depressurization, flange-breaking techniques and so on).
Throughout the maintenance and/or servicing activity, operations personnel normally maintain
control of the equipment. The use of the work permit or master tag system (with each employee
or the designated person in charge personally signing on and off the job to insure continual
employee accountability and control), combined with verification of hazardous energy control,
work procedures and walk-through, is an acceptable approach to compliance with the group
lockout/tagout and shift transfer provisions of the standard.
The following scenarios illustrate two examples of control methods that may be used during
isolation of hazardous energy found in complex processes demonstrating acceptable approaches
to compliance with the group lockout/tagout provisions of the standard:
Scenario #1
1 . Complex process equipment scheduled for servicing/maintenance operations is
generally identified by plant supervision. Plant supervision issue specific work orders
regarding the operations to be performed.
2. In most instances where complex process equipment is to be serviced or maintained,
the process equipment operators can be expected to conduct the shutdown
procedure. This is due to their in-depth knowledge of the equipment and the need to
conduct the shutdown procedure in a safe efficient and specific sequence.
,

3. The operations personnel normally prepare the equipment for lockout/tagout as they
proceed and identify the locations for blanks and blocks by placing operations locks
and/or tags on the equipment. The operations personnel can be expected to isolate

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

the hazardous energy and drain and flush fluids from the process equipment
following a standard procedure or a specific work permit procedure.
4. Upon completion of shutdown, the operations personnel review the intended job with
the servicing and maintenance crew(s) and insure their full comprehension of the
energy controls necessary to conduct the servicing and maintenance safely. During
or immediately after the review of the job, the servicing and maintenance crews
install locks, tags and/or special isolating devices at previously identified equipment
locations following the specified work permit procedure.
5. Line openings necessary for the isolation of the equipment would normally be
permitted only by special work permits issued by operations personnel. (Such line
openings should be monitored by operations personnel as an added safety
measure.)
6. All of the previous steps should be documented by a master system of accountability
and retained at the primary equipment control station for the duration of the job. The
master system of accountability may manifest itself as a master tag that is
subsequently signed by all of the maintenance/servicing workers if they fully
comprehend the details of the job and the energy isolation devices actuated or put in
place.
7. After the system has been rendered safe, the authorized employees verify energy
controls.
8. Specific work functions are controlled by work permits issued for each shift: Every
day, each authorized employee assigned must sign in on the work permit at the time
of arrival to the job and sign out at departure. Signature, date and time for sign-in and
sign-out are recorded and retained by the applicable crew supervisor who, upon
completion of the permit requirements, returns the permit to the operations
supervisor. Work permits can extend beyond a single shift and may subsequently be
the responsibility of several supervisors.
9. Upon completion of the tasks required by the work permit, the authorized employees’
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signed off the work permit. The work permit is then attached to the master tag.
(Accountability of exposed workers is maintained.)
1 0. As the work is completed by the various crews, the work permits and the
accountability of personnel are reconciled jointly by the primary authorized employee
and the operations supervisor.
1 1 . During the progress of the work, inspection audits are conducted.
1 2. Upon completion of all work, the equipment is returned to the operations personnel
after the maintenance and servicing crews have removed their locks, tags and/or
special isolating devices following the company procedure.
1 3. At this time, all authorized employees who were assigned to the tasks are again
accounted for and verified to be clear from the equipment area.
1 4. After the completion of the servicing/maintenance work, operations personnel remove
the tags originally placed to identify energy isolation.
1 5. Operations personnel then begin checkout, verification and testing of the equipment
prior to being returned to production service.
Scenario #2
1 . When work is to be performed that requires removing hazardous energy from all or a
portion of an operating system, a work request is submitted to the operating authority
that has exclusive administrative control of all or a portion of the operating system.
2. That operating authority determines the operations that are to be performed
(switching, valving, tagging, etc.) and documents the sequence of operations to be
performed.
3. An authorized employee is then assigned to perform the operations creating an
isolated zone and installs a master lock/tag for the operating authority.

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

4. The operating authority informs the person in charge of performing the work that the
isolation and locking/tagging have been performed (person in charge is defined as
the supervisor, foreman or lead worker, depending on agreements and past practice.
That person then presents themself to the operating authority receives and reviews
the isolation steps (typically on a uniquely numbered permit or work order) that have
been performed and signs on to a clearance sheet.
5. The person in charge then reports to the work location, or another central meeting
place, and confers with all the personnel that will perform the work. A job briefing is
conducted which includes a thorough review and a walk-down by the personnel that
will perform the work, of the principle isolation points and locking/tagging that has
been performed. The personnel that will perform the work will then take a physical
step (such as signing on a work permit/master tag, placing a personal identification
card [PIC] on to energy operating device(s), initialing a work log at the worksite.)
6. Upon completion of the work, all personnel that have performed work shall take a
reverse step (such as signing off the work permit/master tag, removing the personal
identification card, initialing the work log to indicate they are finished and clear of the
worksite). After all personnel have taken the steps necessary to remove themselves
from the lockout/tagout, the person in charge shall perform a walk-down to ensure
that all work is completed and all personnel are clear of the job-site and instructed to
stay clear of the worksite.
7. The person in charge will then report back to the operating authority in-person, report
on the status of the work (completed) and signs off of the clearance sheet, releasing
the clearance back to the operating authority who will assign an authorized employee
to remove the master locks/tags and perform the necessary steps to return the
system to service.

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex E
(Informative)
Group Lockout/Tagout
Figures

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex F
(Informative)
Alternative Method for Freeze Plug Applications
Freeze plug or stop technology, used successfully for many years in the industry, provides a non-intrusive
method for the isolation of piping systems. Line freezing requires no permanent modification or welding
on the piping system. It can be used as a secondary isolation seal for additional protection. Piping
systems containing water, hydrocarbons and any chemical with a suitable freeze point and no flow can be
isolated with freeze plug methods.
Pipe freezing applications make possible the replacement, repair or addition of valves; isolation of work
zones; avoidance of drain downs and maintaining the integrity of critical systems and system operating
pressures.
In addition to developing procedures in compliance with the provisions of 5.4, the user shall ensure that
personnel involved in applying the freeze plug and those potentially exposed performing the servicing or
maintenance comply with the following:

a) An atten d an t wi l l remain at th e freeze poin t(s) at al l times wh il e au th orized in d ivid u al s are

exposed to possibl e con tact with an y l iq u id s con tai n ed in th e pi pin g system .

b) Cryogen ic su ppl y systems sh al l be eq u ipped with l ow l evel warn in g al arms. An adequ ate
cryogen ic su ppl y sh al l be on h an d wh ich i s su fficien t for th e d u ration of th e work.

c) Exposed au th orized i n d ivi d u al s sh al l attach person al tags/l ocks at th e freeze poin t(s) to
in d icate th ei r presen ce an d proh ibit th e cessati on of th e freeze prior to an y removal by
th ose attach ing th e protective d evices.

d) Personn el appl yin g th e freeze shal l immed i atel y com mu n icate to th e exposed au th orized
in d ivid ual s an y ch an ge of con d ition s th at mi ght pl ace th em at risk.

e) I f th e au th orized in d ivid u al s performi ng th e main ten an ce work are ou t of sigh t of th e

person n el respon sibl e for th e appl icati on an d con ti nu ity of th e freeze, a m ean s of effecti ve
comm u n ication sh al l be establ ish ed .

f) I f th e area of th e freeze appl ication is an en cl osed or con fin ed space, precl u d es reason abl e
air ch an ges or is su bstan tial l y obstru cted , con ti nu ou s oxyg en mon itorin g sh al l be
con d u cted an d ad eq u ate ven til ation or su ppl emen tal oxygen provi d ed .

g) Protective practices sh al l be u til i zed to safegu ard person n el d u ri ng a pl an n ed rel ease or

u n pl ann ed ej ection of th e pl u g .

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex G
(Informative)
Remote Low Voltage Lockout System
Remotel y activated el ectrom ech an ical l ockou t system s can provid e an acceptabl e al tern ative
to h azard ou s energy isol ation d evices l ocated d irectl y on mach in es, eq u ipm en t an d processes,
wh ich are l ocated in i n accessi bl e or in con ven i en t l ocation s. Th ese d evices al l ow for a
con venien tl y l ocated l ockou t acti vation d evice that are u ser frien d l y, accept a pad l ock for
person al con trol , are l ocated at mu l tipl e process poin ts an d th erefore en cou rage th e proper
appl ication of l ockou t protection .

Th is techn ol ogy u ses a ded icated system of l ockabl e d u al ch an nel l ow-vol tage safety switch es
l ocated at mu l tipl e l ocation s arou nd a prod u cti on mach ine to activate a l ockou t. Th e l ow-
vol tage l ockou t circu it d e-en ergizes the d u al el ectromech an ical power con tactors th at
discon n ect th e in comin g power after th e main d i scon n ect switch . Th ese u n its u se redu n d an t
circu itry an d mon itorin g by safety rel ays to in su re th e proper activation and d eactivation for
faul t free operation . I f a fau l t d oes occur an d is sen sed as non -si mu l tan eou s activation of an y
compon en t, th e system wil l n ot al l ow reacti vati on of th e m ach in e u n ti l th e repair is mad e.
Th ese d evices mu st be in stal l ed an d main tai ned in accord an ce with m an u factu rer’s gu id el in es
by q u al ifi ed person n el .

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex H
(Informative)
Alternative Method for the Printing Industry

I n th e pri n tin g in d u stry, m an y rou tin e an d repetitive tasks n eed to be d on e with mach in e
motion . Th e in du stry h as d evel oped a meth odol ogy empl oyin g a combin ation of en gin eered
safegu ard s, warn in g d evices, proced u res an d safe work practi ces to provi d e effective
al tern ative protection to l ockou t/tagou t. Th e meth od is kn own in th e ind u stry as th e “in ch-safe-
service” m eth od .
Prin ti n g presses an d oth er l arge eq u ipmen t in th e prin tin g an d bi n d in g i n d u stries su ch as
sad d l e or perfect bin d ing systems are equ ipped with con trol station s con tain in g , at a min imu m ,
a Stop/Safe or Stop/Safe/Read y pu shbu tton . M oti on con trol station s al so in cl u d e an I n ch
bu tton th at en abl es sl ow mach in e m otion wh il e th e bu tton is h el d d own . Th ese con trol station s
are el ectrical l y l in ked to an aud i bl e or area l igh t warn in g system th at provid es an au d ibl e
an d /or visu al in d ication of th e machi ne’s state an d impen d in g moti on . For a compl ete
description of th e safety systems u sed in prin ti n g presses, pl ease see AN SI B65. 1 -1 995. For
th e req u i remen ts for bi n d in g an d fin ish in g systems, pl ease see AN SI B65. 2-2000. Th e i nch -
safe-service proced u re is em pl oyed by person n el wh o operate th e eq u ipmen t an d in
combin ation with th e stop con trol , warn in g system and gu ard s, provid es effecti ve al tern ative
protection to th e in d ivid u al .

Inch-Safe-Service Procedure
 Before an y m in or servicin g is perform ed , the mach in e is stopped by activatin g a Stop/Safe
or Stop/Safe/Read y pu sh bu tton .
 Servicin g is performed with the m ach in e in a “Safe” con di tion.
 Th e in ch bu tton is th en acti vated wh ich starts an au d ibl e al arm th at warn s of im pen d in g
mach in e motion .
 After a d el ay, th e m ach i ne moves to th e n ext position .
 Th e Stop/Safe bu tton is d epressed an d min or servi cin g is ag ain performed .
 Th e process is repeated as man y ti mes as n ecessary.

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex I
(Informative)
Alternative Method for the Plastics Industry
Set-Up with No Motion
On pl astics mol d i n g m ach in es wh ere i t is n ecessary to main tain h eat to a pl asticatin g u n it or
power to th e program mabl e l og ic control l er or microprocessor d u rin g set-u p on l y, a u ser sh al l
d o on e of th e fol l owin g :

Provid e and u se a separate l ockabl e en ergy isol atin g d evice for a m otor, pum p or an y oth er
eq u ipmen t, wh ich cou l d expose an empl oyee to a h azard ;

For a pl astics m ol d in g m ach in e th at is in compl ian ce with th e cu rren t, appl icabl e safety
stan d ard s, th e control l i n g safety gate sh al l be l ocked in th e open position with th e power
sou rce(s) u sed for con trol l in g m otion /movemen t in th e m ol d area tu rn ed off. Wh ere
accu m u l ators are u sed , th ey sh al l au tomatical l y d u mp pressu re to tan k wh en th e h yd rau l ic
pu mp motor(s) is d e-en ergized .
Effects of Gravity
Wh en dan gerou s movemen t(s) in th e mol d area can be prod u ced by the effect of gravity, a
mech an ical restrai n t d evice sh al l be used .
Extrusion Blow and Injection Blow Molding Machines / Set-Up with Motion
Wh en m ovem en t is n ecessary with th e operator’s safety gate open d u rin g settin g operation s
on l y, th e reqGet
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AN SI /SPI B1 51 . 1 5-
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2000; Extrusion Blow Molding Machines an d AN SI /SPI B1 51 . 21 -2000; Injection Blow Molding
Machines , sh al l be fol l owed .
1 . An operatin g mod e sel ector sh al l be provid ed th at can be l ocked in th e set-u p mod e
wi th a rem ovabl e key. Th e sel ector shal l be h ard wired an d mon itored to in sure proper
operation s.
2. Th e key for th e mod e sel ector sh al l on l y be issu ed to person (s) train ed in th e set-u p
operation s
3. H azard ous movemen t/moti on req u ired for th e settin g sh al l on l y be possibl e by mean s of
a h ol d -to-ru n con trol .
N OTE: Su ch m ovem ent/motion req u ired for settin g mi gh t be th at of:
a. ) th e bl ow mol d an d its parts
b. ) th e bl ow pin or bl ow n eed l e
c. ) in d ivid u al bl ow station (mu l ti -station m ach i nes)
d . ) rotary wh eel
e. ) parison d rop
4. Wh en th e h ol d -to-ru n con trol d evice is fitted on a portabl e con trol un it, it sh al l be
capabl e of bein g taken in to the poin t of operation . An en abl in g d evice an d an ad d iti on al
em ergen cy stoppin g d evice sh al l be fitted on su ch a con trol u nit. The emergen cy
stoppin g d evice sh al l act on al l h azard ous movemen ts associated with settin g
operation s.

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

5. Wh en th e h ol d -to-ru n con trol d evice i s n ot on a portabl e u n i t, it sh al l be perm an en tl y

fixed in su ch a position th at th e set-u p person h as a cl ear view of th e poin t of operation .
6. A h ol d -to-ru n con trol device sh al l on l y be operabl e wh en th e mod e sel ector d evi ce is i n
th e settin g mod e.
7. Th e setti n g speed sh al l be d esi gn ed n ot to exceed on e in ch /secon d (25mm /secon d ).
8. A pn eum atic d rive for settin g m ovem ents th at create a h azard sh al l n ot be permitted to
fu n ction in th is mod e.
9. Val ves th at cou l d overrid e set-u p speed restriction s th rou gh activation by h and or tool
sh al l be m ad e in accessibl e (e. g. gu ard in g).

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex J
(Informative)
Alternative Method for Robotic Applications

Robotic appl ication s presen t th e u n iq u e combin ation of a d yn am ic workspace for th e mach in e

as wel l as specific process h azard s. Person n el may be exposed to h azard ou s en ergy in a
nu m ber of rou tin e action s su ch as robot teachin g, servicin g , min or tool ch an ges, removin g
j am s an d trou bl eshootin g. Provision s for effective al tern ate con trol of h azard ou s en ergy in
robotic appl ication s are con tain ed in AN SI /RI A R1 5. 06-1 999, Industrial Robot and Robot
Systems – Safety Requirements .
Wh en access to th e safegu ard ed space of a robot or robot system i s n ecessary wh il e power is
avail abl e, al tern ate safegu ard s or safegu ardin g procedu res are establ ish ed an d u sed to
preven t in j u ry. Al l are based on th e prem ise th at th e person n el performi n g tasks h ave total
con trol of th e robot or robot system in cl u d i n g al l periph eral eq u ipmen t an d process h azard s.
Al tern ate protection meth od s for a typical task m ay in cl u d e:
 Disabl in g th e au tomatic task program
 I sol atin g th e h azard ous en ergy to th e d rive m otors
 U se of moti on en abl in g d evices for each person en terin g safegu ard ed space
 Em ergen cy stop circu it remain s fu n cti on al
 An d ad d iti on al l y, certai n tasks can be perform ed by pl aci n g th e robot arm i n a
pred etermin ed position , or th e u til izati on of d evices su ch as bl ocks/pin s to preven t
potenGet
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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex K
(Informative)
Alternative Methods Involving Trapped Key Interlock Systems
Example 1 : Alternative Method of Control for Machines/Equipment with Run Down Time
M an y mach in es stil l pose a h azard even after en ergy sou rces h ave been isol ated d u e to
resi du al motion . Exam pl es in cl u d e rotatin g eq u ipmen t, fl ywh eel s an d mach in es with h eavy
compon en ts th at take time to cease motion .

A trapped key in terl ock system in corporatin g a time d el ay featu re mitigates th e h azard .

1 . ) Tu rn th e kn ob on th e time del ay u n it, isol atin g power to th e eq uipm en t/mach in e. Th is

wil l start th e timer.
2. ) After th e pre-set ti me h as el apsed, th e B Key will rel ease from th e tim e d el ay u nit.
3. ) Th e B Key i s in serted , tu rn ed an d trapped in to th e mech ani cal key exch an ge pan el .
Th is al l ows th e 4-A Keys to be tu rn ed an d removed from th e key exch an ge pan el . Th e
B Key is trapped in the pan el .
4. ) Th e A Keys are taken to th e access interl ocks an d in serted , tu rn ed an d trapped ,
al l owi n g th e d oor to be open ed . Wh il e th e d oors are open , th e A keys are trapped .
5. ) To re-start th e mach in e, reverse th e above process

Time delay unit

B-key
Exchange panel

A-key A-keys
Access Interlock

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex K (continued)
(Informative)
Alternative Methods Involving Trapped Key Interlock Systems
Example 2: Alternative Method for Dual Pressure Relief Valve Piping Systems
Dual relief valve systems are utilized in many industries including chemical, petrochemical and oil/gas.
The rationale behind having a redundant relief is so that the operational relief valve can be isolated and
serviced/maintained without having to shut the whole process down. The potential danger is that an
operator could isolate the in-service relief valve prior to commissioning the spare relief valve, thereby
creating no relief path for pressure build-up in the system.
A trapped key interlock system mechanically assures that at least one relief path is always open.
1 .) System is shown with Relief Valve 1 (RV1 ) in service and Relief Valve 2 (RV2) isolated.
2.) Take Key E to the outlet block valve (V4) for RV2 and insert, unlocking V4. Open V4. Remove
Key D, locking V4 open.
3.) Take Key D to the inlet block valve (V3) for RV2 and insert, unlocking V3. Open V3. Remove
Key C, locking V3 open.
4.) Take Key C to the inlet valve (V2) for RV1 and insert, unlocking V2. Close V2. Remove Key B,
locking V2 closed.
5.) Take Key B to the outlet block valve (V1 ) for RV1 and insert, unlocking V1 . Close V1 . Remove
Key A, locking V1 closed.
6.) Return Key to the Control Room. RV1 is now isolated for maintenance and RV2 is in service.

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex L
(Informative)
Sample of a Lockout/Tagout Application Inspection Form
(2 pages)
Department: ____________________ Equipment: ________________________
Machine Number: ________________ Task Location: _______________________
Date _____/ _____/ _____ Shift ___________ Time _________________ AM/PM
Authorized person(s) name(s):
Training?
___________________________________________________ ___ Yes ? No ?
___________________________________________________ ___ Yes ? No ?
___________________________________________________ ___ Yes ? No ?
___________________________________________________ ___ Yes ? No ?

Affected person(s) name(s):

Training?
___________________________________________________ ___ Yes ? No ?
___________________________________________________ ___ Yes ? No ?
___________________________________________________ ___ Yes ? No ?
___________________________________________________ ___ Yes ? No ?

Were all affected persons notified of lockout?

Yes ? No ? If so, by whom ______________________________
Name(s) of authorized/affected person(s) supervisor(s)
__________________________________ _________________________________
__________________________________ _________________________________
Written Lockout procedure available? (If yes , state where located)
Yes ? No ? ______________________________________________
Is Lockout procedure being followed? Yes ? No ? (If not, state elements not followed)
___________________________________________________ ________________________
___________________________________________________ ________________________
Is procedure posted? Yes ? No ?
Is procedure in diagram form? Yes ? No ?
Is procedure adequate? Yes ? No ?
Has lockout been performed by all persons involved? Yes ? No ?
Name all required energy isolating devices
______________________________ ______________________________
______________________________ ______________________________
______________________________ ______________________________
Can energy isolating devices be locked out? Yes ? No ?

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 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Where blocks or pins are necessary, were they used? Yes ? No ?

State deficiencies requiring corrective action:
___________________________________________________ ________________________
___________________________________________________ ________________________

Did each authorized person lockout all required energy sources with
their own locks? Yes ? No ?

If not, what action was taken:

___________________________________________________ ________________________

Did each authorized person verify lockout? Yes ? No ?

If not, what changes were needed:

_________________________________________________

CORRECTIVE ACTION(S) RECOMMENDED:

___________________________________________________ ________________________
___________________________________________________ ________________________
___________________________________________________ ________________________
___________________________________________________ ________________________
INSPECTIONGet
PERFORMED BY:
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DATE ____/____/____ TIME: AM/PM

63
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

Annex M
(Informative)

Bibliography
Referenced Standards
Th e fol l owin g stand ard s h ave been referen ced in th is stan d ard. Al l stan d ard s are su bj ect to
revisi on , an d parties to agreemen ts based on th e AN SI /ASSE Z244. 1 are encou raged to
investigate and appl y th e most recen t ed ition of the stan d ard s in d icated bel ow.
AN SI /RI A R1 5. 06 – Industrial Robots and Robot Systems - Safety Requirements
AN SI B1 1 -TR3-2000 – Risk Assessment and Risk Reduction – A Guide to Estimate, Evaluate
and Reduce Risks Associated with Machine Tools
AN SI B1 1 . 1 9 – Performance Criteria for Safeguarding
AN SI B65. 1 – Safety Requirements for Graphic Technology Equipment and Systems, Part 1:
General Requirements
AN SI B65. 2 – Safety Requirements for Graphic Technology Equipment and Systems, Part 2:
Prepress and Press Equipment and Systems
ANSI B65.3 – Safety Requirements for Graphic Technology Equipment and Systems, Part 3:
Binding and Finishing Equipment and Systems
AN SI /SPI B1 51 . 1 5 – Extrusion Blowmolding Machines – Safety Requirements for the
Manufacture, Care and Use
AN SI /SPI B1 51 . 21 – Injection Blowmolding Machinery – Safety Requirements Manufacture,
Care and Use
AN SI /ASSE Z490. 1 – Criteria for Accepted Practices in Safety, Health and Environmental
Training
EN 1 050/I SO 1 41 21 : 1 999 – Safety of Machinery - Principles for Risk Assessment
M I L STD-882D – System Safety
N FPA 79 – Electrical Standard for Industrial Machinery
N FPA 70E – Standard for Electrical Safety in the Workplace
OSH A 29 CFR 1 91 0. 1 47 – The control of hazardous energy (lockout/tagout)

Other Standards and Documents

Th e fol l owin g stan d ard s con tain add ition al an d rel ated in formati on . Wh en su persed ed by an
approved revision , th e revised stan dard sh all appl y. Th e Ameri can N ation al Stan d ard s
I n sti tu te, 23 West 43 rd Street, N ew York, N Y 1 0036, (21 2) 642-4900 offers el ectron ic version s
of AN SI , I SO an d I EC stan d ard s at www. an si. org , N ation al El ectrical Safety Cod e, I AAA,
M ain ten an ce Operation s an d Safety.
AN SI A1 3. 1 – Scheme for the Identification of Piping Systems
AN SI B1 1 Series – Machine Safety Standards
AN SI B1 51 Series – Plastics Machinery Safety
AN SI Z21 . 22 – Relief Valves for Hot Water Supply Systems

64
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

AN SI Z241 . 1 -1 999 – Safety requirements for sand preparation, molding and core making in the
sand foundry industry
AN SI Z535 Series – Safety Signs and Color Code Series
AN SI /ASM E B31 Series – Piping Systems
EN 292-1 /I SO 1 21 00-1 : 1 992 – Safety of Machinery – Basic Concepts, and General Principles
for Design – Part 1: Basic Terminology and Methodology
EN 292-2/I SO 1 21 00-2: 1 992 – Safety of Machinery – Basic Concepts and General Principles
for Design – Part 2: Technical Principles
EN 1 037/I SO 1 41 1 8: 2000 – Safety of Machinery – Prevention of Unexpected Start-up
EN 1 088/I SO 1 41 1 9: 1 998 – Safety of machinery – Interlocking devices associated with guards
– Principles for design and selection
I SO/I EC 1 3849-1 : 1 999 – Safety of Machinery – Safety-Related Parts of Control Systems –
Part 1: General Principles for Design .
OSH A 29 CFR 1 91 0. 1 44 – Safety color code for marking physical hazards
OSH A 29 CFR 1 91 0. 1 45 – Specifications for accident prevention signs and tags
OSH A 29 CFR 1 91 0 Su bpart O (§21 1 -21 9) – Machinery & Machine Guarding
Documents for Additional Assistance
Th e fol l owin g l ist of oth er d ocu men ts may be of add itional assistan ce to th e u ser of th is
Stan d ard bu t is n ot al l in cl usive :
AN SI N ation al El ectrical Safety Cod e, N ESC C-2. Publ ish ed by th e I EEE.
Get
Fren ch N ation al more FREE
Research & standards from
Safety I n stitu te Standard 992) Closure
(I N RS). (1Sharing Group &and
unclosure.
our chats[ED 754].
Paris, Fran ce.
Gru n d , E. V. (1 995), Lockout/tagout – the process of controlling hazardous energy. I tasca, I L:
N ation al Safety Cou n cil Press.
H al l , B. (1 977, Febru ary), Zero en ergy state – h istorical backgrou n d of th e con cept. National
Safety News , Vol . 1 1 5, N o. 2 , 68-72.
I EEE Gu id e for main ten an ce, Operation , an d Safety of I n du strial an d Commercial Power
Systems (Yel l ow Book), I EEE Std . 902-1 998. Pu bl ish ed by th e I EEE.
I n ternation al U n ion , U n i ted Au tomobil e, Aerospace & Agricu l tu ral I m pl em en t Workers of
America, H eal th & Safety Departmen t. (1 993), Occupational fatalities among UAW members: a
twenty year study. Detroit, M I : U n i ted Au to Workers.
M itch el l , R. D. (1 977, M ay), Zero mech an i cal state – d evel opmen t of th e con cept . National
Safety News , Vol . 1 1 5, N o. 5, 87-92.
N ation al I n stitu te for Occu pational Safety an d H eal th . (1 983), Guidelines for controlling
hazardous energy during maintenance and servicing . [Publication number 83-125].
M organ town , WV: N ation al I nstitu te for Occu pation al Safety an d H eal th .
N ation al Safety Cou n cil . (2001 ), Accident Prevention Manual for Business & Industry:
Administration & Programs [12th edition]. I tasca, I L: N ational Safety Cou n cil Press.
N ati on al Safety Cou n cil . (2001 ), Accident Prevention Manual for Business & Industry:
Engineering & Technology [12th edition]. I tasca, I L: N ation al Safety Cou n cil Press.

65
 AMERICAN NATIONAL STANDARD ANSI/ASSE Z244.1 – 2003 (R201 4)

N ation al Tech n ical I n formation Service. (1 982, Au gu st) Selected occupational fatalities related
to lockout/tagout problems (OSHA). [PB83-125724]. Wash in gton , DC: Governm ent Prin tin g
Office.
Electrical power transmission, generation
Occu pational Safety & H eal th Ad min istration. (1 994),
& distribution; electrical safety-related work practices. [Final rule 29CFR1910. 269].
Wash in gton , DC: Govern m ent Prin tin g Office.
Occu pation al Safety & H eal th Ad min istrati on . (1 991 ), Electrical safety – related work
practices. [Final rule 29CFR1910. 331. 335]. Wash in gton , DC: Govern men t Prin tin g Office.
U . S. Departm en t of Labor Bu reau of Labor Statistics. (1 981 , October), Injuries related to
servicing equipment [Bulletin 2115]. Wash ington , DC: Govern men t Prin tin g Office. U n ited
Kin gd om H eal th & Safety Execu tive Acci d en t Preven tion Ad visory U n it. (1 985) Deadly
maintenance – a study of fatal accident at work. Lon d on , En gl an d : H M SO.
U n ited King d om H eal th & Safety Execu tive. (1 992), Safe systems of work. [IND (G) 76L].
Lon d on , En gl an d : H M SO.
Copies of this American National Standard, Z244. 1, may be purchased from the American
Society of Safety Engineers by phoning (847) 699-2929 or visiting the American Society of
Safety Engineers website at www. asse. org .

66
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 ASSE Sets the Standard.
We have a variety of standards for purchase that will improve productivity,
increase efciency, reduce cost and minimize risk.
ANSI Secretariat for:
• A10 Construction & Demolition Operations
• A1264 Protection of Floor & Wall Openings
• Z9 Ventilation Systems
• Z10 Safety & Health Management
• Z15 Motor Vehicle Safety
• Z88 Respiratory Protection
• Z117 Confned Spaces
• Z244 Control of Hazardous Energy – Lockout/Tagout & Alternative Methods
• Z359 Fall Protection
• Z390 Hydrogen Sulfde (H2S) Training Programs
• Z490 Safety, Health & Environmental Training
• Z590 Competence & Certi fcation in the Safety Profession and Prevention Through Design
U.S. Technical Advisory Group Administrator for:
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• Safety & Health Management Systems
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