If employees service or maintain machines where unexpected startup or stored energy could hurt them, 29 CFR 1910.147 requires an energy control program: documented machine-specific procedures, training for authorized and affected employees, lockout or tagout devices, and a periodic inspection of each procedure at least once a year.
Lockout/tagout is among the most cited OSHA standards every year, and the citations often come down to one gap: no written, machine-specific procedures. This page covers the written lockout/tagout program requirements in plain terms. It is one of the OSHA-required written programs.
When 1910.147 applies
The standard applies to the servicing and maintenance of machines and equipment where the unexpected start-up, energization or release of stored energy could injure a worker. It covers electrical, mechanical, hydraulic, pneumatic, chemical and thermal energy. It does not cover normal production operations, except in specific situations the standard defines.
Program components
A compliant written lockout/tagout program has the parts below.
Machine-specific procedures
You need documented energy control procedures for each machine, written so a worker can follow them: how to shut down, isolate each energy source, apply locks or tags, release stored energy and verify a zero-energy state before work begins. (1910.147(c)(4))
Devices
Provide and use lockout and tagout devices that are durable, standardized and substantial enough not to be removed by accident. Each authorized employee applies their own lock.
Training (authorized, affected, other)
Train your people by role: authorized employees who apply the controls and do the servicing, affected employees who operate the machines, and other employees who work in the area. Retrain when procedures, machines or roles change, or when an inspection shows a gap. (1910.147(c)(7))
Annual periodic inspection
Inspect each energy control procedure at least once a year to verify it is being followed and is still adequate. The inspection is done by an authorized employee who is not using the procedure being inspected, and you document who did it and what was reviewed. (1910.147(c)(6))
Exceptions (cord and plug)
There is a limited exception for cord-and-plug connected equipment, where unplugging the equipment controls the energy and the plug stays under the exclusive control of the person doing the work. Know the limits of this exception before relying on it.
Template download
Want a starting point? Download the lockout/tagout program template, then build your machine-specific procedures on top of it. The form routes to our team and we reply within one business day.
FAQs
Do we need a procedure for every machine?
In general, yes, you need machine-specific procedures for equipment covered by the standard. A narrow exception exists for simple machines with a single energy source that meet all of the standard’s conditions, but most equipment needs its own documented procedure.
Who can perform the annual inspection?
An authorized employee other than the one using the energy control procedure being inspected. The point is an independent check that the procedure is current and followed.
Is tagout alone ever allowed?
Lockout is the default. Tagout alone is permitted only where equipment cannot be locked out, or where you can show the tagout program provides full employee protection equivalent to lockout. New or overhauled equipment must be capable of being locked out.
ETC writes this program for Arizona employers and teaches the matching course. See we write your safety programs, OSHA 10-Hour General Industry, arc flash NFPA 70E training, the electrical safety program (NFPA 70E) and our manufacturing safety training.
Need it done right? We will write your program and train your team.
Link: https://e-t-c.com/consulting/written-safety-programs/
Call: (602) 923-9673
Need it done right? We will write your program and train your team.
Call (602) 923-9673