OSHA Lockout/Tagout Requirements (29 CFR 1910.147) Explained
OSHA 29 CFR 1910.147 — The Control of Hazardous Energy — is the federal standard that governs lockout/tagout in general industry. It requires employers to establish an energy control program so that machines are isolated from all energy sources and cannot restart while employees service or maintain them.
The standard is written as a system: a written program, machine-specific procedures, employee training, periodic inspections, and enforcement of device use all have to work together. Missing any one element is one of the most common ways employers end up on OSHA citation lists.
What the standard applies to
1910.147 covers servicing and maintenance of machines and equipment where unexpected energization, start-up, or release of stored energy could injure employees. That includes normal production maintenance, jam clearing, repairs, adjustments, and setup — not just major overhauls.
Notable exclusions include normal, repetitive production operations where guard removal is integral to the job, cord-and-plug equipment under exclusive control, hot tap operations on pressurized systems under documented alternatives, and specific industry scopes covered elsewhere in the OSHA codes (construction, agriculture, marine terminals).
The required elements of an energy control program
OSHA expects a documented program that includes, at minimum:
- A written energy control program with procedures for applying and removing locks
- Machine-specific procedures identifying energy sources, isolation points, and the shutdown sequence
- Lockout devices and tags that are durable, standardized, and identifiable
- Training for authorized, affected, and other employees
- Periodic inspections of each energy control procedure at least annually
- Rules for shift changes, contractor coordination, and group lockout
- Testing and re-energization procedures for restoring equipment to service
The six-step shutdown sequence
Every procedure must follow the same core sequence: prepare for shutdown, shut down the machine by normal stopping methods, isolate all energy sources, apply locks and tags to each isolation point, release or restrain stored energy, and verify zero energy before work begins. The verification step — attempting to start the machine after isolation — is the step most often skipped and the one that most directly prevents injury.
Annual inspections and training refreshers
Each energy control procedure must be inspected at least once per year by an authorized employee other than one who uses the procedure under review. The inspector must review the procedure with the authorized employees who use it, correct any deviations, and certify the inspection in writing with the machine, date, employees included, and inspector identified.
Authorized employees need retraining at least annually in practice, and whenever procedures, machines, or job assignments change. Affected and other employees need re-instruction whenever their understanding lapses.
What non-compliance costs
LOTO is consistently in the top handful of OSHA most-cited standards, generating thousands of citations per year. Serious violations carry maximum penalties in the five-figure range per item, and willful or repeated violations reach six figures. Beyond fines, LOTO failures regularly appear in OSHA severe-injury reports — the standard exists because unexpected start-up kills.
Key takeaways
- 1910.147 requires a written program, machine-specific procedures, training, devices, and annual inspections — all of it.
- The verification step (try to start) is mandatory before servicing.
- Each procedure needs a documented annual inspection by an authorized employee who does not use it.
- LOTO citations remain among the most common OSHA issues in general industry.
Frequently asked questions
Do I need a written lockout/tagout program?
Yes. 1910.147(c)(4) requires documented procedures for controlling hazardous energy, and 1910.147(c)(1) requires the program itself. Small employers are not exempt — the program can be short, but it must exist and match what actually happens on the floor.
How often must lockout/tagout procedures be inspected?
At least annually, per 1910.147(c)(6). The inspection must be performed by an authorized employee other than the ones who use the procedure, and it must be certified in writing with the equipment, date, employees, and inspector identified.
Are generic lockout procedures acceptable?
Only in limited cases. When equipment has a single energy source, a single isolation point, and the isolation fully de-energizes it, a single generic procedure can cover multiple machines. Machines with multiple energy sources or stored energy need machine-specific procedures.
What is the difference between an authorized and an affected employee?
Authorized employees perform servicing and apply locks; affected employees operate the equipment or work nearby and must know not to touch locked-out machines. Training requirements differ for each group.
Manage lockout/tagout procedures digitallyTegis Safety keeps procedures current and audit-ready.
Request a demo