Control of Hazardous Energy (Lockout/Tagout) General Industry • Regulation 29 CFR 1910.147

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Control of hazardous energy, often referred to as lockout/tagout (LOTO), is a critical component of workplace safety protocols, particularly in environments where machinery and equipment are involved. Hazardous energy can take various forms, including electrical, mechanical, hydraulic, pneumatic, chemical, thermal or gravitational energy. Proper management of these energy sources is essential to prevent accidental release during maintenance or servicing tasks, which can lead to severe injuries or fatalities. Employers are responsible for implementing effective LOTO procedures to protect their workers and ensure a safe working environment.

Workers servicing or maintaining machines or equipment may be seriously injured or killed if hazardous energy is not properly controlled. Injuries may include electrocution, burns, crushing, cutting, lacerating, amputating or fracturing body parts. Craft workers, electricians, machine operators and laborers are among the millions of workers who service equipment routinely and face the greatest risk of injury.

The foundation of an effective LOTO program begins with a comprehensive risk assessment. This involves identifying all sources of hazardous energy associated with machinery and equipment used in the workplace. Once these sources are identified, detailed procedures must be developed to control them during maintenance activities. This includes clearly defined steps for shutting down equipment, isolating energy sources, and securing them through locks and tags. By systematically addressing each potential hazard, employers can significantly reduce the risk of accidents and enhance overall workplace safety.

ABOUT THE STANDARD

The OSHA standard for The Control of Hazardous Energy (Lockout/Tagout), Title 29 Code of Federal Regulations (CFR) Part 1910.147, covers the servicing and maintenance of machines and equipment in which the unexpected energization or start-up of the machines or equipment, or release of stored energy could cause injury to employees.

This standard establishes minimum performance requirements for the control of hazardous energy. It addresses the practices and procedures necessary to disable machinery or equipment, thereby preventing the release of hazardous energy while employees perform servicing and maintenance activities. The standard outlines measures for controlling hazardous energies — electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources.

29 CFR 1910.147 gives each employer the flexibility to develop an energy control program suited to the needs of the particular workplace and the types of machines and equipment being maintained or serviced. This is generally done by affixing the appropriate lockout or tagout devices to energy isolating devices and by de-energizing machines and equipment.

• If an energy isolating device is not capable of being locked out, the employer’s energy control program shall utilize a tagout system.
• If an energy isolating device is capable of being locked out, the employer’s energy control program shall utilize lockout, unless the employer can demonstrate that the utilization of a tagout system will provide full employee protection.
• 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 employer shall demonstrate that the tagout program will provide a level of safety equivalent to that obtained by using a lockout program.

TRAINING

All workers involved in the operation, maintenance, or servicing of machinery should receive thorough training on LOTO procedures and the importance of following them. Training should cover how to identify hazardous energy sources, the proper use of lockout devices, and the significance of communication among team members during maintenance activities. Regular refresher courses can reinforce this knowledge and keep safety at the forefront of workplace culture.

The standard requires:

• All employees who work in an area where energy control procedure(s) are utilized need to be instructed in the purpose and use of the energy control procedure(s), especially prohibition against attempting to restart or reenergize machines or other equipment that are locked or tagged out.
• All employees who are authorized to lockout machines or equipment and perform the service and maintenance operations need to be trained in recognition of applicable hazardous energy sources in the workplace, the type and magnitude of energy found in the workplace, and the means and methods of isolating and/or controlling the energy.
• Specific procedures and limitations relating to tagout systems where they are allowed.
• Retraining of all employees to maintain proficiency or introduce new or changed control methods.

Ultimately, the control of hazardous energy is not just a regulatory requirement; it is a moral obligation to protect the health and well-being of workers. A strong commitment to workplace safety, coupled with effective LOTO practices, can lead to a significant reduction in workplace injuries and fatalities. By prioritizing safety and investing in proper training, equipment, and procedures, employers can create a culture of safety that benefits everyone involved. This proactive approach not only safeguards employees but also contributes to improved productivity and morale, reinforcing the idea that safety is integral to the success of any organization. WMHS

RESOURCES

OSHA’s Lockout/Tagout Fact Sheet describes the practices and procedures necessary to disable machinery or equipment to prevent the release of hazardous energy. https://bit.ly/3YEm2gB