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29 CFR | | 40 CFR |
| 49 CFR |
| FR Daily |
| MSDS |
|Seton |
(a) Scope, application and purpose -- (1) Scope. (i) This
standard 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 such hazardous
energy.
(ii) This standard does not cover the following:
(A) Construction, agriculture and maritime employment;
(B) Installations under the exclusive control of electric utilities for the purpose of power generation, transmission and distribution, including related equipment for communication or metering; and
(C) Exposure to electrical hazards from work on, near, or with conductors or equipment in electric utilization installations, which is covered by subpart S of this part; and
(D) Oil and gas well drilling and servicing.
(2) Application. (i) This standard applies to the control of energy during servicing and/or maintenance of machines and equipment.
(ii) Normal production operations are not covered by this standard (See subpart 0 of this part). Servicing and/or maintenance which takes place during normal production operations is covered by this standard only if;:
(A) An employee is required to remove or bypass a guard or other safety device; or
(B) An employee is required to place any part of his or her body into an area
on a machine or piece of equipment where work is actually performed upon the
material being processed (point of operation) or where an associated danger zone
exists during a machine operating cycle. Note: Exception to paragraph (a)(2)(ii): Minor tool changes and
adjustments, and other minor servicing activities, which take place during
normal production operations, are not covered by this standard if they are
routine, repetitive, and integral to the use of the equipment for production,
provided that the work is performed using alternative measures which provide
effective protection (See subpart 0 of this part).
(iii) This standard does not apply to the following.
(A) Work on cord and plug connected electric equipment for which exposure to
the hazards of unexpected energization or start up of the equipment is
controlled by the unplugging of the equipment from the energy source and by the
plug being under the exclusive control of the employee performing the servicing
or maintenance.
(B) Hot tap operations involving transmission and distribution systems for
substances such as gas, steam, water or petroleum products when they are
performed on pressurized pipelines, provided that the employer demonstrates that
(1) continuity of service is essential; (2) shutdown of the system
is impractical; and (3) documented procedures are followed, and special
equipment is used which will provide proven effective protection for employees.
(3) Purpose. (i) This section requires employers to establish a
program and utilize procedures for affixing appropriate lockout devices or
tagout devices to energy isolating devices, and to otherwise disable machines or
equipment to prevent unexpected energization, start-up or release of stored
energy in order to prevent injury to employees.
(ii) When other standards in this part require the use of lockout or tagout,
they shall be used and supplemented by the procedural and training requirements
of this section.
(b) Definitions applicable to this section.
Affected employee. An employee whose job requires him/her to operate
or use a machine or equipment on which servicing or maintenance is being
performed under lockout or tagout, or whose job requires him/her to work in an
area in which such servicing or maintenance is being performed.
Energized. Connected to an energy source or containing residual or
stored energy.
Energy source. Any source of electrical, mechanical, hydraulic,
pneumatic, chemical, thermal, or other energy.
Hot tap. A procedure used in the repair, maintenance and services
activities which involves welding on a piece of equipment (pipelines, vessels or
tanks) under pressure, in order to install connections or appurtenances. It is
commonly used to replace or add sections of pipeline without the interruption of
service for air, gas, water, steam, and petrochemical distribution systems.
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.
Normal production operations. The utilization of a machine or
equipment to perform its intended production function.
Servicing and/or 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 or tool changes, where the employee may be exposed to the
unexpected energization or startup of the equipment or release of
hazardous energy.
Setting up. Any work performed to prepare a machine or equipment to
perform its normal production operation.
Tagout. The placement of a tagout device on 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.
(c) General -- (1) Energy control program. The employer shall
establish a program consisting of energy control procedures, employee training
and periodic inspections to ensure that before any employee performs any
servicing or maintenance on a machine or equipment where the unexpected
energizing, start up or release of stored energy could occur and cause injury,
the machine or equipment shall be isolated from the energy source, and rendered
inoperative.
(2) Lockout/tagout. (i) If an energy isolating device is not capable
of being locked out, the employer's energy control program under paragraph
(c)(1) of this section shall utilize a tagout system.
(ii) If an energy isolating device is capable of being locked out, the
employer's energy control program under paragraph (c)(1) of this section shall
utilize lockout, unless the employer can demonstrate that the utilization of a
tagout system will provide full employee protection as set forth in paragraph
(c)(3) of this section.
(iii) After January 2, 1990, 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 for such machine
or equipment shall be designed to accept a lockout device.
(3) Full employee protection. (i) 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.
(ii) In demonstrating that a level of safety is achieved in the tagout
program which is equivalent to the level of safety obtained by using a lockout
program, the employer shall demonstrate full compliance with all tagout-related
provisions of this standard together with such additional elements as are
necessary to provide the equivalent safety available from the use of a lockout
device. Additional means to be considered as part of the demonstration of full
employee protection shall include the implementation of additional safety
measures such as 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.
(4) Energy control procedure. (i) Procedures shall be developed,
documented and utilized for the control of potentially hazardous energy when
employees are engaged in the activities covered by this section. Note: Exception: The employer need not document the required
procedure for a particular machine or equipment, when all of the following
elements exist: (1) The machine or equipment has no potential for stored or
residual energy or reaccumulation of stored energy after shut down which could
endanger employees; (2) the machine or equipment has a single energy source
which can be readily identified and isolated; (3) the isolation and locking out
of that energy source will completely deenergize and deactivate the machine or
equipment; (4) the machine or equipment is isolated from that energy source and
locked out during servicing or maintenance; (5) a single lockout device will
achieve a locked-out condition; (6) the lockout device is under the exclusive
control of the authorized employee performing the servicing or maintenance; (7)
the servicing or maintenance does not create hazards for other employees; and
(8) the employer, in utilizing this exception, has had no accidents involving
the unexpected activation or reenergization of the machine or equipment during
servicing or maintenance.
(ii) The procedures shall clearly and specifically outline the scope,
purpose, authorization, rules, and techniques to be utilized for the control of
hazardous energy, and the means to enforce compliance including, but not limited
to, the following:
(A) A specific statement of the intended use of the procedure;
(B) Specific procedural steps for shutting down, isolating, blocking and
securing machines or equipment to control hazardous energy;
(C) Specific procedural steps for the placement, removal and transfer of
lockout devices or tagout devices and the responsibility for them; and
(D) Specific requirements for testing a machine or equipment to determine and
verify the effectiveness of lockout devices, tagout devices, and other energy
control measures.
(ii) Lockout devices and tagout devices shall be singularly identified; shall
be the only devices(s) used for controlling energy; shall not be used for other
purposes; and shall meet the following requirements:
(A) Durable. (1) Lockout and tagout devices shall be capable of
withstanding the environment to which they are exposed for the maximum period of
time that exposure is expected.
(2) Tagout devices shall be constructed and printed so that exposure
to weather conditions or wet and damp locations will not cause the tag to
deteriorate or the message on the tag to become illegible.
(3) Tags shall not deteriorate when used in corrosive environments
such as areas where acid and alkali chemicals are handled and stored.
(B) Standardized. Lockout and tagout devices shall be standardized
within the facility in at least one of the following criteria: Color; shape; or
size; and additionally, in the case of tagout devices, print and format shall be
standardized.
(C) Substantial -- (1) Lockout devices. Lockout devices
shall be substantial enough to prevent removal without the use of excessive
force or unusual techniques, such as with the use of bolt cutters or other metal
cutting tools.
(2) Tagout devices. Tagout devices, including and their means
of attachment, shall be substantial enough to prevent inadvertent or accidental
removal. Tagout device attachment means shall be of a non-reusable type,
attachable by hand, self-locking, and non-releasable with a minimum unlocking
strength of no less than 50 pounds and having the general design and basic
characteristics of being at least equivalent to a one-piece,
all-environment-tolerant nylon cable tie.
(iii) Tagout devices shall warn against hazardous conditions if the machine
or equipment is energized and shall include a legend such as the following:
Do Not Start, Do Not Open, Do Not Close, Do Not Energize, Do Not Operate.
(6) Periodic inspection. (i) The employer shall conduct a periodic
inspection of the energy control procedure at least annually to ensure that the
procedure and the requirements of this standard are being followed.
(A) The periodic inspection shall be performed by an authorized employee other
than the ones(s) utilizing the energy control procedure being inspected.
(B) The periodic inspection shall be conducted to correct any deviations or
inadequacies identified.
(C) Where lockout is used for energy control, the periodic inspection shall
include a review, between the inspector and each authorized employee, of that
employee's responsibilities under the energy control procedure being inspected.
(D) Where tagout is used for energy control, the periodic inspection shall
include a review, between the inspector and each authorized and affected
employee, of that employee's responsibilities under the energy control procedure
being inspected, and the elements set forth in paragraph (c)(7)(ii) of this
section.
(ii) The employer shall certify that the periodic inspections have been
performed. The certification 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.
(A) Each authorized employee shall receive training in the recognition of
applicable hazardous energy sources, the type and magnitude of the energy
available in the workplace, and the methods and means necessary for energy
isolation and control.
(B) Each affected employee shall be instructed in the purpose and use of the
energy control procedure.
(C) All 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.
(ii) When tagout systems are used, employees shall also be trained in the
following limitations of tags:
(A) Tags are essentially warning devices affixed to energy isolating devices,
and do not provide the physical restraint on those devices that is provided by a
lock.
(C) Tags must be legible and understandable by all authorized employees,
affected employees, and all other employees whose work operations are or may be
in the area, in order to be effective.
(D) Tags and their means of attachment must be made of materials which will
withstand the environmental conditions encountered in the workplace.
(E) Tags may evoke a false sense of security, and their meaning needs to be
understood as part of the overall energy control program.
(F) Tags must be securely attached to energy isolating devices so that they
cannot be inadvertently or accidentally detached during use.
(iii) Employee retraining.
(A) Retraining shall be provided for all authorized and affected employees
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.
(B) Additional retraining shall also be conducted whenever a periodic
inspection under paragraph (c)(6) of this section reveals, or whenever the
employer has reason to believe, that there are deviations from or inadequacies
in the employee's knowledge or use of the energy control procedures.
(C) The retraining shall reestablish employee proficiency and introduce new
or revised control methods and procedures, as necessary.
(iv) The employer shall certify that employee training has been accomplished
and is being kept up to date. The certification shall contain each employee's
name and dates of training.
(8) Energy isolation. Lockout or tagout shall be performed only bythe
authorized employees who are performing the servicing or maintenance.
(9) Notification of employees. Affected employees shall be notified by
the employer or authorized employee of the application and removal of lockout
devices or tagout devices. Notification shall be given before the controls are
applied, and after they are removed from the machine or equipment.
(d) Application of control. The established procedures for the
application of energy control (the lockout or tagout procedures) shall cover the
following elements and actions and shall be done in the following sequence:
(1) Preparation for shutdown. Before an authorized or affected
employee turns off a machine or equipment, the authorized employee shall have
knowledge of the type and magnitude of the energy, the hazards of the energy to
be controlled, and the method or means to control the energy.
(2) Machine or equipment shutdown. The machine or equipment shall be
turned off or shut down using the procedures established for the machine or
equipment. An orderly shutdown must be utilized to avoid any additional or
increased hazard(s) to employees as a result of the equipment stoppage.
(3) Machine or equipment isolation. All energy isolating devices that
are needed to control the energy to the machine or equipment shall be physically
located and operated in such a manner as to isolate the machine or equipment
from the energy source(s).
(4) Lockout or tagout device application. (i) Lockout or tagout
devices shall be affixed to each energy isolating device by authorized
employees.
(ii) Lockout devices, where used, shall be affixed in a manner to that will
hold the energy isolating devices in a "safe" or "off" position.
(iii) 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.
(A) Where tagout devices are used with energy isolating devices designed with
the capability of being locked, the tag attachment shall be fastened at the same
point at which the lock would have been attached.
(B) Where a tag cannot be affixed directly to the energy isolating device,
the tag shall be located as close as safely possible to the device, in a
position that will be immediately obvious to anyone attempting to operate the
device.
(5) Stored energy. (i) Following the application of lockout or tagout
devices to energy isolating devices, all potentially hazardous stored or
residual energy shall be relieved, disconnected, restrained, and otherwise
rendered safe.
(ii) If there is a possibility of reaccumulation of stored energy to a
hazardous level, verification of isolation shall be continued until the
servicing or maintenance is completed, or until the possibility of such
accumulation no longer exists.
(6) Verification of isolation. Prior to starting work on machines or
equipment that have been locked out or tagged out, the authorized employee shall
verify that isolation and deenergization of the machine or equipment have been
accomplished.
(e) Release from lockout or tagout. Before lockout or tagout devices
are removed and energy is restored to the machine or equipment, procedures shall
be followed and actions taken by the authorized employee(s) to ensure the
following:
(1) The machine or equipment. The work area shall be inspected to
ensure that nonessential items have been removed and to ensure that machine or
equipment components are operationally intact.
(2) Employees. (i) The work area shall be checked to ensure that all
employees have been safely positioned or removed.
(ii) After lockout or tagout devices have been removed and before a machine
or equipment is started, affected employees shall be notified that the lockout
or tagout device(s) have been removed.
(3) Lockout or tagout devices removal. Each lockout or tagout device
shall be removed from each energy isolating device by the employee who applied
the device. Exception to paragraph (e)(3): When the authorized employee
who applied the lockout or tagout device is not available to remove it, that
device may be removed under the direction of the employer, provided that
specific procedures and training for such removal have been developed,
documented and incorporated into the employer's energy control program. The
employer shall demonstrate that the specific procedure provides equivalent
safety to the removal of the device by the authorized employee who applied it.
The specific procedure shall include at least the following elements:
(i) Verfication by the employer that the authorized employee who applied the
device is not at the facility;
(ii) Making all reasonable efforts to contact the authorized employee to
inform him/her that his/her lockout or tagout device has been removed; and
(iii) Ensuring that the authorized employee has this knowledge before he/she
resumes work at that facility.
(f) Additional requirements -- (1) Testing or positioning of
machines, equipment or components thereof. In situations in which lockout or
tagout devices must be temporarily removed from the energy isolating device and
the machine or equipment energized to test or position the machine, equipment or
component thereof, the following sequence of actions shall be followed:
(i) Clear the machine or equipment of tools and materials in accordance with
paragraph (e)(1) of this section;
(ii) Remove employees from the machine or equipment area in accordance with
paragraph (e)(2) of this section;
(iii) Remove the lockout or tagout devices as specified in paragraph (e)(3)
of this section;
(iv) Energize and proceed with testing or positioning;
(v) Deenergize all systems and reapply energy control measures in accordance
with paragraph (d) of this section to continue the servicing and/or maintenance.
(2) Outside personnel (contractors, etc.). (i) Whenever outside
servicing personnel are to be engaged in activities covered by the scope and
application of this standard, the on-site employer and the outside employer
shall inform each other of their respective lockout or tagout procedures.
(ii) The on-site employer shall ensure that his/her employees understand and
comply with the restrictions and prohibitions of the outside employer's energy
control program.
(3) Group lockout or tagout. (i) When servicing and/or maintenance is
performed by a crew, craft, department or other group, they shall utilize a
procedure which affords the employees a level of protection equivalent to that
provided by the implementation of a personal lockout or tagout device.
(ii) Group lockout or tagout devices shall be used in accordance with the
procedures required by paragraph (c)(4) of this section including, but not
necessarily limited to, the following specific requirements:
(A) Primary responsibility is vested in an authorized employee for a set
number of employees working under the protection of a group lockout or tagout
device (such as an operations lock);
(B) Provision for the authorized employee to ascertain the exposure status of
individual group members with regard to the lockout or tagout of the machine or
equipment and
(C) When more than one crew, craft, department, etc. is involved, assignment
of overall job-associated lockout or tagout control responsibility to an
authorized employee designated to coordinate affected work forces and ensure
continuity of protection; and
(D) Each authorized employee shall affix a personal lockout or tagout device
to the group lockout device, group lockbox, or comparable mechanism when he or
she begins work, and shall remove those devices when he or she stops working on
the machine or equipment being serviced or maintained.
(4) Shift or personnel changes. Specific procedures shall be utilized
during shift or personnel changes to ensure the continuity of lockout or tagout
protection, including provision for the orderly transfer of lockout or tagout
device protection between off-going and oncoming employees, to minimize exposure
to hazards from the unexpected energization or start-up of the machine or
equipment, or the release of stored energy. Note: The following appendix to § 1910.147 services as a
non-mandatory guideline to assist employers and employees in complying with the
requirements of this section, as well as to provide other helpful information.
Nothing in the appendix adds to or detracts from any of the requirements of this
section.
The following simple lockout procedure is provided to assist employers in
developing their procedures so they meet the requirements of this standard. When
the energy isolating devices are not lockable, tagout may be used, provided the
employer complies with the provisions of the standard which require additional
training and more rigorous periodic inspections. When tagout is used and the
energy isolating devices are lockable, the employer must provide full employee
protection (see paragraph (c)(3)) and additional training and more
rigorous periodic inspections are required. For more complex systems, more
comprehensive procedures may need to be developed, documented and utilized.
This procedure establishes the minimum requirements for the lockout of energy
isolating devices whenever maintenance or servicing is done on machines or
equipment. It shall be used to ensure that the machine or equipment is stopped,
isolated from all potentially hazardous energy sources and locked out before
employees perform any servicing or maintenance where the unexpected energization
or start-up of the machine or equipment or release of stored energy could cause
injury. All employees are required to comply with the restrictions and limitations
imposed upon them during the use of lockout. The authorized employees are
required to perform the lockout in accordance with this procedure. All
employees, upon observing a machine or piece of equipment which is locked out to
perform servicing or maintenance shall not attempt to start, energize or use
that machine or equipment. (1) Notify all affected employees that servicing or maintenance is required
on a machine or equipment and that the machine or equipment must be shut down
and locked out to perform the servicing or maintenance. (2) The authorized employee shall refer to the company procedure to identify
the type and magnitude of the energy that the machine or equipment utilizes,
shall understand the hazards of the energy, and shall know the methods to
control the energy. (3) If the machine or equipment is operating, shut it down by the normal
stopping procedure (depress stop button, open switch, close valve, etc.). (4) De-activate the energy isolating device(s) so that the machine or
equipment is isolated from the energy source(s). (5) Lock out the energy isolating device(s) with assigned individual lock(s).
(6) Stored or residual energy (such as that in capacitors, springs, elevated
machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or
water pressure, etc.) must be dissipated or restrained by methods such as
grounding, repositioning, blocking, bleeding down, etc. (7) Ensure that the equipment is disconnected from the energy source(s) by
first checking that no personnel are exposed, then verify the isolation of the
equipment by operating the push button or other normal operating control(s) or
by testing to make certain the equipment will not operate.
(8) The machine or equipment is now locked out.
Restoring Equipment to Service. When the servicing or maintenance is
completed and the machine or equipment is ready to return to normal operating
condition, the following steps shall be taken.
(1) Check the machine or equipment and the immediate area around the machine
or equipment to ensure that nonessential items have been removed and that the
machine or equipment components are operationally intact.
(2) Check the work area to ensure that all employees have been safely
positioned or removed from the area.
(3) Verify that the controls are in neutral.
(4) Remove the lockout devices and reenergize the machine or equipment.
Note: The removal of some forms of blocking may require reenergization
of the machine before safe removal.
(5) Notify affected employees that the servicing or maintenance is completed
and the machine or equipment is ready for use.
[54 FR 36687, Sept. 1, 1989, as amended at 54 FR 42498, Oct. 17, 1989; 55 FR
38685, 38686, Sept. 20, 1990] 
Authorized employee. A person who locks out or tags out machines or
equipment in order to perform servicing or maintenance on that machine or
equipment. An affected employee becomes an authorized employee when that
employee's duties include performing servicing or maintenance covered under this
section.
Capable of being locked out. 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, or it has a locking mechanism built into
it. Other energy isolating devices are capable of being locked out, if lockout
can be achieved without the need to dismantle, rebuild, or replace the energy
isolating device or permanently alter its energy control capability.
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. Push buttons, selector switches and other
control circuit type devices are not energy isolating devices.
Lockout
device. A device that utilizes a positive means such as a lock, either key
or combination type, to hold an energy isolating device in a safe position and
prevent the energizing of a machine or equipment. Included are
blank flanges and bolted slip blinds.
Tagout device. A prominent warning device, such as a tag and a 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.
(5) Protective materials and
hardware. (i) Locks, tags, chains,
wedges, key blocks, adapter pins, self-locking fasteners, or other hardware
shall be provided by the employer for isolating, securing or blocking of
machines or equipment from energy sources.
(D) Identifiable. Lockout devices and tagout devices shall indicate
the identity of the employee applying the device(s).
(7) Training and communication. (i) The employer shall provide
training to ensure that the purpose and function of the energy control program
are understood by employees and that the knowledge and skills required for the
safe application, usage, and removal of the energy controls are acquired by
employees. The training shall include the following:
(B) When a tag is attached to an energy isolating means, it is not to be
removed without authorization of the authorized person responsible for it, and
it is never to be bypassed, ignored, or otherwise defeated.