Control of Hazardous Energy: Lockout/Tagout (OSHA 3120)

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1. Page 1

   Control of Hazardous Energy

   • Lockout/Tagout
   • OSHA 3120
   • 2002 (Revised)
2. Page 2

   Control of Hazardous Energy

   • Lockout/ Tagout
   • U.S. Department of Labor Elaine L. Chao, Secretary
   • Occupational Safety and Health Administration John L. Henshaw, Assistant Secretary
   • OSHA 3120
   • 2002 (Revised)
3. Page 3

   Contents

   • Page
   • Background … 1
   • How should I use this booklet? … 1
   • What is “lockout/tagout”? … 1
   • Why do I need to be concerned about lockout/tagout? … 2
   • OSHA Coverage … 3
   • How do I know if the OSHA standard applies to me? … 3
   • When does the standard not apply to service and maintenance activities performed in industries covered by Part 1910? … 3
   • How does the standard apply to general industry service and maintenance operations? … 4
   • Requirements of the Standard … 6
   • What are OSHA’s requirements? … 6
   • What must an energy-control procedure include? … 7
   • What must workers do before they begin service or maintenance activities? … 8
   • …
4. Page 4

   What other options do I have? … 11

   • When can tagout devices be used instead of lockout devices? … 11
   • What are the limitations of tagout devices? … 12
   • What are the requirements for lockout/tagout devices? … 12
   • What do employees need to know about lockout/tagout programs? … 13
   • When is training necessary? … 14
   • What if I need power to test or position machines, equipment, or components? … 15
   • What if I use outside contractors for service or maintenance procedures? … 16
   • What if a group performs service or maintenance activities? … 16
   • What if a shift changes during machine service or maintenance? … 16
   • How often do I need to review my lockout/tagout procedures? … 17
   • …
5. Page 5

   What are state plans? … 23

   • How can consultation assistance help employers? … 23
   • Who can get consultation assistance and what does it cost? … 24
   • Can OSHA assure privacy to an employer who asks for consultation assistance? … 24
   • Can an employer be cited for violations after receiving consultation assistance? … 24
   • What incentives does OSHA provide for seeking consultation assistance? … 24
   • What are the Voluntary Protection Programs? … 25
   • How does the VPP work? … 25
   • How does VPP help employers and employees? … 26
   • How does OSHA monitor VPP sites? … 26
   • Can OSHA inspect an employer who is participating in the VPP? … 26
   • …
6. Page 6

   Does OSHA have other assistance materials available? … 30

   • What do I do in case of an emergency or to file a complaint? … 31
   • OSHA Regional and Area Offices … 32
   • OSHA Consultation Projects … 36
   • OSHA-Approved Safety and Health Plans … 38
   • iv
7. Page 7

   Background

   • How should I use this booklet?
   • This booklet presents OSHA’s general requirements for controlling hazardous energy during service or maintenance of machines or equipment. It is not intended to replace or to supplement OSHA standards regarding the control of hazardous energy. After reading this booklet, employers and other interested parties are urged to review the OSHA standards on the control of hazardous energy to gain a complete understanding of the requirements regarding the control of hazardous energy. These standards, as well as other relevant resources, are identified throughout this publication.
   • What is lockout/tagout?
   • …
8. Page 8

   Why do I need to be concerned about lockout/tagout?

   • positive restraints that no one can remove without a key or other unlocking mechanism, or through extraordinary means, such as bolt cutters. Tagout devices, by contrast, are prominent warning devices that an authorized employee fastens to energy-isolating devices to warn employees not to reenergize the machine while he or she services or maintains it. Tagout devices are easier to remove and, by themselves, provide employees with less protection than do lockout devices.
   • Employees can be seriously or fatally injured if machinery they service or maintain unexpectedly energizes, starts up, or releases stored energy. …
   • …
9. Page 9

   OSHA Coverage

   • How do I know if the OSHA standard applies to me?
   • If your employees service or maintain machines where the unexpected startup, energization, or the release of stored energy could cause injury, the standard likely applies to you. The standard applies to all sources of energy, including, but not limited to: mechanical, electrical, hydraulic, pneumatic, chemical, and thermal energy.
   • The standard does not cover electrical hazards from work on, near, or with conductors or equipment in electric utilization (premise wiring) installations, which are outlined by Subpart S of 29 CFR Part 1910. …
   • …
10. Page 10

    How does the standard apply to general industry service and maintenance operations?

    • An employee performs hot-tap operations on pressurized pipelines that distribute gas, steam, water, or petroleum products, for which the employer shows the following:
    • Continuity of service is essential;
    • Shutdown of the system is impractical; and
    • The employee follows documented procedures and uses special equipment that provides proven, effective employee protection.
    • The employee is performing minor tool changes or other minor servicing activities that are routine, repetitive, and integral to production, and that occur during normal production operations. …
    • …
11. Page 11
    • Place any part of their bodies in a danger zone associated with machine operations.
    • Work involving minor tool changes and adjustments or other minor servicing activities that are routine, repetitive, and integral to the use of the production equipment and that occur during normal production operations are not covered by the lockout/tagout standard. This exception is limited, however, and applies only when economic considerations prevent the use of prescribed energy-isolation measures and when the employer provides and requires alternative measures to ensure effective, alternative protection.
    • Whenever the standard is applicable, the machinery must be shut off and isolated…
    • …
12. Page 12

    Requirements of the Standard

    • What are OSHAs requirements?
    • OSHA’s standard establishes minimum performance requirements for controlling hazardous energy. The standard specifies that employers must establish an energy-control program to ensure that employees isolate machines from their energy sources and render them inoperative before any employee services or maintains them.
    • As part of an energy-control program, employers must:
    • Establish energy-control procedures for removing the energy supply from machines and for putting appropriate lockout or tagout devices on the energy-isolating devices to prevent unexpected reenergization. …
    • …
13. Page 13

    What must an energy-control procedure include?

    • Employers must develop, document, and use procedures
    • to control potentially hazardous energy. 3 The procedures
    • explain what employees must know and do to control hazardous energy effectively when they service or maintain machinery.
    • If this information is the same for the various machines used at a workplace, then a single energy-control procedure may suffice. For example, similar machines (those using the same type and magnitude of energy) that have the same or similar types of control measures can be covered by a single procedure. …
    • …
14. Page 14

    What must workers do before they begin service or maintenance activities?

    • In Appendix A to 1910.147, OSHA provides a Typical Minimal Lockout Procedure for employers to consult when preparing their own specific energy-control procedures. The outline is a nonmandatory guideline to help employers and employees comply with the standard. Nothing in the appendix adds to or detracts from any of the requirements in the standard.
    • Before beginning service or maintenance, the following steps must be accomplished in sequence and according to the specific provisions of the employer’s energy-control procedure:
    • (1) Prepare for shutdown;
    • (2) Shut down the machine;
    • …
15. Page 15
    • Before removing lockout or tagout devices, the employees must take the following steps in accordance with the specific provisions of the employer’s energy-control procedure:
    • Inspect machines or their components to assure that they are operationally intact and that nonessential items are removed from the area; and
    • Check to assure that everyone is positioned safely and away from machines.
    • After removing the lockout or tagout devices but before reenergizing the machine, the employer must assure that all employees who operate or work with the machine, as well as those in the area where service or maintenance is performed, know that the devices have been removed and that the…
    • …
16. Page 16

    How can I determine if the energy-isolating device can be locked out?

    • employees to follow an established procedure to ensure that machinery will not be reenergized until the same employee who placed the lockout device on the energy-isolating device removes it.
    • An energy-isolating device is considered “capable of being locked out” if it meets one of the following requirements:
    • Is designed with a hasp or other part to which you can attach a lock such as a lockable electric disconnect switch;
    • Has a locking mechanism built into it; or
    • Can be locked without dismantling, rebuilding, or replacing the energy-isolating device or permanently altering its energy-control capability…
    • …
17. Page 17

    What other options do I have?

    • If it is possible to lock out an energy-isolating device, employers must use lockout devices unless they develop, document, and use a tagout procedure that provides employees with a level of protection equal to that provided by a lockout device. In a tagout program, an employer can attain an equal level of protection by complying with all tagout-related provisions of the standard and using at least one added safety measure that prevents unexpected reenergization. …
    • …
18. Page 18

    What are the limitations of tagout devices?

    • A tagout device is a prominent warning that clearly states that the machinery being controlled must not be operated until the tag is removed in accordance with an established procedure. Tags are essentially warning devices and do not provide the physical restraint of a lock. Tags may evoke a false sense of security. For these reasons, OSHA considers lockout devices to be more secure and more effective than tagout devices in protecting employees from hazardous energy.
    • What are the requirements for lockout/tagout devices?
    • Whether lockout or tagout devices are used, they must be the only devices the employer uses in conjunction with…
    • …
19. Page 19

    What do employees need to know about lockout/tagout programs?

    • of 50 pounds. Tags must be attachable by hand, and the device for attaching the tag should be a one-piece nylon cable tie or its equivalent so it can withstand all environments and conditions.
    • Labeled to identify the specific employees authorized to apply and remove them.
    • Training must ensure that employees understand the purpose, function, and restrictions of the energy-control program. Employers must provide training specific to the needs of “authorized,” “affected,” and “other” employees. …
    • …
20. Page 20

    When is training necessary?

    • Understand the purpose of the procedure, and
    • Understand the importance of not tampering with lockout or tagout devices and not starting or using equipment that has been locked or tagged out.
    • All other employees whose work operations are or may be in an area where energy-control procedures are used must receive instruction regarding the energy-control procedure and the prohibition against removing a lockout or tagout device and attempting to restart, reenergize, or operate the machinery.
    • In addition, if tagout devices are used, all employees must receive training regarding the limitations of tags.
    • (See 29 CFR 1910.147(c)(7)(ii).)
    • …
21. Page 21

    What if I need power to test or position machines, equipment, or components?

    • OSHA allows the temporary removal of lockout or tagout devices and the reenergization of the machine only in limited situations for particular tasks that require energization — for example, when power is needed to test or position machines, equipment, or components. However, this temporary exception applies only for the limited time required to perform the particular task requiring energization. Employers must provide effective protection from hazardous energy when employees perform these operations. The following steps must be performed in sequence before reenergization:
    • …
22. Page 22

    What if I use outside contractors for service or maintenance procedures?

    • If an outside contractor services or maintains machinery, the onsite employer and the contractor must inform each other of their respective lockout or tagout procedures. The onsite employer also must ensure that employees understand and comply with all requirements of the contractor’s energy-control program(s).
    • What if a group performs service or maintenance activities?
    • When a crew, department, or other group performs service or maintenance, they must use a procedure that provides all employees a level of protection equal to that provided by a personal lockout or tagout device. …
    • …
23. Page 23

    How often do I need to review my lockout/tagout procedures?

    • Employees are required to review their procedures at least once a year to ensure that they provide adequate worker protection. As part of the review, employers must correct any deviations and inadequacies identified in the energy-control procedure or its application.
    • What does a review entail?
    • The periodic inspection is intended to assure that employees are familiar with their responsibilities under the procedure and continue to implement energy-control procedures properly.
    • The inspector, who must be an authorized person not involved in using the particular control procedure being inspected, must be able to…
    • …
24. Page 24

    What additional information does OSHA provide about lockout/tagout?

    • To gain a more comprehensive understanding of the requirements for controlling hazardous energy, employers and other interested persons should review the following:
    • OSHA standards with provisions regarding the control of hazardous energy such as 29 CFR 1910.147, The control of hazardous energy (lockout/tagout); 29 CFR 1910.269, Electric power generation, transmission, and distribution; and 29 CFR 1910.333, Selection and use of work practices. …
    • …
25. Page 25
    • Additionally, OSHA offers a variety of web-based tools to help educate employers and employees about the lockout/tagout standard and how to apply it in their workplace. These include the following:
    • The Lockout/Tagout Interactive Training Program, which includes a tutorial, five abstracts with a detailed discussion of major lockout/tagout issues involved, and interactive case studies;
    • The Lockout/Tagout Plus Expert Advisor, an interactive, expert, diagnostic software package to help users understand and apply OSHA standards that protect workers from the release of hazardous energy; and
    • The Lockout/Tagout electronic Compliance Assistant Tool (eCAT), an illustrated tool to…
    • …
26. Page 26

    Commonly Used Terms

    • 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.
    • 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 the standard.
    • …
27. Page 27
    • 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.
    • Lockout device. A device that uses a positive means such as a lock, either key or combination type, to hold an energyisolating device in the safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds.
    • …
28. Page 28

    OSHA Assistance, Programs, and Services

    • How can OSHA help me?
    • OSHA can provide extensive help through a variety of programs, including assistance about safety and health programs, state plans, workplace consultations, voluntary protection programs, strategic partnerships, training and education, and more.
    • How does safety and health program management assistance help employers and employees?
    • Effective management of worker safety and health protection is a decisive factor in reducing the extent and severity of work-related injuries and illnesses and their related costs. …
    • …
29. Page 29

    What are state plans?

    • State plans are OSHA-approved job safety and health programs operated by individual states or territories instead of Federal OSHA. The Occupational Safety and Health Act of 1970 (OSH Act) encourages states to develop and operate their own job safety and health plans and permits state enforcement of OSHA standards if the state has an approved plan. Once OSHA approves a state plan, it funds 50 percent of the program’s operating costs. State plans must provide standards and enforcement programs, as well as voluntary compliance activities that are at least as effective as those of Federal OSHA.
    • …
30. Page 30

    Who can get consultation assistance and what does it cost?

    • Consultation assistance is available to small employers with fewer than 250 employees at a fixed site and no more than 500 corporatewide who want help in establishing and maintaining a safe and healthful workplace.
    • Funded largely by OSHA, the service is provided at no cost to the employer. Primarily developed for smaller employers with more hazardous operations, the consultation service is delivered by state governments employing professional safety and health consultants. No penalties are proposed or citations issued for hazards identified by the consultant. …
    • …
31. Page 31

    What are the Voluntary Protection Programs?

    • for participation in SHARP includes, but is not limited to, receiving a full-service, comprehensive consultation visit, correcting all identified hazards, and developing an effective safety and health management system.
    • Employers accepted into SHARP may receive an exemption from programmed inspections (not complaint or accident investigation inspections) for a period of 1 year initially, or
    • 2 years upon renewal.
    • For more information concerning consultation assistance, see the list of consultation offices beginning on page 34, contact your regional or area OSHA office, or visit OSHA’s website at www.osha.gov.
    • …
32. Page 32

    How does VPP help employers and employees?

    • VPP participation can mean the following:
    • Reduced numbers of worker fatalities, injuries, and illnesses;
    • Lost-workday case rates generally 50 percent below industry averages;
    • Lower workers’ compensation and other injury- and illness-related costs;
    • Improved employee motivation to work safely, leading to a better quality of life at work;
    • Positive community recognition and interaction;
    • Further improvement and revitalization of already-good safety and health programs; and
    • A positive relationship with OSHA.
    • How does OSHA monitor VPP sites?
    • OSHA reviews an employer’s VPP application and conducts a VPP Onsite Evaluation to verify that the…
    • …
33. Page 33
    • Additional information on VPP is available from OSHA national, regional, and area offices, listed beginning on page 34. Also, see Outreach at OSHA’s website at www.osha.gov.
    • How can a partnership with OSHA improve worker safety and health?
    • OSHA has learned firsthand that voluntary, cooperative partnerships with employers, employees, and unions can be a useful alternative to traditional enforcement and an effective way to reduce worker deaths, injuries, and illnesses. This is especially true when a partnership leads to the development and implementation of a comprehensive workplace safety and health management system.
    • What is OSHAs Strategic Partnership Program (OSPP)?
    • …
34. Page 34

    What are the different kinds of OSPPs?

    • There are two major types:
    • Comprehensive, which focuses on establishing comprehensive safety and health management systems at partnering worksites; and
    • Limited, which helps identify and eliminate hazards associated with worker deaths, injuries, and illnesses, or have goals other than establishing comprehensive worksite safety and health programs.
    • OSHA is interested in creating new OSPPs at the national, regional, and local levels. OSHA also has found limited partnerships to be valuable. Limited partnerships might address the elimination or control of a specific industry hazard.
    • What are the benefits of participation in the OSPP?
    • …
35. Page 35

    Does OSHA have occupational safety and health training for employers and employees?

    • Yes. The OSHA Training Institute in Des Plaines, IL, provides basic and advanced training and education in safety and health for federal and state compliance officers, state consultants, other federal agency personnel, and private-sector employers, employees, and their representatives.
    • Institute courses cover diverse safety and health topics including electrical hazards, machine guarding, personal protective equipment, ventilation, and ergonomics. The facility includes classrooms, laboratories, a library, and an audiovisual unit. …
    • …
36. Page 36

    Does OSHA have other assistance materials available?

    • OSHA expects each organization awarded a grant to develop a training and/or education program that addresses a safety and health topic named by OSHA, recruit workers and employers for the training, and conduct the training. Grantees are also expected to follow up with people who have been trained to find out what changes were made to reduce the hazards in their workplaces as a result of the training.
    • Each year OSHA has a national competition that is announced in the Federal Register and on the Internet at www.osha-slc.gov/Training/sharwood/sharwood.html. …
    • …
37. Page 37

    What do I do in case of an emergency or to file a complaint?

    • To report an emergency, file a complaint, or seek OSHA advice, assistance, or products, call (800) 321– OSHA or contact your nearest OSHA regional or area office listed at the end of this publication. The teletypewriter (TTY) number is (877) 889–5627.
    • You can also file a complaint online and obtain more information on OSHA federal and state programs by visiting OSHA’s website at www.osha.gov.
    • For more information on grants, training, and education, write: OSHA Training Institute, Office of Training and Education, 1555 Times Drive, Des Plaines, IL 60018;
    • …
38. Page 38

    OSHA Regional and Area Offices

    • OSHA Regional Offices
    • Region I
    • Region VI
    • (CT,* MA, ME, NH, RI, VT*) JFK Federal Building
    • Room E-340
    • Boston, MA 02203 Telephone: (617) 565–9860
    • (AR, LA, MN,* OK, TX)
    • 525 Griffin Street
    • Room 602
    • Dallas, TX 75202
    • Telephone: (214) 767–4731
    • Region II
    • Region VII
    • (NJ,* NY,* PR,* VI*)
    • 201 Varick Street
    • Room 670
    • New York, NY 10014
    • Telephone: (212) 337–2378
    • (IA,* KS, MO, NE)
    • City Center Square
    • 1100 Main Street, Suite 800 Kansas City, MO 64105 Telephone: (816) 426–5861
    • Region III
    • Region VIII
    • (DC, DE, MD,* PA, VA,* WV)
    • The Curtis Center —Suite 740 West
    • 170 S. Independence Mall West
    • Philadelphia, PA 19106-3309
    • Telephone: (215) 861–4900
    • …
39. Page 39

    OSHA Area Offices

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    • …
40. Page 40

    Bangor, ME

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    • …
41. Page 41

    Philadelphia, PA

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    • OSHA Regional and Area Offices
    • Houston, TX
    • (281) 591–2438 (2787)
    • Houston, TX
    • (281) 286–0583/0584 (5922) Lubbock, TX
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    • Salt Lake City, UT
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    • Norfolk, VA
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    • Bellevue, WA
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    • Appleton, WI
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    • Eau Claire, WI
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    • Madison, WI
    • …
42. Page 42

    OSHA Consultation Projects

    • Anchorage, AK
    • (907) 269–4957
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    • (205) 348–3033
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    • (501) 682–4522
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    • Atlanta, GA
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    • …
43. Page 43

    Albany, NY

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    • Henderson, NV
    • (702) 486–9140
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    • OSHA Consultation Projects
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44. Page 44

    OSHA-Approved Safety and Health Plans

    • Juneau, AK
    • (907) 465–2700
    • Phoenix, AZ
    • (602) 542–5795
    • San Francisco, CA
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    • Indianapolis, ID
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    • Frankfort, KY
    • (502) 564–3070
    • Baltimore, MD
    • (410) 767–2215
    • Lansing, MI
    • (517) 322–1814
    • St. Paul, MN
    • (651) 284–5010
    • Raleigh, NC
    • (919) 807–2900
    • Trenton, NJ
    • (609) 292–2975
    • Santa Fe, NM
    • (505) 827–2850
    • Carson City, NV
    • (775) 684–7260
    • Salem, OR
    • (503) 378–3272
    • Hato Rey, PR
    • (787) 754–2119
    • Columbia, SC
    • (803) 896–4300
    • Nashville, TN
    • (615) 741–2582
    • Salt Lake City, UT
    • (801) 530–6901
    • Richmond, VA
    • (804) 786–2377
    • …