INFORMATION DATE 19890613
DESCRIPTION USDOL Program Highlights - Control of Hazardous Energy Sources (Lock-out/Tagout)
STANDARD NUMBER 1910.1450
SUBJECT Control of Hazardous Energy Sources (Lock-out/Tagout)
U.S. Department of Labor
Program Highlights
Fact Sheet No. OSHA 89-32
CONTROL OF HAZARDOUS ENERGY SOURCES (LOCK-OUT/TAGOUT)
SCOPE
The standard for the control of hazardous energy sources (lock-out/tagout) covers 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.
The rule generally requires that energy sources for equipment be turned off or disconnected, and that the switch either be locked or labeled with a warning tag.
About three million workers actually servicing equipment face the greatest risk. These include craft workers, machine operators, and laborers. OSHA data show that packaging and wrapping equipment, printing presses, and conveyors account for a high proportion of the accidents associated with lock-out/tagout failures. Typical injuries include fractures, lacerations, contusions, amputations, and puncture wounds with the average lost time for injuries running 24 days.
Agriculture, maritime, and construction employers would be covered under future rulemakings. The generation, transmission, and distribution of electric power by utilities and work on electric conductors and equipment are excluded because lock-out/tagout procedures for these specific industries are being included in separate standards under development for them.
GENERAL REQUIREMENTS
Under the ruling employers must:
- Develop an energy control program.
- Use locks when equipment can be locked out.
- Ensure that new equipment or overhauled equipment can accommodate locks.
- Employ additional means to ensure safety when tags rather than locks are used by utilizing an effective tagout program.
- Identify and implement specific procedures (generally in writing) for the control of hazardous energy including preparation for shutdown, shutdown, equipment isolation, lock-out/tagout application, release of stored energy, and verification of isolation.
- Institute procedures for release of lock-out/tagout including machine inspection, notification, safe positioning of employees, and removal of the lock-out/tagout device.
- Obtain standardized locks and tags which indicate the identity of the employee using them and are of sufficient quality and durability to ensure their effectiveness.
- Require that each lock-out/tagout device be removed by the employee who applied the device.
- Conduct inspections of energy control procedures at least annually.
- Train employees in the specific energy control procedures with training reminders as part of the annual inspections of the control procedures.
- Adopt procedures to ensure safety when equipment must be tested during servicing, when outside contractors are working at the site, when a multiple lock-out is needed for a crew servicing equipment, and when shifts or personnel change.
EXCLUSIONS
Excluded from coverage are:
- Normal production operations including repetitive, routine minor adjustment which would be covered under OSHA's machine guarding standards.
- Work on cord and plug connected electrical equipment when it is unplugged, and the employee working on the equipment has complete control over the plug.
- Hot tap operations involving gas, steam, water, or petroleum products when the employer shows that continuity of service is essential, shutdown is impractical, and documented procedures are followed to provide proven effective protection for employees.
COMPLIANCE COSTS
Estimated costs for the 1.7 million affected establishments-mostly in manufacturing and service industries, many of which are already in compliance -- was expected to be $214 million the first year and approximately $135 million in subsequent years. Small establishments can expect implementation costs to be approximately $125, while cost estimates for very large firms are approximately $28,000.
BENEFITS
OSHA estimates compliance with the standard will prevent about 120 fatalities and approximately 28,000 serious and 32,000 minor injuries each year. About 39 million general industry workers will be protected from accidents during maintenance and servicing of equipment under this ruling.
This is one of a series of fact sheets highlighting U.S. Department of Labor programs. It is intended as a general description only and does not carry the force of legal opinion.