1915.89—Control of hazardous energy (lockout/tags-plus).
Code of Federal Regulations
Effective Date Note:
At 76 FR 24698, May 2, 2011, subpart F was revised, effective Aug. 1, 2011. For the convenience of the user, the added and revised text is set forth as follows:
Subpart F—General Working Conditions
§ 1915.89
Control of hazardous energy (lockout/tags-plus).
(a)
Scope, application, and effective dates . (1) Scope. This section covers the servicing of machinery, equipment, and systems when the energization or startup of machinery, equipment, or systems, or the release of hazardous energy, could endanger an employee.
(2)
Application.
(i)
This section applies to the servicing of any machinery, equipment, or system that employees use in the course of shipyard employment work and that is conducted:
(A)
In any landside facility that performs shipyard employment work; and
(B)
On any vessel or vessel section.
(ii)
This section applies to such servicing conducted on a vessel by any employee including, but not limited to, the ship's officers and crew unless such application is preempted by the regulations of another federal agency.
(3)
When other standards in 29 CFR part 1915
and applicable standards in 29 CFR part 1910
require the use of a lock or tag, the employer shall use and supplement them with the procedural and training requirements specified in this section.
(4)
Exceptions.
This section does not apply to:
(i)
Work on cord-and-plug-connected machinery, equipment, or system, provided the employer ensures that the machinery, equipment, or system is unplugged and the plug is under the exclusive control of the employee performing the servicing;
(ii)
Minor servicing activities performed during normal production operations, including minor tool changes and adjustments, that are routine, repetitive, and integral to the use of the machinery, equipment, or system, provided the employer ensures that the work is performed using measures that provide effective protection from energization, startup, or the release of hazardous energy.
(b)
Lockout/tags-plus program.
The employer shall establish and implement a written program and procedures for lockout and tags-plus systems to control hazardous energy during the servicing of any machinery, equipment, or system in shipyard employment. The program shall cover:
(1)
Procedures for lockout/tags-plus systems while servicing machinery, equipment, or systems in accordance with paragraph (c) of this section;
(2)
Procedures for protecting employees involved in servicing any machinery, equipment, or system in accordance with paragraphs (d) through (m) of this section;
(3)
Specifications for locks and tags-plus hardware in accordance with paragraph (n) of this section;
(4)
Employee information and training in accordance with paragraph (o) of this section;
(5)
Incident investigations in accordance with paragraph (p) of this section; and
(6)
Program audits in accordance with paragraph (q) of this section.
(c)
General requirements.
(1)
The employer shall ensure that, before any authorized employee performs servicing when energization or startup, or the release of hazardous energy, may occur, all energy sources are identified and isolated, and the machinery, equipment, or system is rendered inoperative.
(2)
If an energy-isolating device is capable of being locked, the employer shall ensure the use of a lock to prevent energization or startup, or the release of hazardous energy, before any servicing is started, unless the employer can demonstrate that the utilization of a tags-plus system will provide full employee protection as set forth in paragraph (c)(6) of this section.
(3)
If an energy-isolating device is not capable of being locked, the employer shall ensure the use of a tags-plus system to prevent energization or startup, or the release of hazardous energy, before any servicing is started.
(4)
Each tags-plus system shall consist of:
(i)
At least one energy-isolating device with a tag affixed to it; and
(ii)
At least one additional safety measure that, along with the energy-isolating device and tag required in (c)(4)(i) of this section, will provide the equivalent safety available from the use of a lock.
Note to paragraph (c)(4) of this section:
When the Navy ship's force maintains control of the machinery, equipment, or systems on a vessel and has implemented such additional measures it determines are necessary, the provisions of paragraph (c)(4)(ii) of this section shall not apply, provided that the employer complies with the verification procedures in paragraph (g) of this section.
(5)
After October 31, 2011, the employer shall ensure that each energy-isolating device for any machinery, equipment, or system is designed to accept a lock whenever the machinery, equipment, or system is extensively repaired, renovated, modified, or replaced, or whenever new machinery, equipment, or systems are installed. This requirement does not apply when a shipyard employer:
(i)
Does not own the machinery, equipment, or system; or
(ii)
Builds or services a vessel or vessel section according to customer specifications.
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(6)
Full employee protection.
(i)
When a tag is used on an energy-isolating device that is capable of being locked out, the tag shall be attached at the same location that the lock would have been attached, and;
(ii)
The employer shall demonstrate that the use of a tags-plus system will provide a level of safety equivalent to that obtained by using a lock. In demonstrating that an equivalent level of safety is achieved, the employer shall:
(A)
Demonstrate full compliance with all tags-plus-related provisions of this standard; and
(B)
Implement such additional safety measures as are necessary to provide the equivalent safety available from the use of a lock.
Note to paragraph (c)(6) of this section:
When the Navy ship's force maintains control of the machinery, equipment, or systems on a vessel and has implemented such additional measures it determines are necessary, the provisions of paragraph (c)(6)(ii)(B) of this section do not apply, provided that the employer complies with the verification procedures in paragraph (g) of this section.
(7)
Lockout/tags-plus coordination.
(i)
The employer shall establish and implement lockout/tags-plus coordination when:
(A)
Employees on vessels and in vessel sections are servicing multiple machinery, equipment, or systems at the same time; or
(B)
Employees on vessels, in vessel sections, and at landside facilities are performing multiple servicing operations on the same machinery, equipment, or system at the same time.
(ii)
The coordination process shall include a lockout/tags-plus coordinator and a lockout/tags-plus log. Each log shall be specific to each vessel, vessel section, and landside work area.
(iii)
The employer shall designate a lockout/tags-plus coordinator who is responsible for overseeing and approving:
(A)
The application of each lockout and tags-plus system;
(B)
The verification of hazardous-energy isolation before the servicing of any machinery, equipment, or system begins; and
(C)
The removal of each lockout and tags-plus system.
(iv)
The employer shall ensure that the lockout/tags-plus coordinator maintains and administers a continuous log of each lockout and tags-plus system. The log shall contain:
(A)
Location of machinery, equipment, or system to be serviced;
(B)
Type of machinery, equipment, or system to be serviced;
(C)
Name of the authorized employee applying the lockout/tags-plus system;
(D)
Date that the lockout/tags-plus system is applied;
(E)
Name of authorized employee removing the lock or tags-plus system; and
(F)
Date that lockout/tags-plus system is removed.
Note to paragraph (c)(7) of this section:
When the Navy ship's force serves as the lockout/tags-plus coordinator and maintains control of the lockout/tags-plus log, the employer will be in compliance with the requirements in paragraph (c)(7) of this section when coordination between the ship's force and the employer occurs to ensure that applicable lockout/tags-plus procedures are followed and documented.
(d)
Lockout/tags-plus written procedures.
(1)
The employer shall establish and implement written procedures to prevent energization or startup, or the release of hazardous energy, during the servicing of any machinery, equipment, or system. Each procedure shall include:
(i)
A clear and specific outline of the scope and purpose of the lockout/tags-plus procedure;
(ii)
The means the employer will use to enforce compliance with the lockout/tags-plus program and procedures; and
(iii)
The steps that must be followed for:
(A)
Preparing for shutting down and isolating of the machinery, equipment, or system to be serviced, in accordance with paragraph (e) of this section;
(B)
Applying the lockout/tags-plus system, in accordance with paragraph (f) of this section;
(C)
Verifying isolation, in accordance with paragraph (g) of this section;
(D)
Testing the machinery, equipment, or system, in accordance with paragraph (h) of this section;
(E)
Removing lockout/tags-plus systems, in accordance with paragraph (i) of this section;
(F)
Starting up the machinery, equipment, or system that is being serviced, in accordance with paragraph (j) of this section;
(G)
Applying lockout/tags-plus systems in group servicing operations, in accordance with paragraph (k) of this section;
(H)
Addressing multi-employer worksites involved in servicing any machinery, equipment, or system, in accordance with paragraph (l) of this section; and
(I)
Addressing shift or personnel changes during servicing operations, in accordance with paragraph (m) of this section.
Note to paragraph (d)(1) of this section:
The employer need only develop a single procedure for a group of similar machines, equipment, or systems if the machines, equipment, or systems have the same type and magnitude of energy and the same or similar types of controls, and if a single procedure can satisfactorily address the hazards and the steps to be taken to control these hazards.
(2)
The employer's lockout procedures do not have to be in writing for servicing machinery, equipment, or systems, provided that all of the following conditions are met:
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(i)
There is no potential for hazardous energy to be released (or to reaccumulate) after shutting down, or restoring energy to, the machinery, equipment, or system;
(ii)
The machinery, equipment, or system has a single energy source that can be readily identified and isolated;
(iii)
The isolation and lock out of that energy source will result in complete de-energization and deactivation of the machinery, equipment, or system, and there is no potential for reaccumulation of energy;
(iv)
The energy source is isolated and secured from the machinery, equipment, or system during servicing;
(v)
Only one lock is necessary for isolating the energy source;
(vi)
The lock is under the exclusive control of the authorized employee performing the servicing;
(vii)
The servicing does not create a hazard for any other employee; and
(viii)
The employer, in utilizing this exception, has not had any accidents or incidents involving the activation or reenergization of this type of machinery, equipment, or system during servicing.
(e)
Procedures for shutdown and isolation.
(1)
Before an authorized employee shuts down any machinery, equipment, or system, the employer shall:
(i)
Ensure that the authorized employee has knowledge of:
(A)
The source, type, and magnitude of the hazards associated with energization or startup of the machine, equipment, or system;
(B)
The hazards associated with the release of hazardous energy; and
(C)
The means to control these hazards; and
(ii)
Notify each affected employee that the machinery, equipment, or system will be shut down and deenergized prior to servicing, and that a lockout/tags-plus system will be implemented.
(2)
The employer shall ensure that the machinery, equipment, or system is shut down according to the written procedures the employer established.
(3)
The employer shall use an orderly shutdown to prevent exposing any employee to risks associated with hazardous energy.
(4)
The employer shall ensure that the authorized employee relieves, disconnects, restrains, or otherwise renders safe all potentially hazardous energy that is connected to the machinery, equipment, or system.
Note to paragraph (e) of this section:
When the Navy ship's force shuts down any machinery, equipment, or system, and relieves, disconnects, restrains, or otherwise renders safe all potentially hazardous energy that is connected to the machinery, equipment, or system, the employer will be in compliance with the requirements in paragraph (e) of this section when the employer's authorized employee verifies that the machinery, equipment, or system being serviced has been properly shut down, isolated, and deenergized.
(f)
Procedures for applying lockout/tags-plus systems.
(1)
The employer shall ensure that only an authorized employee applies a lockout/tags-plus system.
(2)
When using lockout systems, the employer shall ensure that the authorized employee affixes each lock in a manner that will hold the energy-isolating device in a safe or off position.
(3)
When using tags-plus systems, the employer shall ensure that the authorized employee affixes a tag directly to the energy-isolating device that clearly indicates that the removal of the device from a safe or off position is prohibited.
(4)
When the tag cannot be affixed directly to the energy-isolating device the employer shall ensure that the authorized employee locates it as close as safely possible to the device, in a safe and immediately obvious position.
(5)
The employer shall ensure that each energy-isolating device that controls energy to the machinery, equipment, or system is effective in isolating the machinery, equipment, or system from all potentially hazardous energy source(s).
Note to paragraph (f) of this section:
When the Navy ship's force applies the lockout/tags-plus systems or devices, the employer will be in compliance with the requirements in paragraph (f) of this section when the employer's authorized employee verifies the application of the lockout/tags-plus systems or devices.
(g)
Procedures for verification of deenergization and isolation.
(1)
Before servicing machinery, equipment, or a system that has a lockout/tags-plus system, the employer shall ensure that the authorized employee, or the primary authorized employee in a group lockout/tags-plus application, verifies that the machinery, equipment, or system is deenergized and all energy sources isolated.
(2)
The employer shall ensure that the authorized employee, or the primary authorized employee in a group lockout/tags-plus application, continues verifying deenergization and isolation while servicing the machinery, equipment, or system.
(3)
Each authorized employee in a group lockout/tags-plus application who will be servicing the machinery, equipment, or system must be given the option to verify that the machinery, equipment, or system is deenergized and all energy sources isolated, even when verification is performed by the primary authorized employee.
(h)
Procedures for testing.
In each situation in which a lockout/tags-plus system must be removed temporarily and the machinery, equipment, or system restarted to test it or
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to position a component, the employer shall ensure that the authorized employee does the following in sequence:
(1)
Clears tools and materials from the work area;
(2)
Removes nonessential employees from the work area;
(3)
Removes each lockout/tags-plus system in accordance with paragraph (i) of this section;
(4)
Restarts the machinery, equipment, or system and then proceeds with testing or positioning; and
(5)
After completing testing or positioning, deenergizes and shuts down the machinery, equipment, or system and reapplies all lockout/tags-plus systems in accordance with paragraphs (e)-(g) of this section to continue servicing.
Note to paragraph (h) of this section:
When the Navy ship's force serves as the lockout/tags-plus coordinator, performs the testing, and maintains control of the lockout/tags-plus systems or devices during testing, the employer is in compliance with paragraph (h) when the employer's authorized employee acknowledges to the lockout/tags-plus coordinator that the employer's personnel and tools are clear and the machinery, equipment, or system being serviced is ready for testing, and upon completion of the testing, verifies the reapplication of the lockout/tags-plus systems.
(i)
Procedures for removal of lockout and tags-plus systems.
(1)
Before removing any lockout/tags-plus system and restoring the machinery, equipment, or system to use, the employer shall ensure that the authorized employee does the following:
(i)
Notifies all other authorized and affected employees that the lockout/tags-plus system will be removed;
(ii)
Ensures that all employees in the work area have been safely positioned or removed; and
(iii)
Inspects the work area to ensure that nonessential items have been removed and machinery, equipment, or system components are operationally intact.
(2)
The employer shall ensure that each lock or tags-plus system is removed by the authorized employee who applied it.
(3)
When the authorized employee who applied the lockout/tags-plus system is not available to remove it, the employer may direct removal by another authorized employee, provided the employer developed and incorporated into the lockout/tags-plus program the specific procedures and training that address such removal, and demonstrates that the specific procedures used provide a level of employee safety that is at least as effective in protecting employees as removal of the system by the authorized employee who applied it. After meeting these requirements, the employer shall do the following in sequence:
(i)
Verify that the authorized employee who applied the lockout/tags-plus system is not in the facility;
(ii)
Make all reasonable efforts to contact the authorized employee to inform him/her that the lockout/tags-plus system has been removed; and
(iii)
Ensure that the authorized employee who applied the lock or tags-plus system has knowledge of the removal before resuming work on the affected machinery, equipment, or system.
Note to paragraph (i) of this section:
When the Navy ship's force serves as lockout/tags-plus coordinator and removes the lockout/tags-plus systems or devices, the employer is in compliance with the requirements in paragraph (i) of this section when the employer's authorized employee informs the lockout/tags-plus coordinator that the procedures in paragraph (i)(1) of this section have been performed.
(j)
Procedures for startup.
(1)
Before an authorized employee turns on any machinery, equipment, or system after servicing is completed, the employer shall ensure that the authorized employee has knowledge of the source, type, and magnitude of the hazards associated with energization or startup, and the means to control these hazards.
(2)
The employer shall execute an orderly startup to prevent or minimize any additional or increased hazard(s) to employees. The employer shall perform the following tasks before starting up the machinery, equipment, or system:
(i)
Clear tools and materials from the work area;
(ii)
Remove any non-essential employees from the work area; and
(iii)
Start up the machinery, equipment, or system according to the detailed procedures the employer established for that machinery, equipment, or system.
Note to paragraph (j) of this section:
When the Navy ship's force serves as lockout/tags-plus coordinator and maintains control of the lockout/tags-plus systems or devices during startup, and the employer is prohibited from starting up the machinery, equipment, or system, the employer is in compliance with the requirements in paragraph (j) of this section when the employer's authorized employee informs the lockout/tags-plus coordinator the procedures in paragraphs (j)(2)(i) and (j)(2)(ii) of this section have been performed.
(k)
Procedures for group lockout/tags-plus.
When more than one authorized employee services the same machinery, equipment, or system at the same time, the following procedures shall be implemented:
(1)
Primary authorized employee.
The employer shall:
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(i)
Assign responsibility to one primary authorized employee for each group of authorized employees performing servicing on the same machinery, equipment, or system;
(ii)
Ensure that the primary authorized employee determines the safe exposure status of each authorized employee in the group with regard to the lockout/tags-plus system;
(iii)
Ensure that the primary authorized employee obtains approval from the lockout/tags-plus coordinator to apply and remove the lockout/tags-plus system; and
(iv)
Ensure that the primary authorized employee coordinates the servicing operation with the coordinator when required by paragraph (c)(7)(i) of this section.
(2)
Authorized employees.
The employer shall either:
(i)
Have each authorized employee apply a personal lockout/tags-plus system; or
(ii)
Use a procedure that the employer can demonstrate affords each authorized employee a level of protection equivalent to the protection provided by having each authorized employee apply a personal lockout/tags-plus system. Such procedures shall incorporate a means for each authorized employee to have personal control of, and accountability for, his or her protection such as, but not limited to, having each authorized employee:
(A)
Sign a group tag (or a group tag equivalent), attach a personal identification device to a group lockout device, or performs a comparable action before servicing is started; and
(B)
Sign off the group tag (or the group tag equivalent), remove the personal identification device, or perform a comparable action when servicing is finished.
Note to paragraph (k)(2) of this section:
When the Navy ship's force maintains control of the machinery, equipment, or systems on a vessel and prohibits the employer from applying or removing the lockout/tags-plus system or starting up the machinery, equipment, or systems being serviced, the employer is in compliance with the requirements in paragraphs (k)(1)(iii) and (k)(2), provided that the employer ensures that the primary authorized employee takes the following steps in the following order: (1) Before servicing begins and after deenergization, (a) verifies the safe exposure status of each authorized employee, and (b) signs a group tag (or a group tag equivalent) or performs a comparable action; and (2) after servicing is complete and before reenergization, (a) verifies the safe exposure status of each authorized employee, and (b) signs off the group tag (or the group tag equivalent) or performs a comparable action.
(l)
Procedures for multi-employer worksites.
(1)
The host employer shall establish and implement procedures to protect employees from hazardous energy in multi-employer worksites. The procedures shall specify the responsibilities for host and contract employers.
(2)
Host employer responsibilities.
The host employer shall carry out the following responsibilities in multi-employer worksites:
(i)
Inform each contract employer about the content of the host employer's lockout/tags-plus program and procedures;
(ii)
Instruct each contract employer to follow the host employer's lockout/tags-plus program and procedures; and
(iii)
Ensure that the lockout/tags-plus coordinator knows about all servicing operations and communicates with each contract employer who performs servicing or works in an area where servicing is being conducted.
(3)
Contract employer responsibilities.
Each contract employer shall perform the following duties when working in a multi-employer worksite:
(i)