CONTROL OF HAZARDOUS ENERGY LOCKOUT/TAGOUT PROCEDURES (Revised 8/05) 29CFR1910.147 Purpose Scope This policy establishes the requirements for 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, startup or release of stored energy could occur and cause injury, the authorized person is capable of isolating all energy sources and rendering equipment inoperative. Energy can be electrical, pneumatic, hydraulic, steam vacuum, spring, thermal, chemical, stored or gravity. No matter what the source or sources of energy, all energy sources must be isolated by locking out and/or tagging out and/or blocking out prior to any maintenance, repair, inspection, or like activity can be preformed. This policy outlines the minimum requirements of Millard s Lockout/Tagout Program. The program applies to the control of all energy sources during repair and/or maintenance of machines/equipment. It also applies to any actions that require: (a)(2)(ii)(a) An employee to remove or bypass a guard or other safety device; or (a)(2)(ii)(b) An employee 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 material being processed (point of operation), or where an associated danger zone exists during a machine cycle. (a)(2)(ii)(b) Exceptions: If minor tool changes and adjustments and other minor servicing activities, which take place during normal production operations, provided that the work is performed using alternative measures which provide effective protection. (a)(2)(iii)(a) Work on cord and plug-connected equipment in which start-up is controlled by unplugging the power source and in which the employee performing service has the plug under his or her exclusive control. Definitions Authorized employee; An employee who locks/tags out machines or equipment in order to perform service or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee s duties includes performing service or maintenance covered under this policy - 1 -
Affected employee; An employee whose job requires him/her to operate or use a machine or equipment on which service or maintenance is being performed under lockout and/or tagout, or whose job requires him/her to work in an area in which such service or maintenance is being performed. Protective Materials and Hardware (5)(i) Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, electrical plug caps, valve caps or other hardware shall be provided when needed for isolating, securing or blocking of machines and equipment from energy sources. Lockout or Tagout Devices (5)(c)[A][B][C][D] 1) Only those lockout devices provided by the company shall be used and shall not be used for any other purpose. Authorized employees will be issued locks to perform lockout procedures. The locks must be standardized in color. These locks must be constructed of substantial material to prevent removal without the use of excessive force or unusual techniques and must withstand the environment in which they are applied. 2) Only those tagout devices provided by the company shall be used and shall not be used for any other purpose. Authorized employees will be issued tags to perform lockout/tagout procedures. The tags must be standardized in color. The tags must identify of the applier. If your tag has a place for the date then the date should be provided. These tags, including their means of attachment, shall be substantial enough to prevent inadvertent or accidental removal and must withstand the environment in which they are applied.. 3) The tag s means of attachment shall be of a non-reusable type, attachable by hand, self-locking, and with a minimum unlocking strength of no less then 50 pounds and must withstand the environment in which they are applied. 4) Identifiable. Lockout devices and tagout devices shall indicate the identity of the person applying the device. Enforcement 1) Unauthorized removal As the placement of a lockout/tagout device is the essential part of this program, tampering, removing, altering or disregarding a lockout/tagout device will result in disciplinary action against the involved employee. 2) Authorized Employees The lockout/tagout policies and procedures will be enforced for authorized employees. The failure to follow proper lockout/tagout procedures will result in disciplinary action. - 2 -
Lockout/tagout General Procedures Before any employee performs any servicing or maintenance on a machine or equipment where the unexpected energizing, startup or release of stored energy could occur and cause injury, the machine or equipment shall be isolated from all energy sources and rendered inoperative. Protective materials and hardware such as Locks, tags, electrical plug caps, valve caps, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware shall be used when needed for isolating, securing or blocking of machines and equipment from energy sources. The general lockout procedures apply to all machines and equipment with one energy source. 1) The implementation of the lock is the required method for isolating an energy source when physically possible and shall be affixed in a manner that will hold the energy isolating devices in a safe or off position. 2) Tagout procedures are not to be used except when equipment is not capable of being locked out. In the event the equipment cannot be locked out, tagout procedures must be followed. 3) Only authorized employees shall implement lockout/tagout procedures. 4) When locking/tagging out equipment or machines, use only locks/tags supplied by the company. 5) In general, the following procedures shall be used for the lockout/tagout of machines and equipment: a) The machine or equipment shall be inspected for the type and magnitude of energy, hazards of the energy and control methods. b) Check the area for other employees and inform them that the equipment is to be shut down. c) Shut down the machine or equipment using normal stopping procedures. d) Shut off power source to isolate equipment. e) Lockout/tagout the power source. f) Release any stored energy (release hydraulic and air pressure, lower mechanical devices acting on gravity or block in place, release any spring tension, etc.) - 3 -
g) Using normal operating control(s) for the machine or equipment test the effectiveness of the lock out. Ensure the control(s) are returned to the "off" position after the test. h) Test any electrical equipment on which work is to be performed for any live or stored energy. i) Discharge any stored electrical power (i.e., capacitors) Verification of isolation Prior to beginning work on a machine or equipment that has been locked out or tagged out, the authorized employee will verify that isolation or de-energized of the machine or equipment has been accomplished. 6) In general, the following procedures shall be used for removal of lockout/tagout devices on machinery or equipment: a) Inspect the area for non-essential items, tools, etc., and ensure that all components are intact. b) Check that all employees are safely positioned and are notified that equipment or machine is being restarted. c) A lockout/tagout device may be removed only by the employee that originally applied it. d) In the event equipment must be tested or otherwise activated while work is being performed, removal procedures shall be followed. Lockout/tagout procedures shall be reinstated before continuation of service or maintenance. Verification of re-energization Only authorized employees will conduct tests and visual inspections, as necessary. Authorized employees will ensure that all lockout/tagout devices have been removed and equipment can be safely energized. Affected employees exposed to hazards associated with re-energizing the equipment will be warned to stay clear of the area. 7) Emergency Lock/tag Removal If the authorized employee that applied the lockout/tagout device is not available to remove it, it may be removed by the Plant Manager, the Plant Engineer or Assistant Engineer only AFTER completing the following: a) Ensure all repairs have been completed. - 4 -
b) Verify that the employee who applied the lockout/tagout device is not still on the premises. c) A reasonable effort has been made to contact the employee who applied the lockout/tagout device for removal. d) Steps are taken to ensure that the authorized employee who applied the lockout/tagout device is notified that the device has been removed before he or she returns to work. e) If any of the above (a, b, c or d) cannot be accomplished, removal of the device is prohibited except by the authorized employee who applied the lockout/tagout device. 8) Group Lockout/Tagout a) If more than one crew or department is involved in the lockout/tagout, each authorized employee from each crew or department is to attach a lock/tag to a group lockout device. b) Each authorized employee shall follow all of the preceding steps in application and/or removal of any lockout/tagout device. 9) Shift Change a) The authorized employee going off duty will inform the authorized employee coming on duty or the shift supervisor of any lockout/tagout devices that were left in place and the reason why. b) The authorized employee or shift superintendent coming on duty will notify all affected employees of any machine or equipment with a lockout device. c) The authorized employee coming on duty will place his assigned lockout/tagout device on the machinery or equipment before the authorized employee going off duty removes his device if work is going to continue. 10) Outside contractors a) Whenever outside service personnel are engaged in an activity covered by this procedure, the plant engineer or assistant engineer and the contractor shall inform each other of their respective lockout/tagout procedures. - 5 -
b) This review will be communicated to all onsite employees involved. Compliance with outside contractors will be enforced. If an outside contractor has no procedure or after review of the Plant Engineer shows their procedures to be lacking then these policies and procedures will be enforced. c) The Plant Engineer is to ensure his employees understand the lockout/tagout procedures of outside contractors. Specific Lockout/tagout Procedures Specific lockout/tagout procedures must be developed for all machines and equipment with multiple energy sources. Each location must use the provided Specific Energy Control Procedure form or similar documentation for developing the specific lockout procedures for all machines and equipment. All developed specific lockout procedures shall be place at the end of this policy and procedure and an index listing all equipment with specific procedures must be provided. TAGOUT PROCEDURES Tagout procedures are to be used only if the machine or equipment is not capable of being locked out. 1) Employees shall be informed of the following: a) Tags are warning devices only and will not prevent activation of machine or equipment. b) Tags are not to be removed, bypassed, etc., except by the authorized person who attached the tag. c) Tags must have warnings that are legible and easy to understand (i.e., DO NOT START, DO NOT OPERATE, etc.). Information on the tag must be specific for the work and equipment involved and must contain the name of the authorized employee who attached the tag. d) Only authorized tags are to be used. e) Tags are to be securely attached to energy isolating devices using a nylon cable tie or its equivalent. f) Where a tag cannot be affixed directly to the energy isolating devices, the tag shall be located as close as is safely possible to the device in a position that will be immediately obvious to anyone trying to operate the machine or equipment. - 6 -
ANNUAL INSPECTIONS 1) An annual inspection shall be conducted of the lockout/tagout procedures by an authorized employee not utilizing the procedure. For example, the Plant Engineer will review the lockout/tagout procedure for forklifts that his assistants follow. His assistant will review the lockout/tagout procedure for ammonia equipment that the Plant Engineer will follow. A record of these inspections shall be maintained in the lockout/tagout section of the safety manual. 2) This inspection shall include the following information: a) Identification of the machine or equipment on which the energy control procedures are utilized. b) The date of the inspection. c) Employees included in the inspection. d) Name of person performing the inspection. e) A review between the inspector and authorized employee of his/her responsibilities under the energy control procedure being inspected. 3) Each step of this energy control procedure shall be checked for compliance. 4) Any deviation noted shall require retraining of all authorized employees. TRAINING 1) All authorized employees shall receive initial training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available and the control procedures, including both lockout and tagout procedures. 2) Affected employees exposed in the area where energy controls may be utilized shall be instructed about the procedure and the prohibition of attempts to restart or re-energize locked out or tagged out controls. 3) Retraining shall be provided when there is: a) A change in job assignment. b) A change in machines, equipment or processes that presents a new hazard. - 7 -
c) A change in energy control procedures. d) A deviation from the energy control procedure revealed by a periodic inspection. e) A reason to believe that there is an inadequacy in an employee's knowledge of the energy control program. Training Comments: All persons that will be required to perform any service or maintenance on a machine or equipment must understand the lockout/tagout procedures, complete the attached test, signs the program review form and have a certification audit completed on them before they can be authorized to implement the lockout/tagout procedures. For completed OSHA requirements pertaining to lockout/tagout see the OSHA s web site at www.osha.gov click on standards click on general industry click on 1910.147 for all requirements of lockout/tagout (the control of hazardous energy). - 8 -
Initial/Annual Lockout/Tagout Audit Certification for Authorized Employees Auditor: Date: Person Audited: The Machine/Equipment Audited: This audit certifies that the Auditor has administered a detailed audit on the specific Lockout/Tagout procedure applied by the person being audited. The auditor did check the accuracy and the completeness of the applied procedure. The Engineer and authorized maintenance personnel must be audited. This audit must be completed initially (before being identified as an authorized employee) and then completed annual. Passed: Failed: Failed Audits: If the specific procedure was not properly implemented, then list the corrective actions taken below. Re-training and a new audit must be performed before the failed person can resume the authorized status and they must demonstrate their knowledge of the Lockout/Tagout requirements. Re-Audit Date: Corrective Actions: The completed audit forms must be placed in the LO/TO section of the Safety Manual. Blank copies of the audit forms must also be kept in the LO/TO section of the Safety Manual for future use with new employees.. - 9 -
Program Review Lockout/Tagout Program (LO/TO): The Engineer has conducted the necessary training to ensure all authorized employees clearly understand Millard s LO/TO requirements. A copy of this Program Review form, the LO/TO test and the annual audit certification must be placed in the Lockout/Tagout section of the safety manual. Reference resource: The LO/TO program located in the safety manual. Name of Authorized Employee Department Date - 10 -
Lockout/Tagout Program (LO/TO) Test Instructions: Circle the correct answers. To be an authorized worker you must complete this test. A copy of each completed and graded test shall be kept in the LO/TO section of the Safety Manual. 1) An Authorized Employee is a person that has been trained to implements a lockout / tagout procedure on machines or equipment to perform service or maintenance? 2) Energy can be electrical, pneumatic, hydraulic, steam vacuum, spring, thermal, chemical or gravity. No matter what the source or sources of energy, all must be isolated by locking and/or tagging out of service prior to any maintenance, repair, or like activity can be conducted? 3) LO/TO procedures are developed to ensure that an authorized person is capable of isolating all potentially hazardous energy where unexpected energizing, start up, or release of stored energy could cause injury. 4) Lockout devices and tagout devices shall indicate the identity of the person applying the devices? 5) Lockout devices and tagout devices are supplied by the company and shall not be used for any other purpose? 6) If more than one person, crew or department is involved in the lockout/tagout, each authorized employee or authorized person from each crew or department is to attach a lock/tag to a group lockout device. 7) The authorized employee going off duty will inform the authorized employee coming on duty of any lockout/tagout devices that were left in place and the reason why? 8) All equipment or machinery that is equipped with multiple energy sources is required to have written specific lockout/tagout procedure developed? 9) A master list of all equipment or machinery with written specific lockout/tagout procedures is required to be maintained with the written specific procedures? 10) An annual LO/TO audit must be completed on all authorized persons and a copy of this audit must be kept in the LO/TO section of the Safety Manual? 11) A list of all authorized persons must be maintained and the list must be maintained in the LO/TO section of the Safety Manual? - 11 -
12) Verification of isolation is required for all energy sources for the machine or equipment being locked out of service? 13) If service work is continuing the authorized employee coming on duty will place his assigned lockout/tagout device on the machinery or equipment before the authorized employee going off duty removes his device if work is continuing? 14) To be an authorized person, you must receive initial training in the lockout/tagout procedures, able to recognize the applicable hazardous energy sources and must understand the lockout/tagout requirements for isolating each energy source, complete the attached test, signs the program review form and have a certification audit completed. 15) Emergency lock/tag removal is allowed only by the General Manager, Plant Engineer and assistant Engineer and only after the required four verification steps are completed? Employee: Date: Comments: - 12 -
Specific Energy Control Procedure The following energy control procedure shall be used for the equipment listed below Date Written: Authors: Reviewing Personnel: Revision Dates: Review Date: Machine/equipment Description: General Description: Manufacturer: Model: Department/Location: Serial Number: Controls: The following controls, including start/stop buttons. toggle switches, emergency stop buttons, shut-off valves, etc. have been identified for this equipment. Description of control Location of control Energy Types: Electrical Hydraulic Stored energy Gravity Pneumatic Steam Chemical Thermal Sources/Devices Type of (and magnitude) Location lock/tag needed Employees involved with servicing, maintenance, shut down and starting this equipment. Authorized Employee 1) 2) 3) - 13 -
Shutdown Procedures: The steps listed below must be followed to properly shut down and deenergize this machine or equipment. Lockout/Tagout Procedure Device used How to Verify Notify Affected/other employees of impending Shutdown. Release and Restart Procedures: The steps listed below must be followed to properly release this machine or equipment from a lockout And/or Tagout condition and restart it. Procedure Location Inspect work area and remove tools and other non-essential items Inspect machine/equipment and components to make sure it is intact and ready to run Notify affected/other employees in the area of pending restart and make sure they are safety positioned away from the machine/equipment - 14 -
Example ONLY Specific Energy Control Procedure Example Only The following energy control procedure shall be used for the machine or equipment listed below Date Written: 07/02/02 Revision Dates: Authors: John The Engineer Reviewing Personnel: Jim The Maintenance Man Review Date: 07/05/02 Machine/equipment Description: General Description: Air Compressor Manufacturer: AMP Air Compress Model: 021-0024 Serial Number: 362029 Department/Location: East Sprinkler Room Controls: The following controls, including start/stop buttons. toggle switches, emergency stop buttons, shut-off valves, etc. have been identified for this equipment. Description of control Location of control Main electrical disconnect Box marked East wall behind riser # 1 Machine electrical disconnect Switch ON/OFF On left side of compressor Air release valve on storage tank Top tank @ gauge Air line supply control valve Left side of tank Energy Types: X Electrical Hydraulic Stored energy X Pneumatic Steam Chemical Thermal Gravity Sources/Devices Type of (and magnitude) Location lock/tag needed Main electrical disconnect circuit marked East wall- behind riser # 1 Lockout/Tagout Machine electrical disconnect Switch On/Off On left side compressor None Air line supply control valve Left side of tank Visual Air storage tank release valve Front-top tank None Employees involved with servicing, maintenance, shut down and starting this equipment. Authorized Employee 1) Engineering 2) Maintenance - 15 -
Shutdown Procedures: The steps listed below must be followed to properly shut down and deenergize this machine or equipment. Lockout/Tagout Procedure Device used How to Verify Notify Affected/other employees of impending Shutdown. Switch OFF the main electrical disconnect Lo/to Try to activate compressor Box marked motor by removing air Switch the machine electrical disconnect in the None None OFF position Keep the airline control valve in the open position None Valve/hose in alignment Open the air release valve on top right storage tank None Ensure all air is Removed from system. Gage must read O pressure. Release and Restart Procedures: The steps listed below must be followed to properly release this machine or equipment from a lockout And/or Tagout condition and restart it. Procedure Location Inspect work area and remove tools and other non-essential items Inspect machine/equipment and components to make sure it is intact and ready to run Notify affected/other employees in the area of pending restart and make sure they are safely positioned away from the machine/equipment Ensure the air supply line control valve in the Open position Left side of tank Ensure the air release valve for the storage tank is closed front- top tank Switch ON machine electrical disconnect On west side of compressor Remove lockout/tagout from main electrical disconnect, switch ON East wall-behind riser # 1-16 -
Lockout/Tagout Master Equipment List All machines and equipment requiring specific lockout/tagout procedures must be listed below. Specific procedures are required for all machines and equipment that has multiple energy sources List of equipment Location 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) - 17 -