Lockout/Tagout - Energy Control Program

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1 Lockout/Tagout - Energy Control Program Lockout and Tagging of ELECTRICAL Circuits This portion of the K.R. Miller Contractors, Inc. safety program has been created to maintain a written copy of procedures to be followed during work on (or in close proximity to) exposed de-energized parts of conductors, and electrical equipment that may expose any workers to an electrical hazard. The requirements apply to all of K.R. Miller Contractors, Inc. construction job sites. This written procedure includes procedural steps for each one of the following: De-energizing equipment. Application of locks and tags. Verification of de-energized condition. Re-energizing equipment, and electrical circuits. While any worker is exposed to contact with parts of fixed electrical equipment, or electrical circuits which have been de-energized, the circuits energizing the parts will be locked out, and tagged according to the requirements of this written plan. Conductors, and parts of electrical equipment, that have been de-energized but have not been locked out, and tagged, according to these procedures will be treated as energized parts. Additional PPE and worker qualifications must be adhered to in order to work on an energized circuit. (PPE items such as approved insulating gloves, leather outer gloves, flame retardant clothing, face shields, and approved insulating boots, etc.) The requirements must be followed in the order in which they are presented. K.R. Miller Contractors, Inc. maintains this written copy of procedures, and makes it available for inspection by workers and other interested parties. De-energizing Equipment Safe procedures for de-energizing circuits and equipment will be determined before circuits or equipment are de-energized. The electrical circuits and/or equipment to be worked on will be disconnected from all electrical energy sources. Control circuit devices, such as push buttons (circuit breakers), selector switches, and interlocks, may not be Page: 1

2 used as the sole means for de-energizing circuits or equipment. Interlocks for electric equipment may not be used as a substitute for lockout and tagging procedures. Application of Locks and Tags A lock and a tag will be placed on each disconnecting means (e.g a circuit breaker) used to de-energize circuits and equipment on which work is to be performed. The lock will be attached so it prevents all persons (except the affected worker) from removing the disconnecting means. Each tag will contain a statement prohibiting unauthorized operation of the disconnecting means and removal of the tag. Only the affected worker(s) will have a key to the lock. If multiple workers will be working on a de-energized, and locked and tagged circuit, each worker must apply their own lock (in addition to any others) to the circuit disconnecting means. If a lock cannot be applied, and if an affected worker can demonstrate that a tagging procedures will provide a level of safety equivalent to that obtained by the use of a lock, a tag may be used without a lock. (This will require written authorization- when only a tag is used and not a lock) Note: If a tag is used without a lock, the tag will be supplemented by at least one additional safety measure that provides a level of safety equivalent to that obtained by the use of a lock. Examples of additional safety measures include the removal of an isolating circuit element, blocking of a controlling switch, or opening of an extra disconnecting device. A lock may be placed without a tag only under the following conditions: Only one circuit or piece of equipment is de-energized, and The lockout period does not extend beyond the work shift, and Workers exposed to the hazards associated with re-energizing the circuit or equipment are familiar with this procedure. This procedure can only be applied when a physical lock CANNOT be used, and is not a standard operating practice. Page: 2

3 Verification of De-energized Condition The following requirements must be met before any electrical circuits or equipment can be worked upon as de-energized: A qualified person will operate the equipment operating controls or otherwise verify that the equipment cannot be restarted. A qualified person will use test equipment to test the electrical circuit elements and electrical parts of equipment to which workers will be exposed and will verify that the circuit elements and equipment parts are de-energized. The test will also determine if any energized condition exists as a result of inadvertently induced voltage or unrelated voltage back-feed even though specific parts of the circuit have been de-energized and presumed to be safe. If the circuit to be tested is over 600 volts, nominal, the test equipment will be checked for proper operation immediately before and immediately after this test. Re-Energizing Equipment and Electrical Circuits The following requirements will be met, in the order given, before circuits or equipment are re-energized, even temporarily: A qualified person will conduct tests and visual inspections, as necessary, to verify that all tools, electrical jumpers, shorts, grounds, and other such devices have been removed, so that the circuits and equipment can be safely energized. Workers exposed to the hazards associated with re-energizing the circuit or equipment will be warned to stay clear of electrical circuits and equipment. Each lock and tag will be removed by only the worker(s) who applied it. However, if this worker is absent from the workplace, then the lock or tag may be removed by a qualified person designated to perform this task provided that the worker who applied the lock or tag is not available at the workplace, and the worker is made aware that the lock or tag has been removed before he or she resumes work at that workplace. Page: 3

4 Purpose (for maintenance and servicing of equipment) This procedure establishes K.R. Miller Contractors, Inc. requirements for the lockout, and tagout of energy isolating devices whenever maintenance or servicing is done on machines or equipment, in accordance with the requirements of OSHA's It is used to ensure that the machine or equipment is stopped, isolated from all potentially hazardous energy sources and locked out before workers 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. This program applies to all work operations at K.R. Miller Contractors, Inc. where workers must deal with lockout/tagout (LOTO) situations as part of their job duties. Control of Hazardous energy is the purpose of the Lockout- Tagout Program. This program establishes the requirements for isolation of both kinetic and potential electrical, chemical, thermal, hydraulic and pneumatic and gravitational energy prior to equipment repair, adjustment or removal. Reference: OSHA Standard 29 CFR , the control of hazardous energy. Definitions Authorized (Qualified) Workers are the only ones certified to lock and tagout equipment or machinery. Whether an worker is considered to be qualified will depend upon various circumstances in the workplace. It is likely for an individual to be considered "qualified" with regard to certain equipment in the workplace, but "unqualified" as to other equipment. An worker who is undergoing on-the-job training and who, in the course of such training, has demonstrated an ability to perform duties safely at his or her level of training and who is under the direct supervision of a qualified person, is considered to be "qualified" for the performance of those duties. Affected Workers are those workers who operate machinery or equipment upon which lockout or tagging out is required under this program. Training of these individuals will be less stringent in that it will include the purpose and use of the lockout procedures. Other Workers are identified as those that do not fall into the authorized, affected or qualified worker category. Essentially, it will include all other workers. These workers will be provided instruction in what the program is and not to touch any machine or equipment when they see that it has been locked or tagged out. Page: 4

5 Training Lockout/Tagout - Energy Control Program Authorized Workers Training All Maintenance Workers, Department Supervisors and Janitorial workers will be trained to use the Lock and Tag Out Procedures. The training will be conducted by the Maintenance Supervisor or Safety Coordinator at time of initial hire. Retraining shall be held at least annually. The training will consist of the following: 1. Review of General Procedures 2. Review of Specific Procedures for machinery, equipment and processes 3. Location and use of Specific Procedures 4. Procedures when questions arise Affected Worker Training 1. Only trained and authorized Workers will repair, replace or adjust machinery, equipment or processes 2. Affected Workers may not remove Locks, locking devices or tags from machinery, equipment or circuits. 3. Purpose and use of the lockout procedures. Other Worker Training 1. Only trained and authorized Workers will repair, replace or adjust machinery or Equipment. 2. Other Workers may not remove Locks, locking devices or tags from machinery, equipment or circuits Preparation for Lock and Tag Out Procedures A Lockout - Tagout survey has been conducted to locate and identify all energy sources to verify which switches or valves supply energy to machinery and equipment. Dual or redundant controls have been removed. A Tagout Schedule has been developed for each piece of equipment and machinery. This schedule describes the energy sources, location of disconnects, type of disconnect, special hazards and special safety procedures. The schedule will be reviewed each time to ensure workers properly lock and tag out equipment and machinery. If a Tagout Schedule does not exist for a particular piece of equipment, machinery and process, one must be developed prior to conducting a Lockout - Tagout. As repairs and/or renovations of existing electrical systems are made, standardized controls will be used. Page: 5

6 Lockout/Tagout - Energy Control Program Routine Maintenance & Machine Adjustments Lock and Tag Out procedures are not required if equipment must be operating for proper adjustment. This rare exception may be used only by trained and authorized Workers when specific procedures have been developed to safely avoid hazards with proper training. All consideration shall be made to prevent the need for an worker to break the plane of a normally guarded area of the equipment by use of tools and other devices. Locks, Hasps and Tags All Qualified Maintenance Personnel will be assigned a lock with one key, hasp and tag. All locks will be keyed differently, except when a specific individual is issues a series of locks for complex lockout-tagout tasks. In some cases, more than one lock, hasp and tag are needed to completely de-energize equipment and machinery. Additional locks may be checked out from the Department or Maintenance Supervisor on a shift-by-shift basis. All locks and hasps shall be uniquely identifiable to a specific worker. General Lock and Tag Out Procedures Before working on, repairing, adjusting or replacing machinery and equipment, the following procedures will be utilized to place the machinery and equipment in a neutral or zero mechanical state. Preparation for Shutdown. Before authorized or affected workers turn off a machine or piece of equipment, the authorized worker will have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the means to control the energy. Notify all affected Workers that the machinery, equipment or process will be out of service Machine or Equipment Shutdown. The machine or equipment will be turned or shut down using the specific procedures for that specific machine. An orderly shutdown will be utilized to avoid any additional or increased hazards to workers as a result of equipment de-energization. If the machinery, equipment or process is in operation, follow normal stopping procedures (depress stop button, open toggle switch, etc.). Move switch or panel arms to "Off" or "Open" positions and close all valves or other energy isolating devices so that the energy source(s) is disconnected or isolated from the machinery or equipment. Page: 6

7 Lockout/Tagout - Energy Control Program Machine or Equipment Isolation.All energy control devices that are needed to control the energy to the machine or equipment will be physically located and operated in such a manner as to isolate the machine or equipment from the energy source. Lockout or Tagout Device Application. Lockout or tagout devices will be affixed to energy isolating devices by authorized workers. Lockout devices will be affixed in a manner that will hold the energy isolating devices from the "safe" or "off" position. Where tagout devices are used they will be affixed in such a manner that will clearly state that the operation or the movement of energy isolating devices from the "safe" or "off" positions is prohibited. The tagout devices will be attached to the same point a lock would be attached. If the tag cannot be affixed at that point, the tag will be located as close as possible to the device in a position that will be immediately obvious to anyone attempting to operate the device. Lock and tag out all energy devices by use of hasps, chains and valve covers with an assigned individual locks. Stored Energy Following the application of the lockout or tagout devices to the energy isolating devices, all potential or residual energy will be relieved, disconnected, restrained, and otherwise rendered safe. Where the re-accumulation of stored energy to a hazardous energy level is possible, verification of isolation will be continued until the maintenance or servicing is complete. Release stored energy (capacitors, springs, elevated members, rotating fly wheels, and hydraulic/air/gas/steam systems) must be relieved or restrained by grounding, repositioning, blocking and/or bleeding the system. Verification of Isolation Prior to starting work on machines or equipment that have been locked or tagged out, the authorized workers will verify that isolation or deenergization of the machine or equipment have been accomplished. After assuring that no Worker will be placed in danger, test all lock and tag outs by following the normal start up procedures (depress start button, etc.). Caution: After Test, place controls in neutral position. Page: 7

8 Extended Lockout - Tagout Lockout/Tagout - Energy Control Program Should the shift change before the machinery or equipment can be restored to service, the lock and tag out must remain. If the task is reassigned to the next shift, those Workers must lock and tag out before the previous shift may remove their lock and tag. Release from LOCKOUT/TAGOUT Before lockout or tagout devices are removed and the energy restored to the machine or equipment, the following actions will be taken: 1. The work area will be thoroughly inspected to ensure that nonessential items have been removed and that machine or equipment components are operational. 2. The work are will be checked to ensure that all workers have been safely positioned or removed. Before the lockout or tagout devices are removed, the affected workers will be notified that the lockout or tagout devices are being removed. 3. Each lockout or tagout device will be removed from each energy isolating device by the worker who applied the device. LOTO Procedure for Electrical Plug-Type Equipment This procedure covers all Electrical Plug-Type Equipment such as Battery Chargers, some Product Pumps, Office Equipment, Powered Hand Tools, Powered Bench Tools, Lathes, Fans, etc. When working on, repairing, or adjusting the above equipment, the following procedures must be utilized to prevent accidental or sudden startup: 1. Unplug Electrical Equipment from wall socket or in-line socket. 2. Attach "Do Not Operate" Tag and Plug Box & Lock on end of power cord. An exception is granted to not lock & tag the plug is the cord & plug remain in the exclusive control of the Worker working on, adjusting or inspecting the equipment. 3. Test Equipment to assure power source has been removed by depressing the "Start" or On" Switch. 4. Perform required operations. 5. Replace all guards removed. 6. Remove Lock & Plug Box and Tag. Page: 8

9 Lockout/Tagout - Energy Control Program 7. Inspect power cord and socket before plugging equipment into power source. Any defects must be repaired before placing the equipment back in service. NOTE: Occasionally used equipment may be unplugged from power source when not in use. LOTO Procedures Involving More Than One Worker In the preceding SOPs, if more than one Worker is assigned to a task requiring a lock and tag out, each must also place his or her own lock and tag on the energy isolating device(s). Management's Removal of Lock and Tag Out Only the Worker that locks and tags out machinery, equipment or processes may remove his/her lock and tag. However, should the Worker leave the facility before removing his/her lock and tag, the Maintenance Manager may remove the lock and tag. The Maintenance Manager must be assured that all tools have been removed, all guards have been replaced and all Workers are free from any hazard before the lock and tag are removed and the machinery, equipment or process are returned to service. Notification of the worker who placed the lock is required prior to lock removal. Sub-Contractors. Sub-contractors, working on company property and equipment must use this Lockout - Tagout procedure while servicing or maintaining equipment, machinery or processes Machinery and Equipment The machinery and equipment at this company that fall under the Control of Hazardous Energy Standard includes the following: Electrical (See our Electrical Safety Plan) Machinery (All jobsite machinery) Lockout is the preferred method of isolating machines or equipment from energy sources. Tagout is to be performed instead of lockout only when there is no way to lockout a machine. Affected workers are notified when any machine is to be locked out. Page: 9

10 Lockout/Tagout - Energy Control Program All machinery and equipment, that has electrical, steam, hydraulic, tension, gravity, etc., as power sources must follow the shutdown, isolation, blocking and securing procedures for lockout/tagout. When machinery is worked on. either in our shop, yard, or on the jobsite, we must secure and isolate all power sources first. After this is accomplished it is imperative that machinery be properly blocked and cribbed, when workers will be working under equipment, or under hydraulic lifting devices. When this type of work is being performed there shall always be two workers present. All locking and tagging of electrical equipment shall follow the guidelines as established and stated in out electrical safety programs. Periodic Inspection A periodic inspection is done, looking at the energy control procedures performed to ensure that the procedure and requirements of the standard are being followed. This inspection is performed by our Safety Director.. Administrative Duties The Safety Director has the overall responsibility for coordinating safety and health programs in this company. This s the person having overall responsibility for the Lockout/Tagout Program. The Safety Director will review and update the program, as necessary. Copies of the written program may be obtained from the Safety Director, and copies are maintained at the office... Page: 10

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