0 Appendix C OCCUPATIONAL SAFETY AND HEALTH PROGRAM LOCKOUT/TAGOUT PROGRAM
Hazardous Energy Control Lockout/Tagout Program TABLE OF CONTENTS Section Page I. Purpose and Scope. 1 II. Definitions 1 III. Responsibility 2 IV. Application 3 V. Lockout/Tagout Hardware Requirements 3 VI. Lockout/Tagout Procedure 4 VII. Outside Personnel (Contractors, Etc.) 6 VIII. Group Lockout/Tagout 6 IX. Shift or Personnel Changes 6. X. Annual Inspection 6 XI. Training/Retraining 6 XII. Record Keeping 7 Attachment A: Equipment Specific Lockout/Tagout Procedure (form) 8 Attachment B: Lockout/Tagout Inspection 9 Attachment C: Use and Control of Locks 10 Appendix C 1
I. PURPOSE AND SCOPE HAZARDOUS ENERGY CONTROL LOCKOUT/TAGOUT PROGRAM The Purpose of the program is to prevent or minimize the potential for injury during service or maintenance activities on machinery, equipment and circuits. The risk of injury is reduced by the application of locks and/or danger tags; which prevents the unexpected release of operating or stored energy. The need for the program at High Schools has been determined as a result of a hazard assessment. II. DEFINITIONS Affected employee: An employee whose job requires him/her to operate or use machine/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 and Authorized employee when that employee s duties include performing servicing or maintenance covered under this section. Capable of being locked out: An energy-isolating device is capable of being locked out if it has a hasp or other means of attachment to which, or through which, a lock can be affixed, or it has locking mechanism built into it. Other energy isolating devices are capable of being locked out, if lockout can be achieved without the need to dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy control capability. Energized: Connected to an energy source or containing residual or stored energy. Energy isolating device: A mechanical d3evice that physically prevents the transmission or release of energy, including but not limited to the following: A manually operated electrical circuit breaker, a disconnect switch, a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors and, in addition, no pole cab be operated independently; a line valve; a block; and any similar device used to block or isolate energy. Push buttons, selector switches and other control circuit type devices are not energy isolating devices. Energy source: Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal or other energy. Lockout: The placement of a lockout device on an energy-isolating device, in accordance with an established procedure, ensuring that the energy iso9lating device and the equipment being controlled cannot be operated until the lockout device is removed. Lockout device: A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of an machine or equipment included are blank flanges and bolted slip blinds. Appendix C - 1
Normal production operation: The utilization of a machine or equipment to perform its intended production function. Servicing and/or maintenance: Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or unjamming of machines or equipment and making adjustments or tool changes, where the employee bay is exposed to the unexpected energization or startup of the equipment or release of hazardous energy. Setting up: Any work performed to prepare a machine or equipment to perform its normal production operation. Tagout: The placement of a Tagout device on an energy-isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the Tagout device is removed. Tagout device: A prominent warning device, such as a tag and means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the Tagout device is removed. III. RESPONSIBILITY 1) Employees shall be instructed in the significance of the lockout/tagout program and how to apply procedures outlined therein. Training shall be conducted by: Name: (Insert name of Safety Trainer) Position: (Insert Safety Trainer) 2) The respective Supervisor responsible for the operation and the use of affected equipment shall ensure only Qualified employees are authorized to lockout or Tagout machinery or equipment. Authorized employees shall be identified on the Use and Control of Locks form (Attachment C). 3) Support personnel, such as custodial staff and service personnel, performing duties in the immediate area of the equipment shall be informed of the lockout/tagout program and the necessary precautions to observe while in the area. 4) The following Supervisors shall be responsible for approving the equipment specific lockout/tagout procedure. They shall also ensure that employees are trained in their area of control. Name Title Shop/Function Appendix C 2
IV. APPLICATION 1) Employees performing service and/or maintenance on equipment/machines are subject to lockout/tagout when any of the following conditions occur: a. The employee must remove or bypass a machine guard or other safety device, resulting in exposure to hazards at the point of operation (operating area); or b. The employee is required to place any part of his/her body in contact with the point of operation of the machine or piece of equipment; or c. The employee is required to place any part of his/her body in any danger zone associated with the equipment or machine operating cycle; or d. The employee would directly contact energized equipment or circuit parts with any part of his/her body or indirectly through some other conductive object; or e. When installing and/or repairing electrical circuits, power transmission equipment or high-pressure lines where the means of disconnect are not in view and in the immediate vicinity of the employee performing work 2) Tags are to be affixed to energy isolating devices for warning and information regardless of whether a lock is used or not. Tags are essentially warning devices and do not provide the physical restraint on energy isolating devices that is provided by a lock. a. A tagout system shall be used only if the energy-isolating device cannot be locked out b. When machinery or equipment lacking an energy-isolating device undergoes major repair, renovation or modification, an energy-isolating device that can be locked out shall be installed. 3) The affected Supervisor shall maintain a list of employees authorized to perform lockout/tagout. The list shall indicate each employee s assigned color-coded padlock along with his/her signature (Attachment C). 4) These exceptions apply to lockout/tagout: a. Lockout/tagout is not required where employees perform minor tool changes, adjustments or troubleshooting which take place during normal production operations if they are routine repetitive and integral to the use of the equipment b. Certain service and/or maintenance operations must be performed with the power on. Supervisors shall ensure that only Qualified employees perform operation where a power on condition is essential. Examples are: 1. Making fine adjustments to the equipment, such as centering the belt on a conveyor; or 2. Certain aspects of troubleshooting, requiring the person to correctly identify the source of the problem and then to check to ensure the defect is corrected. 5) Energized equipment or circuit parts that operate at less than 50 volts to grounded need not be de-energized if there will be no increased exposure to electrical burns or to explosion due to electric arcs. V. LOCKOUT/TAGOUT HARDWARE REQUIREMENTS The affected Supervisor shall ensure that the hardware used meet the following requirements: 1) Lockout locks can have a key or combination, but they cannot be a lock that is used for any purpose other than lockout. Tagout uses special tags that warn people of the danger of starting up the machine. These tags shall not be used for any other purpose. Appendix C 3
2) Locks and tags must be standardized b color, shape, size, print, and format througho0ut the facility. 3) Locks and tags must be durable enough to withstand environmental conditions (i.e., heat, cold, humidity, or corrosiveness) in the area where they are used, for as long as needed and still be effective and/or legible. 4) Locks must be strong enough so they cannot be removed without heavy force or special tools like bolt cutters. 5) Tags shall be attached by hand with a non-reusable, self-locking apparatus (i.e., nylon cable which cannot be released with less than 50 pounds of strength. 6) Locks and tags must show the identity of the Authorized employee who installs and removes it. Only Authorized employees or the onsite Supervisor can perform lockout or tagout procedures or remove locks or tags. 7) Tagout devices shall catch the employee s attention with warnings such as: Do not Start or Do not Open or Do not Operate. 8) Tags must be legible and understandable by all employees. VI. LOCKOUT/TAGOUT PROCEDURE A lockout or tagout device must be affixed to each energy isolating device anytime it is necessary to shut down identified equipment for servicing or maintenance. Only Authorized employees are permitted to perform lockout procedures. These steps shall be completed in the following sequence: 1) Prepare for shutdown. a. Review the Equipment Specific Lockout/Tagout Procedure (ESLP) for the equipment to be locked out and/or tagged out a) Determine what types(s) of energy the machine uses, (e.g., electrical, pneumatic, chemical, mechanical, hydraulic, thermal, U.V. or electromagnetic) b) Identify all potential hazards, (e.g. shock, burn, fire, mechanical pinch points, moving parts, crush, laceration, flying debris, impalement, or corrosive toxic, reactive chemicals) b. Review the Affected employees list on the ESLP and take necessary steps to relay information about the impending lockout/tagout. Let them know that a piece of equipment is being locked or tagged and why c. Locate all switches, valves, or other devices that control energy and need to be locked out, (e.g., main switch, plug, fuse, valve, flange plate, or circuit breaker). It is important that all power sources be de-energized. Pulling a fuse is no guarantee that the circuit is dead and should never be substituted for locking out. There is no certain that someone might not replace the fuse d. When pulling a main switch, check to be sure that is not under load. To be extra safe, stand to the right of the switch, never in front and pull the lever with your left hand. A switch under high voltage load could arc or cause an explosion when the lever is pulled 2) Locate and isolate all energy sources and energy isolating devices. a. Shut down by normal stopping procedures b. Operate the switch, valve or other isolating devices so that the equipment is isolated from its energy source. (Example: move the circuit breaker to the off position). All stored energy must be released or restrained by methods, such as blocking, bleeding down or repositioning. Be sure there is nothing left to move a machine part Appendix C - 4
c. Attempt to restart with normal switch to make certain the equipment will not operate. Be sure no one is close enough to get hurt. Put all controls in the on position. Make sure the power does not go on and the equipment will not operate. Put operating controls back in the off or safe position 3) Use of Lock and/or Tag a. Apply the lockout or tagout device- applied only by Authorized emplo0yees, use the lock and/or tag assigned to the individual performing the lockout. (Do not use locks or tags, which have been assigned to other employees) 1. Lockout devices must be placed in a manner so that they will hold the energyisolating device in a safe or off position. 2. When a lock is affixed to a lockout device, a tag will be attached to the lock identifying who attached the lock and the reason for locking out the equipment. 3. If tagout devices are used, they must clearly indicate that the operation or movement of the energy-isolating device from the safe or off position is prohibited. b. Verify that non potential energy fan be released. Test circuits and electrical parts of equipment with proper test equipment to be sure they are de-energized. This step will ensure that equipment with capacitors that have stored electrical energy will be discharged to ground to assure zero energy c. The equipment is now locked out, proceed with service or repair d. During repair it is sometimes necessary to return power and operate equipment momentarily. When this occurs, follow the lockout removal and restoring procedures each time equipment must be energized. 4) Restoring Equipment to normal use. a. Remove tools and any non-essential items. Check that equipment/machine components are intact and capable of operating properly b. Make sure all employees are a safe distance from equipment/machine. c. Reinstall any machine guards d. Remove lockout device(s). Only the same Authorized employee who installed the lock may remove it. (See special circumstances below) e. Notify Affected employees that lockout devices have been removed before starting equipment or machines f. Restore energy and operate equipment to check quality of service and the safe operation Special Circumstances: When maintenance or service is done, only the same Authorized employee who installed the lock or tag may remove it. If the employee that locked out the equipment is not available and it becomes necessary to remove a lock from locked out equipment, the onsite Supervisor shall be contacted for instructions on removing the lock. The affect Supervisor shall provide and follow the specific procedures outlander in this lockout/tagout program. In addition, the Supervisor shall: a. Verify that the Authorized employee who applied the lockout or tagout device is not at the facility; b. Make all reasonable efforts to notify the Authorized employee that his/her lockout or tagout device has been removed c. Ensure that the Authorized employee has this knowledge before he/she resumes work at that facility Appendix C - 5
VII. OUTSIDE PERSONNEL (CONTRACTORS, ETC.) Contracted or outside service personnel shall submit to the Site Administrator/Principal a copy of their energy control procedures. Supervisors shall ensure outside service personnel performing work I areas where lockout activities take place are familiar with these procedures. VIII. GROUP LOCKOUT/TAGOUT Group lockout/tagout occurs when two or more employees are assigned to perform service or repair on the same equipment at the same time. When an employee fines that a machine or process is presently locked out by another employee, he shall: 1) Inform his Supervisor of the situation. The Supervisor shall monitor and control the group lockout until the process is complete. 2) Affix his/her personal lock or tag to the equipment along with the one, which should be presently attached. 3) \Each employee will remove their own lock or tag when their part of the operation is over and inform the Supervisor who is monitoring the job. Be sure to never remove another employee s lock or gag. 4) The Supervisor will complete the restoring operation or assign the last employee working to perform the restoring operation. IX. SHIFT OR PERSONNEL CHANGES During shift or job assignment changes, employees will remove or apply lockout/tagout devices as appropriate. This will ensure the continuity of lockout/tagout protection until the necessary service or maintenance work is complete. X. ANNUAL INSPECITION 1) The Supervisor shall conduct an annual inspection of the energy control procedure to ensure that the steps outlined in this program are being followed. Any deviations from this program that the Supervisor notes shall be corrected. 2) The Supervisor shall document that the annual inspection was performed (Attachment B). Information shall include: a. The machine or equipment on which the energy controls procedure was done b. The date of inspection c. The employees included in the inspection; and d. The person performing the inspection XI. TRAINING/RETRAINING 1) Training a. All employees authorized to perform lockout/tagout shall be trained by the appropriate Supervisor identified in Section III D. Training shall consist of the following: 1. Understanding why lockout/tagout is important 2. How lockout/tagout procedures work 3. The importance of not attempting to repair or service machinery without going through the proper procedures for lockout/tagout 4. Recognition of hazardous energy sources 5. Understanding the types of energy that may be encountered in the workplace 6. The methods and devices required for proper control of energy sources Appendix C 6
b. The Supervisor shall train all other employees: 1. To be familiar with lockout/tagout procedures 2. To know the importance of never trying to restart machines or equipment which are locked out or tagged out 3. To know that tags or locks should never be passed, ignored, or removed 2) Retraining The Supervisor shall retrain employees on the lockout/tagout program when any of the following occur: 1. Annually 2. When there is a change in the employee s job 3. When there is a change in machines, equipment or processes that present a new hazard 4. When there is a change in the energy control procedures; or 5. When deficiencies in the employee s knowledge and performance of lockout/tagout are noted upon periodic inspection (Section X). XII. RECORD KEEPING The Supervisor shall keep records of: 1) Employee training in the lockout/tagout program. The record shall include the employee s name and date of training. 2) The written Equipment Specific Lockout/Tagout Procedure (ESLP) for a particular piece of equipment (Attachment A). The Supervisor need not develop an ESLP for a machine when all of the following elements exist: a. Machine has no potential for stored energy release after shut down b. Machine has a single energy source that can be isolated c. The isolation and lockout of that single energy source will complete de-energize it d. That single energy source is isolated and looked out during repair or maintenance e. A single lockout device achieves a locked out condition f. The single lockout device is under the exclusive control of the Authorized employee performing repair or maintenance g. The repair or maintenance does not create hazards for other employees; and h. There have been no accidents associated with an unexpected release of energy during the repair or maintenance of that machine when it was de-energized. 3) The Supervisor shall maintain a file of all annual inspection s performed at the site (Attachment B). 4) The Supervisor shall maintain a list of employees authorized to perform lockout/tagout. The list shall indicate each employee s assigned color-coded padlock along with his/her signature (Attachment C). Appendix C - 7
ATTACHMENT A: EQUIPMENT SPECIFIC LOCKOUT/TAGOUT PROCEDURE FORM EQUIPMENT SPECIFIC LOCKOUT/TAGOUT PROCEDURE Department Work Area Description (Equipment/Machine/Process Equipment/Machine Process Date Energy Sources (type/magnitude) Energy Isolation Devices No. Device Location Lockout/Tagout Means Comments Locked Tagged Stored/Residual Energy List of Affected Employees & Any Comments Completed By: Date: Approved By: Date: Appendix C 8
ATTACHMENT B: LOCKOUT / TAGOUT INSPECTION FROM Facility: LOCKOUT / TAGOUT INSPECTION Location: DATE: Person Performing Inspection: Lockout/Tagout Observed Machine Employees Included in Inspection Findings DEVIATIONS OR INADEQUACIES OBSERVED: RECOMMENDATIONS: CORRECTIVE ACTION TAKEN: REVIEWED BY: DATE: CORRECTIVE ACTION BY: DATE: Appendix C 9
ATTACHMENT C: USE & CONTROL OF LOCKS All repair and maintenance off the site s machines or equipment will be conducted under the supervision of: (insert responsible supervisor s name) Machines or equipment will be locked out and/or tagged out as needed during repair or maintenance as outlined under the Hazardous Energy Control Lockout/Tagout Program. Color-coded locks are assigned to following employees authorized to perform lockout/tagout: Table 1: Assignment of Locks NAME LOCK COLOR SIGNATURE Appendix C - 10