Lock Out - Tag Out Safety Program Daniel Schmid 4-22-15 Pam Schmid 4-22-15 Dan Schmid Pam Schmid Safety Director Quality Director
Table of Contents DOCUMENT REVISION TABLE... 3 PURPOSE... 4 RESPONSIBILITY... 4 GENERAL LOCKOUT TAGOUT PROCEDURES... 4 EMPLOYEE CLASSIFICATIONS... 4 PROTECTIVE MATERIAL AND HARDWARE... 5 LOCKOUT PROCEDURES... 6 RELEASE FROM LOCKOUT/TAGOUT... 7 UNLOCKING PROCEDURE... 7 TAGOUT PROCEDURES... 8 SHIFT OR PERSONNEL CHANGES... 8 MULTIPLE LOCK-OUT... 8 NEW EQUIPMENT/EXISTING EQUIPMENT... 9 SPECIFIC EQUIPMENT LOCKOUT/TAGOUT PROCEDURES... 9 TRAINING... 9 ACCOUNTABILITY... 10 OUTSIDE PERSONNEL (CONTRACTORS), ETC.)... 11 ADDITIONAL INFORMATION... 11 APPENDIX A... 11
DOCUMENT REVISION TABLE Revision Date Description of Change A 12/30/04 Initial release B 03/06/07 C 11/11/09 D 01/18/13 Review and update by Safety Director E 09/27/2013 Convert from Ritalka Document to Ritalka F 4-22-15 Minor wording edits
PURPOSE This lockout/tag-out procedure has been established to prevent injury to employees or damage to equipment from unexpected start up or a release of stored energy while employee s service or maintain equipment or machinery. This program shall establish procedures for employees to use before performing such tasks as adjusting, cleaning, repairing, inspecting, or installing equipment and machinery. RESPONSIBILITY The Safety Director or their designee will be responsible for the implementation of the Lockout Tagout Tryout procedures to be used. All employees shall be instructed in the safety importance of the Lockout TagOut procedures to be used. Employees will be retrained whenever there is a change in processes or equipment, which may present a new hazard to the employee. The Safety Director will perform periodic inspections of the procedures at least annually as required by the OSHA standard. The periodic inspections will be performed according to the guidelines in Appendix A of this procedure. GENERAL LOCKOUT TAGOUT PROCEDURES All equipment shall be locked and/or tagged out to protect against accidental or inadvertent operation when such operation could cause injury to personnel or damage to equipment. No attempts are to be made to operate any switch, valve, or other energy-isolating device where it is locked and/or tagged. A tag will accompany a lockout device at all times. If it is not physically possible to lockout the equipment, then the tag-out procedure must be implemented. Tag-out devices are also utilized on low energy sources, such as water. A lockout device may consist of the following: locks; chains; wedges; key block; adapter pins; self-locking fasteners; blocks; blanks; etc. used for reducing energy to its lowest state. EMPLOYEE CLASSIFICATIONS Authorized Employees: Only authorized employees may perform physical lockout of equipment. An authorized employee has had the proper training and is the one who actually performs the lockout of the equipment.
Affected Employees: An affected employee is an employee whose job requires him/her to operate or use a machine or equipment in which the Lockout Tag-out is being conducted by an authorized employee. An affected employee is also someone whose job requires him/her to work in an area in which the Lockout Tag-out is being conducted. Other Employees: Other employees whose work operations are or may be in an area where energy control procedures may be utilized shall be instructed about the procedures and about the prohibition relation to attempts to restart or reenergize machine or equipment which are locked out or tagged out. Qualified Employees: Qualified employees are those whose work on energized equipment which involve either direct contact or indirect contact by means of tools or materials. Only qualified persons may work on electrical circuit parts or equipment that have not been de-energized. Such persons shall be capable of working safely on energized circuit and shall be familiar with the proper use of special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools. Qualified employees must be familiar with the construction and operation of the equipment and the hazards involved. If work is needed on electrical power lines, high voltage sources, or any other electrical source over 50 volts, contact should be made with the Power Company or an outside electrical contractor. Employees at Ritalka, Inc may be considered qualified if he/she attends certified training classes to become qualified to work on electrical equipment (Refer to training requirements) Unqualified Employees: Unqualified employees are those employees who have not had training in avoiding the electrical hazards of working on or near exposed energy parts. For purpose of this program, many employees of Ritalka, Inc are considered to be designated Unqualified. People designated as unqualified are still required to receive training on the provisions of 29 CFR 1910.331 -.335, Electrical Safety Standards. PROTECTIVE MATERIAL AND HARDWARE Ritalka, Inc will provide to all employees all the necessary protective materials and hardware needed to effectively isolate, secure, and/or block all machinery and equipment from energy sources. Ritalka, Inc uses a Master lock as a Lockout Device. Other equipment supplied includes: Lockout tags, Hasps and Plug Lockouts. Tag-out devices including their means of attachment, must be substantial enough to prevent inadvertent or accidental removal. The tag-out device attachment means shall be of a self-locking and non-releasable type with a minimum locking strength of 50 pounds or more.
LOCKOUT PROCEDURES Prior to attempting to lockout or tag-out a device, each employee involved in the process whether they are authorized, affected, other, qualified or unqualified must receive training regarding the lockout/tag-out standard and the electrical safety standard. Only Authorized Employees shall perform a lockout or a tag-out procedure. Only Qualified Employees shall perform a lockout or a tag-out procedure for work on exposed live electrical equipment. 1. Employees must first review the specific Lockout Tagout also referred to as Hazardous Energy Control Procedure prior to attempting any work on a piece of equipment. 2. Physically locate and identify all isolating devices to be certain which switches, valves, or other energy isolating devices apply to the equipment to be shut down. (Note-more than one energy source may be involved) 3. Physically locate all energy isolating devices needed to control the energy to the machine or equipment and establish where the lock(s) are to be installed: a. Electrical Disconnects b. Control Panel Boards c. Valves (air, hydraulic, gas, steam, vacuum and water) d. Suspended loads (suspended loads must be supported and potential loads must be removed) e. Stored Energy The electrical circuits and equipment to be worked on must be disconnected from all electric energy sources. Control devices (e.g. push buttons, selector switches and interlocks) may not be used as the sole means of de-energizing circuits. All lockout devices must have a DANGER DO NOT OPERATE tag affixed identifying the employee who applied the lockout device. 4. Notify all Affected Employees that lockout and/or tag-out devices are being placed on the equipment and the reason for doing a lockout and/or tag-out. 5. If the machine or equipment is operating, it must be shut down by the normal stopping procedures (depress stop button, open toggle switch, etc.). The equipment must also be placed in local control rather than computer control, this insures that the start/stop stations are under the control of the authorized employee who locked-out and/or tagged-out the machine or equipment.
6. Lockout the equipment by affixing a personal lock at each energy isolating device. Lockout devices must be placed in a manner that will hold the energy-isolating device in a safe or off position. If more than one person is to be working on the equipment, each individual must apply his/her own lock to the lockout device. Each lock must identify the person who applied it. The person performing the task must have the key to the padlock in his/her possession. 7. Following the application of lockout devices to energy isolation devices, all potentially hazardous stored energy or residual energy (such as that in springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas or steam or water pressure, etc.) must be dissipated or restrained. 8. After assuring that no personnel are exposed and prior to working on the machine or equipment verify that complete de-energization of the machine or equipment has be accomplished by operating the start switch or other operating control. 9. If the lockout required is due to an electrical situation, a qualified person must use test equipment to test the circuit elements and electrical components of the equipment to verify that the circuit elements are de-energized. 10. Service or maintenance of the equipment may only begin after all prior steps have been completed. RELEASE FROM LOCKOUT/TAGOUT UNLOCKING PROCEDURE After the work is completed, the unlocking procedures are: 1. A check of the area for cleanliness and remove all tools from the machine or equipment. 2. Check to ensure all guards have been reinstalled. 3. Notify employees that the machine will be started and they are instructed to stand clear. 4. Employees affixing the lock may remove their lock out device. 5. Operation of the equipment may commence in a normal manner.
TAGOUT PROCEDURES Tag-out should be utilized in conjunction with the lockout portion of this program. All tagout devices will be treated as lockout devices. Tag-out without lockout is to be allowed only when there is no means to lock out the equipment and the tag-out device will provide the same level of protection as a lockout device. All procedures for the lockout must be adhered to, however, instead of affixing the lock, a tag must be used which would indicate: 1. The Identity of the person who applied the tag. 2. The tag must indicate what hazards will exist if the machine or equipment is operated. 3. The tag must state DO NOT START, or DO NOT OPEN, or DO NOT OPERATE. 4. Each employee working on the equipment must have his or her own tags and no one can remove a tag except the person who applies it. If there is a change of shift the incoming employees shall affix their own tag device and the outgoing employees may remove their tags. 5. Tags must be securely attached to the energy device, be legible, and understandable by authorized and affected employees. 6. Environmental conditions must be taken into consideration when selecting a proper tag to affix to the machine or equipment. SHIFT OR PERSONNEL CHANGES If at the end of a shift, the work is not completed or there is not another shift, employees may leave the lockout and tag-out devices in place. If the work is to be completed by other employee s removal of the lockout and tag-out device may only proceed when the next employee is present and is ready to place their lockout device on the equipment. MULTIPLE LOCK-OUT Multiple lockout devices must be used if more than one person is required to work on the equipment. (e.g. an outside contractor) When multiple lockouts are required a scissors hasp lock should be used to allow more than one lock to be used. Only after all work is completed shall all locks be removed.
NEW EQUIPMENT/EXISTING EQUIPMENT All equipment changes or new equipment purchased (after October 31, 1989) will be designed and installed to accept a lockout device. SPECIFIC EQUIPMENT LOCKOUT/TAGOUT PROCEDURES All specific lockout/tag-out procedures also referred to as Hazardous Energy Control Procedures, are located with this procedure in the following plant locations. Company SpecSys Plant Location Granite Falls Location of Procedures The Employee Portal Site under Safety and the Safety Director s Office SpecSys Benson The Plant Manager s Office SpecSys New Ulm The First Aid Room RVI Redwood Safety Director s Office Falls TRAINING Each authorized employee will receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control. Each affected employee will be instructed in the purpose and use of the energy control procedure. Each qualified and unqualified employee will receive training on the provisions of 29 CFR 1910.331-335, Electrical Safety Standards. All other employees who work in an area where energy control procedures may be utilized, will be made aware of proper lockout/tag-out procedures, and the prohibition of attempting to restart or re-energize machines or equipment which are locked out or tagged out. Employees will also be trained in the following limitations of tags: 1. Tags are warning devices affixed to energy devices, and do not provide as much restraint on those devices that is provided by a lock.
2. When a tag is attached to an energy isolating means, it is not to be removed unless the authorized person responsible for it removes the tag, and it is never to be bypassed, ignored, or otherwise defeated. 3. Tags must be legible and understandable by all authorized employees, affected employees, and all other employees whose work operations are or may be in the area, in order to be effective. 4. Tags and their means of attachment must be made of materials that will withstand the environmental conditions encountered in the workplace. 5. Tags may evoke a false sense of security, and their meaning must be understood. 6. Tags must be securely attached to energy devices so that they cannot be inadvertently or accidentally detached during use. Employee retraining will be provided for all employees whenever there is a change in their job assignments, a change in machines, equipment or processes that present a new hazard, or when there is a change in the energy control procedures. Additional training shall also be conducted whenever a periodic inspection reveals, or the Safety Director and/or his designee has reason to believe, that there are deviations from the employee s knowledge or use of these energy control procedures. ACCOUNTABILITY Any employee found in non-compliance with any portion of this program will be disciplined in accordance to company policy. First Offense- Three day suspension which includes: 1. Documentation of unacceptable behavior; 2. A review with employee, the employee s immediate supervisor and the plant manager. 3. Scheduled three-day suspension; 4. Employee retraining; 5. Follow-up formal review. Second Offense- Formal Review that includes: 1. Documentation of unacceptable behavior; 2. Automatic suspension and/or termination; 3. A review with employee, immediate supervisor and plant manager to determine appropriate punishment, up to and including termination. Employee will be notified with three days of beginning suspension. Immediate termination can be invoked for any infraction that endangers the safety of life or limb of the employee or any co-worker of Ritalka, Inc.
OUTSIDE PERSONNEL (CONTRACTORS), ETC.) All contractors or outside servicing personnel will be informed of the lockout and tagout procedures and will be expected to comply with the program. If the contractors program is equally effective, Ritalka, Inc will accept their program and the contractor may use their program. Employees of Ritalka, Inc will comply with the restrictions and prohibitions of the outside contractor s or service personnel s energy control procedure. No work will be started in the plant by outside personnel before the Safety Manager has certified that they are aware of Ritalka, Inc. procedures. ADDITIONAL INFORMATION In accordance to OSHA standards on Lockout/Tag-out (29 CFR 1910.147) and the Electrical Safety Standard (29 CFR 1910.331-335), Employees must follow set forth guidelines listed in this program. Copies of both standards have been included in this program for further clarification and reference. APPENDIX A Periodic Inspection The Safety Manager and an authorized employee will conduct a periodic inspection of the energy control procedures at least annually. The purpose of the periodic inspection is to ensure that the procedure and requirements of the policy are being adhered to and to correct any deviations or inadequacies observed. The periodic inspection shall include a review, between the inspector and each authorized employee, of that employee s responsibilities under the energy control procedure being inspected. All periodic inspections will be documented. The documentation shall identify the machine or equipment on which the energy control procedure was being utilized, the date of the inspection, the employees included in the inspection, and the person performing the inspection. To ensure that this program is being properly implemented random inspections and planned visual observations will be conducted to determine if the energy control procedures are followed: if employees know their responsibilities: and if the procedures are adequate and what changes are needed. Retraining will be necessary if the inspections determine deviations from the written program. Where tag-out is used for energy control, the inspector shall inspect for the following: 1. The tag is attached to the machine needing service. 2. The tag is not removed without authorization.
3. The tag is never by passed, ignored, or otherwise defeated. 4. The tag is legible and understandable by all employees 5. The tag and means of attachment are able to withstand the environmental conditions, and; 6. The tag is securely attached to the equipment.