LockOut/TagOut Program

1. Introduction

   1. Scope

      1. This procedure covers the servicing and/or maintenance of the machines or equipment connected to an energy source capable of causing injury to personnel or damage to equipment. Energy sources shall include, but not necessarily be limited to the following:

         1. Mechanical

         2. Electrical

         3. Hydraulic

         4. Pneumatic

         5. Chemical

         6. Thermal

         7. Kinetic Energy

   2. When Does the Lockout/Tagout Program Apply

      1. OSHA’s 29 CRF 1910.147 states that the standard covers the servicing of maintenance of machines and equipment in which the unexpected energization or startup of the machines or equipment or release of stored energy could cause injury to employees. The standard applies to the control of energy during servicing and/or maintenance of machines and equipment.

      2. Normal production operations are not covered by the standard. Servicing and/or maintenance which takes place during normal production operations is covered only if:

         2. 1. An employee is required to remove or bypass a guard or other safety device.

            2. An employee is required to place any part of his/her body into an area on a machine or piece of equipment where work is actually performed upon the material being processed (point of operation).

            3. Where an associated danger zone exists during a machine operating cycle.

3. Purpose

   1. This procedure establishes the requirements for the lockout and tagout of hazardous energy sources. It shall be used to ensure that the machine or equipment being serviced or repaired is isolated from all potentially hazardous energy sources before work begins. It shall be used to prevent injury to personnel and/or damage to equipment, which could result from the unexpected start-up or release of stored energy.

4. Responsibility

   1. The Operations Manager shall ensure the implementation and compliance with the provisions of the Lockout/Tagout procedures. The Operations Manager may designate other employees to assist in the compliance with portions of this procedure. Persons responsible for the segments of this procedure (inspection, training, etc.) shall be specifically identified.

   2. The Operations Manager shall review and identify the sources of energy for each piece of machinery and equipment, which may require the use of a Lockout/Tagout device. The maintenance manager shall issue all locking devices and tags under this procedure.

5. Training

   1. On an annual basis, a training session will be held for maintenance employees and all plant employees.

   2. Recognitions of potential hazardous energy sources and the purpose and function of the Lockout/Tagout procedure will be covered. A written record is to be maintained of the dates of training and employees attending.

2. Procedures

   1. Preparation

      1. Determine the energy types and sources and how to disconnect and control them. To prepare for a lockout/tagout, a survey must be made to locate and identify all isolating devices to be certain which switches, valves, or other isolation devices apply to the equipment to be locked or tagged out. Different sources may be involved (electrical, hydraulic, air, water, steam, etc.). The authorized employee must have knowledge of the type and magnitude of the energy to be controlled, and the methods or means to control the energy.

   2. Notification

      1. When lockout/tagout controls are going to be applied, affected employees must be notified that a device is going to be used and the reason for it.

   3. Isolation

      1. Physically operate the switch, valve, or other energy-isolating device so that the equipment is isolated from its energy sources and apply adequate hardware (locks, tags, chains, blocks, etc.). Verbal descriptions and pictures of the physical locations of the lockout points are posted on all machines.

   4. Dissipation

      1. After lockout has been achieved, release any stored energy that may be present in the section, upon which work is to be performed.

      2. Stored energy could consist of: Springs, elevated machine members, rotating flywheels, hydraulic and/or pneumatic systems, steam, or water pressure. Stored energy is to be dissipated by such methods as repositioning, blocking, bleeding, draining etc…

      3. NOTE: Blocking devices used to prevent motion of elevated members must be firmly positioned so that they cannot move or shift unexpectedly.

      4. Rather than installing a blocking device so that it would “catch” an elevated member “in case” there is inadvertent motion, the elevated member should be positioned so that it firmly contracts the blocking device and places the blocking device under compression or tension, as appropriate.

      5. Due to possibility of mechanical failure, the following types of devices are specifically prohibited as a means of blocking or supporting elevated members:

         1. Devices which employ pneumatic or hydraulic pressure to prevent motion – including forklifts, hand trucks, pneumatic lifts, and hydraulic jacks

         2. Devices which employ electrical power as a means of motive force or control of motion, regardless of whether power is supplied by a battery or a cord and plug.

   5. Verification

      1. Prior to starting work on machines or equipment that have been locked out and after ensuring that no personnel are exposed, the authorized employee must operate the push button or other normal operating controls to verify the equipment or machine has been de-energized and make certain it will not operate. CAUTION: return operating controls to neutral or off position after test.

      2. As an additional safety precaution, prior to the commencement of work, the AUTHORIZED employee shall have each AFFECTED employee install departmental locks on the primary point of isolation (such as the main machine disconnect.) Alternatively, a multiple lockout lock box may also be used for this purpose.

   6. No Reprisals

      1. Concern for the safety of employees performing work and other employees affected by the lockout/tagout procedure is of PRIMARY IMPORTANCE. No reprisals or disciplinary action will be taken against any employee requesting the use of additional reasonable and appropriate safety measures or obtaining clarification prior to commencing or continuing work.

   7. Removal

      1. After servicing or maintenance has been completed and before lockout devices are removed and the energy restored, the following sequence of activities must be completed.

      2. Check the work area to be sure the machine or equipment is intact, unnecessary items (tools, rags, etc.) have been removed and guards have been reinstalled.

      3. Check to be sure all employees around the machine or equipment are safely positioned or removed from the area. Affected employees must be notified before removal of devices and re-energizing of machine or equipment.

      4. The authorized employee who applied a lock to the device will remove each lockout device from every energy source and restore energy to the machine or equipment.

   8. Temporary Removal of Devices

      1. In situations in which lockout devices must be temporarily removed from the isolating device and the machine or equipment energized to test or position the machine, equipment or components thereof, the following sequence of activities must be followed:

         1. Clear the machines or equipment of tools and materials.

         2. Remove employees from machine or equipment area.

         3. Remove lockout devices

         4. Energize and proceed with testing or positioning.

         5. De-energize all systems and reapply devices as above.

   9. Group Lock Out

      1. If more than one individual is required to lockout equipment, the following procedures should be followed.

         1. One authorized employee will be responsible for the number of people working under the protection of the group lockout. This employee will be the supervisor of the project and determine the exposure status of the individual members in the group. He/she will control the job-related lockout procedure. However, every employee directly involved in the work must have a lock on the isolation device.

   10. Outside Contractor Lockout

       1. All outside contractors, if applicable, must comply with the plant’s lockout/tagout procedure. It is the responsibility of the manager or supervisor that makes the arrangements for the outside contractor to perform work in the plant to review the plant’s Safety and Environmental Rules form and sign off that it has been explained and understood (please refer to the Outside Vendors & Contractors Safety and Environmental Rules form at the end of this procedure.) This includes reviewing the plant’s lockout/tagout procedures, if applicable. This must be completed before any work begins by any new contractor personnel. Outside contractor personnel that have been in the plant do not need to sign the form again. However, they must always comply with it. If necessary, the lockout/tagout and other safety rules should be reviewed with them before any work begins.

   11. Lockout Over More Than One Shift

       1. It is the responsibility of the authorized employee going off shift to inform the authorized employee going on shift of the work to be continued. When a lockout procedure is extended into the following shift, the authorized employee who originally placed the locks will remove them and they will be immediately replaced.

       2. If there is a time gap between the authorized employee’s shift, a written machine status is to be attached to the energy source with a “DO NOT OPERATE” tag. In addition, a lock must remain on the isolating device. If no further work is anticipated to be performed until the original authorized employee returns, his/her lock shall remain on it and it shall not be removed without proper authorization as outlined in the Authorized Lock Removal section. If further work is to be performed before the original authorized employee returns, then the procedures outlined in paragraph one above should be followed even if the shift immediately following is not performing any work. This is to ensure that there is proper communication from one shift to another. Before the next shift begins service or repairs, the authorized employee must review the machine status and complete full lockout procedures. The authorized employee going off shift may then remove his/her lockout device following proper procedure.

   12. Notes

       1. Lockout devices will be substantial enough to prevent removal without the use of excessive force or unusual techniques, such as the use of bolt cutters.

          1. They must be able to withstand any environmental condition they are exposed to.

          2. They must be provided by the employer

          3. They should only be used for the lockout program

          4. They should indicate the identity of the employee.

          5. They must be standardized by color, shape, size and print.

       2. Failure to follow these procedures will result in disciplinary action up to and including discharge.

   13. Points to Emphasize

       1. Locks are to be used only for lockout purposes. ID numbers have been written on locks for identity purposes. Locks must be returned to the employer at change of job for review. Need for review for reissue at termination of employment.

       2. This procedure is taken from OSHA Code of Federal Regulations. Violations are subject to fines, penalties, or disciplinary action.

Related and Supporting Documents

8.1.1.9-P LOTO Procedure

8.1.1.10-F LOTO Annual Inspection Form

LOTO Procedure - Forklift