Lockout/Tagout Program
Purpose and Objective
The objective of this program is to establish a means of controlling energy to prevent the accidental start-up of equipment or release of energy. This policy applies to all employees who conduct work where the unexpected start-up or energization of the equipment or release of stored energy could be hazardous.
Definitions
Affected Employee: A person who uses equipment that is being serviced under lockout or tagout procedures, or who works in an area where equipment is being serviced.
Authorized Employee: A person who locks out or tags out equipment to do service or maintenance work. An affected employee becomes an authorized employee when that employee’s duties include service or maintenance work on equipment.
Capable of Being Locked Out: An energy-isolating device that is designed with a hasp or other means of attachment to which or through which a lock can be affixed or if it has a locking mechanism built into it. Other energy-isolating devices will also be considered to be capable of being locked out if lockout can be achieved without the need to dismantle, rebuild, replace the energy-isolating device, or permanently alter its energy-control capability.
Disconnect: A switch that disconnects an electrical circuit or load (motor, transformer, or panel) from the conductors that supply power to it. An open circuit does not allow electrical current to flow. Under a lockout procedure, a disconnect must be capable of being locked in the open position.
Energized: Connected to an energy source or containing potential energy.
Energy Source: Any source of energy. Examples include electrical, gravitational, mechanical, hydraulic, pneumatic, chemical, and thermal.
Energy Isolating Device: A mechanical device that physically prevents transmission or release of energy.
Hazardous Energy: Any source of energy existing at a level or quantity that could be harmful to workers or cause injury through inadvertent release or start-up of equipment.
Hot Tap: A procedure used for repair, maintenance, and service activities which involves welding on a piece of equipment (pipelines, vessels, or tanks) under pressure in order to install connections or appurtenances.
Lockout: Placing a lockout device on an energy-isolating device under an established procedure to ensure the energy-isolating device is removed.
Lockout Device: A device that locks an energy-isolating device in the safe position.
Procedure: A series of steps taken to isolate energy and shut down equipment.
Servicing or Maintenance: Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining machines or equipment. Also includes lubricating, cleaning, unjamming, and making adjustments or tool changes if a worker may be exposed to the unexpected start-up of the equipment during such activities.
Tagout Device: A prominent warning sign, such as a tag, that can be securely fastened to an energy-isolating device to indicate that energy-isolating device and the equipment it controls can’t be operated until the tagout device is removed.
Tagout: Placing a tagout device on an energy-isolating device under an established procedure to indicate that the energy-isolating device and the equipment it controls can’t be operated until the tagout device is removed.
Responsibilities
Management
Management is responsible for implementing, supporting, and enforcing this program.
Supervisors are responsible for being familiar with this program and for complying with the requirements. Supervisors have the added responsibility of aiding and ensuring that employees adhere to the requirements as well. The supervisors are responsible for overseeing work and conducting periodic checks to ensure energy isolation procedures are adequately followed.
Employees are responsible for being familiar with this program and complying with the requirements where applicable. Such responsibilities include:
- Complying with the restrictions and limitations imposed during the use of lockout
- Performing the lockout or tagout in accordance with procedures
- Never attempting to start a piece of equipment which is locked out for servicing or maintenance
- Notifying supervisors as quickly as practical of any accidents or incidents that occur during energy isolation procedures or work on equipment
Authorized employees are responsible for following established lockout/tagout procedures. An authorized employee is a person who locks or tags out machines or equipment in order to perform servicing on equipment.
Affected employees are responsible for ensuring they do not attempt to restart or reenergize machines or equipment that are locked or tagged out.
General Requirements
This program applies to any work, servicing, or maintenance of and on machines or equipment in which the unexpected start-up or release of energy could cause injury or death. Some examples of energy sources to be considered are electrical, gravitational, air pressure, hydraulic pressure, chemical, thermal, springs, and other devices under tension. Any time energy control points such as switches or valves must be locked out, lockouts must be conducted.
This program does not apply to cord and plug-connected equipment if the plug can be unplugged and controlled by the employee who is performing maintenance. It also does not apply to hot tap work. In addition, normal operations in production are not covered unless a guard or similar safety device is removed or the employee is exposed to a point of operation hazard.
Identifying Energy Hazards
A survey of all company locations must be conducted to determine the presence of hazardous energy sources. These energy sources may include the following:
- Electrical
- Pneumatic
- Hydraulic
- Gas
- Mechanical
- Springs and similar devices
- Gravitational
- Water pressure
- Chemical
- Steam
- Thermal
- Nuclear
Once sources of hazardous energy have been identified, methods to control the unintended operation of machines or equipment being serviced or maintained will be devised. These methods will focus on written procedures for affixing lockout or tagout devices and to otherwise disable machines or equipment to prevent unexpected energization, start up, or other release of stored energy. This may also include blocking movable parts which may create a hazard.
Controlling Energy Hazards
Employees who are required to use lockout/tagout procedures must be knowledgeable in the types of energy sources present and the proper sequence of shutting off or disconnecting a system. This section contains methods of mitigating the hazards of energy sources during the service and maintenance of equipment.
Lockout and Tagout Devices
Lockout and tagout devices used must meet the following criteria to ensure they are effective and only removed intentionally after procedures have been followed:
- Lockout devices must work under the environmental conditions in which they are to be used.
- A tagout device warning must be constructed to remain legible even when used in wet, damp, or corrosive conditions.
- Lockout and tagout devices must be designated by color, shape, or size.
- Tagout devices must have a standardized print and warning format.
- Lockout and tagout devices must be strong enough so that they can’t be removed inadvertently.
- Tagout devices must be attached with a single-use, self-locking material such as nylon cable ties.
- Employees who see a lockout or tagout device must be able to recognize who attached it and the device’s purpose with regard to energy isolation.
- Each lock must have a unique key combination.
Energy-isolating devices are a primary means for protecting employees who service equipment and must be designed to accept a lockout device. Energy-isolating devices must clearly identify function.
Energy Control Procedures
Authorized employees who lockout or tagout equipment for service or maintenance must follow specific, written, energy-control procedures. The procedures must include the following:
- The intended use of the procedure
- Steps for shutting down, isolating, blocking, and securing equipment
- Steps for placing, removing, and transferring lockout devices
- Equipment-testing requirements to verify the absence or residual energy
When re-energization of equipment becomes necessary for testing or to position the equipment, temporary removal of lockout or tagout devices is allowed (see Special Situations). This applies only for the time required to perform the task and the procedure used must be documented.
In order to perform service or maintenance work, employees must do the following:
- Inform all affected employees of equipment shutdown.
- Preparation for shutdown of equipment.
- Shut down equipment.
- Isolate and/or block all sources of hazardous energy.
- Apply lockout/tagout devices.
- Remove any potential or stored energy sources.
- Verify the equipment is isolated and de-energized.
The following are examples of energy types and procedures to isolate them.
Electrical
- Shut off power at machine and disconnect.
- Lock or tag equipment.
- Press start button to test start and ensure that correct systems are locked out.
- Validate that all controls are returned to their safest position.
- Also included is:
- If machine has capacitators, they must be drained of stored energy
- Possible disconnecting means include the power cord, power panels, breakers, operators station, motor circuit, relays, limit switches, and interlocks
- If isolating electrical energy is done by simply unplugging the power cord, the cord must be kept under the control of the authorized employee or the plug must be locked and tagged out
Fluids and Gases
- Identify the type of fluid or gas and the necessary personal protective equipment for employees.
- Close valves to prevent flow and proceed to lockout/tagout.
- Determine the isolating device, close it, and lockout/tagout.
- Drain and bleed lines and ensure residual energy has been drained.
- If electrical systems are in place, such as electrically controlled valves, ensure they are shut off and tagged out.
- Check for zero energy state prior to beginning work.
Hydraulic/Pneumatic
- Shut off all energy sources (pumps and compressors). If the pumps and compressors supply energy to more than one piece of equipment, lockout or tagout the valve supplying energy to the piece of equipment being serviced.
- Ensure that stored energy from hydraulic or pneumatic lines is drained and bled.
- Validate that controls are returned to their safest position.
- Check for zero energy state prior to beginning work.
Mechanical Energy
Mechanical energy may include gravitational activation, energy stored in springs, and other mechanisms.
- Block out or use safety chains to ensure movement is restricted as much as possible.
- Lockout or tagout device.
- Shut off and lockout electrical system.
- Check for zero energy state prior to beginning work.
- Return controls to safest position.
Release from Lockout/Tagout
In order to remove locks, the following procedure should be followed to ensure energy sources are controlled and employees are safe:
- Inspect equipment and ensure that the work is completed. All tools should be collected and all employees cleared of the area.
- Clean up all towels, rags, paperwork, etc.
- Replace guards.
- Check controls and ensure they are all in the original safe position.
- Ensure all employees have been safely positioned outside the hazardous equipment areas.
- Remove lockout devices and tags:
- Each employee may only remove his or her own lock and tag
- Document the procedures.
Service or Maintenance Involving More Than One Person
When servicing and/or maintenance is performed by more than one person, each authorized employee shall place his own lock or tag on the energy isolating source. This shall be done by utilizing a multiple lock clamp on the equipment that is being locked out. If the equipment cannot be locked out, then each authorized employee must place a tag on the equipment.
Special Situations
Energized Testing
When an energy-isolated device is locked or tagged and it is necessary to test or position equipment, the following procedure must be observed:
- Remove unnecessary tools and materials.
- Ensure that employees are out of the area.
- Remove locks or tags from energy-isolating devices.
- Proceed with test.
- De-energize equipment and lockout or tagout energy-isolating devices.
- Operate equipment controls to verify equipment is de-energized.
Lock Removal
When an employee’s lock remains, either accidentally or inadvertently, it should only be removed if the person who initiated the lockout is not able to complete the process and remove the lock. After servicing or maintenance is complete and the equipment is ready to be returned to service, the following procedure must be observed:
- Verify the location of the employee whose lock is to be removed and receive consent from that employee to remove the lock or tag.
- Only remove the tag if the individual who initiated the lockout is not able to remove his or her own lock.
- Management must approve the lock removal. Locks are only to be removed by authorized personnel after approval.
- Remove the lock and follow start up procedures.
Shift Changes
When shifts change and lockout/tagout procedures are still in use, the outgoing shift and incoming shift will coordinate as necessary to ensure energy isolation is managed.
Alternative Methods
There are certain situations in which lockout or tagout is not used and a minor servicing exception may apply. Those tasks are those that are:
- Routine
- Repetitive
- Integral to the production process
In those cases, an alternative method may be used to control hazardous energy. Selection of the alternative control method must be based on a risk assessment of the machine, equipment, or process. The risk assessment must include existing safeguards provided with a machine, equipment, or process that must be removed or modified to perform a given task.
Under all circumstances, the individual must have exclusive control over the means to maintain the state of the control circuit in a protective mode.
Procedures for Contractors and Outside Personnel
Contractors and outside personnel will be advised of the company Lockout/Tagout Program and procedures. They will be informed of the use of locks and tags and notified that it is prohibited to attempt to start or energize machines or equipment that are locked or tagged out.
The company will obtain information from contractors about their lockout/tagout procedures and advise affected employees of this information.
Inspection and Authorization of Procedures
The company will perform and document inspections of energy-control procedures to ensure that the procedure correctly isolates all energy sources and that employees understand and use procedures effectively. Documentation will include the following:
- The equipment on which the procedure is used
- The date of inspection
- The employees included in the inspection
- The inspector’s name and signature
If a deficiency is found in employees following energy-control procedures or that the procedure is not adequately protective, employees must be retrained and the deficiencies corrected.
The inspector must understand the procedure and must be an individual other than those following the procedure at the time of the inspection. The procedure’s accuracy, completeness, and effectiveness must be verified.
If the inspection covers a procedure for equipment with an energy-isolating device that can be locked out, the inspector must review the procedure with employees who use it to service the equipment. This review can be done individually or in a group.
If the inspection covers a procedure for equipment with energy-isolating devices that can only be tagged out, the inspector must review the procedure with the authorized employees who service the equipment and with affected employees who work in the area. This can be done individually or in a group.
Training
All involved employees who will be involved in energy isolation work will receive training prior to participating in lockout/tagout activities initially and annually thereafter.
Each authorized employee who will be utilizing lockout/tagout procedures will be trained in the recognition of applicable hazardous energy sources, type and magnitude of energy available, and methods for energy isolation and control. They must also be trained in the means of verifying that energy is controlled. Authorized employees will also be retrained whenever their job assignments change, energy-control procedures change, equipment or work processes present new hazards, or when found not following energy control procedures.
Each affected employee (all employees other than authorized employees utilizing the lockout/tagout procedure) shall be instructed in the purpose and use of the lockout/tagout procedure and the prohibition of attempts to restart or re-energize machines or equipment that are locked out or tagged out.
Employees whose jobs are in areas where energy-control procedures are used will be trained about the procedures and the prohibition against starting machines that are locked or tagged out.
Additional training is required when:
- Job duties change
- There is a change in machines
- A change occurs in the Lockout/Tagout Program
- An employee’s job performance shows deficiencies
Recordkeeping
It is critical that all training is documented.
The annual program review and document updates must be maintained indefinitely.
