This customizable program is specific to OSHA Lockout/Tagout Control of Hazardous Energy Standard 29 CFR 1910.147. The standard covers the servicing and maintenance of machines and equipment in which the unexpected energization or startup of the machines or equipment, or release of stored energy, could harm employees. The standard establishes minimum performance requirements for the control of such hazardous energy. / “Lockout/Tagout” refers to specific practices and procedures to safeguard employees from the unexpected energization or startup of machinery and equipment, or the release of hazardous energy during service or maintenance activities. This requires, in part, that a designated individual turns off and disconnects the machinery or equipment from its energy source(s) before performing service or maintenance and that the authorized employee(s) either lock or tag the energy-isolating device(s) to prevent the release of hazardous energy and take steps to verify that the energy has been isolated effectively. If the potential exists for the release of hazardous stored energy or for the reaccumulation of stored energy to a hazardous level, the employer must ensure that the employee(s) take steps to prevent injury that may result from the release of the stored energy.
If your employees service or maintain machines where the unexpected startup, energization, or the release of stored energy could cause injury, the standard likely applies to you. The standard applies to all sources of energy, including, but not limited to: mechanical, electrical, hydraulic, pneumatic, chemical and thermal energy.
The standard does not cover agriculture, construction and maritime industries, or oil and gas well drilling and servicing. Other standards concerning the control of hazardous energy, however, apply in many of these industries/situations.
*information from OSHA Publication 3120 – Control of Hazardous Energy
Purpose and Use
This document is a customizable program designed to help you develop or enhance your organization’s internal safety and health program. It is designed to provide a framework to help build an organization-specific program by giving you some standard practices and procedures that most employers must implement. This material is not all-inclusive and may not address special safety issues unique to your industry. It may not fulfill written or minimum performance standards of your state and federal regulations. Be certain to evaluate additional needs, related regulations and your commitment to workplace safety. Solicit input from members of your workforce and management team when developing this program. Remember, a written plan is only as good as the commitment behind it.
Instructions
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Company Name
Lockout/Tagout
Control of Hazardous Energy
OSHA 29 CFR 1910.147
Version 1.0 Updated: Date

Table of Contents

Purpose / 4
Program Scope / 4
Administrative Responsibilities / 4
Hardware and Materials / 5
Periodic Inspection / 7
Sequence of Lockout/Tagout / 7
Testing Machines, Equipment, or Components / 8
Non-Company Personnel (Contractors, Etc.) / 8
Appendix I – Energy Sources and Controls / 10
Appendix II – Terms and Definitions / 12
This safety program and accompanying information does not identify all possible hazards and we cannot be responsible on your behalf for your obligations under any law, rule or regulations. The principles contained in the material are general in scope and, to the best of our knowledge, current at the time of publication. Liberty Mutual specifically disclaims all liability for damages or personal injury alleged to arise from reliance on the information contained in this document.

Purpose

This procedure helps to establish general requirements for controlling hazardous energy during service or maintenance of machines or equipment, in accordance with the requirements of OSHA 1910.147.This program assists with practices and procedures necessary to disable machinery and prevent the release of potentially hazardous energy while maintenance or servicing activities are performed at Company2.

Program Scope

Lockout/Tagout will be used when employees are involved in constructing, installing, setting up, adjusting, inspecting, modifying and maintaining or servicing machines or equipment. These activities include lubricating, cleaning or unjamming machines, and making adjustments or changes to tools, guards or safety devices where the employees may be exposed to hazardous energy.

The standard applies to all sources of energy, including, but not limited to:

  • mechanical
  • electrical
  • hydraulic
  • pneumatic
  • chemical
  • radiation
  • thermal energy
  • kinetic

Authorized employees subject to the requirements of this program are to be trained on their duties within it, including:

  • Recognizing applicable hazardous energy sources
  • Type and magnitude of the energy available in the workplace
  • Methods and means necessary for energy isolation, control and verification
  • Limitation of energy control devices
  • Procedure for complying with Company3‘s lockout/tagout procedure

Affected employees are subject to the requirements of this program and are to be trained on their duties within it, including:

  • Understanding the lockout/tagout procedure
  • Recognizing lockout/tagout devices and identifying that equipment is out of operation
  • Purpose and use of energy control procedures
  • To never re-energize or start equipment that is actively controlled by lockout or tagout procedures

All employees are required to comply with the restrictions and limitations imposed upon them during lockout. Authorized employees are required to perform the lockout in accordance with this procedure.All employees, upon observing a machine or piece of equipment that is locked out for servicing or maintenance shall not attempt to start, energize or use that machine or equipment.

Administrative Responsibilities

Implement1 will be the one ultimately responsible for implementing these procedures. The procedures will clearly outline the scope, purpose, authorization, rules and techniques to be utilized for controlling hazardous energy and the means to enforce compliance. This includes but is not limited to:

  • A specific statement on the intended use of the procedure
  • Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy (manufacturer's specification will be followed whenever possible)
  • Specific procedural steps for placing, removing and transferring lockout/tagout devices, and the person(s) responsible for them
  • Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout/tagout devices and other energy control measures.

Hardware and Materials

Lockout devices must be identified as such, and not used for any other purpose. All locks used for energy isolation will be kept in a designated box at identified locations (see Appendix I). Each specific department shall be responsible for distributing the locks and securing the keys.

Both lockout and tagout devices must be capable of withstanding environmental conditions in the workplace (locks should not rust or tags deteriorate). All tagout devices will be standard with a "DO NOT OPERATE" warning. All lockout/tagout devices will be uniform in color, shape, design or size to maintain integrity of the program.

Each authorized employee will receive one lock and one key. Individual employee locks shall be permanently marked to identify the intended user. The second key will be destroyed or maintained in a locked supervisory key case in the employee's department.

Periodic Inspection

A periodic inspection of the energy control procedure(s) shall be conducted at least annually to ensure that the procedure and the requirements of the program are being followed.The periodic inspection shall be performed by InspectProcedures and not by the one(s) utilizing the energy control procedure being inspected.Any deviations or inadequacies identified during the inspection shall be corrected. Documentthat the inspection has been performed.

Sequence of Lockout/Tagout

  1. Preparation for Shut Down
  • Energy Source Identification: Before an authorized or affected employee turns off a machine or equipment, the authorized employee must have knowledge of the type and magnitude of the energy sources, the hazards of the energy to be controlled, and the method or means to control the energy.
  • Notification: Notify all affected employees that equipment or machines will be shut down and the energy isolated by the .
  1. Machine or Equipment Shut Down

The machine or equipment will be turned off or shut down using the specific procedures established for the machine or equipment. Develop a step-by-step list to perform a systematic and uniform shut down to avoid any additional or increased hazard(s) to employees as a result of disabling equipment.

The authorized employee will refer to our procedure to identify the type and magnitude of the energy that the machine or equipment utilizes. This employee should understand the energy hazards and the methods to control the energy.

  1. Lockout Device Application

Lockout/tagout devices must be affixed to each energy-isolating device by authorized employees and must be affixed in a manner that will hold the energy isolating devices in a "safe" or "off" position. Lock and tag the energy-isolating device(s) with assigned individual lock(s), couplings, valve covers, etc., as per machine-specific procedure. Lockout/tagout devices shall be designed and installed to prevent inadvertent or accidental removal.

Group Lockout/Tagout

When servicing and/or maintenance is performed by a crew, department or other group, they will use our procedure which affords employees a level of protection equivalent to that provided by implementing a personal lockout or tagout device. Group lockout or tagout devices will isolate the energy sources with a unique operations lock, with all authorized employees then securing that key in a group lockout box or similar device.

  1. Stored Energy

After applying the lockout/tagout devices to energy isolating devices, all potentially hazardous stored or residual energy will be relieved, disconnected, restrained and otherwise rendered safe. Residual energy (such as that in capacitors, springs, upper dies, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding, dissipation, etc.

If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation must be continued until the servicing or maintenance is complete, or until the possibility of such accumulation no longer exists.

  1. Verification of Isolation

Prior to starting work on machines or equipment that have been locked/tagged, the authorized employee will verify that the machine or equipment has been isolated and de-energized. This process must include at least:

  • Assuring that all materials, equipment, tools and persons are clear of hazardous moving parts
  • Verifying that all potential residual energy sources have been bled, withheld, or are in a “zero energy state”
  • Verifying that the electrical current flow in the system is isolated from the main power source, by using a multimeter
  • Viewing all gauges to verify zero pressure on pipeways and lines
  • Attaching a unique lock and tag device to the machine or equipment for each crew member
  • Verifying “zero energy state” by attempting startup. (Finish by activating the “stop” button, and be certain that all affected persons are clear of the machine)
  • If equipment can be started remotely, verifying that all remote controls are identified, locked out and tested
  1. Lockout or Tagout Release

Before removing lockout/tagout devices and restoring energy to the machine or equipment, the following procedures will be taken by the authorized employee(s):

  • Machine or equipment: Inspect the work area to ensure that nonessential items have been removed and that the machine or equipment components are functional. Also, verify that any machine safeguards and devices that were removed have been properly reinstalled.
  • Employees: The work area will be checked to ensure that all employees are safely positioned or removed. After lockout/tagout devices are removed and before the machine or equipment is started, affected employees will be notified that the lockout or tagout device(s) have been removed.

  1. Removing Lockout/Tagout Devices

Each lockout/tagout device will be removed from each energy-isolating device by the employee who applied the device. In the event the authorized employee who applied the lockout/tagout device is not available to remove it, that device may be removed under the direction of the LOTORemoval.

Testing Machines, Equipment or Components

When the lockout/tagout device must be temporarily removed and the machine re-energized, test or position the machine by:

  • Clearing away tools and materials from the equipment or machine
  • Removing employees from the machine or equipment area
  • Removing the lockout/tagout devices, as specified, as part of the individual machine procedures
  • Energizing the equipment or machine and proceeding with testing or positioning
  • De-energizing all systems and reapplying energy control devices and features in accordance with machine procedures, and continuing the servicing and/or maintenance
  • Caution: Be certain to return operating control(s) to neutral or "off" position after verifying the equipment has been isolated

NonCompany Personnel (Contractors, Etc.)

When outside servicing personnel are engaged in activities covered by the scope and application of this instruction, Contractors1 and the outside employer will inform each other of their respective lockout/tagout procedures.

  • The Contractors2 will ensure that our employees understand and comply with the restrictions and prohibitions of the outside employer's energy control program.
  • A copy of the contractor’s plan will be compared with our plan. The contracting company official will be required to sign an agreement stating that they will follow our policy which is unique to our equipment and operations. This agreement will be maintained with the contractor file and retained after job completion.
  • The Contractors3 will inspect the work of the contractor to assure that the agreement is being upheld. Any problem or lack of follow through with the lockout procedure, as identified in the agreement, will be grounds for work to be temporarily stopped and reevaluated. Disregard for the policy and procedure in this plan will be grounds for actions as stipulated in the contract.

Appendix I

Energy Sources and Controls

Appendix I Energy Sources and Controls

Type(s) of Energy Source(s)
Per Machine Affected / Machine/Equipment / Control Method(s) and
Location of Placement

Appendix II

Sample Sharps Injury Log Form

Appendix II Lockout/Tagout Terms and Definitions*

*Information from OSHA Lockout/Tagout eTool
(

This program contains the following terms:

Authorized employee: An employee who locks or tags machines or equipment in order to perform servicing or maintenance.

Affected employee: An employee who is required to use machines or equipment on which servicing is performed under the Lockout/Tagout standard or who performs other job responsibilities in an area where such servicing is performed.

Other employees: All employees who are or may be in an area where energy control procedures may be utilized.

Capable of being locked out: An energy-isolating device is considered capable of being locked out if it:

  • Is designed with a hasp or other means of attachment to which a lock can be affixed.
  • Has a locking mechanism built into it.
  • Can be locked without dismantling, rebuilding, or replacing the energy-isolating device or permanently altering its energy control capability.

Energized: Machines and equipment are energized when they are connected to an energy source or they contain residual or stored energy.

Energy-isolating device: A mechanical device that physically prevents the transmission or release of energy. Examplesinclude:

  • 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 can be operated independently
  • A line valve, block, and any similar device used to block or isolate energy
  • Note: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, kinetic, radiation 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-isolating device and the equipment being controlled cannot be operated until the lockout device is removed.

Lockout device: Any device that uses positive means, such as a lock, blank flanges and bolted slip blinds, to hold an energy-isolating device in a safe position, thereby, preventing the energizing of machinery or equipment.

Normal production operations: Utilizing 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, maintaining and/or servicing machines or equipment. This includes lubricating, cleaning or unjamming machines or equipment, and making adjustments or tool changes where employees could be exposed to the unexpected energization or startup of the equipment or release of hazardous energy.

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: Any prominent warning device, such as a tag and a means of attachment that can be securely fastened to an energy-isolating device to indicate that the machine or equipment to which it is attached may not be operated until the tagout device is removed.