Release Authorized by: / Danny Trahan, Safety Director / Manual Rev 4
LOTO – HAZARDOUS ENERGY ISOLATION
LOTO - HAZARDOUS ENERGY ISOLATION
TABLE OF CONTENTS
PURPOSE 3
SCOPE 3
APPLICATION 3
DEFINITIONS 3
1.0 PRINCIPLES OF LOCKOUT/TAGOUT 6
2.0 GENERAL REQUIREMENTS 7
3.0 AUTHORIZED WORKER LOCKOUT/TAGOUT PROCESS 7
3.1 Machine-Specific Energy Control Process 8
3.2 Authorized Worker Lockout/Tagout Application 8
3.3 Lock Cutting and Removal 9
4.0 CONTROLLING ORGANIZATION LOCKOUT/TAGOUT PROCESS 9
4.1 Energy Control Requirements 9
A. Lock and Tag Logbook 9
B. Locks and Tags 9
C. Lockboxes 10
D. Locks and Danger – Do Not Operate Tags 10
E. Isolating Devices that cannot be Locked 10
F. Caution Tags 11
G. Determining the Need for Lockouts/Tagouts 11
4.2 Preparation 13
A. Preparing, Reviewing, and Documenting Lockouts/Tagouts 13
B. Preparing Lockouts/Tagouts 14
C. Performing a Technical Review 14
D. Documenting Lockout/Tagout 14
4.3 Installation 14
A. Lock/Tag Installation 14
B. Verifying Lockouts/Tagouts 15
C. Performing Safe-Condition Checks for Lockouts/Tagouts 15
D. Notifying Authorized Workers 15
4.4 Removal 15
A. Lock/Tag Removal 15
B. Approving Removal of Lock(s)/Tag(s) 16
C. Removing Lock(s)/Tag(s) 16
D. Verifying Lock/Tag Removal 16
5.0 SURVEILLANCE PROGRAM 17
5.1 Lock and Tag Surveillance Program 17
5.2 Periodic Inspection (Program Review) 18
6.0 TRAINING 18
6.1 Affected Worker 19
6.2 Authorized Worker 19
6.3 Controlling Organization Lockout/Tagout Administrator 20
6.4 Refresher Training 20
7.0 REFERENCES 20
8.0 ATTACHMENTS 20
PURPOSE
This practice establishes the requirements for locking and tagging equipment and systems to protect personnel, property, and the environment from events that may be caused by the unexpected release of hazardous energy or materials, the unexpected startup of machines or equipment, or the unexpected release of stored energy.
Note: Examples of hazardous energy include electrical, mechanical, hydraulic, pneumatic, chemical, radiation, and thermal energies, as well as various forms of potential (stored) energy, such as in springs, compressed gases, or suspended objects.
SCOPE
This practice includes the following major sections:
· Principles of Lockout/Tagout
· General Requirements
· Authorized Worker Lockout/Tagout Process
- Authorized Worker Lockout/Tagout Application
- Lock Cutting and Removal
· Controlling Organization Lockout/Tagout Process
- Energy Control Requirements
- Preparation
- Installation
- Removal
· Surveillance Program
- Lock and Tag Surveillance Program
- Periodic Inspection (Program Review)
· Training
- Affected Worker
- Authorized Worker
- Controlling Organization Lockout/Tagout Administrator
- Refresher Training
APPLICATION
This practice applies to work activities and employees under the control of P2S and its contractors.
DEFINITIONS
AAffected Worker – A person whose job requires him or her to be in an area where equipment or system(s) have been deenergized under the lockout/tagout program. The affected worker cannot perform work under a lockout/tagout.
Authorized Worker – A person who locks out and tags out machines, equipment, or systems to perform servicing or maintenance on that machine or equipment. This person must have completed the mandatory training to qualify as an authorized worker. Only an authorized worker installs and removes his or her own lock(s) and “Danger Tag(s)” as required by this program.
Boundary – The safe limits of a given lockout/tagout as determined by those components that are configured to provide asafe condition where the work is to be performed.
Controlling Organization (CO) – The organization or individual responsible for the implementation and documentation of the lockout/tagout process, including identifying the hazards, controlling the boundaries, understanding the impacts, and directing the authorized workers. The designated controlling organization may be a contractor responsible to install asystem or equipment; the facility owner or manger; or the construction management contractor. The Project/Site Manager designates which organization(s) or individual(s) acts as the CO.
Controlling Organization Lockout/Tagout Administrator – The CO trained worker responsible to perform the duties of the controlling organization. These duties include performing the technical review, providing approvals, completing appropriate documentation, and installing/removing tags.
Danger Tag – The tag that is used by authorized workers to perform authorized worker lockout/tagout. This tag is for the protection of the individual employee.
Danger – Do Not Operate Tag: The tag that is used by the controlling organization to set the boundaries for the purpose of hazardous energy control. No work may be performed under this tag unless an Authorized Worker Danger Tag has also been installed.
Energy Source – Any source of hazardous energy or materials. Sources include electrical, mechanical, hydraulic, pneumatic, chemical, radiation, and thermal energies; as well as various forms of potential energy such as that stored in springs, compressed gases, or in suspended objects (gravitational).
Isolating Device – A device that prevents the transmission or release of hazardous energy or hazardous materials. Examples include restraint blocks, electrical circuit breakers, disconnect switches, slide gates, slip blinds, or line valves. For lockout/tagout purposes, isolating devices that provide visible indication of the device's position are desirable.
Lockbox – A device that is capable of being locked in which the key(s) for the energy control boundary lock(s) is stored.
Lock(s) – A device that requires a key to operate (not a combination lock) and holds an isolating device in the required position for the protection of employees. The lock(s) used for control of hazardous energy must be singularly identified by color, shape, or size. This lock(s) shall be the only device used for controlling hazardous energy and shall not be used for other purposes.
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 a machine or equipment. Included are blank flanges and bolted slip blinds.
Lockout/Tagout – Installation of lock(s) and tag(s) on the isolating device(s) to ensure that work can be performed safely. The lock(s) and tag(s) ensure that the isolating device(s) and the equipment or system(s) they isolate or control cannot be operated until the lock(s) and tag(s) are removed.
Overlock/Overtag – Lock(s) and Danger Tag(s) installed by an authorized worker on top of the controlling organization’s Danger – Do Not Operate Tag(s).
SafeCondition Check – The inspection or test of a system or component performed by the controlling organization to ensure that the hazardous energy or materials are controlled adequately to prevent injury or accident.
Note: This is a mandatory step to ensure safety for employees.
Servicing and Maintenance – Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, maintaining, 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 may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy. This applies to all employees regardless of job title (operator, researcher, maintenance crafts, engineer, or construction craft).
Simple Lockout/Tagout – A lockout/tagout activity that meets all of the following (also refer to Practice 000.653.1302, Permit to Work):
1. The machine or equipment has no potential for stored or residual energy or re-accumulation of stored energy after shutdown that could endanger employees.
2. The machine or equipment has a single energy source that can be readily identified and isolated.
3. The isolation and locking out of that energy source that completely de-energizes and deactivates the machine or equipment.
4. The machine or equipment is isolated from that energy source and locked out during service or maintenance.
5. A single lockout device achieves a locked out condition.
6. The lockout device is under the exclusive control of the authorized worker performing the service or maintenance.
7. The service or maintenance does not create hazards for other employees.
8. The employer, in using this exception, has had no accidents involving the unexpected activation or re-energization of the machine or equipment during service or maintenance.
Tag – Danger Tag or a Danger – Do Not Operate Tag and a means of attachment, which can be securely fastened to an energy-isolating device in accordance with this program, to indicate that the energy-isolating device and the equipment being controlled cannot be operated until the tag is removed.
Tagout – The installation of a danger tag on an isolating device to prevent the operation of the component or equipment when operation could cause personal injury or death, and to indicate that the energy-isolating device and the equipment being controlled may not be operated until the tag is removed. A tag is used by itself only when the isolating device is physically incapable of being locked.
Tagout Authorization Form (TAF): The controlling organization’s form used to document the implementation of the lockout/tagout process. When used, a copy of this form is given to the authorized workers to communicate the work scope, the hazards involved, the isolation methods, and other information specific to the work assignment.
Work Assignment – An activity an authorized worker performs under a lockout/tagout. The time period required to complete the work assignment may be a single shift, or part of a shift, or may extend beyond a work shift or several work shifts. The time period for the work assignment may be specified by the controlling organization.
1.0 PRINCIPLES OF LOCKOUT/TAGOUT
The following 14principles provide the fundamental basis for successful employee protection while performing hazardous energy control/lockout-tagout:
· Each authorized worker will install his/her personal lock(s) and Danger Tag(s) before starting work and will remove them when leaving that work assignment. The personal lock and Authorized Worker Danger Tag signifies that an authorized worker is working on a component.
· The Authorized Worker Danger Tag is for the exclusive use of the authorized worker identified on that Danger Tag. Information on the tag must include the following:
- Name and telephone number of the authorized worker who installed the Danger Tag (use permanent ink).
- Name and telephone number of the authorized worker’s supervisor.
- Name of the authorized worker’s organization.
· A safe-condition check is always required.
· No one will remove a lockout or tagout device when an unsafe condition exists until that condition has been made safe or another lockout device has been installed. No one will operate any equipment on which a lockout/tagout device is installed.
· No authorized worker will install a lock/tag on any system without notifying the controlling organization, unless the work control system specifically addresses this issue. This is to ensure the controlling organization knows the status of its equipment/systems.
· Only keyed locks are authorized for lockout.
· The authorized worker will maintain control of the key(s) for any lock(s) he/she applies. If abackup key exists, it is locked in a safe location away from the worksite and controlled by the authorized worker’s supervisor to use only in extreme circumstances.
· Locks and Authorized Worker Danger Tags can only be removed by the worker who originally installed them. When the authorized worker is not on site, the device(s) may be removed under the direction of the authorized worker’s management after all reasonable efforts to reach the worker have been taken.
A phone conversation with the original authorized worker is considered adequate when documented. If contact with the original authorized worker was not possible, he/she must be informed of the lock/tag removal upon returning to work.
· New designs include isolating devices for machines or equipment that accept alock when the machines or equipment are being replaced, repaired, renovated or modified, or when new equipment is being installed.
· When an Authorized Worker Danger Tag(s) used in a radiological or hazardous chemical control zone cannot be released, it must be destroyed or defaced to prevent reuse and disposed of in accordance with appropriate disposal procedures.
· Appropriate training and annual refresher training will be provided and documented.
· The execution of the energy control and lockout/tagout processes to assess employee understanding and compliance will be documented in an annual review and will include interviews with affected and authorized workers.
· Compliance with this hazardous energy control program and its requirements is mandatory. To maintain consistency, use only the Danger Do Not Operate Tag (Controlling Organization) (Form 000.653.F0281); TagoutIndex(Form 000.653.F0279); Tagout Authorization Form (TAF) (Form 000.653.F0278); Authorized Worker DangerTag (Form 000.653.F0280); and Caution Tag (Controlling Organization) (Form 000.653.F0282).
· Tags used for hazardous energy control will not be used for any other purpose. For example, the Authorized Worker Danger Tag and the controlling organization Danger – Do Not Operate Tag cannot be used to identify equipment as “out of service” or “defective.” “Out of service” or “defective equipment” tags must be substantially different.
2.0 GENERAL REQUIREMENTS
Each employer will supply uniquely identified locks and associated hardware for use by their authorized workers. The locks may be issued on a permanent basis or on an asneeded basis.
If an isolating device has the physical capability of being locked out, it will be locked out and an Authorized Worker Danger Tag installed with each lock. If the isolating device cannot be physically locked out, it will be tagged out.
If an isolating device cannot be locked, then protection equivalent to that provided by locks must be established and a tag(s) will be used to ensure that the equivalent protection is maintained.
Note: Examples of measures that could be used to provide protection equivalent to locks and prevent a system from being energized include removing an isolating circuit element or fuse, blocking switch controls, opening extra circuit disconnects, and removing valve handles.
Note: When a lock cannot be applied along with a tag, the tagout devices, including their means of attachment, must be durable and substantial enough to prevent inadvertent or accidental removal. Tagout attachment devices are of anon-reusable type, attachable by hand, self-locking, and non-releasable with aminimum unlocking strength of not less than 50pounds force (222.4newtons) and having the general design and basic characteristics of being at least equivalent to aonepiece, all-environment-tolerant nylon cable tie.