Section 10

LOCKOUT/TAGOUT OF HAZARDOUS ENERGY SOURCES

INTRODUCTION

The Code of Federal Regulations - 29 CFR 1910.147 standard helps protect associates from hazardous energy while they are performing servicing or maintenance on machines and equipment. The law requires that, in general, before servicing or maintenance is performed on machinery or equipment, the machinery or equipment must be turned off and disconnected from the energy source, and the energy-isolating device must be either locked or tagged out. Additionally any stored energy must be dissipated before work begins.

PURPOSE

The purpose of lockout/tagout is to prevent energy from accidentally being released while a machine or equipment is being serviced. The primary purpose of lockout/tagout is to protect the safety and health of associates. Secondary is the protection of the equipment from damage.

Objectives

The objectives of these guidelines are:

  • Inform associates of the requirements under 29 CFR 1910.147
  • Provide information and the requirements of the law.
  • Provide a model lockout/tagout procedure for each facility that complies with the standard.

SCOPE AND APPLICATION

The lockout-tagout standard applies to most industries and covers the servicing and maintenance of machines and equipment in which the unexpected startup or the release of stored energy could cause injury to associates. (If associates are performing service or maintenance tasks that do not expose them to the unexpected release of hazardous energy, the standard does not apply.) The standard establishes minimum performance requirements for the control of hazardous energy.

Industries not covered under the standard:

Construction, agriculture, maritime and, oil and gas well drilling services.

Application Of The Standard

The lockout/tagout standard apples whenever an employee:

1. Removes or bypasses machine guards or other safety devices resulting in exposure

to hazards at the point of operation

2. Places any part of their body in contact with the point of operation of the

machine or piece of equipment

3. Places any part of their body into a danger zone associated with a machine

operating cycle

The standard does not apply to the following circumstances:

  • While servicing or maintaining cord and plug powered electrical equipment. (The potential hazard can be controlled by unplugging equipment from the energy source; "and" the plug must be under the exclusive control of the associate performing the servicing and/or maintenance.)
  • During hot tap operations that involve transmission and distribution systems for power systems, gas, steam, water; when continuity of service is essential, and shutdown of the system is impractical; and associates are provided with an alternative type of protection and/or training that is equally effective.

However, proper training, precautions and when necessary protective equipment, will be required when conducting the tasks listed above.

PROVISIONS OF THE OSHA STANDARD

The OSHA standard requires Mid-South Electronics, Inc. to establish procedures for isolating machines or equipment and affixing appropriate locks or tags to energy-isolating devices to prevent any unexpected energization, startup, or release of stored energy that could injure workers. The standard also requires the training of associates, area in which the energy control procedure is implemented and servicing or maintenance to maintain or improve their effectiveness.

DEFINITIONS

"AFFECTED" Associate -- An associate who performs the duties of his or her job in an area in which the energy control procedure is implemented and servicing or maintenance operations are performed. An affected associate does not perform servicing or maintenance on machines, and consequently, is not responsible for implementing the energy control procedure. An affected associate becomes an 'authorized' associate whenever he or she performs servicing or maintenance functions on machines or equipment that must be locked or tagged.

"AUTHORIZED" Associate -- An associate who performs servicing or maintenance on machines and equipment. Lockout or tagout is used by these associates for their protection when adjusting, maintaining essential network equipment may remain energized.

Capable Of Being Locked Out -- An energy-isolating device is considered capable of being locked out if it meets one of the following requirements:

  • It is designed with a hasp to which a lock can be attached.
  • It is designed with any other integral part through which a lock can be attached.
  • It has a locking mechanism built into it.
  • It can be locked without dismantling, rebuilding, or replacing the energy-isolating device or permanently altering its energy control capability.

The Communications Network -- a low voltage, continuously energized, integrated system of interconnected wires, conductors, cables, and equipment that allow the transmission of voice and data signals. Because during normal operations the communications network is continuously energized and low voltage electrical energy is not unexpected or hazardous, the lockout/tagout requirements do not apply.

Department Lock -- A lock that is specifically colored to identify a specific

department.

Double Block and Bleed -- The closure of a line, duct, or pipe by closing and locking or tagging two in-line valves and by opening and locking or tagging a drain or vent valve in the line between the two closed valves.

Energized -- Machines and equipment are energized when:

  • They are connected to an energy source or,
  • They contain residual or stored energy.

Energy-Isolating Device -- Any mechanical device that physically prevents the transmission or release of energy. These include, but are not limited to, manually operated electrical circuit breakers, disconnect switches, line valves, and blocks.

Push buttons and selector switches are not energy isolating devices.

Energy Source -- Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy.

Energy Control Procedure -- A written document that contains those items of information an authorized associate needs to know in order to safely control hazardous energy during servicing or maintenance of machines or equipment.

Energy Control Program -- A program intended to prevent the unexpected energizing or the release of stored energy in machines or equipment. The program consists of energy control procedure(s), an associate training program, and periodic inspections.

Line Blanking or Blinding --The absolute closure of a pipe, line or duct by fastening of a solid plate (spectacle blind or skillet blind) that completely covers the bore and that is capable of withstanding the maximum pressure of the pipe, line or duct with no leakage beyond the plate.

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 Boundary -- The pathway through which energy is supplied to a machine or equipment, and, the control sequence all inclusive of all lockable energy isolating devices that is established and locked out prior to servicing or maintenance of equipment.

Lockout Device -- Any device that uses positive means such as a lock, either key or combination type, to hold an energy-isolating device in a safe position, thereby preventing the energizing of machinery or equipment. When properly installed, a blank flange or slip blind are considered equivalent to lockout devices. An associate's name, number or other identification means shall be used to identify the lockout device,

Lockout/Tagout Lock Box -- Box made of sturdy material that cannot be opened without force that secures the keys of department locks.

Multiple Lockout Device -- A device (HASP) that enables more than one authorized associate to affix their lock to an energy-isolating device.

Normal Operations -- Operations that include activities which enables the equipment to perform its intended function and permits associates to perform certain operations with the equipment energized. Some examples are: minor adjustments, lubrication, cleanup, etc., and the associate(s) are not required to place their hands/body in the point of operation.

“Other” associate -- All other associates who are not otherwise authorized or affected. They are not affected by any provisions of the lockout/tagout standard with the exception that they must be trained to recognize a lockout/tagout device and not to remove it under any circumstances.

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 securely fastened to an energy-isolating device in accordance with an established procedure. The tag indicates that the machine or equipment to which it is attached is not to be operated until the tagout device is removed in accordance with the control procedure.

Unexpected Release Of Energy -- when a source of energy, stored or continuous, is released (accidental) in a manner that could cause sudden activation, movement, change in position, etc. of equipment, machinery, processes, etc. such that an associate could be caught, trapped, shocked, etc. and could cause potential injury to the associate. Additionally the unexpected release of energy could also damage equipment or machinery.

ASSOCIATE TRAINING

Initial training and retraining (as necessary) must be provided and must certify that such training has been given to all associates who work in or around lockout/tagout hazards by recording training in the associate's permanent training record.

For the purpose of the standard, there are three types of associates - "AUTHORIZED" "AFFECTED", and "OTHER". The amount and type of training that each associate receives is based upon (1) the relationship of that associate's job to the machine or equipment being locked or tagged out, and (2) the degree of knowledge relevant to hazardous energy that he or she must possess.

For example, the training for "AUTHORIZED" associates (those supervisors, managers or associates who are charged with the responsibility for implementing the energy control procedures and performing the service or maintenance) must cover, at minimum, the following areas:

  • Details about the type and magnitude of the hazardous energy sources of stored energy and methods to dissipate it.
  • The methods and means necessary to isolate any sources, i.e., the elements of the energy control procedure(s).
  • Sources of energy and methods to dissipate it.

By contrast, "AFFECTED" Associates and all "OTHER" associates need only be able to:

  • Recognize when the control procedure must outline the following:
  • Understand the purpose of the procedural steps needed to shut down, isolate, block, attempting to start up or use equipment that has been locked or tagged out.

Retraining must be provided, as required, whenever there is a change in job assignments, a change in machines, equipment or processes that present a new hazard, or a change in energy control procedures. Additional retraining must be conducted whenever a periodic inspection reveals, or whenever a supervisor has reason to believe, that there are deviations from or inadequacies in the associate's knowledge or use statement on how the procedure will be used.

WRITTEN ENERGY CONTROL PROCEDURES

A written procedure must identify the information that "AUTHORIZED" associates must know in order to control hazardous energy during servicing or maintenance. If this information is the same for various machines or equipment or if other means of logical grouping exist, then a single energy control procedure may be sufficient. If there are other conditions - such as multiple energy sources, different connection means, or a particular sequence that must be followed to shut down the machine or equipment -- separate energy control procedures must outline the following:

  • Scope
  • Purpose
  • Authorization (who can do or authorize the work)
  • Rules
  • Techniques that will be used to control hazardous energy sources

At a minimum, this includes, but is not limited to, the following elements:

  • A statement on how the procedure will be used.
  • The procedural steps needed to shut down, isolate, block and secure machines or equipment..
  • The steps designating the safe placement, removal, and transfer (at shift change) of lockout/tagout devices and who has the responsibility for them.
  • The specific requirements for testing machines or equipment to determine and verify the effectiveness of locks, tags, and other energy control measures.

The procedure must include the following steps:

(1) Preparing for shutdown and notifying affected associates

(2) Shutting down the machine(s) or equipment.

(3) Isolating the machine or equipment from the energy source(s).

(4) Applying the lockout or tagout device(s) to the energy-isolating device(s).

(5) Safely releasing all potentially hazardous stored or residual energy

(6) Verifying the isolation of the machine(s) or equipment prior to the start of servicing or maintenance work.

In addition, before lockout or tagout devices are removed and energy is restored to the re-energizing equipment, including:

(1)Assuring that machines or equipment components are operationally intact.

(2)Notifying affected associates that lockout or tagout devices are being removed, and ensure that all associates are safely positioned or removed from equipment.

(3)Assuring that lockout or tagout devices are removed from each energy-isolating device by the associate who applied the device.

PERIODIC INSPECTIONS

At least annually an inspection by the supervisor or manager of every department with a review of the written procedures and confirm that they are being followed, review of hazards must be completed and documented. The inspection must include a review of the written procedures and confirm that they are being followed, review of locks and tagout equipment, and discussion of procedures with each associate. This should be documented in a manner determined by the subsidiary. At a minimum, the documentation shall have the equipment inspection date, associates affected (or group's name) and inspector's name.

SERVICING AND/OR MAINTENANCE OPERATIONS

If servicing activity such as lubricating, cleaning, or un-jamming production equipment takes place during production, the associate performing the servicing may be subjected to hazards that are not encountered as part of the production operation itself. Workers engaged in these operations are covered by lockout/tagout requirements when any of the following conditions occur:

  • The associate must either remove or bypass machine guards or other safety devices resulting in exposure to hazards at the point of operation;
  • The associate is required to place any part of his or her body in contact with the point of operation of the operational machines or equipment
  • The associate is required to place any part of his or her body into a danger zone associated with a machine operating cycle.
  • When the above situations occur, the equipment must be de-energized and locks or tags must be applied to the energy-isolation devices.

In addition, when normal servicing tasks, such as setting up equipment, and/or making significant adjustments to machines that do not occur during normal production operations, associates performing such tasks are required to lock out or tag out if they can be injured by unexpected energization of the equipment.

Some operations must be performed with the power on. Making many types of fine adjustments, such as centering the belt on billing machines, as one example. Certain aspects of trouble-shooting, such as identifying the source of the problem as well as checking to ensure that it has been corrected is another. DTD is required to provide effective protection for associates performing such operations. Although, in these cases, a power-on condition is essential either to accomplish the particular type of servicing or to verify that it was performed properly, lockout or tagout procedures are required when servicing or maintenance occurs with the power off.

MINOR SERVICING TASKS

Associates performing minor tool changes and adjustments or other minor servicing activities during normal production operations that are routine, repetitive, and integral to the use of the production equipment are not covered by the lockout/tagout standard provided the work is performed using alternative measures that give effective protection against unexpected machine cycling, for example.

EQUIPMENT MODIFICATIONS

After October 31, 1989, whenever major replacement, repair, renovation or modification of machines is performed, and whenever new machines or equipment are installed, energy-isolating devices for machines and equipment shall be designed or retrofitted to ensure that lockout devices may be placed on the equipment.

APPENDIX B – MACHINE SPECIFIC SHUTDOWN PROCEDURES

Appendix B – Machine Specific Shutdown Procedures is the form used to guide and document all lockout/tagout procedures. The following steps should be followed prior to any lockout/tagout activity:

1. Supervisor or authorized designee issues the Appendix B to the authorized

associate when lockout is needed.

2. The authorized associate will follow and complete the Appendix B and return

to the supervisor or authorized designee for final verification and signature.

3. The supervisor or authorized designee will retain the Appendix B until the

authorized associate is ready to clear the lockout.

4. For re-energization of machines prior to clearing the lockout, see Testing or

Positioning Of Machines.

APPLICATION OF CONTROLS AND LOCKOUT/TAGOUT DEVICES

The established procedure of applying energy controls includes the specific elements and actions that must be implemented in sequence. These are briefly identified as follows:

  1. Prepare for shutdown – Discuss with supervisor - Establish boundary Notify affected persons
  1. Shut down the machine or equipment.
  1. Apply the lockout or tagout device.
  1. Render safe all stored or residual energy - Cycle the machine and return to the off position
  1. Verify the isolation and de-energization of the machine or equipment.
  2. Place department lock keys in lockout/tagout lockbox
  3. Have Supervisor walk down and verify lockout boundary and sign verification

REMOVAL OF LOCKS AND TAGS, RETURN TO SERVICE

  1. Notify supervisor that job is completed, retrieve department keys from lockout/tagout lockbox.
  2. Check the machine or equipment and the immediate area around the machine to ensure that non-essential items have been removed and that the machine or equipment components are operationally intact.
  3. Check the work area to ensure that all associates have been safely positioned or removed from the area.
  4. Verify that the controls are in the neutral or off position.
  5. Remove the lockout/tagout devices in reverse order of application and re-energize the machine. NOTE: The removal of some forms of blocking may require re-energizing of the machine before safe removal.
  6. Notify affected employees that the servicing or maintenance is completed and the machine is ready for use.
  7. Sign the verification area (step 6) of Appendix B.

ADDITIONAL SAFETY REQUIREMENTS