CONTROL OF HAZARDOUS ENERGY: LOCKOUT/TAG OUT

Control of Hazardous energy is the purpose of the Lockout- Tagout Program. This program establishes
the requirements for isolation of both kinetic and potential electrical, chemical, thermal, hydraulic and
pneumatic and gravitational energy prior to equipment repair, adjustment or removal. Reference: OSHA
Standard 29 CFR 1910. 147, the control of hazardous energy. 

• Authorized (Qualified) Employees:
  • are the only ones certified to lock and tagout equipment or
    machinery. Whether an employee is considered to be qualified will depend upon various
    circumstances in the workplace. It is likely for an individual to be considered "qualified" with
    regard to certain equipment in the workplace, but "unqualified" as to other equipment. An
    employee who is undergoing on-the-job training and who, in the course of such training, has
    demonstrated an ability to perform duties safely at his or her level of training and who is
    under the direct supervision of a qualified person, is considered to be "qualified" for the
    performance of those duties. 
• Affected Employees:
  • are those employees who operate machinery or equipment upon which
    lockout or tagging out is required under this program. Training of these individuals will be
    less stringent in that it will include the purpose and use of the lockout procedures. 
• Other Employees
  • are identified as those that do not fall into the authorized, affected or qualified
    employee category. Essentially, it will include all other employees. These employees will be
    provided instruction in what the program is and not to touch any machine or equipment when
    they see that it has been locked or tagged out. 

• Authorized Employees Training
  • All Maintenance Employees, Department Supervisors and Janitorial employees will be
    trained to use the Lock and Tag Out Procedures. The training will be conducted by the
    Maintenance Supervisor or Safety Coordinator at time of initial hire. Retraining shall be
    held at least annually.
    • The training will consist of the following:
      1. Review of General Procedures
      2. Review of Specific Procedures for machinery, equipment, and processes
      3. Location and use of Specific Procedures
      4. Procedures when questions arise
• Affected Employee Training
  • Only trained and authorized Employees will repair, replace or adjust machinery, equipment or processes
  • Affected employees may not remove locks, locking devices or tags from machinery, equipment or circuits.
  • Purpose and use of the lockout procedures
• Other Employee Training
  • Only trained and authorized employees will repair, replace or adjust machinery or equipment
  • Other employees may not remove Locks, locking devices or tags from machinery, equipment or circuits

• A Lockout- Tagout survey has been conducted to locate and identify all energy sources to verify which switches or valves supply energy to machinery and equipment. Dual or
  redundant controls have been removed. 
• A Tagout Schedule has been developed for each piece of equipment and machinery. This schedule describes the energy sources, location of disconnects, type of disconnect, special hazards and special safety procedures. The schedule will be reviewed each time to ensure employees properly lock and tag out equipment and machinery. If a Tagout Schedule does not exist for a particular piece of equipment, machinery and process, one must be developed prior to conducting a Lockout - Tagout. As repairs and/or renovations of existing electrical systems are made, standardized controls will be used. 

• Before working on, repairing, adjusting or replacing machinery and equipment, the following procedures will be utilized to place the machinery and equipment in a neutral or zero mechanical state.
• Preparation for Shutdown. Before authorized or affected employees turn off a machine or piece of equipment, the authorized employee will have knowledge of the type and
  magnitude of the energy, the hazards of the energy to be controlled, and the means to control the energy.
• Notify all affected Employees that the machinery, equipment or process will be out of service
• Machine or Equipment Shutdown.The machine or equipment will be turned or shut down using the specific procedures for that specific machine. An orderly shutdown will be utilized to avoid any additional or increased hazards to employees as a result of equipment de-energization.
• If the machinery, equipment or process is in operation, follow normal stopping procedures (depress stop button, open toggle switch, etc.).
• Move switch or panel arms to "Off" or "Open" positions and close all valves or other energy
  isolating devices so that the energy source(s) is disconnected or isolated from the
  machinery or equipment.
  
  

• Lockout or tagout devices will be affixed to energy isolating devices by authorized
  employees.
• Lockout devices will be affixed in a manner that will hold the energy isolating devices from
  the "safe" or "off" position.
• Where tagout devices are used they will be affixed in such a manner that will clearly state that the operation or the movement of energy isolating devices from the "safe" or "off" positions is prohibited.
• The tagout devices will be attached to the same point a lock would be attached. If the tag cannot be affixed at that point, the tag will be located as close as possible to the device in a position that will be immediately obvious to anyone attempting to operate the device.
• Lock and tag out all energy devices by use of hasps, chains and valve covers with an
  assigned individual locks.

• Following the application of the lockout or tagout devices to the energy isolating devices, all potential or residual energy will be relieved, disconnected, restrained, and otherwise rendered safe.
• Where the re-accumulation of stored energy to a hazardous energy level is possible, verification of isolation will be continued until the maintenance or servicing is complete.
• Release stored energy (capacitors, springs, elevated members, rotating fly wheels, and hydraulic/air/gas/steam systems) must be relieved or restrained by grounding, repositioning, blocking and/or bleeding the system.

• Prior to starting work on machines or equipment that have been locked or tagged out, the authorized employees will verify that isolation or de-energization of the machine or
  equipment have been accomplished.
• After assuring that no Employee will be placed in danger, test all lock and tag outs by following the normal start up procedures (depress start button, etc.).
• Caution: After Test, place controls in neutral position.

Should the shift change before the machinery or equipment can be restored to service, the lock and tag
out must remain. If the task is reassigned to the next shift, those Employees must lock and tag out before
the previous shift may remove their lock and tag.

Before lockout or tagout devices are removed and the energy restored to the machine or equipment, the following actions will be taken:

• The work area will be thoroughly inspected to ensure that nonessential items have been removed and that machine or equipment
• The work area will be checked to ensure that all employees have been safely positioned or removed. Before the lockout or tagout devices are removed, the affected employees will be notified that the lockout or tagout devices are being removed
• Each lockout or tagout device will be removed from each energy isolating device by the employee who applied the device.

This procedure covers all Electrical Plug-Type Equipment such as Battery Chargers, some Product
Pumps, Office Equipment, Powered Hand Tools, Powered Bench Tools, Lathes, Fans, etc. When working
on, repairing, or adjusting the above equipment, the following procedures must be utilized to prevent
accidental or sudden startup:

• Unplug Electrical Equipment from wall socket or in-line socket
• Attach "Do Not Operate" Tag and Plug Box & Lock on end of power cord. An exception is granted to not lock & tag the plug is the cord & plug remain in the exclusive control of the Employee working on, adjustin or inspecting the equipment.
• Test Equipment to assure power source has been removed by depressing the "Start" or On" Switch.
• Perform required operations
• Replace all guards removed.
• Remove Lock & Plug, Box and Tag.
• Inspect power cord and socket before plugging equipment into power source. Any defects must be repaired before placing the equipment back in service.
  
  NOTE: Occasionally used equipment may be unplugged from power source when not in use.
  
  

In the preceding SOPs, if more than one Employee is assigned to a task requiring a lock and tag out, each must also place his or her own lock and tag on the energy isolating device(s).

Only the Employee that locks and tags out machinery, equipment or processes may remove his/her lock and tag. However, should the Employee leave the facility before removing his/her lock and tag, the Maintenance Manager may remove the lock and tag. The Maintenance Manager must be assured that all tools have been removed, all guards have been replaced and all Employees are free from any hazard before the lock and tag are removed and the machinery, equipment or process are returned to service. Notification of the employee who placed the lock is required prior to lock removal.

Contractors, working on company property and equipment must use this Lockout - Tagout procedure while servicing or maintaining equipment, machinery or processes