HARVARD-SMITHSONIAN CENTER FOR ASTROPHYSICS CONTROL OF HAZARDOUS ENERGY SOURCES LOCKOUT/TAGOUT PROGRAM MANUAL

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1 1 HARVARD-SMITHSONIAN CENTER FOR ASTROPHYSICS CONTROL OF HAZARDOUS ENERGY SOURCES LOCKOUT/TAGOUT PROGRAM MANUAL (ADAPTED FROM THE HARVARD CONTROL OF HAZARDOUS ENERGY SOURCES LOCKOUT/TAGOUT PROGRAM) For additional assistance or information about the OSHA Control of Hazardous Energy Sources Standard or this written manual, please contact: Karen Lawley CfA Safety Office (617)

2 2 Harvard-Smithsonian Center For Astrophysics Control Of Hazardous Energy Sources (Lockout/Tagout) Policy Center for Astrophysics employees who service or maintain machines or equipment may be at risk of injury due to the unexpected startup, energization or release of stored energy from these machines. The Occupational Health and Safety Administration (OSHA) has issued a safety standard to protect workers from this type of injury. The OSHA standard CFR , Control of Hazardous Energy Sources (Lockout/tagout) details safety requirements for working with potentially hazardous energy sources. Under the standard, employers must develop a written program detailing procedures for disabling energy sources, provide training to involved employees, obtain standardized lockout/tagout devices and perform periodic audits of the program. It should be noted that regular building maintenance and repair at CfA is not performed by Smithsonian employees. The only S. I. employees to whom this standard would apply are: 1) some working in the labs and machine shops who maintain or repair high energy equipment, 2) some working on telescopes (esp. with revolving roofs), and 3) some working on antennae with motor controls. Of these, OSHA exempts those cases as outlined in section 1.7. As a practical matter, Harvard exempts lab equipment that is not hard-wired or where the equipment plug is visible to the person working on it. For the sake of common sense and to be consistent with Harvard policy, these criteria also apply to S. I. personnel. Responsibilities Each department is responsible for implementation of the Lockout/tagout program in compliance with the OSHA standard. The Safety Office is responsible for providing technical expertise as requested by the departments regarding all aspects of complying with the Lockout/Tagout Standard. This may include assistance with training, worksite evaluations and program audits.

3 3 PROGRAM IMPLEMENTATION Implementation of the Control of Hazardous Energy Program entails several key elements. These components enumerated below will assist the departments in establishing their lockout/tagout programs. Written Program CfA departments, where applicable, will maintain a written lockout/tagout program. To comply with this requirement, Departments will add machine-specific information to Appendices C-F of the Harvard-Smithsonian Control of Hazardous Energy Program and keep a copy of the completed document available to everyone in their department to whom the document applies. Facility Survey Each affected area will perform a site survey to determine which equipment and machinery will be governed by lockout/tagout procedures. This survey will enable departments to ascertain which employees must be trained in lockout/tagout, what lockout/tagout equipment to obtain and what machinery require specific written procedures. As indicated in the body of this document (see sec. 1.7) certain cord- and plug-connected electrical equipment which does not contain stored energy and is under the exclusive control of the employee (e.g., laboratory centrifuge that is not hard wired and whose plug is visible) is exempt from this standard. In addition, certain routine servicing activities are not covered by this standard. The Safety Office is available to assist with facility surveys. Lockout/Tagout Accessories Each department will obtain appropriate locks, tags and accessories for their own authorized employees who will be servicing machinery or equipment in their respective areas if one of the following apply: 1) The equipment is hard-wired into the wall, or 2) The plug for the equipment cannot be seen by the person repairing or maintaining the equipment. Training Departments will provide training for all of their affected employees (see sec. 14). The purpose of this training is to assure that the lockout/tagout procedures contained in this manual are understood and followed by all involved CfA employees. The Safety Office is available to assist in this training upon request.

4 4 Program Audit A facility review should be conducted annually by the CfA Safety Office and the Safety Committees. The purpose of this periodic inspection is to ensure that the procedures and requirements of this standard are being followed. The audit will also identify new equipment or machinery that may be covered.

5 5 Harvard-Smithsonian Center For Astrophysics Control Of Hazardous Energy Sources (Lockout/Tagout) Policy Table Of Contents 1.0 General 2.0 Purpose 3.0 Definitions 4.0 Responsibility 5.0 Safety Locks 6.0 Safety Tags 7.0 Documentation 8.0 Preparation for Lockout and Tagout 9.0 Sequence 10.0 Restoring Equipment or System to Normal Operations 11.0 Procedure Involving More Than One Person 12.0 Shift Changes 13.0 Outside Contractors 14.0 Training Program and Materials 15.0 Machine Specific Procedures

6 6 Harvard-Smithsonian Center For Astrophysics Control Of Hazardous Energy Sources (Lockout/Tagout) Policy 1.0 General 1.1 The Occupation Safety and Health Administration (OSHA) has issued a safety standard (29 CFR 1910, Section ) concerning the control of hazardous energy sources. It is intended to prevent injuries and fatalities caused by the inadvertent start-up of equipment or release of stored energy. This standard became effective October 31, 1989 and complements a 1971 OSHA safety standard. (appendix B contains a complete citation of the standard) 1.2 The OSHA standard requires employers to develop and implement a comprehensive program outlining procedures for employees to lockout or tagout energy-isolating devices, or to release stored energy during routine and emergency maintenance activities. 1.3 This lockout and tagout procedure is based upon the OSHA lockout/tagout standard. It has been developed and will be periodically reviewed and updated. 1.4 The employer is required to develop a specific procedure for all equipment which is unique in design and application, and is covered by the lockout/tagout standard. These machine specific procedures will be enumerated in Appendix C of this document. OSHA permits an exception to the required specific procedure when the following conditions exist: "The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist: (1) The machine or equipment has no potential for stored or residual energy or re accumulation of stored energy after shut down which could endanger employees; (2) the machine or equipment has a single energy source which can be readily identified and isolated; (3) the isolation and locking out of that energy source will completely de energize and deactivate the machine or equipment; (4) the machine or equipment is isolated from that energy source and locked out during servicing or maintenance; (5) a single lockout device will achieve a locked-out condition; (6) the lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; (7) the servicing or maintenance does not create hazards for other employees; and (8) the employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance."

7 1.5 The employer may develop a generic lockout/tagout procedure for pieces of equipment that are not unique, but identical in design, installed in identical applications, and are connected to energy sources of identical type and magnitude. 1.6 A tagout procedure is acceptable only when the affected equipment/system is not designed to accommodate a lock and when the employer can demonstrate that full employee protection (the level of safety equivalent to that of a safety lock) can be achieved. It must be understood that a safety tag can become inadvertently detached without major effort or it may be misunderstood by those who do not read English or are not familiar with the lockout/tagout requirements. 1.7 OSHA permits the following exceptions to the lockout/tagout procedure: "Minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations, are not covered by this standard if they are routine, repetitive, and integral to the use of the equipment for production, provided that the work is performed using alternative measures which provide effective protection." This first exception does not apply if an authorized employee is required to remove or bypass a guard or safety device, or if he/she is required to place any part of his/her body into an area of the equipment where work is being performed. "Work on cord and plug connected electrical equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by, the unplugging of the equipment from the energy source and by the plug being under the exclusive control of the employee performing the servicing or maintenance." "Hot tap operations involving transmission and distribution systems for substances such as gas, steam, water or petroleum products when they are performed on pressurized pipelines, provided that the employer demonstrates that (1) continuity of service is essential; (2) shutdown of the system is impractical; and (3) documented procedures are followed, and special equipment is used which will provide proven effective protection for the employees." 1.8 The OSHA standard requires employers to conduct lockout/tagout procedural training and retraining sessions for all of its authorized and affected employees. Also, the employer is required to perform periodic site inspections to ensure that the lockout/tagout procedure is fully understood and followed by each employee. 1.9 All new equipment and systems must be capable of accepting a lockout-device. Also, all equipment undergoing a major replacement, repair, renovation or modification must have provisions for accepting a lockout device. 2.0 Purpose 2.1 This procedure establishes the minimum requirements for the lockout/tagout of energy-isolating devices. It shall be used to ensure that the effected equipment or system is isolated from all potential hazardous energy and is locked/tagged out before 2

8 authorized employees perform any maintenance activities where the unexpected energization, start-up or release of stored energy could cause a serious personal injury or fatality. 2.2 This procedure is to be used in conjunction with and not a substitute for other industry-accepted safety procedures, such as the use of safety tapes, signs, guards and barriers. An authorized employee shall require his/her supervisor's expressed authorization before utilizing an alternative means of system lockout. 2.3 Aimed primarily to prevent serious personal injury or a fatality from stored energy, this procedure shall be used to prevent the introduction of hazardous material (including chemicals and asbestos) into a worksite, avoid a hazardous work condition (including limited confinement) or damage equipment inadvertently. 3.0 Definitions 3.1 An affected employee is one who operates the equipment or system being maintained and is being locked/tagged out, or whose job requires him/her to work in the area in which the maintenance is being performed. 3.2 An authorized employee is one who has undergone training on the lockout/tagout procedure and implements the procedure to perform maintenance on a piece of equipment or system. An authorized employee and an affected employee may be the same person. 3.3 An energy system or source shall include but not be limited to electrical, thermal (including steam, hot water), hydraulic, liquid (including water, chemicals)pneumatic (including compressed air, natural gas and other gases) radiation, and mechanical (including pulley and gear drives). An affected piece of equipment is considered energized if it is connected to an energy source or contains residual or stored energy. 3.4 An energy-isolating device shall include but not be limited to an electrical switch, a circuit breaker, or a valve. It can also be a mechanical device which physically prevents the transmission or release of any type of stored or kinetic mechanical energy, such as a mechanical brake. 3.5 A lockout device utilizes a positive means to hold an energy-isolating device in a safe position and prevent a piece of equipment from being energized. 3.6 A tagout device is a prominent warning device which can be secured to an energyisolating device to indicate that a piece of equipment or system and its associated energy-isolating device must not be operated until the tagout device is removed. 3.7 A piece of equipment is capable of being locked out if it is equipped/designed with an integral hasp or locking mechanism upon/through which a lockout device can be affixed. 4.0 Responsibility 3

9 4.1 All employees whose work operations are or may be affected (affected and authorized employees) shall be instructed in the purpose and use of the lockout/tagout procedure. All outside contractors or utility companies shall also conform to either their own or this lockout/tagout procedure. 4.2 Since equipment is locked/tagged out to prevent inadvertent personal injury or equipment damage, employees should not attempt to operate any switch, device or other energy isolating device that is locked/tagged out. 4.3 An employee shall not secure or remove the safety lock of any authorized employee and shall not permit another employee to secure or remove his/her safety lock Only with the expressed authorization of his/her supervisor, may an employee remove the safety lock of an authorized employee. This action shall only be taken in the event of an emergency after the authorized employee who placed the safety lock cannot be located or made available for removal, and after the authorized employee's supervisor has deemed the equipment, system or worksite safe. The supervisor will verify that the authorized employee is not at the facility and is not at any risk. The authorized and affected employees shall be contacted and informed that safety locks and tags have been removed before any work is further resumed on that equipment/system On occasion, a supervisor will need to contact an employee at home regarding a lockout situation. It will be that supervisor's discretion whether to call the employee into work to remove the lock; or, with the employee's concurrence, remove the lock with a master key. 4.4 Failure to observe the lockout/tagout procedure or unauthorized safety lock removal shall warrant disciplinary action and possible state and federal prosecution. 5.0 Safety Locks 5.1 Keyed padlocks will be centrally distributed and will be assigned to an authorized employee when a lockout is to be performed (see Appendix D for location of locks and specific details of distribution system). 5.2 Each authorized employee shall be issued padlocks with its own key series. Each authorized employee shall have the keys to his/her own set of locks only and will not be able to unlock another employee's lock. 5.3 Supervisors shall have a master key so that an authorized employee's safety lock can be removed during an emergency. Each Area will have its own master keying. 5.4 When more than one authorized employee is involved with a lockout procedure and the particular equipment/system can only accommodate one safety lock, a multiple lock device will be used. For complex lockout situations, a group lock box may be required to house all safety lock keys. 4

10 5.5 To secure valving, a chain or valve lockout device may be required in conjunction with the safety lock. 5.6 Appendix D lists the specific location and system for distribution of locks, tags, devices, etc. 6.0 Safety Tags 6.1 A generic safety ("Danger - Do Not Operate") tag shall be used in all applications. There will be space for the authorized employee's name and department, a description of the work being performed and other affected systems, and the date that the system was taken out of service and can be expected to be restored to service. The safety tag should also list the location of other safety locks/tags associated with the particular activity. 6.2 The safety tag shall be placed at the closest disconnect point to the affected system. It shall also be placed in clear view as a reminder and a warning to the issuer and others in the area. A preferred location is at an energy-isolating device. 6.3 Tagout of machinery or equipment as the exclusive means of hazardous energy control will only be done when lockout procedures are practically or physically impossible. 6.4 Specific information on location and procurement of tags is located in Appendix D of this manual. 7.0 Documentation 7.1 Each department will maintain records use of any master keys, customer and contractor notifications, and deviations from the prescribed lockout/ tagout procedure. The Safety Office will maintain records to document the issuance of safety locks, related training and retraining, and site inspections. 7.2 The aforementioned documentation will be located in the office indicated in Appendix E. 8.0 Preparation for Lockout and Tagout 8.1 The authorized employee(s) shall inspect the area and make a survey to locate and identify all isolating devices to be certain which switch(es), valve(s), or other energyisolating devices apply to the system to be locked/tagged out. More than one energy source (electrical, mechanical or others) may be involved. 8.2 Should an authorized employee be unsure of all of the involved energy sources or isolating devices, he/she should consult his/her supervisor or affected employee responsible for the equipment or system. 9.0 Sequence 5

11 9.1 The authorized employee shall notify all affected employees, operators and supervisors that a lockout/tagout procedure is going to be utilized and the reason therefore. The authorized employee shall know the type and magnitude of energy that the system utilizes and shall understand the hazards thereof. The employee shall confirm his/her understanding of the system and the associated hazards with the affected employees, operators or supervisors. 9.2 If equipment or energy system is operating, it shall be shut down by its normal stopping procedure. 9.3 Operate and lockout/tagout the necessary switch, valve, and /or other energy isolating device(s) so that the system is isolated from its energy source(s). With electrically operated systems, it may be required or desirable to complement a lockout/tagout procedure with the removal of control and power fuses, circuit breakers, and/or wiring. With mechanical systems, it may be required or desirable to secure valving with a chain and lock. The valve shall be either locked open or closed, whichever is appropriate to isolate or dissipate energy stored in a pressurized vessel or piping system. For further safety assurance, additional measures, such as the removal of a valve handle or the removal of fuses, may be required to ensure the isolation from hazardous energy sources and to prevent inadvertent equipment or system reenergization Stored energy (such as that in springs, elevated members, rotating flywheels, hydraulic systems; air, gas, steam, or water pressure; electrical charge, etc..) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, discharged, etc. 9.4 Lockout/tagout the energy-isolating devices with assigned lock(s)/tag(s). It is suggested to use a safety tag in conjunction with any lockout means to inform and remind employees in the area that a particular piece of equipment or system has been secured. To ensure personal safety, an authorized employee must lockout/tagout all energy-isolating devices associated with the equipment or system to be serviced or maintained, even if the particular isolating device is not normally associated with his/her trade. For additional assurances in complex lockout/tagout situations, the authorized employee may enlist the assistance of other authorized trades people or a supervisor to secure supplemental safety locks and tags. 9.5 After ensuring that no personnel are exposed, and as a check on having disconnected the energy sources, operate the normal operating control(s) or perform other methods of testing to make certain the equipment or system will not operate and all hazardous energy sources have been isolated and dissipated. CAUTION: Return operating control(s) to "neutral" or "off" position after performing the test. 6

12 9.6 The system is now locked or tagged out and is considered safe for maintenance activities. If an employee is unsure that a particular lockout/tagout procedure can provide adequate worker safety, he/she shall notify his/her immediate supervisor for further instructions Restoring Equipment or System to Normal Operations 10.1 After the servicing/maintenance is completed and the system is ready for normal operation, check the area around the system to ensure that no one is exposed to a possible unsafe situation. Notify all affected employees and supervisors in the area or associated with the work After all tools and nonessential items have been removed from the equipment/system, all guards have been reinstalled and employees are in the clear, remove all lockout/tagout devices. All affected employees shall be notified that the locks and tags have been removed Operate all of the energy isolating devices to restore energy to the system. The system shall be left in its normal state, either operating or ready for operation Procedure Involving More Than One Person 11.1 In situations where more than one authorized person is involved in the lockout procedure, one person shall be chosen to coordinate the work force, and the extent and continuity of lockout/tagout protection In the preceding steps, if more than one individual is required to lockout or tagout the system, each shall place his/her own personal lockout/tagout device(s) on the energy isolating device(s). When an energy isolating device cannot accept multiple locks or tags, a multiple safety lockout device shall be used A single lock may be used to lockout the equipment or system with the key being placed in a lockout box or cabinet which allows the use of multiple locks to secure it. Each authorized employee will then use his/her lock to secure the box or cabinet. As each person no longer needs to maintain his or her lockout protection, the person initiating the lockout procedure will remove his/her lock from the box or cabinet to unlock the energy-isolating device Shift Changes 12.1 If the work activity is continued into another shift, the incoming authorized employee must secure his/her safety lock before the departing authorized employee removes his/her safety lock The incoming and outgoing authorized employees shall review the workscope of the maintenance activities and examine or retest the affected equipment or system to verify its de-energized state Outside Contractors 7

13 13.1 Whenever outside service and maintenance contractors are to be engaged, the representative should determine, before the contract is finalized, whether the contractor's activities are covered by the OSHA lockout/tagout standard. This provision also pertains to outside utility companies If the contractor's activities are covered by the OSHA lockout/tagout, the CfA representative should furnish a copy of this lockout/tagout procedure to the contractor and ascertain whether the contractor has its own lockout/tagout procedure If the Contractor does not have its own lockout/tagout procedure, it should familiarize itself with and follow this lockout/tagout procedure Notwithstanding the provisions of section , if the CfA representative determines that the Contractor's work is to be carried out in an area in which CfA personnel will not be affected, the Contractor may utilize its own lockout/tagout procedure without regard to the level of protection that it affords compared to this procedure CfA and Contractor personnel should be aware that their interaction can be a possible source of injury and that close coordination of their activities is needed in order to reduce the likelihood of such injury The individual listed in Appendix F of this manual will be responsible for exchange of lockout/tagout information with the outside contractor Training 14.1 The Center for Astrophysics will provide training to all affected and authorized employees not already covered by training to ensure that the purpose and methods of implementation of its program are understood. The training includes the following elements: recognition of applicable hazardous energy sources, methods and procedures for energy isolation and control, lockout/tagout equipment and supplies and limitations of tagout. 8