Control of Hazardous Energy (Lockout Tagout) Plan

Transcription

1 RIT Internal Use Only Control of Hazardous Energy (Lockout Tagout) Plan RELATED REGULATORY STANDARDS: OSHA 29 CFR Revision Date: January 2010 Prepared By: R I T Environmental Health & Safety Department Q:\Lock Out Tag Out\Current Program\Current - Control of Hazardous Energy-LOTO Plan January 2010-v6.doc

2 TABLE OF CONTENTS Page I. INTRODUCTION 4 II. RESPONSIIBILITIES 5-6 RIT Environmental Health and Safety (EH&S) 5 Department Manager or Designee 6 Employees 6 Contractors 6 III LOCK OUT TAG OUT PROCEDURES AND REVIEW/INSPECTION PROCESSES 7-8 Exception to Written Procedure Requirements 7 Emergency Lockout Device Removal Procedure 7-8 Machine/Equipment Specific Procedures 8 Lockout Tagout Procedure Inspection Process 8 IV. APPLICATION OF LOCKS, TAGS, AND OTHER ENERGY CONTROL DEVICES 9-12 Requirements of LOTO Equipment 9 Seven Steps of LOTO Process 9-10 Group Lockout or Tagout Requirement Procedure Shift or Personnel Change Procedure 11 Tagout Process Procedure 11 Application of Other Energy Control Devices 12 Motor Vehicle & Powered Industrial Truck Procedure 12 V. TRAINING 13 VI. PROGRAM EVALUATION 14 VII. IMPLEMENTATION AND DISCIPLINARY ACTIONS 15 VIII. DEFINTIONS

3 APPENDICES Appendix A Link to OSHA Website for Lock Out Tag Out Standards Appendix B Departmental Contact Names Appendix C Reference Forms-SOP Template, LOTO Absent Employee Lock Removal, Annual Inspection Checklist for SOP Reviews, Determination & Assessment Form Appendix D Contractor tification Form Appendix E Lock Out Tag Out Program Assessment Tool Appendix F Document Changes/Revision History Log 3

4 I. INTRODUCTION The Rochester Institute of Technology (RIT) Control of Hazardous Energy (Lock Out Tag Out- LOTO) Plan and written procedures have been developed in accordance with the OSHA Control of Hazardous Energy Standard (29 CFR (a)(3)). RIT employees, students, visitors and/or contractors can be injured because of the failure to identify and isolate energy sources prior to servicing RIT equipment. This program intends to outline practices and procedures for affixing appropriate locks and tags to energy-isolating devices to disable machinery/equipment during maintenance and service work. The written procedures shall be used to ensure all machines or equipment are completely stopped and isolated from all potentially hazardous energy (including kinetic and potential), and locked or tagged out before employees perform any servicing or maintenance activities where the unexpected energizing, start-up or release of stored energy could cause employee injuries or damage equipment/machinery. Employees must verify or test machines and equipment that all energy sources are isolated prior to commencing servicing and/or maintenance tasks. EXEMPTION: This Plan applies to all locations and covers the servicing and/or maintenance of machines and equipment. The standard does not apply to cord and plug connected electrical equipment that is under the exclusive control of the servicing employee, normal production operations, or to hot tap (i.e. welding) operations. This program and procedures will be reviewed by RIT s Environmental Health & Safety Department (EH&S) and revised as necessary on an annual basis for effectiveness ( (c)(6)). The program will be reviewed and revised more frequently if it is determined that the measures taken under this Plan do not adequately protect RIT employees. Appendix F contains the Document Change/Revision History Log which records each update and/or revision to this program. The program review will include a review of elements such as a review of procedures to consider any problems or concerns that are identified by an Authorized Employee. This Authorized Employee must be someone other than the one(s) utilizing the energy control procedure being inspected. The inspection is led by a LOTO Authorized employee who has been trained in that procedure (Appendix C). The written Plan will be posted on the EH&S Department website and will also be available in the EH&S Department Office for review by RIT employees, the Assistant Secretary and their authorized representatives upon request. This program applies to RIT employees and contractors at any facility or job-site where locking/tagging out machinery/equipment will be encountered at RIT. 4

5 II. RESPONSIBILITIES RIT Environmental Health and Safety (EH&S) The RIT EH&S Department is responsible for the overall administration of this Plan and serve as the program administrator. The following tasks are included in this scope of responsibility, but are not limited to: 1. Establish a written Control of Hazardous Energy (Lockout Tagout) Plan. 2. Assure that new equipment (or changes to old equipment) has LOTO capability. 3. Help assess new equipment/machines and help prepare written specific procedures. 4. Help establish and assist in writing LOTO procedures for each individual or group of similar machines/equipment when requested. 5. Inform contractors of their requirements to have their own company Lockout/Tagout Program. This is done via the RIT LOTO Contractor tification Form (Appendix D). 6. Ensure that LOTO locks and tags are used only for LOTO purposes. 7. Verify Lock/Tag application process. 8. Implement Lock Removal for Absent Employee procedure. 9. Establish Group Lockout Requirement procedure. 10. Establish End of Shift Responsibilities procedure. 11. Help evaluate the potential hazards of specific machine/equipment and assist in reducing those hazards when requested. 12. Perform annual and periodic inspections of the Plan and written procedures, as required. 13. Provide training for employees (3 levels: Authorized, Affected and Other). 5

6 Department Manager or Designee The day-to-day aspects of the program are the responsibility of the Department Manager or Chair. The Department Manager may use someone within their department to assist in the daily activities of the program. 1. Assure when purchasing new equipment (or when making modifications and/or changes are made to old equipment) that it has LOTO capability and prepare procedures along with EH&S if needed. 2. Update LOTO procedures as required by equipment/machine changes. 3. Employees use designated LOTO devices during machine/equipment service or maintenance. 4. Employees follow written LOTO specific procedures. 5. LOTO procedures are reviewed by Authorized Employee(s) annually in accordance with the RIT Plan requirements. 6. Requesting training and education sessions through the EH&S Department. Employee Responsibilities It is the responsibility of each employee to have an awareness of the LOTO program requirements for their work areas (as explained by management). Employees are also responsible for: 1. Use of designated LOTO devices. 2. Follow written equipment/machine LOTO procedures. 3. Adhere to all program requirements. 4. Attend appropriate level of training per assignment by your area management (3 different levels: Authorized, Affected or Others). Contractor s Responsibilities Contractors are required to develop and implement a Control of Hazardous Energy (LOTO) program for their employees who must enter into or work in areas where exposure exists to hazardous energy sources which must be controlled before commencing work. This program must meet OSHA regulations and include issuance of designated LOTO devices, follow RIT machine/equipment written procedures, and work with RIT employees when group LOTO efforts are required. RIT will provide information (i.e. written procedures and information about designated LOTO devices) to the contracting firm(s). Contractors will also inform the assigned Principle Authorized Employee of their lock/tag out devices and procedures. The Contractor tification Form (Appendix D) will be completed prior to LOTO procedures by the contractor(s). The individual departments will work with the contractors to complete the LOTO Contractor tification Form. Copies of completed forms will be kept with the affected departments with their local LOTO procedures. 6

7 III. LOCK OUT TAG OUT PROCEDURES AND REVIEW/INSPECTION PROCESSES The OSHA Lockout Tagout Standard requires a specific set of procedures to be followed during shutdown and subsequent start up of energized equipment. This Lockout/Tagout Plan includes several types of written procedures: emergency lockout device removal procedure and equipment/machine specific procedures. The specific procedures have been written to provide detailed instructions for equipment/machines. When it is determined there is similarity among types of equipment or machines, then a common written LOTO procedure(s) will be written. A template procedure form is included in Appendix C. Exception to Written Procedure Requirements A documented energy control procedure does not need to be followed to achieve acceptable control of an energized machine or equipment when all of the following conditions exist from 29 CFR (c)(4): 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 de-activate 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 lockout 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; 8. There have been no accidents involving the unexpected activation or re-energization of the machine or equipment during previous servicing or maintenance. These eight requirements will be reviewed on a case by case basis to determine whether or not a written procedure is required. Emergency Lockout Device Removal Procedure The OSHA Lockout Tagout Standard requires that each lockout device is to be removed only by the employee who applied the device. Occasionally, under emergency or unusual conditions, it becomes necessary to remove a lockout device in the absence of the employee who applied it. The following procedure must be used to remove someone else s lockout device. A supervisor must verify that the Authorized Employee who applied the device is no longer on campus via one of these example communication methods: a message to his/her supervisor, or a phone call. The Authorized Employee must be informed as soon as possible that his/her lockout device has been removed. This process can be documented using the LOTO Absent Employee Lock Removal form 7

8 located in Appendix C. Example Removal Procedure used by Facilities Management Services (FMS): The following designated FMS Principle Authorized Employee(s) may remove a lockout device in an Other Employee s/contractor s absence. Principle Authorized Employees are listed below: 1. Electrical Foreman 2. HVAC Technician Foreman 3. Maintenance Foreman 4. Grounds Foreman Machine/Equipment Specific Procedures Area specific LOTO procedures must be accessible to employees. This can be achieved by posting the procedures at the machine/equipment requiring LOTO, storing them in a resource binder, or keeping the procedures at accessible computer terminal(s). These are examples of how to make procedures accessible. Lockout Tagout Procedure Inspection Process All Lockout Tagout procedures need to be reviewed at least annually (29 CFR (c)(6)(i)(a) and (C) by an Authorized Employee. This Authorized Employee must be someone other than the one(s) utilizing the energy control procedure being inspected. The inspection is led by a LOTO Authorized employee who has been trained in that procedure. The inspections requirements include: 1. Checking training records to verify people have been trained to the level necessary. 2. Ensuring normal or routine LOTO procedures are reviewed within a calendar year of the last review. Reviews must ensure the procedures are adequate, understandable and being followed. 3. Conducting LOTO procedure reviews with the employees that are authorized to use that procedure (group meeting reviews are acceptable). 4. Certifying the review by using the inspection certificate form provided with this program, or an equivalent record. Both the inspector and the person performing the LOTO inspection must sign the assessment certificate. See Appendix C for an example inspection certificate form. 5. Conducting field checks of the actual lockout to assure the equipment is being locked out properly. The inspector and the person locking the equipment are required to participate, at a minimum. 6. Asking authorized employees how they would lock/tag equipment, and verify by demonstration. 7. Correcting any deviations or inadequacies identified during the review. 8. Retraining all employees about the revised procedure changes before servicing or maintaining equipment/machine is conducted. 8

9 9. Reviewing non-routine lockouts must be reviewed before the procedure is used, if it hasn t been used in the last calendar year. 9

10 IV. APPLICATION OF LOCKS, TAGS, AND OTHER ENERGY CONTROL DEVICES A. Requirements of LOTO Equipment All LOTO equipment (locks and tags) must be: Used only for LOTO applications; Identified (either through marking or labeling and training) as LOTO devices; Durable and capable of withstanding the environment (such as: weather, wet or damp conditions, or corrosive environments)and pressures ( 50psi) applied to them; Standardized (same color, unique shape, same size/type of print and format, etc.) Substantial in that locks may not be easily removable (without the use of tools or excessive force) and that tags must not be accidentally removed or fall off; Identifiable to the person who applied them, either by name or number system; and Tags must warn against hazardous conditions with words such as: Do t Start or Do t Operate. The locks/tags and other devices specified above are the only authorized LOTO devices to be used at by RIT employees and SHALL NOT be used for locking equipment other than for LOTO and Energy Control purposes. Combination locks are not to be used for LOTO applications. NOTE: Facilities Management Services (FMS) will be using only orange locks for LOTO purposes. All other areas of the RIT campus will be exclusively using red locks for LOTO purposes. IMPORTANT NOTE: Implementation of lockout and/or tagout devices shall be performed ONLY by trained Authorized Employees. B. Seven Steps of LOTO Process: RIT requires each Authorized Employee to follow the Seven Steps of LOTO Process to ensure the proper safety procedures are conducted prior to performing service or maintenance on a machine. The seven steps are designed to ensure the safety of the Authorized Employee, Affected employees and Others in the work area. NOTE: The LOTO process does not apply to cord and plug connected electrical equipment that is under the exclusive control of the servicing employee, normal production operations, or to hot tap (i.e. welding) operations. The process needs to be performed in the following sequence: 1. Preparation for Shut down The Authorized Employee must have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled and the methods and means to control the energy. This should include a review of the procedure prior to initiating the LOTO process. Prior to the shut down step, the Authorized Employee must notify Affected Employees that the machine or equipment will be shut down and locked/tagged out for service or maintenance. 10

11 2. Machine or Equipment Shut down Shut down machine or equipment using the established written procedures after notifying Affected Employees in the area of the shut down. 3. Machine or Equipment Isolation Locate and operate all energy control devices in order to isolate all energy sources. 4. Hazardous Energy Control Device Application Apply or affix locks and tags (or other devices) so that equipment is held in a safe or off position. Tags will always accompany lock devices. If only a tagging system can be utilized, tagout devices shall be fastened at the same location where a lock would have been attached. 5. Stored Energy Relieve, disconnect or restrain all energy sources so that they are made safe. If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists. 6. Verification of Isolation The Authorized Employee will verify the isolation and de-energization of the machine or equipment by trying to activate it or by some other methods to ensure energy sources are off or in a safe position. 7. Release from LOTO or Restoring Equipment/Machine to Service Before lockout or tagout devices are removed and energy sources restored, the following procedures must be followed by the Authorized Employee who applied the devices: a. Check the work area to ensure that tools and other non-essential items have been removed and that the machine or equipment components are intact. b. Check the area to ensure that employees have been safely moved away from the work area. c. Verify that the machine or equipment controls are in neutral or off. d. Remove all lockout/tagout device(s). e. Re-energize the machine or equipment. NOTE: the removal of some forms of blocking may require re-energizing the machine before safe removal. f. tify area employees that the servicing or maintenance work is completed and the machine or equipment is ready for use. In the event that the machine or equipment need to be energized to test or position the machine, equipment or component thereof, procedures a-f of this step (Step 7) shall be followed prior to the testing and energizing of the machine, equipment or component. Once the testing is complete, if more work is necessary, the machine should be deenergized before reapplying energy control measures consistent with the seven steps of the LOTO process. C. Group Lockout or Tagout Procedure When employees of more than one trade (i.e. electricians and plumbers) must jointly work on machinery or equipment, then a procedure must be used that protects all employees performing lockout / tagout. This is accomplished by providing all trades with designated locking devices that individuals will control. An Authorized Employee will be assigned to the group project who shall ascertain the exposure status of 11

12 individual group members with regard to the lockout or tagout of the machine or equipment used. The following steps must be followed in conjunction with the seven steps of the LOTO process: All locks are to be secured to a multi-hold lockout hasp. The hasp is attached to the machine or equipment requiring de-energization. Lock placement and removal must be coordinated between all the trades. This can be done by the assigned primary Authorized Employee to the project. The assigned primary Authorized Employee will also attach his/her lock and remove the multi-lock hasp when all service or maintenance work is completed. D. Shift or Personnel Change Procedure Employees who have locked out a machine or piece of equipment but who have not completed the servicing or maintenance work must follow these steps: If the Authorized Employee is the only person scheduled to work on the equipment and work will carry over to the next day, then that Authorized Employee s lock and tag will stay in place until the machine or equipment servicing or maintenance is completed. If another shift will be continuing the maintenance or service work, then the Authorized Employee from the off-going shift will transfer responsibilities to the Authorized Employee from the on-coming shift. The off-going shift will remove their locks and the on-coming shift will install their own locks and follow the machine/equipment specific procedure to ensure all energy sources have been deenergized and it is safe to service or maintain the equipment/machine. E. Tagout Only Procedure RIT s Lockout/Tagout plan utilizes a tagout system where an energy isolating device is not capable of being locked out. If the energy isolating device is capable of being locked out, this plan requires the use of a lock and tag. Tags will always accompany LOTO specific locks unless the following situations occur: a. If locks can not be used, tags must be supplemented by other means to ensure an equivalent level of safety to that of a lock application (i.e. circuit breaker, valve handle, or removing a control switch). b. The tagout device shall be attached at the same location that the lockout device would have been attached. c. Where locks are not used, the supplemental means including specific procedures must be reviewed with each Authorized and Affected Employee on an annual basis, at a minimum. d. When equipment is being taken out of service, abandoned in place or no longer used, non- LOTO locks and tags will be used. The tag will contain wording such as Out of Service. 12

13 F. Application of Other Energy Control Devices Blocks, wedges, chains, adapter pins, and self-locking fasteners are some examples of types of other devices that may be used to block machines or equipment from unexpected energization. For example a block may be used to wedge open a mechanical power press during toll changes to prevent the machine from cycling. Departments are responsible for providing these devices as needed. G. Motor Vehicle & Powered Industrial Truck (PIT) Procedure To prevent unexpected energization of vehicles and PITs during servicing and maintenance, the Authorized Employee performing the work must follow these steps: Remove ignition keys and maintain control of keys throughout procedure. Secure all hydraulic and pneumatic systems to prevent accidental movement. Block wheels of vehicle to prevent accidental movement. De-energize sources. Tag appropriate energy sources such as supply tank valves, leads to battery, and steering wheel. 13

14 V. TRAINING RIT EH&S shall provide general training to Authorized, Affected, and Other Employees, based on their level of exposure to LOTO procedures. General training/retraining shall be provided to each employee: before the employee is first assigned duties; before there is a change in assigned duties; whenever new equipment, processes are brought into the area requiring LOTO; whenever there is a change in LOTO procedures in their area(s); for tagout processes, employees will be trained on the limitations of this process; and whenever RIT EH&S and/or the department supervisor has a reason to believe that there are deficiencies or deviations from established written equipment/machine specific SOPs are noted including those found during inspection reviews. AUTHORIZED EMPLOYEES- Formal training to include: recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, the methods and means necessary for energy isolation and control. This will be supplemented with localized application per each department, and the review of written procedure process. Also information about the RIT LOTO Plan will be reviewed. AFFECTED EMPLOYEES- Affected employees are those who jobs require them to operate or use equipment or machines on which servicing or maintenance is being performed under lockout or tagout, or whose job requires them to work in an area in which servicing or maintenance is being performed. Formal training to include: the purpose and use of energy control procedures, where workplace specific procedures are located per department. Also information about the RIT LOTO Plan will be reviewed. OTHER EMPLOYEES- This is to include all Other Employees whose work operations are or may be in the area where LOTO procedures may be utilized. Formal training to include: the purpose and use of energy control procedures, and the prohibition to restart/reenergize equipment or machines which are locked out or tagged out. Also information about the RIT LOTO Plan will be reviewed. RIT EH&S and all RIT departments shall certify that the training required to perform these duties have been accomplished. This certification shall contain each employee s name, the signature or initials of the trainers, a description of the training content, and the dates of training. This certification shall be forwarded to RIT EH&S where it will be made available for inspection by employees, their authorized representatives, and OSHA upon request. 14

15 VI. PROGRAM EVALUATION This energy control program and procedures will be reviewed by RIT s EH&S Department and revised as necessary on at least an annual basis ( (c)(6)). The program will be reviewed and revised more frequently if it is determined that the measures taken under the plan do not adequately protect RIT employees. Furthermore, all program points shall be reviewed in comparison to current State and Federal Regulations to ensure proper compliance. Examples of updates and/or revisions may include situations where undocumented LOTO procedures are being performed, the occurrence of an injury during a LOTO procedure, or an employee complaint regarding the effectiveness of the program. The annual program review will include an inspection of equipment/machine LOTO procedures per affected areas by an Authorized Employee. These inspections will ensure that persons doing LOTO are doing so correctly and consistently. Verification of these inspections will be documented on the Inspection Certification form in Appendix C. EH&S is also authorized to perform periodic inspections. Any changes to this written Control of Hazardous Energy (Lock Out Tag Out) Plan shall be documented in the Document Changes/Revision History Log located in Appendix F. 15

16 VII. IMPLEMENTATION AND DISCIPLINARY ACTIONS This program shall be managed through each applicable department, with assistance from EH&S Department. The steps in the implementation of the program shall consist of: 1. EH&S will assist individual departments in identifying the various machines and equipment requiring LOTO written procedures and the energy sources associated with each. 2. Assist with writing LOTO procedures when requested. 3. Review procedures to ensure compliance with the program as needed. 4. Employee training as required per Section 5 of this program. Disciplinary action shall be taken against any employee who fails to follow the guidelines established by this program. Retraining and/or disciplinary action will result in accordance with procedures established by the Human Resources Department and the Department Manager for these employees. Simply employees must follow proper lockout tagout procedures, use appropriate lockout and/or tagout or similar devices is an expectation of the job, and improper use or non use when required to do so will not be tolerated. 16

17 VIII. DEFINTIONS Authorized Employee - A person who locks or tags out machines or equipment in order to perform servicing or maintenance. Affected Employee A person whose job requires them to work in an area or operate machinery or equipment on which servicing or maintenance is being performed under lockout or tagout. Capable of Being Locked Out - An energy isolating device is capable of being locked out if it has a hasp or other means of attachment to which (or through which) a lock can be affixed, or it has a locking mechanism built into it. Other energy-isolating devices are "capable of being locked out" if energy isolation can be achieved without the need to dismantle, rebuild or replace the isolating device, or permanently alter its capability. Exclusive Control Cord and plug must be within line of sight and within arm s reach of the Authorized Employee performing the servicing or maintenance of the equipment/machine. Electrical Qualified Person shall use test equipment to test circuit elements and electrical parts of equipment to which employees will be exposed and shall verify that the circuit elements and equipment parts are de-energized. The test shall also determine if any energized condition exists as a result of inadvertently induced voltage or unrelated voltage back feed even though specific parts of the circuit have been deenergized and presumed to be safe. If the circuit to be tested is over 600 volts, nominal, the test equipment shall be checked for proper operation immediately after this test. The qualified person shall conduct tests and visual inspections, as necessary, to verify that all tools, electrical jumpers, shorts, grounds, and other such devices have been removed, so that the circuits and equipment can be safely energized. Energized Connected to an energy source or containing residual or stored energy. Energy source - any source of electrical, mechanical, hydraulic, pneumatic, chemical, natural (wind, gravity, potential, and kinetic), thermal or other type of energy. Lockout The placement of a lockout device on an energy-isolating equipment or machine that is used in accordance with established procedures to ensure all machines or equipment are completely stopped and isolated from all potentially hazardous energy sources. LOTO or Energy-Isolating Device - A mechanical device that physically prevents the transmission or release of energy, including, but not limited to the following: a manually-operated electrical circuit breaker, a disconnect switch, or a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors and, in addition, where no pole can be operated independently a line valve a block any similar device used to block or isolate energy Push buttons, selector switches and other control-circuit type devices are not energyisolating devices. 17

18 rmal Production Operations The utilization of a machine or equipment to perform its intended production function. Other Employees - All persons who are or may be in an area when LOTO procedures or devices may be utilized. Principle Authorized Person - An authorized person with the primary responsibility for group lockout applications. Qualified - Familiar with the construction and operation of the equipment and the hazards involved. Servicing and/or Maintenance Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or un-jamming 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 a release of hazardous energy. Tagout The placement of a tagout device that prevents the transmission or release of energy especially when locks can not be applied. Machines or equipment may not be operated until the tag has been removed. 18

19 Appendices 19

20 Appendix A Link to OSHA Website for Applicable Standards 29 CFR See for a copy of the latest standard 20

21 Appendix B Departmental Contact Names 21

22 Environmental Health and Safety Judy Foster, Assistant Director EH&S Grace Watson Hall (585) Hazardous Control of Energy (Lockout Tagout) Contact List Jody lan, Occupational Health and Safety Specialist Grace Watson Hall (585) David Armanini, Director EH&S Grace Watson Hall (585) Facilities Management Services Dave Harris Bldg 99 (585)

23 Appendix C Reference Forms Standard Operating Procedure Template LOTO Absent Employee Lock Removal Form Annual Inspection Checklist for SOP Reviews Form Determination & Assessment Form 23

24 24

25 25

26 ENERGY ISOLATING DEVICES (e.g., circuit breakers, ball valves) Device/Operation Location Lockout Capable ( ) ( ) Device/Operation Location Lockout Capable ( ) ( ) Device/Operation Location Lockout Capable ( ) ( ) Device/Operation Location Lockout Capable ( ) ( ) Device/Operation Location Lockout Capable ( ) ( ) ENERGY CONTROL PROCEDURE STEP 1 NOTIFY AFFECTED EMPLOYEES. tify all affected employees that the machine or equipment will be shut down and locked/tagged out for service or maintenance. STEP 2 SHUT DOWN EQUIPMENT/MACHINERY. List the normal stopping procedure below. STEP 3 ISOLATE THE MACHINE/EQUIPMENT FROM ALL ENERGY SOURCES. List all types, locations, and operation of energy isolating devices for this piece of equipment. (below) STEP 4 APPLY LOCKOUT-TAGOUT DEVICES. List what lockout/tagout device will be used on each isolating device (e.g., ball and valve lockout, chains with locks). STEP 5 DISSIPATE OR RESTRAIN ALL STORED OR RESIDUAL ENERGY. List all stored energy and the methods to be used to dissipate, restrain, or release. STEP 6 VERIFY/TEST THAT THE MACHINE/EQUIPMENT HAS BEEN ISOLATED. List ways to attempt a restart of the machine/equipment (e.g., press start buttons, open valves). STEP 7 REMOVAL/RESTORE FROM LOCKOUT/TAGOUT Clear all nonessential tools/personnel and verify that all machine/equipment components are operationally intact. Verify that the controls are in neutral/off position. Replace all safety guards. Remove lockout/tagout devices. tify affected employees that machine/equipment is ready for use. REENERGIZE MACHINE/EQUIPMENT NAME OF AUTHORIZED LOTO EMPLOYEE TITLE DATE 26

27 Rochester Institute of Technology LOCKOUT/TAGOUT ABSENT EMPLOYEE LOCK REMOVAL PROCEDURE is the single, designated person to contact when a lock or other device requires removal by someone other than the Authorized Employee who applied the device. List the steps taken to verify that the absent employee is not at the facility: List the steps taken to contact the absent employee (if different from above): List the steps taken to ensure the absent employee knows their device has been removed (if different from above): Completed by: Date: COMPLETED FORMS CAN BE FAXED TO: RIT ENVIRONMENTAL HEALTH & SAFETY at (585) OR SEND ELECTRONICALLY TO JAFEHS@RIT.EDU. 27

28 Department Name: ROCHESTER INSTITUTE OF TECHNOLOGY LOCKOUT/TAGOUT INSPECTION CERTIFICATE Internal Procedure number (if applicable): Last Updated: Machinery/Equipment Name or Type: Persons trained as Authorized for this procedure: Name Employee Identification Number Elements of Inspection: Preparation for Shutdown - knowledge of the type and magnitude of the hazardous energy Machine or Equipment Shutdown - performed using established procedure Machine or Equipment Isolation - all energy sources located and isolated Hazardous Energy Control Device Application - affixed to the energy isolation device by authorized individuals Stored Energy - all potentially hazardous stored or residual energy shall be relieved, disconnected, restrained and otherwise rendered safe Verification of Isolation - Authorized Employee will verify the isolation and de-energizing of the machine or equipment has been accomplished. Release from LOTO or Restoring Equipment/Machine to Service Authorized Employee will verify area is cleared before removal of lockout or tagout devices and before energy sources restored Certification: A field-check of the utilization of this procedure was performed on the following Authorized individuals (enter name and/or Other Employee identification): Name Employee Identification Number Authorization: This field check was performed by the following person authorized to use this procedure and not the person being field-checked: Name Date Deficiencies noted during field-check (if any): Certification Statement: The inspected individuals demonstrated adequate knowledge of locking/tagging this piece of equipment. Any deficiencies noted above have been corrected and proper techniques have been verified. Signature of field-check Inspector: Signature of LOTO Employee: 28

29 Rochester Institute of Technology LOCKOUT/TAGOUT DETERMINATION AND ASSESSMENT Equipment/Machine Name: Date Assessed: Related Operating Procedures Reviewed: Location: Related Maintenance Procedures Reviewed: LOCKOUT / TAGOUT ASSESSMENT CHECKLIST Is there a potential for stored, residual, or reaccumulation of energy after shutdown? * Does the unit have multiple energy sources that cannot be readily identified and isolated? * The isolation and lock out of energy sources will not completely deenergize or deactivate the unit? * The unit is not isolated from its energy source and locked out during servicing or maintenance? * A single lockout device will not achieve a locked out condition? * The lockout device is not under the exclusive control of an Authorized Employee? * The servicing or maintenance creates hazards for other employees? * Have accidents involving unexpected activation/reenergization occurred during servicing? * *Written procedures must be developed if any answers have been given ASSESSED ENERGY SOURCES: (indicate specific sources with initials) Initials Energy Source Magnitude and Unit of Measure Method to Dissipate or Restrain Chemical: Hydraulic: Pneumatic: Mechanical: Electrical: Thermal: Radioactive: Other: TYPES AND LOCATIONS OF OPERATING CONTROLS: * Further Detailed on Attachment: Types of Operating Controls Location on Unit TYPES AND LOCATIONS OF ENERGY ISOLATING DEVICE(S):* Further Detailed on Attachment: Types of Energy Isolating Devices Location(s) METHODS TO VERIFY ISOLATION OF THE UNIT: * Further Detailed on Attachment: Verification Method Location(s) 29

30 DIAGRAM OR PHOTOS OF UNIT: Schematic/Blue Print Attached? WRITTEN PROCEDURES AUTHOR: To be Developed by (date): To be Implemented by (date): REMARKS: Approved AUTHORIZATION I certify that I have conducted a Lockout Tagout Assessment of the equipment or machine named above and have detailed the findings of the assessment on this form. * Further detailed on attachment: Name: Signature: Title: Date: Time: ASSESSMENT FORM RETENTION INFORMATION ATTACHMENTS Permanent Retention File: Location: 30

31 Date Filed: Filed By: *See Following Pages Appendix D Contractor tification Form 31

32 RIT Host Employer Contractor tification for Control of Hazardous Energy (Lock Out Tag Out) 1. The work you will be performing at the Rochester Institute of Technology (RIT) involves the use of lockout/tagout devices and procedures. 2. The servicing or maintenance of RIT s equipment/machinery is only authorized through the use of your company s Control of Hazardous Energy (Lock Out Tag Out) Program. Your Program is required to be in compliance with OSHA s Control of Hazardous Energy (Lockout Tagout) Standard 29 CFR The energy source hazards of the machine/equipment involved with the work you will be performing at RIT include (filled out by dept. the contractor is working with): 4. RIT requires the following precautions to be taken for our employees around or near the equipment/machinery being serviced/maintained where you will be working: notify department before beginning LOTO process; eliminate energy source hazards before servicing/maintenance work begins; and follow RIT LOTO machine/equipment specific written procedures. 5. RIT employees can be involved with any tasks related to this LOTO process. The host contractor and RIT employees must work together when group LOTO efforts are required. By signing this notification you acknowledge your understanding that your work at RIT will involve the need to follow procedures for notification of RIT employees and affixing the appropriate locks and tags or energy-isolating devices on machines and equipment to disable the machinery/equipment during maintenance or service work. Name (printed): Company: Signature: Date: COMPLETED FORMS CAN BE FAXED TO: RIT ENVIRONMENTAL HEALTH & SAFETY at (585) OR SEND ELECTRONICALLY TO JAFEHS@RIT.EDU. 32

33 Appendix E Lock Out Tag Out Program Assessment Tool 33

34 Rochester Institute of Technology LOCKOUT/TAGOUT PROGRAM ASSESSMENT TOOL Area or Department Assessed: Assessor: Date: Description of Requirement Compliant? LOTO (29 CFR ) Is all machinery or equipment capable of movement required to be de-energized or disengaged and locked-out during cleaning, servicing, adjusting or setting up operations, whenever required? Are written procedures established for machinery/equipment that requires control of energy or movement? Are all LOTO procedures reviewed with Authorized Employees within one calendar year prior to use? Does the lockout procedure require that stored energy (mechanical, hydraulic, air, etc.) be released or blocked before equipment is lockout for repairs? Is it required that employees check the safety of the lockout by attempting a startup after making sure not one is exposed? Are employees instructed to always push the control circuit stop button immediately after checking the safety of the lockout (i.e. is the de-energization verified)? Where the power disconnecting means for equipment does not also disconnect the electrical control circuit, are the appropriate electrical enclosures identified? (Control circuits sometimes have different sources of energy. Have all the energy sources been identified for each discreet piece of equipment?)? Where the power disconnecting means for equipment does not also disconnect the electrical control circuit, is means provided to assure the control circuit can also be disconnected and locked-out? Is the locking-out of control circuits in lieu of locking-out main power disconnects prohibited? Are all equipment control valve handles provided with a means for locking-out? Are appropriate employees provided with individually keyed personal-safety locks and/or other appropriate devices? Are employees required to keep personal control of their key(s) while they have safety locks in use, or in group lock out situations is a designated person established for this control? Is it required that only the employee exposed to the hazard, place or remove the safety lock? Is there a means provided to identify any or all employees who are working on lockout equipment by their locks or accompanying tags? Are a sufficient number of accident preventive tags and safety padlocks provided for any reasonably foreseeable repair emergency? 34

35 Description of Requirement When machine operations, configuration or size requires the operator to leave his or her control station to install tools or perform other operations, and that part of the machine could move if accidentally activated, is such element required to be separately locked or blocked out? In the event that equipment or lines cannot be shut down, locked out and tagged, is a safe job procedure established and rigidly followed? Have all persons utilizing or exposed to LOTO devices trained to the appropriate level of their involvement? Are contractors informed of company LOTO procedures and familiar with company LOTO devices, where applicable? Electrical Lockouts - (29 CFR ) Does the organization have a valid lockout/tagout program per OSHA 29 CFR The Control of Hazardous Energy? Have all live parts to which an employee may be exposed been de-energized prior to work or where de-energization is infeasible, other specific safeguards and procedures enforced to ensure the safety of the employees? Are conductors and parts of electrical equipment that have been de-energized but have not been locked out and tagged treated as energized parts? Have safe procedures for de-energizing circuits and equipment been determined before circuits are (or equipment is) de-energized? Compliant? Are circuits and equipment to be worked on disconnected from all electrical energy sources? Are control circuit devices, such as push buttons, selector switches, and interlocks, prohibited from use as the sole means of de-energizing circuits or equipment? Are interlocks for electric equipment prohibited from use as a substitute for lockout/tagout procedures? Have capacitors and high capacitance elements been short-circuited and grounded, where appropriate? Has any non-electrical energy that could energize electric circuit parts (i.e. trip an interlock) been blocked or relieved to prevent accidental energization? Are all locks accompanied by tags and have the tags been appropriately filled-out with all pertinent information? Do only qualified persons verify the release of stored energy? Do only qualified persons re-energize the equipment? Where work on live parts and circuits must be performed, does only a qualified person performs this work? Where there is exposure to overhead power sources and power lines, are these lines deenergized prior to work, or sufficient safeguards in place to assure employee safety? 35

36 36

37 Appendix F Document Changes/Revision History Log 37

38 REVISION HISTORY LOG Date of Latest Review/Revision Comments on Review/Revision and Affected Sections Person(s) Making Review/Revision 10/2008 Original-version 1 Judy Foster 12/2208-1/2009 Changes throughout document-version 2 & 3 Judy Foster 2/ / /2009 1/2010 Changes throughout Plan to finalize and to match LOTO general training package version 4 Changes per RIT Legal review of Personal Protective Equipment Program-version 5 Update various forms with additional information-version 5 Remove contractors from emergency absent LOTO removal section. Contractors responsibility to follow through on removal of locks/tags. Wording changes in the same section. Fix page numbering in TOC. Judy Foster Judy Foster Judy Foster Judy Foster 38