LOCKOUT/TAGOUT PROGRAM. Table of Contents

Transcription

1 Western University of Health Sciences IIPP SUB-PROGRAM LOCKOUT/TAGOUT PROGRAM Table of Contents 1.0 INTRODUCTION PURPOSE RESPONSIBILITIES 1 Supervisors 1 Employees TRAINING WRITTEN PROCEDURES PROCEDURE REVIEW OTHER PROCEDURAL REQUIREMENTS RECORDKEEPING 5 Forms Lockout/Tagout Written Procedure Lockout/Tagout Certification Inspection Lockout/Tagout Training Outline Lockout/Tagout Safety Rules

2 Western University of Health Sciences IIPP SUB-PROGRAM LOCKOUT/TAGOUT PROGRAM 1.0 INTRODUCTION The University will maintain an effective Lockout/Tagout Program in accordance with CAL/OSHA Standard All employees affected by this regulation will fully cooperate and participate in this program. This policy applies to: A. Activities such as, but not limited to constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. B. Energy sources such as, but not limited to electrical, mechanical, hydraulic, pneumatic, and potential energy from suspended parts (gravity). 2.0 PURPOSE To provide an effective control program for servicing and maintenance of machines and equipment in which the unexpected energization, start-up or release of stored energy could cause injury. 3.0 RESPONSIBILITIES A. Applicable Department Heads 1. Implement and administer an effective lockout/tagout system. 2. Prepare written procedures for de-energizing machines and equipment for servicing and maintenance. 3. Train involved employees on lockout/tagout procedures as required. 4. Ensure that an annual assessment of lockout/tagout procedures is reviewed to assure the effectiveness of the program. B. Employees 1. Comply with the provisions of the lockout/tagout system. 2. Participate in training activities to develop an understanding of responsibilities under the lockout/tagout procedures. 3. Use or remove lockout/tagout devices only when authorized to do so by assignment and training.

3 Western University of Health Sciences IIPP SUB-PROGRAM 4.0 TRAINING A. Training shall be provided to employees on the purpose and function of the lockout/tagout program so that they possess the knowledge and skills required for safe application, usage, and removal of energy controls. Training will include the following: Affected employees must know the dangers of starting or energizing machines or equipment which is locked out or tagged out. Affected employees (machine/equipment users or those who work in an area where lockout/tagout devices are used) must receive instruction on the purpose and use of lockout/tagout procedures. Authorized employees (those who use lockout/tagout devices) must receive training on: 1. Recognizing the sources of energy and related hazards; and 2. Methods to isolate and control energy. When tagout devices are the only control used on machines and equipment, employees shall be trained on the Basic Tagout Rules (see Item 13 of the Lockout/Tagout Safety Rules in the program appendix). A training outline, the Lockout/Tagout Safety Rules and other resource information are included in the program appendix. B. All training shall be documented to note the employee's name, date of training, topics covered, and the trainer's name. C. Retraining shall be provided to authorized and affected employees whenever there is: 1. A change in their job assignment. 2. A change in machines, equipment or processes that present a new hazard. 3. A change in lockout/tagout procedures. Retraining will be provided to employees when inspections, observations or other conditions reveal that there are deviations from lockout/tagout procedures or employees lack knowledge on the use of those procedures. Retraining will reestablish employee proficiency and introduce new or revised lockout/tagout procedures.

4 Western University of Health Sciences IIPP SUB-PROGRAM 5.0 WRITTEN PROCEDURES Basic lockout/tagout procedures are explained below. These are supplemented by the Lockout/Tagout Safety Rules included in the program appendix. In more complex situations, detailed procedures are needed to supplement the basic procedures. A form is included at the end of this program which can be used to document equipment specific lockout/tagout procedures. Once developed, procedures should be maintained on file with this program. The following minimal steps will be part of every lockout/tagout procedure: A. Job Task - Briefly describe the servicing or maintenance activity which requires use of lockout/tagout devices. This can be a generic job task which applies to a group of like machinery or equipment. Include the name and location of the machine or equipment to be serviced or maintained in specific procedures which are not considered generic. B. Employee Assignments Facilities employees are authorized to use lockout/tagout devices. C. Preparation for Shutdown - Authorized employees should review the type, magnitude, hazards and control methods of energy prior to starting work. D. Notification of Employees - Authorized employees are required to verbally notify affected employees (identify by name or job title) that lockout/tagout devices will be used. Posting notices on or around the machine or equipment where they are clearly visible is another acceptable notification method. E. Machine or Equipment Shutdown - Turn off or shut down machines or equipment. F. Machine or Equipment Isolation - Locate the type(s) and location(s) of energy isolating devices and isolate the machine or equipment from the energy source. G. Lockout/Tagout Device Application - Apply the lockout device(s) to hold the energy isolating device in a safe or off position. Apply the tagout only device(s) if a lockout device cannot be used. Tagout only devices should be placed so that anyone attempting to operate the machine or equipment will be aware that it is prohibited. H. Stored Energy Isolation - Locate the type(s) and source(s) of stored energy and relieve, disconnect or restrain them. Continually verify isolation of stored energy if accumulation to an action level is possible. I. Verification of Isolation - Verify that isolation and deenergization of machines or equipment has been accomplished prior to starting work on machines or equipment. J. Release from Lockout/Tagout - Remove lockout/tagout devices and restore energy to the machine or equipment. At a minimum this includes: 1. An inspection of the work area to ensure that non-essential items have been removed and machine or equipment components are operationally intact. 2. A check to ensure that all employees have been safely positioned or removed. 3. Notification to affected employees that lockout/tagout devices have been removed.

5 Western University of Health Sciences IIPP SUB-PROGRAM 4. A requirement that lockout/tagout devices will only be removed by the authorized employee who applied the device unless special procedures have been developed. K. Testing or Adjusting Energized Machines and Equipment - Temporarily remove the lockout/tagout devices to test or adjust energized machines and equipment. At a minimum this includes: 1. Clear the machine or equipment of tools and materials. 2. Remove employees from machine or equipment area. 3. Remove the lockout/tagout device. 4. Energize and proceed with testing or adjusting. 5. Deenergize all systems and reapply all energy control measures. 6.0 PROCEDURE REVIEW Annual review by the USC shall be conducted for each lockout/tagout procedure to assess the procedure and correct problems. Inspections shall be conducted by an authorized employee other than the one(s) utilizing the energy control procedure being inspected. Where lockout devices are used, a review of responsibilities with authorized employees utilizing the energy control procedure will be completed. Where tagout devices are used, a review of responsibilities with authorized and affected employees utilizing the energy control procedure being inspected, and the Basic Tagout Rules which are included with this policy, will be completed. The USC shall provide a certification that the review has been performed. The certification shall identify the machine or equipment, the date of the inspection, the employees included in the review. A certification form is included in the program appendix. 7.0 OTHER PROCEDURAL REQUIREMENTS A. Removal of Lockout/Tagout Devices by Others - When the authorized employee who applied the lockout/tagout device is not available to remove it, the device may be removed under the direction of a supervisor or by another authorized employee after the following conditions have been met: 1. Verification is obtained that the authorized employee who applied the device is not at the facility.

6 Western University of Health Sciences IIPP SUB-PROGRAM 2. Reasonable efforts have been made to contact the authorized employee to inform him/her that the lockout/tagout device has been removed. 3. The authorized employee has knowledge of the lockout/tagout device removal before he/she resumes work at the facility. B. Outside Contractors - Whenever outside contractors are performing servicing or maintenance activities on-site, lockout/tagout procedures used by the University and the outside contractor will be exchanged. Facilities will inform affected employees so they understand the lockout/tagout procedures of the outside contractor. C. Group Lockout/Tagout - Whenever more than one authorized employee performs servicing or maintenance, a group lockout/tagout device will be used to provide protection. One authorized employee will be designated to supervise the group lockout/tagout activity and review the status of the individual authorized employees performing servicing or maintenance to ensure continuity of protection. Each authorized employee will attach a personal lockout/tagout device to the group lockout/tagout device at the beginning of work and remove it at the conclusion. D. Shift or Personnel Changes - Whenever shift or personnel changes take place, lockout/tagout devices will be transferred between the off-going and on-coming authorized employees to ensure continuity of lockout/tagout protection. 8.0 RECORDKEEPING All records of training and program records are maintained by the Safety Department. The following records will be maintained: A. Training records. B. Lockout/tagout written procedures used by the plant. C. Annual review and certification of lockout/tagout procedures.

7 LOCKOUT/TAGOUT FORMS

8 LOCKOUT/TAGOUT WRITTEN PROCEDURE Department: Reference Number or Job Task: Approved By: Date: A. Job Task: B. Employee Assignments: C. Preparation for Shutdown: D. Notification of Employees: E. Machine or Equipment Shutdown Steps:

9 F. Machine or Equipment Isolation Steps: G. Lockout/Tagout Device Application Steps: H. Stored Energy Isolation Steps: I. Verification of Isolation: J. Release from Lockout/Tagout: At a minimum, these steps include Inspect the work area to ensure that nonessential items have been removed and machine or equipment components are operationally intact. 2. Check to ensure that all employees have been safely positioned or removed. 3. Notify affected employees that lockout/tagout devices have been removed. 4. Lockout/tagout devices shall only be removed by the authorized employee who applied the device. Contact Facilities if the device must be removed and that employee is not available. (Other steps, if necessary)

10 K. Testing or Adjusting Energized Machines and Equipment: At a minimum, these steps include Clear the machine or equipment of tools and materials. 2. Remove employees from machine or equipment area. 3. Remove the lockout/tagout device. 4. Energize and proceed with testing or adjusting. 5. Deenergize all systems and reapply all energy control measures. (Other steps, if necessary)

11 LOCKOUT/TAGOUT CERTIFICATION REVIEW Procedure Reference Number of Job Task: Machine or Equipment Involved: Employees Involved: Review of Responsibilities Completed With: Authorized employees? (lockout and tagout situations) Yes No Affected employees? (only with tagout situations) Yes No USC Date of Review

12 LOCKOUT/TAGOUT PROGRAM TRAINING OUTLINE AND RESOURCE MATERIALS

13 WESTERN UNIVERSITY OF HEALTH SCIENCES LOCKOUT/TAGOUT TRAINING OUTLINE PURPOSE OF THE LOCKOUT/TAGOUT PROGRAM Protect employees from the unexpected energization, start-up or release of stored energy while servicing and maintaining machines and equipment. WHAT ARE THE SOURCES OF ENERGY (HAZARDS)? 1. Electrical 2. Mechanical 3. Chemical 4. Thermal 5. Pneumatic 6. Hydraulic 7. Stored Energy LOCKOUT/TAGOUT DEVICES ARE USED TO CONTROL ENERGY 1. Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners and other hardware are used. 2. Devices are standardized in color, shape or size. 3. Devices must withstand accidental removal (tags) or must be cut off (locks). 4. User must be identified on the device. WHAT PROGRAM ELEMENTS ARE REQUIRED? 1. Employee Training/Retraining 2. Written Procedures For Use of Lockout/Tagout Devices 3. Annual Inspections of Procedures

14 LOCKOUT/TAGOUT TRAINING OUTLINE (CONT'D) EMPLOYEE TRAINING/RETRAINING 1. All employees must know the dangers of starting or reenergizing machines or equipment which is locked out or tagged out. 2. Affected employees (machine/equipment operators or those who work in an area where lockout/tagout devices are used) must receive instruction on the purpose and use of lockout/tagout procedures. 3. Authorized employees (those who use lockout/tagout devices) must receive training on: A. Recognizing the sources of energy and related hazards; and B. Methods to isolate and control energy. 4. When tagout procedures are used, additional training is required on the Basic Tagout Rules: A. Tags are a warning device only; B. Tags should not be removed without authorization or bypassed; C. Tags must be legible and understood by all; D. Tags must be durable; E. Tags are not the same as a lockout device; and F. Tags must be securely attached. 5. Retraining must be provided to authorized and affected employees whenever there is: A. A change in machines, equipment or processes that present a new hazard; or B. A change in lockout/tagout procedures. 6. All training must be documented to note the trainer's name, employee's name and date of training. WRITTEN PROCEDURES 1. Procedures can be general, or specific to an individual machine or piece of equipment; 2. Includes the steps for shutting down, isolating, blocking and securing machines; and 3. Testing procedures to verify the effectiveness of lockout/tagout devices.

15 LOCKOUT/TAGOUT TRAINING OUTLINE (CONT'D) ELEMENTS OF WRITTEN PROCEDURES 1. Job Task 2. Employee Assignment 3. Preparation for Shutdown 4. Notification of Employees 5 Machine or Equipment Shutdown 6 Machine or Equipment Isolation 7 Lockout/Tagout Device Application 8 Stored Energy Isolation 9. Verification of Isolation 10. Release From Lockout/Tagout 11. Testing or Adjusting Energized Machines/Equipment OTHER PROCEDURAL REQUIREMENTS 1. Removal of Lockout/Tagout Devices by Others Facilities can direct an employee to remove a lockout/tagout device after the following conditions have been met: A. It is verified that the authorized employee who applied the device is not at the facility. B. Reasonable efforts have been made to contact the authorized employee. C. The authorized employee who applied the lockout/tagout device is notified before he resumes work that it has been removed. 2. Outside Contractors - Lockout/tagout procedures will be exchanged between the University and the outside contractor. Facilities informs affected employees so they understand the lockout/tagout procedures of the outside contractor. 3. Group Lockout/Tagout - One authorized employee is designated to supervise the group lockout/tagout activity to ensure continuity of protection. Each authorized employee attaches a personal lockout/tagout device to the group lockout/tagout device at the beginning of work and removes it at the conclusion.

16 LOCKOUT/TAGOUT TRAINING OUTLINE (CONT'D) 4. Shift or Personnel Changes - Lockout/tagout devices will be transferred between the authorized employees coming off a shift and those coming on to ensure continuity of lockout/tagout protection. PERIODIC INSPECTIONS 1. Annually conducted and documented. 2. Conducted by an authorized employee to assess procedures and correct problems. 3. Includes a review with authorized employees of their responsibilities for the lockout procedure being inspected. 4. Includes a review with authorized and affected employees of their responsibilities when a tagout procedure is used. The Basic Tagout Rules must be reviewed at this time.

17 WESTERN UNIVERSITY OF HEALTH SCIENCES LOCKOUT/TAGOUT SAFETY RULES 1. Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners or other hardware are used for isolating, securing or blocking energy sources of machines and equipment. 2. Lockout/tagout devices are the only approved device(s) used for controlling energy sources and will not be used for other purposes. 3. If energy isolating devices (switch, valve, etc.) can be locked out, a lockout device will be utilized. 4. If an energy isolating device cannot be locked out, a tagout device will be utilized. Existing machines and equipment will be changed to accept lockout devices whenever major replacement, repair, renovation or modification takes place. 5. Individual lockout/tagout devices will only be applied and removed by the authorized employee using them other than in special situations where procedures have been developed. 6. Lockout/tagout devices will identity the employee supplying the devices. 7. Lockout/tagout devices will be individually keyed so that they can only be removed by the authorized employee applying the device. 8. Lockout/tagout devices must be capable of withstanding weather conditions, wetness and corrosive environments for the maximum period of time exposure is expected. 9. Lockout/tagout devices will be standardized by color, shape or size. Tagout devices will have a standard print and format. 10. Lockout devices will be substantial enough to prevent removal without the use of excessive force or unusual techniques, such as bolt cutters or metal cutting tools. 11. Tagout devices and their means of attachment will be substantial enough to prevent inadvertent or accidental removal. All environment tolerant nylon cable ties will be used to attach tagout devices. Cable ties will be non-reusable, attachable by hand, self-locking, and able to withstand at least 50 pounds of pressure. 12. Tagout devices warn against hazardous conditions if the equipment or machine is energized. They will include a warning such as: DO NOT OPERATE, DO NOT START, DO NOT OPEN 13. The Basic Tagout Rules will be reviewed with employees when lockout devices cannot be used. A. Tags are a warning device only and not a physical restraint. B. Tags will not be removed without authorization and never bypassed. LOCKOUT/TAGOUT SAFETY RULES (CONT'D) C. Tags must be legible and understandable by all.

18 D. Tags must be durable to withstand environmental conditions. E. Tags are not the same as a lockout device. F. Tags must be securely attached. 14. When the authorized employee is not available to remove a lockout/tagout device, Facilities can direct another employee to remove it after the following conditions have been met: A. Verification is obtained that the authorized employee who applied the device is not at the facility. B. Reasonable efforts have been made to contact the authorized employee to inform him/her that the lockout/tagout device has been removed. C. The authorized employee has knowledge of the lockout/tagout device removal before he/she resumes work at the facility. 15. Lockout/tagout procedures will be exchanged between the plant and outside contractors. The maintenance supervisor will inform plant employees so they understand the lockout/tagout procedures of the outside contractor. 16. One authorized employee will be designated to supervise group lockout/tagout activity to ensure continuity of protection. Each authorized employee will attach a personal lockout/tagout device to the group lockout/tagout device at the beginning of work and remove it at the conclusion. 17. Lockout/tagout devices will be transferred between the authorized employees coming off a shift and those coming on to ensure continuity of lockout/tagout protection.

19 TABLE OF CONTENTS I. INTRODUCTION... 1 II. PURPOSE... 1 III. RESPONSIBILITIES... 1 Supervisors... 1 Employees... 1 IV. TRAINING... 2 V. WRITTEN PROCEDURES... 3 VI. PROCEDURE REVIEW... 4 VII. OTHER PROCEDURAL REQUIREMENTS... 4 VIII. RECORDKEEPING... 5 Forms Lockout/Tagout Written Procedure Lockout/Tagout Certification Inspection Lockout/Tagout Training Outline Lockout/Tagout Safety Rules