Lockout/Tagout Training Program

Lockout/Tagout Training Program (Student Handouts) Name Date

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Sample Written Program for Control of Hazardous Energy (Lockout/Tagout) 4

1910.147 The Control of Hazardous Energy (Lockout/Tagout) The following lockout/tagout program is provided only as a guide to assist employers and employees in complying with the requirements of 29 CFR 1910.147, as well as to provide other helpful information. It is not intended to supersede the requirements of the standard. An employer should review the standard for particular requirements which are applicable to their individual situation and make adjustments to this program that are specific to their company. An employer will need to add information relevant to their particular facility in order to develop an effective, comprehensive program. 5

1910.147 The Control of Hazardous Energy (Lockout/Tagout) Procedure Table of Contents I. Objective II. Assignment of Responsibility III. Procedures A. Preparation for Lockout or Tagout B. Electrical C. Hydraulic/Pneumatic D. Fluids and Gases E. Mechanical Energy F. Release from Lockout/Tagout G. Service or Maintenance Involving More than One Person H. Removal of an Authorized Employee s Lockout/Tagout by the Company I. Shift or Personnel Changes J. Procedures for Outside Personnel/Contractors K. Training and Communication L. Periodic Inspection IV. Attachments A. List of Authorized Personnel for Lockout/Tagout Procedures Form B. Certification of Training of Authorized Personnel Form C. Certification of Training of Affected Personnel Form D. Lockout/Tagout Inspection Certification Form E. Lockout/Tagout Energy Control Procedures 6

Company Name Lockout/Tagout Procedure I. OBJECTIVE The objective of this procedure is to establish a means of positive control to prevent the accidental starting or activating of machinery or systems while they are being repaired, cleaned and/or serviced. This program serves to: A. Establish a safe and positive means of shutting down machinery, equipment and systems. B. Prohibit unauthorized personnel or remote control systems from starting machinery or equipment while it is being serviced. C. Provide a secondary control system (tagout) when it is impossible to positively lockout the machinery or equipment. D. Establish responsibility for implementing and controlling lockout/tagout procedures. E. Ensure that only approved locks, standardized tags and fastening devices provided by the company will be utilized in the lockout/tagout procedures. II. ASSIGNMENT OF RESPONSIBILITY A. Responsible Person will be responsible for implementing the lockout/tagout program. B. Responsible Persons are responsible for enforcing the program and insuring compliance with the procedures in their departments. C. Responsible Person is responsible for monitoring the compliance of this procedure and will conduct the annual inspection and certification of the authorized employees. D. Authorized employees (those listed in Attachment A) are responsible for following established lockout/tagout procedures. E. Affected employees (all other employees in the facility) are responsible for insuring they do not attempt to restart or re-energize machines or equipment which are locked out or tagged out. III. PROCEDURES The ensuing items are to be followed to ensure both compliance with the OSHA Control of Hazardous Energy Standard and the safety of our employees. A. Preparation for Lockout or Tagout Employees who are required to utilize the lockout/tagout procedure (see Attachment A) must be knowledgeable of the different energy sources and the proper sequence of shutting off or disconnecting energy means. The four types of energy sources are: 7

1. electrical (most common form); 2. hydraulic or pneumatic; 3. fluids and gases; and 4. mechanical (including gravity). More than one energy source may be utilized on some equipment and the proper procedure must be followed in order to identify energy sources and lockout/tagout accordingly. See Attachment F for specific procedure format. B. Electrical 1. Shut off power at machine and disconnect. 2. Disconnecting means must be locked or tagged. 3. Press start button to see that correct systems are locked out. 4. All controls must be returned to their safest position. 5. Points to remember: a. If a machine or piece of equipment contains capacitors, they must be drained of stored energy. b. Possible disconnecting means include the power cord, power panels (look for primary and secondary voltage), breakers, the operator's station, motor circuit, relays, limit switches, and electrical interlocks. c. Some equipment may have a motor isolating shut-off and a control isolating shut-off. d. If the electrical energy is disconnected by simply unplugging the power cord, the cord must be kept under the control of the authorized employee or the plug end of the cord must be locked out or tagged out. C. Hydraulic/Pneumatic 1. Shut off all energy sources (pumps and compressors). If the pumps and compressors supply energy to more than one piece of equipment, lockout or tagout the valve supplying energy to the piece of equipment being serviced. 2. Stored pressure from hydraulic/pneumatic lines shall be drained/bled when release of stored energy could cause injury to employees. 3. Make sure controls are returned to their safest position (off, stop, standby, inch, jog, etc.). D. Fluids and Gases 1. Identify the type of fluid or gas and the necessary personal protective equipment. 2. Close valves to prevent flow, and lockout/tagout. 3. Determine the isolating device, then close and lockout/tagout. 4. Drain and bleed lines to zero energy state. 5. Some systems may have electrically controlled valves. If so, they must be shut off and locked/tagged out. 6. Check for zero energy state at the equipment. 8

E. Mechanical Energy Mechanical energy includes gravity activation, energy stored in springs, etc. 1. Block out or use die ram safety chain. 2. Lockout or tagout safety device. 3. Shut off, lockout or tagout electrical system. 4. Check for zero energy state. 5. Return controls to safest position. F. Release from Lockout/Tagout 1. Inspection: Make certain the work is completed and inventory the tools and equipment that were used. 2. Clean-up: Remove all towels, rags, work-aids, etc. 3. Replace guards: Replace all guards possible. Sometimes a particular guard may have to be left off until the start sequence is over due to possible adjustments. However, all other guards should be put back into place. 4. Check controls: All controls should be in their safest position. 5. The work area shall be checked to ensure that all employees have been safely positioned or removed and notified that the lockout/tagout devices are being removed. 6. Remove locks/tags: Remove only your lock or tag. G. Service or Maintenance Involving More than One Person When servicing and/or maintenance is performed by more than one person, each authorized employee shall place his own lock or tag on the energy isolating source. This shall be done by utilizing a multiple lock scissors clamp if the equipment is capable of being locked out. If the equipment cannot be locked out, then each authorized employee must place his tag on the equipment. H. Removal of an Authorized Employee s Lockout/Tagout by the Company Each location must develop written emergency procedures that comply with 1910.147(e)(3) to be utilized at that location. Emergency procedures for removing lockout/tagout should include the following: 1. Verification by employer that the authorized employee who applied the device is not in the facility. 2. Make reasonable efforts to advise the employee that his/her device has been removed. (This can be done when he/she returns to the facility). 3. Ensure that the authorized employee has this knowledge before he/she resumes work at the facility. 9

I. Shift or Personnel Changes Each facility must develop written procedures based on specific needs and capabilities. Each procedure must specify how the continuity of lockout or tagout protection will be ensured at all times. See 1910.147(e)(4). J. Procedures for Outside Personnel/Contractors Outside personnel/contractors shall be advised that the company has and enforces the use of lockout/tagout procedures. They will be informed of the use of locks and tags and notified about the prohibition of attempts to restart or re-energize machines or equipment that are locked out or tagged out. The company will obtain information from the outside personnel/contractor about their lockout/tagout procedures and advise affected employees of this information. The outside personnel/contractor will be required to sign a certification form. If outside personnel/contractor has previously signed a certification that is on file, additional signed certification is not necessary. K. Training and Communication Each authorized employee who will be utilizing the lockout/tagout procedure will be trained in the recognition of applicable hazardous energy sources, type and magnitude of energy available in the work place, and the methods and means necessary for energy isolation and control. Each affected employee (all employees other than authorized employees utilizing the lockout/tagout procedure) shall be instructed in the purpose and use of the lockout/tagout procedure, and the prohibition of attempts to restart or re-energize machines or equipment that are locked out or tagged out. Training will be certified using Attachment B (Authorized Personnel) or Attachment C (Affected Personnel). The certifications will be retained in the employee personnel files. L. Periodic Inspection A periodic inspection (at least annually) will be conducted of each authorized employee under the lockout/tagout procedure. This inspection shall be performed by the (Responsible person). If (Responsible person) is also using the energy control procedure being inspected, then the inspection shall be performed by another party. The inspection will include a review between the inspector and each authorized employee of that employee's responsibilities under the energy control (lockout/tagout) procedure. The inspection will also consist of a physical inspection of the authorized employee while performing work under the procedures. The (Responsible person) shall certify in writing that the inspection has been performed. The written certification (Attachment D) shall be retained in the individual's personnel file. 10

ATTACHMENT A List of Authorized Personnel for Lockout/Tagout Procedures NAME JOB TITLE 11

ATTACHMENT B Certification of Training (Authorized Personnel) I certify that I received training as an authorized employer under Company Name Lockout/Tagout program. I further certify that I understand the procedures and will abide by those procedures. AUTHORIZED EMPLOYEE SIGNATURE DATE 12

ATTACHMENT C Certification of Training (Affected Personnel) I certify that I received training as an Affected Employee under Company Name Lockout/Tagout Program. I further certify and understand that I am prohibited from attempting to restart or re-energize machines or equipment that are locked out or tagged out. AFFECTED EMPLOYEE SIGNATURE DATE 13

ATTACHMENT D Lockout/Tagout Inspection Certification I certify that Equipment was inspected on this date utilizing lockout/tagout procedures. The inspection was performed while working on Equipment. AUTHORIZED EMPLOYEE SIGNATURE DATE INSPECTOR S SIGNATURE DATE 14

ATTACHMENT E Lockout/Tagout Energy Control Procedures Specific To Each Machine Preparation for Shut Down 1. Identify equipment to be shut down: 2. Location in facility: 3. Procedures to notify all affected employees: 4. Identify all power sources: a) Electrical: b) Air: c) Steam: d) Hydraulic: e) Gravity: f) Other: 5. Identify lockout/tagout devices to be used: Shut Down Description of the shut down procedures: Isolation Procedures for isolation of equipment from all power sources: 15

Lockout/Tagout Device Application Procedure for locking out or tagging out equipment: Release of Stored Energy Procedures for the release of stored energy (where applicable): Verification of Isolation Procedures to ensure that equipment is isolated from all power sources: Start-Up 1. Visual inspection of the machine and equipment. Ensure all tools have been removed. Return guards to place. 2. Notify all affected employees and other employees of the start up. 3. Remove all lockout/tagout devices and restore power. 16

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Lockout/Tagout General Checklist Use the following checklist when locking and tagging out: Identify ALL sources of electrical energy for the circuits, tools and equipment in question. Disable backup energy sources such as generators and batteries. Identify all shut-offs for each energy source. Notify all personnel that equipment and circuitry must be shut off, locked out and tagged out. (Turning a switch off is NOT enough.) Shut off energy sources and lock switchgear in the OFF position. Each worker should apply his or her individual lock (if necessary). DO NOT give your key to anyone. Test equipment and circuitry to make sure they are de-energized. This must be done by a qualified person. Deplete stored (residual) energy by bleeding, blocking, grounding, etc. Apply a tag to alert other workers than an energy source or piece of equipment has been locked out. Make sure everyone is alerted, safe and accounted for before equipment and circuits are unlocked and turned back on. Not that only a qualified person may determine when it is safe to re-energize circuits. 17

Questions to Ask when Locking & Tagging Out Ask the following questions when locking and tagging out: Is all machinery or equipment capable of movement required to be de-energized or disengaged and blocked or locked out during cleaning, servicing, adjusting or setting up operations? If the power disconnected for equipment does not also disconnect the electrical control circuit, are the appropriate electrical enclosures identified and is a means provided to ensure that the control circuit can also be disconnected and locked out? Is the locking out of control circuits instead of locking out the main power disconnects prohibited? Are all equipment control valve handles provided with a means for locking out? Does the lockout procedure require that stored energy (mechanical, hydraulic, air, etc.) be released of blocked before equipment is locked out for repairs? Are appropriate (authorized) employees provided with individually keyed personal safety locks? Are employees required to keep personal control of their key(s) while they have safety locks in use? Is it required that only the employee exposed to the hazard can place or remove the safety lock? Is it required that employees check the safety of the lockout by attempting a startup after making sure no one is exposed? Are employees instructed to always push the control circuit stop button prior to reenergizing the main power switch? Is there a means provided to identify any or all employees who are working on locked out equipment by their locks or accompanying tags? Are a sufficient number of accident prevention signs or tags and safety padlocks provided for any reasonable foreseeable repair emergency? When machine operations, configurations or size require an operator to leave the control station and part of the machine could move if accidentally activated, is the part required to be separately locked out or blocked? If the equipment or lines cannot be shut down, locked out and tagged, is a safe job procedure established and rigidly followed? 18

Lockout/Tagout Cautions Hazardous energy releases may occur during the installation, maintenance, service or repair of machines, equipment, processes or systems. Turning off a machine (placing the switch to OFF) for maintenance or repair DOES NOT mean that all the energy from the machine has been released. Authorized employees must know WHY lockout/tagout is important & WHY repairs & maintenance on machines & equipment must not be attempted without first going through proper lockout/tagout procedures. Often, an authorized employee & an affected employee may be the same person. Employers must periodically review the effectiveness of the lockout/tagout program & ensure that all employees are following established guidelines & procedures. Servicing & maintenance activities: constructing, installing, setting up, adjusting, inspecting, modifying, lubricating, cleaning, unjamming, & making tool changes. NEVER use lockout/tagout devices for any other purpose other than locking & tagging out energy sources. Remember, ONLY an authorized employee may apply a lockout device & ONLY that employee should have the key or combination to remove it. Remember, ONLY authorized employees may perform lockout/tagout procedures. NEVER loan out your lockout device & NEVER use another workers lockout device. NEVER apply a lockout/tagout device unless you are instructed to do so by a shop or job foreman, or other appropriate supervisor. NEVER remove another workers lockout/tagout device & NEVER allow another worker to remove your lockout/tagout device. Under certain situations it may be appropriate to position employees in specific locations in order to protect against unauthorized reconnection of energy sources. Remember, tagout devices can be used to add further clarification to lockout devices. If outside personnel refuse to comply with your lockout/tagout procedures & OSHA regulations for any reason, it may be best to refrain from doing business with them. If it is not possible for oncoming personnel to apply their lockout/tagout device(s) before the exiting personnel removes their devices, oncoming personnel should apply their device(s) immediately after the exiting personnel removes theirs. 19

Procedures for Isolating and Blocking Energy (Examples) Note: Following are some examples of procedures that are used to isolate and block energy sources. These examples are not meant to be all encompassing and you should be appropriately trained on the lockout/tagout procedures used in your shop. Mechanical Motion Energy Type: Mechanical Motion (rotation, translation, linear, oscillation) Method 1: Remove segments Method of isolating or blocking energy: Remove segments of operating mechanical linkages such as dismantling push rids, removing belts and removing flywheels. Method of securing the point of control: Tag the linkage and place them in a locked cabinet away from the machine. OR Attach warning tags where linkages were removed and restrict access to trained/authorized personnel. OR Post a person to protect against unauthorized reinstallation of the linkages. 20

Mechanical Motion Energy Type: Mechanical Motion (rotation, translation, linear, oscillation) Method 2: Blocking devices Method of isolating or blocking energy: Use blocking devices such as wood or metal blocks. Method of securing the point of control: Chain and lock in point of control or use metal pins driven or welded in place. OR Attach warning tags on the blocking devices and restrict access into the area to trained/authorized personnel. OR Post a person to protect against unauthorized removal of the blocking devices. 21

Mechanical Motion Energy Type: Mechanical Motion (rotation, translation, linear, oscillation) Method 3: Remove power Note: Method of isolating or blocking energy: Remove power or energy from the driving mechanism such as: Disconnect main electrical source. OR Close hydraulic or pneumatic valves and bleed. Method of securing the point of control: Padlock in the OFF position. Disconnect pneumatic and hydraulic lines and tag. OR Attach warning tags at control points and restrict access to trained/authorized personnel. Post a person to protect against unauthorized reconnection of the energy source. Check for alternate sources of power. Check for stored (residual) pneumatic and hydraulic energy. 22

Electrical Energy Energy Type: Electrical Method 1: Turn off disconnect switch Note: Method of isolating or blocking energy: Place the main electrical disconnect switch in the OFF position. Method of securing the point of control: Secure by a padlock, a clip and padlock, or a bar and padlock. OR Attach a warning tag and restrict access into the area to trained/authorized personnel. OR Post a person to protect against unauthorized actuation of the switch. Check for alternate sources of power. 23

Electrical Energy Energy Type: Electrical Method 2: Remove electrical circuits Method of isolating or blocking energy: Remove segments of electrical circuit, such as printed circuit modules. Method of securing the point of control: Tag the module and place in a locked cabinet away from the control center and tag the control center door. OR Attach a warning tag at the module location and restrict access to trained/authorized personnel. OR Have a person remain at the control center to protect from unauthorized installation or a spare of replacement module. 24

Energy Type: Potential (Pressure) Method: Close valves Potential Energy (Pressure) Method of isolating or blocking energy: Close valves and maintain open vent to relieve. Method of securing the point of control: Secure/block valve with locking device. OR Attach warning tags and restrict access to trained/authorized personnel. OR Station a person at the valves to protect against unauthorized actuation. 25

Energy Type: Potential (Gravity) Method: Blocking devices Note: Potential Energy (Gravity) Method of isolating or blocking energy: Block in place by using metal or wood blocks under the mechanism or pin the linkage in a position where gravity will not cause the mechanism to inadvertently fall. Method of securing the point of control: Secure, block or pin with a locking device. OR Attach warning tags to blocks, linkages and pins, and restrict access to trained/authorized personnel. OR Station a person at the mechanism to prevent unauthorized removal of blocks and pins, and reinstallation of linkages. Energy can be dissipated by lowering to a point where gravity could no longer cause inadvertent falling. 26

Energy Type: Potential (Springs) Method: Blocking Note: Potential Energy (Springs) Method of isolating or blocking energy: Block in a safe position by pinning or clamping the device, eliminating the potential of unrestricted and undesired travel. Method of securing the point of control: Secure pin or clamp in place with a locking device. OR Attach warning tags to the pins and clamps, and restrict release or access to trained/authorized personnel. OR Station a person at the control point to protect against pin or clamp removal, and unauthorized activation of the spring mechanisms. Spring energy can be dissipated by release or dismantling of the mechanism. 27

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Resource URLs Note: Select the hyperlink or copy/paste the URL in your web browser address bar. OSHA 29 CFR 1910.147 The control of hazardous energy (lockout/tagout) http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=sta NDARDS&p_id=9804 OSHA Control of Hazardous Energy (lockout/tagout) Safety & Health Topics http://www.osha.gov/sltc/controlhazardousenergy/index.html OSHA Compliance Assistance/Outreach http://www.osha.gov/dcsp/compliance_assistance/index.html CDC/NIOSH Control of Hazardous Energy Self-inspection Checklist http://www.cdc.gov/niosh/docs/wp-solutions/2011-156/pdfs/2011-156.pdf 28

OSHA 29 CFR 1910.147(b) Definitions applicable to this section. Affected employee. An employee whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed. Authorized employee. A person who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee's duties include performing servicing or maintenance covered under this section. 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 lockout can be achieved without the need to dismantle, rebuild, or replace the energy isolating device or permanently alter its energy control capability. Energized. Connected to an energy source or containing residual or stored energy. 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; a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors, and, in addition, no pole can be operated independently; a line valve; a block; and any similar device used to block or isolate energy. Push buttons, selector switches and other control circuit type devices are not energy isolating devices. Energy source. Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy. Hot tap. A procedure used in the repair, maintenance and services activities which involves welding on a piece of equipment (pipelines, vessels or tanks) under pressure, in order to install connections or appurtenances. it is commonly used to replace or add sections of pipeline without the interruption of service for air, gas, water, steam, and petrochemical distribution systems. Lockout. The placement of a lockout device on an energy isolating device, in accordance with an established procedure, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed. 29

Lockout device. A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds. Normal production operations. The utilization of a machine or equipment to perform its intended production function. 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 unjamming 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 release of hazardous energy. Setting up. Any work performed to prepare a machine or equipment to perform its normal production operation. Tagout. The placement of a tagout device on an energy isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed. Tagout device. A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed. 30

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