a Environmental Health & Safety Compliance Procedure for FIT Lockout/Tagout Safety Program For Studios, Labs and Shops
Lockout/Tagout Safety Program-Studios, Labs, and Shops Control of Hazardous Energy Table of Contents INTRODUCTION 3 Hazards Hazard Controls RESPONSIBILITIES - COLLEGE-WIDE Vice-Presidents Facilities Management.4 Human Resources Purchasing Office of Environmental, Health and Safety Compliance (EHS) Students, faculty, staff and visitors (including contractors) RESPONSIBILITIES - DEPARTMENT Deans and Directors Department Chairs and Department Heads.. 5 Lockout/Tagout Program (Qualified) Employee(s) COMPLIANCE REQUIREMENTS Training Authorized Employees Training Affected Employee Training...6 Other Employee and Student Training Preparation for Lockout/Tagout Procedures Routine Maintenance & Machine Adjustments...7 Damaged Equipment- Out of Service Definitions Authorized (Qualified) Employees Affected Employees Other Employees and Students...8 Attachment 1 9 General Lockout/Tagout Procedures Preparation for Shutdown Machine or Equipment Shutdown Machine or Equipment Isolation Lockout or Tagout Device Application Stored Energy. 10 Verification of Isolation Extended Lockout - Tagout Release from Lockout/Tagout Lockout/Tagout Procedures Involving More Than One Employee.....11 Management's Removal of Lockout/Tagout Lockout/Tagout Procedure for Electrical Plug-Type Equipment Attachment 2.12 Contents of FIT Lockout/Tagout Kit and Restocking Request 2
Fashion Institute of Technology Office of Environmental Health and Safety Compliance Revision: Third Dated 4/8/14 Lockout/Tagout Safety Program-Studios, Labs, and Shops Control of Hazardous Energy INTRODUCTION Control of Hazardous energy is the purpose of the Lockout/Tagout Safety Program. This program establishes the College requirements for isolation of both kinetic and potential hazardous energy prior to equipment repair, adjustment, or removal. This program applies to students, faculty, staff, contractors, and visitors while in College studios, labs, or shops and working on campus. Hazards - Improper or failure to use Lockout/Tagout procedures may result in: Electrical shock Chemical exposure Skin burns Lacerations & amputation Fires & explosions Chemical releases Eye injury Death Hazard Controls: Only authorized and trained employee or students may engage in tasks that require use of Lockout/Tagout procedures. Confirm that all equipment has single sources of hazardous energy. Develop written lockout procedures for all equipment and processes. Require inspection of all equipment before each use and immediate lockout and removal from service of damage equipment. Restoration of equipment from lockout condition as a controlled operation. Questions about this critically important Program should be directed to Office Environmental, Health & Safety Compliance at (212) 217-3752. RESPONSIBILITIES - COLLEGE-WIDE Vice-Presidents: Designate employees as Authorized (Qualified) Employees who are responsible for ensuring compliance with federal, state, and local regulations, and this FIT Lockout/Tagout Program. 3
Facilities Management: Facilitate the exchange of Lockout/Tagout Program between FIT departments and contractors working in the department area prior to the start of work on the FIT campus. Designate an authorized Lockout/Tagout Program (Qualified) Employee(s) to supervise any contractor working on the FIT campus. Provide FIT Daily Safety Management Work Management to contractors. Retain the contractor s FIT Daily Safety Management Work Management for one (1) year after construction or repair is complete. Human Resources: Maintain copies of FIT employee training records during period of employment. Purchasing: Inform contractors about FIT s Lockout/Tagout Program. Office of Environmental, Health and Safety Compliance (EHS): Ensure that programs and procedures meet all regulatory requirements as part of a formal annual program review. Develop, review and assist with training of FIT employees as required by OSHA/PESH. Provide advice and counsel to FIT employees about OSHA/PESH Lockout/Tagout Program. Serve as FIT s primary point of contact with regulatory agencies such as OSHA/PESH in matters that concern compliance with Lockout/Tagout Program requirements. Respond to reports of suspected health and safety issues that may not meet OSHA/PESH Lockout/Tagout Program and prepare written reports as needed. Provide each College lab, studio, and shop with appropriate Lockout/Tagout supplies (locks, keys, hasp, and tags). Students, faculty, staff and visitors (including contractors): Follow the College s Lockout/Tagout Program. RESPONSIBILITIES - DEPARTMENT Deans and Directors: Either maintain responsibility or designate Department Chairs and Department Heads, to ensure that Lockout/Tagout Program (Qualified) Employee(s) supervise the use of machines, equipment, and systems where hazardous energy is present. Deans and directors also receive reports from the EHS department about compliance with this Program and are responsible to take appropriate administrative and disciplinary action in cases of non-compliance. 4
Department Chairs and Department Heads: Administer the department s compliance with this Program. Designate one or more Lockout/Tagout Program (Qualified) Employee(s) for the departments who will act as program coordinators for each lab or studio where hazardous energy is present. Ensure that Lockout/Tagout Program (Qualified) Employee(s) is scheduled for required annual training by or through EHS. Ensure that employees or students are not exposed to uncontrolled hazardous energy in FIT labs or studios. Prohibit use of equipment in labs and studios where uncontrolled hazardous energy is present. Provide employees on all shifts with access to Lockout/Tagout supplies to prevent exposure to uncontrolled hazardous energy. Provide contractors working for the College with information about hazardous energy to which the contractor's employees may be exposed. Lockout/Tagout Program (Qualified) Employee(s): Maintain a copy of this Program in each FIT lab or studio where hazardous energy is present. Work with students, faculty, staff, and visitors, and EHS to implement this program. Attend Lockout/Tagout training, including annual updates and department-specific training. Evaluate sources of hazardous energy in FIT lab or studio where hazardous energy is present. Maintain sufficient amounts of Lockout/Tagout supplies in FIT lab or studio where hazardous energy is present. COMPLIANCE REQUIREMENTS Training Authorized Employees Training All faculty and staff will receive training about this Lockout/Tagout Safety Program-Studios, Labs, and Shops. The Office of EHS Compliance will arrange for training of authorized employees. Authorized employees will provide training to affected employees, other employees and students, as needed. The Office of EHS Compliance will arrange for retraining of authorized employees at least annually. The authorized employees training will consist of the following: 1. Review of general safety procedures and good work practices. 2. Review of machinery, equipment, and processes specific procedures. 3. Location and use of specific procedures. 4. Need to revise procedures when questions arise. 5. Review of relevant accidents and incidents. 5
Affected Employee Training The lab or studio authorized employee(s) will provide affected employee training. The training will consist of the following: 1. State that only trained and authorized Employees will repair, replace, or adjust machinery, equipment, or processes. 2. State that affected Employees may not remove locks, locking devices or tags from machinery, equipment, or circuits. 3. Review purpose and use of the Lockout/Tagout Safety Program-Studios and Labs and its procedures. 4. Need to inspect equipment and machines before each use. Other Employee and Student Training The lab or studio authorized employee(s) will provide other employee and student training. The training will consist of the following: 1. State that only trained and authorized employees will repair, replace, or adjust machinery or equipment. 2. State that other employees or students may not remove locks, locking devices, or tags from machinery, equipment, or circuits. 3. State that other employees or students may not touch or operate any machine or equipment when they see that it is locked out or tagged out. 4. Need to inspect equipment and machines before each use. Preparation for Lock and Tag Out Procedures Each authorized employee(s) in lab(s), studio(s), and/or shop(s) will conduct a Lockout/Tagout survey to locate and identify all energy sources. The survey will verify which switches or valves supply energy to machinery and equipment. The authorized employee(s) will remove dual or redundant controls found during the survey. Authorized employee(s) will develop a written Lockout/Tagout schedule for each piece of equipment and machinery. This schedule will describe the energy sources, location of disconnects, type of disconnect, special hazards and special safety procedures. The lab or studio authorized employee will review the schedule each time to ensure that equipment and machinery is properly locked out and tagged out. Authorized employee(s) will develop a Lockout/Tagout schedule prior to conducting a Lockout/Tagout if a schedule does not exist for a particular piece of equipment, machinery, and process. As repairs and/or renovations of existing electrical systems are made, lab or studio authorized employee(s) will identify standardized controls needed to update the original Tagout Schedule. 6
The Office of EHS Compliance will assist, as necessary a lab or studio authorized employee(s) to conduct the Lockout/Tagout survey, the written Tagout schedule, and updates as needed. Routine Maintenance & Machine Adjustments Lockout/Tagout procedures are not required if equipment must operate for proper adjustment. Only authorized employees may use this rare exception. Authorized employees must develop specific procedures to avoid hazards of adjusting equipment while equipment is operating. Authorized employees shall always consider the need not to break the plane of a normally guarded area of the equipment by use of tools and other devices when adjusting equipment while equipment is operating. Damaged Equipment- Out of Service All employees and students must inspect equipment and machines for signs of damage before each use. The employee inspection shall include but not limited to inspection of electrical wiring for damaged insulation, damaged plugs, missing guards, missing parts, inoperative safety lights and alarms, etc. All employees and students must report suspected damage to equipment and machines immediately to the lab-, studio-, or shop-authorized employee. In no case when an inspection finds suspected damage to equipment and machines can an employee or student use or allow others to use damaged equipment or machines. The lab-, studio-, or shop-authorized employee will immediately inspect all reports of suspected damaged equipment and machines. The authorized employee will immediately lockout and tagout equipment or machines when the authorized employee s inspection confirms as damaged and remove it from service. At minimum, the tag should indicate the nature of the equipment s damage and possible repair needed. The authorized employee shall record all incidents of locked out and tagged damaged equipment or machines in a repair log that the authorized employee maintains. DEFINITIONS Authorized (Qualified) Employees are the faculty and staff who a department chair or department head authorizes (qualifies) to lockout/tagout equipment or machinery. An employee s qualification will depend upon various circumstances in the workplace. An employee may be considered "qualified" with regard to certain equipment in the workplace, but "unqualified" as to other equipment. An employee who is undergoing on-the-job training and who, in the course of such training, has demonstrated an ability to perform duties safely at his or her level of training and who is under the direct supervision of a qualified person, is considered to be "qualified" for the performance of those duties. Affected Employees are those employees who operate machinery or equipment upon which lockout or tagging out is required under this program. Training of these individuals will be less stringent in that it will include the purpose and use of the lockout procedures. Hazardous energy may be any energy that could cause harm to students, faculty, staff, contractors, and visitors such as: Electrical Mechanical/stored (such as pneumatic, hydraulic, springs, parts moved by gravity, spinning flywheels, pressurized systems, etc.) 7
Radiation High intensity electromagnetic fields Chemical Other Employees and Students are those that do not fall into the authorized or affected employee category. This includes all other employees, students, contractors, and visitors while in a College lab, studio, or shop. Reference: OSHA Standard 29 CFR 1910. 147, The Control of Hazardous Energy. http://safetyinfo.com/guests/safety-program-lockout%20tagout.htm 8
Attachment 1 GENERAL LOCKOUT AND TAGOUT PROCEDURES The following outlines the procedures to use before working on, repairing, adjusting, or replacing machinery and equipment to place the machinery and equipment in a neutral or zero mechanical state. Preparation for Shutdown Before authorized or affected employees turn off a machine or piece of equipment. The authorized employee will understand the type and magnitude of the machine or piece of equipment s energy, the hazards of the energy to be controlled, and the means to control the energy. The authorized employee will notify all affected employee, other employees, and Students that the machinery, equipment, or process will be out of service Machine or Equipment Shutdown The authorized employee will turn off or shut down the machine or equipment using the manufacturer s specific procedures for that specific machine. The authorized employee will use an orderly shutdown to avoid any additional or increased hazards to employee or student s because of equipment de-energization. If the machinery, equipment or process is in operation, the authorized employee will follow normal stopping procedures (depress stop button, open toggle switch, etc.). The authorized employee will move switch or panel arms to "Off" or "Open" positions and close all valves or other energy isolating devices. The authorized employee will disconnect or isolate energy source(s) from the machinery or equipment. Machine or Equipment Isolation The authorized employee will physically locate and operate all energy control devices that control the energy to the machine or equipment in such a manner as to isolate the machine or equipment from the energy source. Lockout or Tagout Device Application The authorized employee will affix lockout or tagout devices to energy isolating devices. The authorized employee will affix lockout devices in a manner that will hold the energy isolating devices from the "safe" or "off" position. The authorized employee will affix tagout devices to prohibit the operation or the movement of energy isolating devices from the "safe" or "off" positions. The authorized employee will attach a tag to the same point where a lockout device is attached. If the authorized employee cannot be affix the tag at lockout device point, the authorized employee place the tag as close as possible to the lockout device in a location that is immediately obvious to anyone who attempts to operate the device. 9
The authorized employee will lock and tag out all energy devices by use of hasps, chains and valve covers with assigned individual locks. Stored Energy Following the application of the lockout or tagout devices to the energy isolating points, all potential or residual energy will be relieved, disconnected, restrained, and otherwise rendered safe. Where the re-accumulation of stored energy to a hazardous energy level is possible, the authorized employee will periodically verify that continued isolation of energy until the maintenance or servicing is complete. Release stored energy (capacitors, springs, elevated members, rotating fly wheels, and hydraulic/air/gas/steam systems) must be relieved or restrained by grounding, repositioning, blocking and/or bleeding the system. Verification of Isolation Prior to starting work on machines or equipment that have been locked or tagged out, the authorized employee will verify that isolation or de-energization of the machine or equipment have been accomplished. The authorized employee will test all lock and tag outs after assuring that no employee or student is in danger. The authorized employee will attempt to follow the normal start up procedures (depress start button, etc.) test all lock and tag outs. Caution: After testing, the authorized employee will place controls in neutral position. Extended Lockout Tagout Should the lab, studio, or shop class of work period change before the machinery or equipment can be restored to service, the lock and tag out must remain. If the task to restore machinery or equipment is reassigned and will take place during the another lab or studio period the next period s lab or studio authorized employee must lock and tag the machinery or equipment before the previous lab or studio period authorized employee may remove his or her lock and tag. Release from Lockout/Tagout Before the authorized employee removes lockout or tagout devices and energy restored to the machine or equipment, the lab-, studio-, or shop- authorized employee shall take the following actions: 1. Thoroughly inspect the work area to ensure that nonessential items were removed and that machine or equipment components are operational. 2. Check the work area will be to ensure that all employees or students have been safely positioned or moved to safe area. Before the lockout or tagout devices are removed, notify the affected employees that the lockout or tagout devices are being removed. 10
3. Remove each lockout or tagout device from each energy-isolating device by the employee who applied the device. Lockout/Tagout Procedures Involving More Than One Employee In the case that more than one authorized employee is assigned to a task requiring a lock and tag out, each must also place his or her own lock and tag on the energy isolating device(s). Management's Removal of Lockout/Tagout Only the authorized employee that locks and tags out machinery, equipment, or processes may remove his/her lock and tag. However, should the authorized employee leave the facility before removing his/her lock and tag, the department chair or department head may remove the lock and tag. The department chair or department head must be assured that all tools have been removed, all guards have been replaced and all employee and students are free from any hazard before the lock and tag are removed and the machinery, equipment or process are returned to service. The department chair or department head shall attempt to notify the authorized employee who placed the lock prior to lock removal. LOCKOUT/TAGOUT PROCEDURE FOR ELECTRICAL PLUG-TYPE EQUIPMENT This procedure covers all electrical plug-type equipment such as battery chargers, some product pumps, office equipment, powered hand tools, powered bench tools, lathes, fans, etc. Qualified employees shall use the following procedures when working on, repairing, or adjusting the above equipment, to prevent accidental or sudden startup: 1. Unplug Electrical Equipment from wall socket or in-line socket. 2. Attach "Do Not Operate" Tag and Plug Box & Lock on end of power cord. NOTE: The only exception to the above is when the cord and plug remain in the exclusive control of the qualified employee working on, adjusting or inspecting the equipment. 3. Test Equipment to assure power source has been removed by depressing the "Start" or On" Switch. 4. Perform required operations. 5. Replace all guards removed. 6. Remove Lock & Plug Box and Tag. 7. Inspect power cord and socket before plugging equipment into power source. Repair any defects before placing the equipment back in service. NOTE: Unplug occasionally used equipment from power source when not in use. 11
ATTACHMENT 1 Contents of FIT Lockout/Tagout Kit for Studios, Lab and Shops and Restocking Request RESTOCKING REQUEST: Circle supplies needed and Fax request to: Office of EHS Compliance at 212/217-3751 or send request via InterOffice Mail to EHS Office. Department Name: Room Number: Date of Request: Requestor s Name: Contents of Kit: Three (3) Laminated Master Padlocks Blue for OSHA Lockout Three (3) Nonconductive Steel Lockout Hasps Two (2) Multi-pole Breaker Lockouts Three (3) Single Pole Breaker Lockouts One (1) Electrical Plug Lockout, 3-1 Twenty (20) Do Not Operate Lockout Tags Twenty eight (28) Lockout Identifier Stickers 12