Written
Program : Energy Control Procedure (Lockout/Tagout)
Energy
Control Procedure (Lockout/Tagout)
This
is a sample written Energy Control
Procedure provided only as a guide
to assist in complying with 29 CFR
1910.147, OSHA's Energy Control standard.
It is not intended to supersede the
requirements detailed in the standards
but only as an aid in developing your
procedures so they meet the requirements
of this standard. You need to review
the standard for particular requirements
which are applicable to your specific
situation. This program must be tailored
to fit your facility. When the energy
isolating devices are not lockable,
tagout may be used, provided you comply
with the provisions of the standard
which require additional training
and more rigorous periodic in-spection.
For complex systems, more comprehensive
procedures may need to be developed,
documented and utilized.
This material and safety and health
consultation services are provided
at no cost to owners, proprietors,
and managers of small businesses by
the Illinois Onsite Safety & Health
Consultation Program, Industrial Services
Division, Department of Commerce and
Economic Opportunity under a program
funded largely by the Occupational
Safety and Health Administration (OSHA),
an agency of the U.S. Department of
Labor.
ONSITE SAFETY & HEALTH CONSULTATION
PROGRAM
Illinois Department of Commerce and
Economic Opportunity
Industrial Services Division
100 West Randolph, Suites 3-400
Chicago, Illinois 60601
Phone: 312-814-2337 Fax: 312-814-7238
TDD: 800-419-0667
LOCKOUT/TAGOUT
PROCEDURE
A.
Purpose. This procedure establishes
the minimum requirements for the lockout
of energy isolating devices whenever
maintenance or servicing is done on
machines or equipment. It will be
used to ensure that the machine or
equipment is stopped, isolated from
all potentially hazardous energy sources
and locked out before employees perform
any servicing or maintenance where
the unexpected energization or start-up
of the machine or equipment or release
of stored energy could cause injury.
B. Hardware. Every employee authorized
to perform lockout procedures will
be assigned the lock(s) needed to
safely lockout and repair company
equipment. Each lock used for lockout
will identify the person using it.
The company will purchase all lockout
hardware and employees are responsible
for using it properly. Lockout hardware
will be used ONLY for lockout. It
will not be used on toolboxes, lockers
or for any other reason.
C.
Compliance with this Program. All
employees are required to comply with
the restrictions and limitations imposed
upon them during the use of lockout.
The authorized employees are required
to perform the lockout in accordance
with this procedure. All employees,
upon observing a machine or piece
of equipment which is locked out to
perform servicing or maintenance will
not attempt to start, energize, or
use that machine or equipment.
D. Cord-n-plug Connected Equipment.
Potentially hazardous energy in cord
and plug connected equipment must
be controlled by the employee. Employees
can protect themselves by preventing
the equipment from becoming re- energized
during the servicing operation. Follow
either of these two procedures.
1.
Unplug the equipment from its electrical
socket. Place a lockable cover over
the plug. Place your lock on the
plug cover.
2. Unplug equipment from its electrical
socket. Keep the plug in your possession
at all times during equipment servicing;
OR keep the plug within arm's reach
and in your line of sight at all
times during equip-ment servicing.
E.
Sequence of Lockout. Lockout procedures,
other than cord-n-plug, will follow
this sequence.
1.
Notify all affected employees that
servicing or maintenance is required
on a machine or equipment and that
the machine or equipment must be
shut down and locked out to perform
the servicing or maintenance.
2. The authorized employee will
refer to the company procedure to
identify the type and magnitude
of the energy that the machine or
equipment utilizes, will understand
the hazards of the energy, and know
the methods to control the energy.
3. If the machine or equipment is
operating, shut it down by the normal
stopping procedure (depress the
stop button, open switch, close
valve, etc.).
4. De-activate the energy isolating
device(s) so that the machine or
equipment is isolated from the energy
source(s).
5. Lock out the energy isolating
device(s) with assigned individual
lock(s).
6. Stored or residual energy (such
as that in capacitors, springs,
elevated machine members, rotating
flywheels, hydraulic systems, and
air, gas, steam, or water pressure,
etc.) must be dissipated or restrained
by methods such as grounding, repositioning,
blocking, bleeding down, etc.
7. Ensure that the equipment is
disconnected from the energy source(s)
by first checking that no personnel
are exposed, then verify the isolation
of the equipment by operating the
push button or other normal operating
control(s) or by testing to make
certain the equipment will not operate.
Caution:
Return operating control(s) to neutral
or "off" position after verifying
the isolation of the equipment.
8.
The machine or equipment is now
locked out.
F.
Testing or Positioning of Machines.
In situations where the lockout/tagout
device must be temporarily removed
and the machine or equip-ment is to
be energized in order to test or position
the machine, the following will apply:
1.
Clear the machine/equipment of all
tools and materials;
2.
Remove employees from the machine/equipment
area;
3. Remove the lockout/tagout device;
4.
Energize and perform the testing
or positioning of the machine/equipment;
5. De-energize machine/equipment
and reapply the lockout/tagout device.
G.
Restoring Equipment to Service. When
the servicing or maintenance is completed
and the machine or equipment is ready
to return to normal operat-ing condition,
the following steps will be taken.
1.
Check the machine or equipment and
the immediate area around the machine
to ensure that nonessential items
have been removed and that the machine
or equipment components are operationally
intact.
2. Check the work area to ensure
that all employees have been safely
positioned or removed from the area.
3.
Verify that the controls are in
neutral.
4. Remove the lockout devices.
5. Re-energize the machine or equipment.
Note: The removal of some forms
of blocking may require re-energization
of the machine before safe removal.
6.
Notify affected employees that the
servicing or maintenance is completed
and the machine or equipment is
ready for use.
H.
Electrical Lockout. Authorized employees
who perform electrical maintenance
where the electrical circuit has been
locked out, will follow these procedures.
No work is to be done on live parts.
1.
A tag used without a lock will be
supplemented by at least one addition-al
safety measure that provides a level
of safety equivalent to that obtained
by use of a lock. Examples of additional
safety measures include the removal
of an isolating circuit element,
blocking of a controlling switch,
or opening of an extra disconnecting
device.
2.
A qualified person will use test
equipment to test the circuit elements
and electrical parts of equipment
to which employees will be exposed
and will verify that the circuit
elements and equipment parts are
de--energized. The test will also
determine if any energized condition
exists as a result of inadvertently
induced voltage or unrelated voltage
backfeed even through specific parts
of the circuit have been de--energized
and presumed to be safe. If the
circuit to be tested is over 500
volts, nominal, the test equipment
will be checked for proper operation
immediately after this test.
Note:
If your employees work on de-energized
electrical parts, you need to comply
with the requirements for a written
program under 1910.331-335 Safe
Work Practices standard. Including
these two paragraphs in your lockout
program will enable you to use a
single lockout/tagout program to
cover all hazards addressed by both
the electrical standard and the
energy control standard.
I.
Procedure Involving More than One
Person. Every employee servicing a
piece of equipment that must be locked
out is required to be protected from
accidental machine movement or startup
with his or her own personal lock.
In the preceding steps, if more than
one individual is required to lockout/tagout
equipment, each will place his/her
own personal lockout device or tagout
device on the energy isolating devices.
When an energy isolating device cannot
accept multiple locks/tags, a single
lock may be used to lockout the machine
or equipment with the key being placed
in a lockout box or cabinet which
allows the use of multiple locks to
secure it. Each employee will then
use his/her own lock to secure the
box or cabinet. As each person no
longer needs to maintain his/her lockout
protection, that person will remove
his/her lock from the box or cabinet.
J. Shift or Personnel Changes. In
the event of a shift/personnel change,
the on-coming authorized person will
check out the machine/equipment and
ensure proper lockout procedures have
been followed and will apply their
personal lock when the procedures
have been verified.
OR
(select the one that fits your operation
best)
In
the event of a shift/personnel change,
a special supervisory lock will be
applied by the leaving authorized
person and will remain until the new
authorized person begins work and
will apply their own personal lock.
K. Lock Removal. An employee will
never remove another person's lockout
without management approval and/or
supervision. If an employee forgets
to remove a lockout/tagout device
and goes home, the company management
will make every effort to get in touch
with the authorized employee. If the
employee cannot be contacted, another
authorized employee and the supervisor
will check out the equipment and make
sure there is no danger in removing
the lock. A supervisor will remove
the device. The absent authorized
employee will be notified that his
lock was removed before he returns
to work.
L.
Lockout/tagout Procedures for Outside
Contractors. Outside contractors will
use the lockout/tagout procedure enforced
by their own company. If the outside
contractor does not have procedures
regarding control of hazard-ous energy,
they may use our procedures. The outside
contractor will provide us a copy
or description of their procedure
so that we can ensure that our employees
understand and comply with the restrictions
and pro-hibitions of the outside contractors
lockout procedures.
M.
Training. All employees will be trained
in our lockout/tagout pro-cedures.
Levels of training will depend upon
each employees involvement with our
procedures. All training will be documented
and placed in the employees personnel
file.
1.
"Authorized" employees are those
who perform machine maintenance
and servicing that requires lockout.
They are the only individuals who
will lockout equipment and will
be expected to know our lockout
procedures. Training for authorized
employees will include the recognition
of applicable hazardous energy sources,
the type and magnitude of the energy
available in the workplace, and
the methods and means necessary
for energy isolation and control.
2. "Affected" employees are those
who work in areas where lockout
may take place. They will not perform
lockout procedures, nor service
or repair any locked out equipment.
Training for affected employees
will include the purpose and use
of the energy control procedure.
3. "Other" employees are those whose
work may require them to be in areas
where lockout is used. Training
for other employees will include
the procedure and the prohibition
relating to attempts to restart
or re--energize machines or equipment
which are locked or tagged out.
N.
Periodic Inspection. At least annually,
there will be an inspection conducted
by an authorized employee not involved
with the specific lockout/tagout procedures
to ensure that requirements of our
procedures are being followed.
The annual inspection is to be conducted
by an authorized employee (other than
the ones using the lockout/tagout
procedure) and is intended to assure
that the energy control procedures
continue to be implemented properly
and that employees involved are familiar
with their responsibilities. It is
also intended to identify and correct
any deviations or inadequacies ob-served.
The inspector must be able to determine
: whether the steps in the energy
control procedure are being followed;
whether the employees involved know
their responsibilities under the procedures;
and whether the procedure is adequate
to provide the necessary protection
and what changes, if any, are needed.
This
inspection will be documented and
will include the following:
1.
Identity of the machine or equipment
on which the energy control proced-ure
was being utilized;
2. Date of the inspection;
3. Employees included in the inspection;
and
4.
Name of person performing the inspection.
O.
Equipment Replacement, Repair and
Modification. To meet all OSHA requirements
and provide equipment capable of being
locked out effectively and safely,
controls that can accept locks and
lockout devices will be installed
whenever new equipment is purchased,
or old equipment undergoes major repair
or modification. This policy applies
to production machinery, auxiliary
equipment, and any other devices or
machines that must be locked out during
servicing or repair to prevent accidental
machine movement or startup that could
injure employees.
SPECIFIC
ENERGY CONTROL PROCEDURES (LOCKOUT/TAGOUT)
To
assure that before any employee performs
servicing or maintenance on a machine
or equipment, the machine or equipment
was isolated and rendered inoperative,
you need to develop and document specific
pro-cedures for each machine or group
of machines. To assure compliance
you should:
a.
Make an inventory of each machine
or process for the entire works-ite
where servicing and maintenance
are performed.
b. Group the machines/processes
by similar characteristics (i.e.
cord-n-plug; single energy course;
types of energy - hydraulic, pneumatic,
kinetic, thermal, chemical) which
can cause unexpected energization
or start up of the machines/processes
or release of stored energy which
could cause injury to employees.
c. Develop specific procedures to
indicate the proper method to lockout
and tagout machines and equipment
while servicing or maintenance is
being performed. Note that this
should be done for each machine/process
group identified in (a) above.
d.
Use the worksheet attached to help
you develop specific procedures.
Definitions are as follows:
Operator
Controls - The type of controls
available to the operator need
to be determined. This should
help identify energy sources and
lockout capacity.
Energy
Sources - Can the machine be locked
out at the main power source?
Some machine installations involve
complex wiring schemes. A qualified
electrical should evaluate machines
were necessary to determine if
all electrical circuits can be
locked out. Check and/or list
energy sources present on this
equipment.
Shutdown
Procedures - List in order the
steps necessary to shut down and
de-energize the equipment. You
must be specific. For stored energy,
be specific about how the energy
will be dissipated or restrained.
Startup
Procedure - List in order the
steps necessary to re-activate
(energize) the equipment. Ensure
during each step that personnel
are clear during any testing or
activation.
MACHINE
SPECIFIC ENERGY CONTROL PROCEDURES
(LOCKOUT/TAGOUT)
Machine/equipment:
Equipment
Identification:
Operator
Controls:
Energy
Sources:
Electrical
Steam
Pneumatic
Other
Natural Gas
Hydraulic
Stored Energy Source ______________
Identify
Energy Source/location
Lockable
(Yes)(No)
Type
Device Required
Shutdown
Procedures:
Lock
Type & Procedure:
De‑energized
& Verified (How):
Startup
Procedure:
SAMPLE
MACHINE SPECIFIC ENERGY CONTROL
PROCEDURES (LOCKOUT/TAGOUT)
Machine/equipment
Part
Revolution Mechanical Power
Press
Equipment
Identification
Minster
straight‑side press
#38
Minster
OBI press #40
Operator
Controls
Control
panel
Energy
Sources:
Electrical
Steam
Pneumatic
Other
Natural Gas
Hydraulic
Stored Energy Source
Kinetic
Identify
Energy Source/location
Electrical
Hydraulic
(lube system)
Pneumatic
Overhead Air Supply
Lockable
Yes
No
Yes
Type
Device Required
Padlock
De-energized
when power off
Padlock
Shutdown
Procedures:
1.
Notify all affected employees
of lockout
2.
Position slide to desired
position
3.
Turn off all motors
4.
Place tag on controls indicating
lockout
5.
Check to assure the flywheel
is stopped
6.
Turn press controls "off"
and remove key
7.
Install die block
8.
Turn off main electrical supply
9.
Turn off pneumatic supply
and bleed system
10.
Turn all pressure regulators
to zero
11.
Bleed residual air counterbalance
and die cushions
12.
Turn hydraulic pumps off bleed
and check gauges, read "zero"
pressure
Lock
Type & Procedure:
Electrical -disconnect at
bus duct, plug open door,
remove fuses, close door.
Secure with padlock (if needed,
use multiple lock device)
Pneumatic -locate main shutoff
valve at overhead air supply
line. Close valve and lock
(use multiple locking device
when needed). All valves are
self bleeding type.
Check and bleed down counterbalance
and verify all gauges read
"zero".
De-energized
& Verified (How):
Electrical -Use voltmeter
to verify power has been de‑energized.
Attempt to start press by
activating start button.
Pneumatic -Verify all pressure
gauges read "zero".
Hydraulic -Verify all pressure
gauges read "zero".
Startup
Procedure
1.
Remove all tools and materials
from area.
2.
Replace all covers and guarding
devices
3.
Remove die block
4.
Check that all personnel are
in a safe area out from any
hazards
