LOCKOUT/TAGOUT
PROGRAM GUIDE
Developed by: Hortica Loss Control Department
Hortica
The Florists’ Mutual Insurance Company
Instructions for completing the Lockout/Tagout Program Guide.
Ø Replace the words “Company Name” with the name of your company.
Ø Replace the words “Responsible Person” with the name of the individual responsible for those specific duties described.
Ø Replace the words “Authorized Employee” with the name(s) or job position(s) of those responsible for Lockout/Tagout procedures.
Ø Replace the words “Affected Employee” with the name(s) or job position(s) of those affected by Lockout/Tagout procedures.
Ø Replace “Location” with the exact location(s) the item(s) described can be found at your facility.
Ø Replace “Machines” with the particular machine(s) specific to your operation.
Ø Replace “Equipment” with the particular piece(s) of equipment specific to your operation.
This Lockout/Tagout Program Guide was created by the Hortica Loss Control Department to assist our customers in establishing their own Lockout/Tagout program. This program guide was developed using federal standards, and may not include all of the requirements of some state funded Occupational Safety and Health Administrations.
COMPANY NAME
LOCKOUT/TAGOUT PROGRAM
1. SCOPE
This program has been developed in accordance with OSHA regulation 29 CFR 1910.147 (Lockout/Tagout). The Lockout/Tagout standard applies to the servicing and maintenance of machines and equipment in which the unexpected energization or start up of the machines or equipment, or release of stored energy could cause injury to employees. This standard establishes only the minimum performance requirements for the control of such hazardous energy.
2. APPLICATION
The Lockout/Tagout standard applies to the control of energy during servicing and/or maintenance of machines and equipment.
Normal machine/equipment operations are not covered by this standard. Servicing and/or maintenance that takes place during normal production operations is covered if:
A. An employee is required to remove or bypass a guard or other safety device; or
B. An employee is required to place any part of his or her body into the point of operation of a machine or piece of equipment, or where an associated danger zone exists during a machine cycle.
1. Exception to (2)(A)(B): Minor tool changes and adjustments, and other minor servicing activities that take place during normal production operations are not covered by this standard if they are routine, repetitive, and integral to the use of the equipment for production, provided that the work is performed using alternative measures that provide effective protection.
This standard does not apply to the following:
A. Work on cord and plug connected electric equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the energy source and by the plug being exclusive control of the employee performing the servicing or maintenance.
B. Hot tap operations involving transmission and distribution systems for
substances such as gas, steam, water, or petroleum products when they are performed on pressurized pipelines, provided Responsible Person has demonstrated that:
1. Continuity of service is essential
2. Shutdown of the system is impractical; and
3. Documented procedures are followed, and special equipment is
used which will provide proven effective protection for employees.
3. PURPOSE
To ensure that Company Name employees understand the minimum requirements set forth by 29 CFR 1910.147 for locking or tagging out machines and equipment. It is believed that compliance with this program will prevent injury to employees.
4. PROTECTIVE MATERIALS AND HARDWARE
As your employer, Company Name will provide you with all necessary materials and hardware essential for your safety. Items may include but are not limited to: locks, tags, chains, wedges, key blocks, adapter pins, and self-locking fasteners. Lockout/Tagout materials will be durable, standardized, substantial, and identifiable. Protective materials provided shall not be used for any purpose other than controlling energy.
5. RESPONSIBILITIES
A. Responsible Person
1. Updates and maintains general awareness of all aspects of Company Name Lockout/Tagout Program.
2. Maintains updated copies of the written Lockout/Tagout Program and OSHA 29 CFR 1910.147 standard, which will be kept (Location).
3. Relays all necessary Lockout/Tagout safety information through thorough training, and documents all training.
4. Determines and identifies in this program which employees/job positions are considered “authorized and “affected”.
5. Determines and identifies in this program which machines and equipment are required to be locked out or tagged out.
6. Issues appropriate locks, tags, or other necessary equipment.
7. Conducts intermittent inspections of the energy control procedure, at least annually to make certain that the requirements of this program are being obeyed.
8. Documents all necessary inspections of the program.
B. Authorized Employee(s)
1. Shall review this program, and comply with the criteria set forth
within this program.
2. Returns all energy control devices to Responsible Person or Location immediately after use.
3. Reports to Responsible Person, any potential problems or suggestions related to the Lockout/Tagout safety program.
C. Affected Employee(s)
1. Shall review this program, and comply with the criteria set forth within this program.
2. Reports to Responsible Person, any potential problems or suggestions related to the Lockout/Tagout safety program.
6. Machinery and Equipment
The machines and equipment listed below have been identified by, Responsible Person as being required to be either locked or tagged out.
The following list of machines and equipment must be locked out during service or maintenance operations:
A. Machines & Equipment
The following list of machines and equipment must be tagged out during service or maintenance operations:
A. Machines & Equipment
7. EMPLOYEE TRAINING AND COMMUNICATION
The purpose of employee training is to ensure that the function of the Lockout/Tagout Program is fully understood, so that it can be applied effectively and safely.
A. The training shall include the following:
1. Authorized employees will receive training in 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 will be instructed in the purpose and use of the energy control procedure.
3. Other employees whose work operations may be in an area that requires energy control procedures shall be instructed about the procedure, and about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out.
4. Limitations of tag use which are:
a. Tags are essentially warning devices affixed to energy isolating devices, and do not provide the physical restraint on those devices that is provided by a lock.
b. When a tag is attached to an energy isolating means, it is not to be removed without authorization of the authorized person responsible for it, and it is never to be bypassed, ignored, or otherwise defeated.
c. Tags must be legible and understandable by all authorized employees, affected employees, and all other employees whose work operations are or may be in the area, in order to be effective.
d. Tags and their means of attachment must be made of materials, which will withstand the environmental conditions encountered in the workplace.
e. Tags may evoke a false sense of security, and their meaning needs to be understood as part of the overall energy control program.
f. Tags must be securely attached to energy isolating devices so that they cannot be inadvertently or accidentally detached during use.
B. Employee retraining is necessary when:
a. A change in job assignments, machines, equipment, or processes that presents a new safety hazard, or when there is a change in the energy control procedures.
b. Responsible Person has reason to believe that there are deviations from or inadequacies in the employee’s knowledge or use of the energy control procedures.
C. Documentation & Records
a. Attendance sheets will be used to document name(s) of trainee, trainer, and date of the required trainings.
b. A Lockout/Tagout training file will be kept in the Location.
8. NOTIFICATION OF EMPLOYEES
Affected employees must be notified by, Responsible Person or the authorized employee of the application and removal of Lockout/Tagout devices. Notification is required to be given before an energy control device is applied, and after an energy control device is removed from the machine or equipment. All reasonable efforts must be made to notify affected employees such as: verbal and written communication.
9. ENERGY CONTROL PROCEDURES
The following procedures apply to authorized employee(s) servicing or conducting maintenance work on machines and equipment in which the unexpected energization or start up of the machines or equipment, or release of stored energy, could cause injury to employees. It is intended that the procedures listed will prevent loss related to unexpected energization or start-up of machines, or equipment, or the release of stored energy.
Note: The procedures listed below may vary slightly from one machine or piece of equipment to another. Indicate the proper energy control procedures for each individual piece of equipment or machinery.
A. Notify all affected employees that a lockout or tagout device is required on the machine or equipment, and the reason therefore. Refer to section (8).
B. If the machine or equipment is running, shut it down by the manufacturers guidelines (stop button, toggle switch etc.).
C. De-activate the energy isolating device(s) so that the machine or equipment is isolated from the energy sources.
D. Apply necessary Lockout/Tagout materials to the energy isolating device(s). Ensure that Lockout device(s) are attached in a manner that guarantees energy isolating device(s) will be held in a “safe” or “off” position.
Tagout devices, where used, must be attached in such a manner as will clearly indicate that the operation or movement of energy isolating devices from the “safe” or “off” position is prohibited.
Where tagout devices are used with energy isolating devices designed with the capability of being locked, the tag attachment must be fastened at the same point at which the lock would have been attached.
Where a tag cannot be attached directly to the energy isolating device, the tag must be located as close as safely possible to the device, in a position that will be immediately obvious to anyone attempting to operate the device.
E. Stored or residual energy such as that in hydraulic systems, capacitators, elevated machine members, springs, rotating flywheels, air, steam, gas, water pressure, etc. must be dissipated or controlled by methods such as grounding, repositioning, blocking, bleeding down, etc..
F. Verify that the machine or equipment is disconnected from the energy source(s) by first checking that no employees are exposed, then by testing the energy-isolating device to make certain the machine or equipment will not start up. Note: Place operating control(s) in the neutral or “off” position after verification is finished. If the Tagout system is used, ensure that the Tag is visible and attached properly.
G. The machine or equipment is now locked or tagged out.
10. RELEASE OF ENERGY CONTROL PROCEDURES
Only after the service or maintenance work is finished, and the machine or equipment is ready to return to regular operating condition, the following procedures shall be taken by the authorized employee(s). Note: Energy control devices shall only be removed by the person(s) who applied the device(s).
A. Conduct an inspection of the work area to ensure that unnecessary items have been removed, and to ensure that the machine or equipment components are in the manufacturers suggested placement for correct operational function.
B. Check the work area to ensure that all affected employees have been safely positioned or removed.
C. The authorized employee who applied the Lockout/Tagout device(s) may remove the device(s), and notify affected employees that protective devices have been removed.
D. If the authorized employee who applied energy control device(s) is not available, refer below:
1. If the authorized employee who applied the Lockout/Tagout device is unavailable to remove it, the device may be removed under the direction of Responsible Person, provided that Responsible Person has accomplished the following:
a. Verification that the authorized employee who applied the device is not at the facility.
b. All reasonable efforts have been made to contact the authorized employee to inform him/her that the Lockout/Tagout Device has been removed.
c. Ensured adequate steps have been taken to inform the authorized employee before he/she resumes work at the facility, that his/her Lockout/Tagout device has been removed.
E. Additional Requirements
1. Should there be a need to remove energy isolating device(s) for testing or positioning of the machine or equipment, the following sequence applies:
a. Clear equipment/process tools and other materials from the work area.
b. Clear personnel from the work area.
c. Clear the control of Lockout/Tagout device(s) according to section (10).
d. Conduct the test, etc.
e. De-energize all systems and re apply proper energy control devices, which are indicated above in section (6).
11. OUTSIDE PERSONNEL (Contractors, etc.)
Whenever outside servicing personnel are required to be engaged in tasks covered by the scope and application of the Lockout/Tagout standard, Company Name and the outside employer will inform each other of the relevant Lockout/Tagout procedures necessary for personnel safety.
Responsible Person(s) will ensure that Company Name employees understand and comply with the restrictions and prohibitions of the outside employer’s energy control program.
12. GROUP LOCKOUT/TAGOUT
If more than one authorized person is required to Lockout/Tagout equipment or machines, each person shall place his/her personal lock or tag on the energy control device(s) in accordance with section (9) of this program. When it is necessary for he/she to stop working on the machine or equipment, those device(s) shall be removed in accordance with section (10) of this program. Responsible Person, with the knowledge of the servicing crew, will lock out equipment for the whole crew. Additionally, Responsible Person shall not remove a crew lock until all members of the crew have been informed and accounted for. Furthermore, each authorized person must attach a personal lockout or tagout device to a group lockout device when he or she begins work, and must remove those devices when he or she stops working on the machine or equipment being serviced or maintained.
12. SHIFT OR PERSONNEL CHANGES
Workers shall be responsible for removing his/her own Lockout/Tagout device(s) at the completion of their shift. If maintenance or service work is required to cease until a future date, Responsible Person shall place his personal Lockout/Tagout device on the equipment, and the workers shall remove their device(s). When work resumes, Responsible Person will remove his lock or tag only after the other workers have affixed their energy control device(s).
13. REFERENCES
A. www.osha.gov/OshStd_data/1910_0147.html
B. www.niehs.nih.gov/odhsb/manual/man11h.htm