FACILITIES MANAGEMENT

Office of the Chief Facilities Officer

DIRECTIVE NO. 269BDATE: September 12, 2002

SUBJECT:Control of Hazardous Energy (Lockout/Tagout)

REFERENCES:

  1. Occupational Safety and Health Administration (OSHA) 1910.147, the Control of Hazardous Energy (lockout/tagout).

PURPOSE:To establish policy and procedure for the administration of lockout/tagout (LOTO) program.

CANCELLATION:Directive No. 269A, Lockout/Tagout, dated August 18, 1995. This directive is a complete rewrite of Directive No. 269A.

BACKGROUND: The OSHA Standards for General Industry, reference (a), requires the establishment of an energy control program consisting of energy control procedures, employee training, and periodic inspections to ensure that machines and equipment that could unexpectedly startup, become energized, or release stored energy, are isolated from their energy source (s) and rendered safe prior to servicing or maintenance being performed.

POLICY: It is Facilities Management’s policy to comply fully with the provisions of reference (a) and to ensure that employees are protected from injury that may result from the unexpected energization or start up of machines or equipment, or the release of stored energy.

DISTRIBUTION LIST:REVIEW DATE:

September, 2004

On Line

Directors

Office of Environmental Health & Safety OFFICE OR DEPARTMENT

Human Resource & Training Manager RESPONSIBLE FOR REVIEW:

Architect for the University

Information Officer Safety & Health Program Manager

Special Distribution:

Bulletin Boards

DIRECTIVE NO. 269BSeptember 12, 2002

page 2

DEFINITIONS:

  1. Affected Employee: An employee who is required to use machines or equipment on which servicing is performed under the Lockout/Tagout standard or who performs other job responsibilities in an area where such servicing is performed.
  1. Authorized Employee: An employee who locks or tags machines or equipment in order to perform servicing or maintenance.
  1. Other Employees: All employees who are or may be in an area where energy control procedures may be utilized.
  1. Capable of being locked out: An energy-isolating device is considered capable of being locked out if it:
  1. Is designed with a hasp or other means of attachment to which a lock can be affixed.
  1. Has a locking mechanism built into it.
  1. Can be locked without dismantling, rebuilding, or replacing the energy-isolating device or permanently altering its energy control capability.
  1. Energized: Machines and equipment are energized when they are connected to an energy source or they contain residual or stored energy.
  1. 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.
  1. Energy source: Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy.
  1. 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.
  1. Lockout devices: Any device that uses positive means, such as a lock, blank flanges and bolted slip blinds, to hold an energy-isolating device in a safe position, thereby preventing the energizing of machinery or equipment.

DIRECTIVE NO. 269BSeptember 12, 2002

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  1. Tagout: The placement of a tagout device on an energy-isolating device, in accordance with established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed.
  1. Tagout device: Any prominent warning device, such as a tag and a means of attachment that can be securely fastened to an energy-isolating device to indicate that the machine or equipment to which it is attached may not be operated until the tagout device is removed.
  1. Zero Mechanical State: The state or condition in which all portions of the equipment or machine are set so that the opening of pipes, tubes, hoses, or actuation of any valve, lever or button, will not produce a movement which could cause injury.
  1. Normal production operations: Utilization of a machine or equipment to perform its intended production function.
  1. Servicing and/or maintenance: Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, maintaining and/or servicing machines or equipment, including lubrication, cleaning or unjamming of machines or equipment, and making adjustments or tool changes, where employees could be exposed to the unexpected energization or startup of the equipment or release of hazardous energy.

GENERAL: An energy control program has three case components: energy control procedures

employee training, and periodic inspections.

  1. Energy control procedures detail and document the specific information that an authorized employee must know to accomplish lockout/tagout; namely, the scope, purpose, and techniques to be utilized for the control of hazardous energy. Appendix I will be used prior to LOTO to document that the equipment being controlled cannot be operated and retained in the supervisor’s files for 3 years.
  1. Periodic inspections of the energy control procedures ensure that the procedures and the requirements of the standard are being followed. Appendix II will be used to document periodic inspections and retained in the supervisor’s files for 3 years.
  1. Employee training and retraining ensures that the purpose and function of the energy control program is understood.

ENERGY CONTROL PROCEDURES: The purpose of these procedures is to document the sequence of steps the authorized employee must follow to identify and control all hazardous energy sources before performing service or maintenance on equipment, machinery or a system. The following requirement must be developed by Facilities Management shops for each item of equipment or machinery that will require lockout or tagout.

DIRECTIVE NO. 269BSeptember 12, 2002

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  1. Develop specific procedural steps for shutting down, isolating, blocking, and securing machines or equipment to control hazardous energy and establish a zero mechanical state;
  1. Develop specific procedural steps for the placement, removal, and transfer of lockout or tagout devices, and a description of who has responsibility for them;
  1. Develop specific requirements for testing a machine or piece of equipment to determine and verify the effectiveness of lockout or tagout devices, and other energy control measures.

Classes of equipment or machinery can be grouped together when their function and operation are similar. NOTE: Exception – The employer need not document the required procedure for a particular machine or equipment when all of the following elements exist:

  1. The machine or equipment has no potential for stored or residual energy or re-accumulation of stored energy after shut down which could endanger employees.
  1. The machine or equipment has a single energy source, which can be readily identified and isolated.
  1. The isolation and locking out of that energy source will completely de-energize and deactivate the machine or equipment.
  1. The machine or equipment is isolated from that energy source and locked out during servicing or maintenance.
  1. A single lockout device will achieve a lock-out condition.
  1. The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance.
  1. The servicing or maintenance does not create hazards for other employees.
  1. The employer, in utilizing this exception, has had no accidents involving the unexpected activation or re-enegization of the machine or equipment during servicing or maintenance.

INSPECTION: Annually, on one item of equipment or machine, the shop supervisor will inspect and document that the authorized employee followed established energy control procedures for the equipment or machinery. Appendix II will also be utilized to document additional retraining as a result of this inspection.

TRAINING AND COMMUNICATION:Different levels of training are required for the three categories of employees (authorized, affected, other employees).

DIRECTIVE NO. 269BSeptember 12, 2002

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  1. Authorized employees must receive training in the recognition of applicable hazardous energy sources, the types of energy sources in the workplace, and the methods of isolating and controlling energy.
  1. Affected employees should be instructed in the purpose and use of the energy control procedure.
  1. Other employees shall be instructed about the procedure and the prohibition relating to attempts to restart machinery or equipment, which have been lockout/tagout.
  1. All employees must be trained on the limitations of tags. If the machine or equipment is capable of being locked out, a tag out procedure will not be used.
  1. After initial training has been accomplished, retraining is only required if:

a)There is a change in their job assignments, machines, equipment, processes that present a new hazard or a change in the energy control procedures;

b)Periodic inspections reveal deviations from or inadequacies in the employee’s knowledge or use of the energy control procedure;

c)The supervisor believes the employee needs further training.

MATERIALS AND HARDWARE: The proper materials and hardware must be used for isolating, securing or blocking machines and equipment from their energy sources. The following guidelines are provided for LOTO devices:

  1. They must be durable and capable of withstanding the environment to which they are exposed for the maximum period of time that exposure is expected;
  1. They must have individually keyed padlocks and warning tags, singularly identified so that only the authorized employee can unlock the padlocks or remove the tag out device.
  1. They must be the only devices used for controlling energy.
  1. They must not be used for other purposes.
  1. Lockout and tagout devices must be standardized within a facility in at least one of the following criteria: color, shape, or size. Tagout devices shall be standardized by print and format.

APPLICATION OF ENERGY CONTROL: The following sequential procedures must be performed by the authorized employee in the order listed to safely apply LOTO to machines and equipment:

DIRECTIVE NO. 269BSeptember 12, 2002

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  1. Preparation for shutdown: The Authorized Employee must know the types of energies to be controlled on the machines or equipment involved.
  1. Machine or equipment shutdown: The Authorized Employee must know about specific turn off or shutdown procedures.
  1. Isolation: The Authorized Employee must use required energy isolating devices.
  1. LOTO device application: The Authorized Employee must affix LOTO devices in accordance with established procedures.
  1. Stored energy: The Authorized Employee must eliminate all potentially stored or residual energy.
  1. Verification of isolation: The Authorized Employee must verify that the machine or equipment has been properly isolated and de-energized. NOTE: test meters are required for electrical LOTO.

RELEASE FROM LOTO:

  1. Machine/equipment inspection: The work area must be inspected for debris and to ensure that components are operationally intact.
  1. Employees: All employees must be clear of the area and all affected employees notified that LOTO devices have been removed.
  1. LOTO device removal: Each LOTO device must be removed by the Authorized Employee who applied the device. When the authorized employee who applied the LOTO device is not available to remove it, the following procedure must be followed.
  1. The supervisor of the Authorized Employee must verify that the Authorized Employee is not at the facility.
  1. The supervisor must try to contract the Authorized Employee to inform that the LOTO has been removed.
  1. The supervisor must ensure that the Authorized Employee knows that the LOTO device has been removed before working at the facility.

TESTING OF MACHINES: When it is necessary to temporarily restore energy, LOTO

devices may be removed using the following sequence:

  1. The machine or equipment must be clear of tools and materials.

DIRECTIVE NO. 269BSeptember 12, 2002

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  1. Employees must be removed from the machine or equipment area.
  1. All lockout or tagout devices may then be removed.
  1. Authorized Employees may then proceed to energize and test or position the equipment or machinery.
  1. Following testing or positioning, all systems must be de-energized and energy control measures reapplied to continue the servicing and/or maintenance.

GROUP LOTO REQUIREMENTS: When it is necessary for a group (crew) to perform a task that requires LOTO devices, the following will apply:

  1. A single Authorized Employee will be assigned the primary responsibility for all employees.
  1. Each Authorized Employee working on the equipment or machines must affix a personal LOTO device.

CONTRACTOR COMPLIANCE: All contractors working at the University of Virginia shall have a written lockout/tagout (LOTO) program, and their workers shall be trained in the use of the contractor’s LOTO devices and energy control procedures. If UVA employees will be affected by equipment or machinery shutdown, the contractor shall inform all such employees about the LOTO devices and contractor procedures prior to work being performed.

RESPONSIBILITIES: Supervisors are responsible for the implementation of this directive including the use of Appendices I and II. The Office of Environmental Health and Safety is available for assisting in the establishment of specific LOTO procedures and employee training.

Robert P. Dillman, P.E.

Chief Facilities Officer

APPENDIX I

LOCKOUT/TAGOUT PROCEDURE

Lockout Procedures for:

Machine/Equipment (name): ______

Location: ______

Lead Authorized Employee: ______

Cost Center: ______

Sequence of Lockout:

  1. Notify all affected personnel.
  1. What energy is to be controlled?
  1. If the equipment or machine is operating, shut it down.
  1. Isolate energy source from machine or equipment.
  1. LOTO energy source with individual locks
  1. Does everyone have control of individual & LOTO device?
  1. Is there stored energy?
  1. Method used to dissipate or restrain.
  1. Verify zero mechanical state.
  1. Method used.

Restoring Equipment to Service:

  1. Check area for non-essential items and all machine components are operationally intact.
  1. Check area to ensure all employees are safely positioned.
  1. Verify controls are in neutral.
  1. Remove LOTO devices.
  1. Notify affected employees, equipment or machine is operational.

g:trixfer/Motto/LOTO2 – Appendix I

APPENDIX II

LOTO ENERGY CONTROL PROCEDURE INSPECTION FORM

Date of Inspection:

Name of authorized employee conducting Inspection: ______

NOTE: Cannot be the one utilizing the energy control procedure being inspected.

Equipment/Machine LOTO procedure used: ______

(motor, fume hood, etc.)

Review Process:

For lockout procedure, review employee responsibilities.

For tagout, review employee responsibilities and the limitations of tags.

Retraining required:  Yes No

Date restraining conducted: ______

Certification: ______

(Signature of Inspector)

g:trixfer/motto/lotoenergycontrol/appendixII

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UNIVERSITY OF VIRGINIA LOCK OUT ANNUAL REVIEW FORM

Department: / Supervisor:
Employee: / Date:
Equipment/Machine LOTO Procedure Used: (i.e. Motor, Fume Hood, Etc.)
Yes / No
1. Are department personnel who conduct work covered by the Lock Out Policy trained as Lockout Authorized Employees? Is training up to date and documented? List those who are trained and those who are not trained but need it.
2. Are Energy Control Procedures developed and documented as required by the Lock Out Policy? List any Energy Control Procedures that need to be developed or documented.
3. Does the department have adequate locks, tags, and lockout devices? List what is needed and whether or not the department has them.
4. Have Lockout Authorized Employees demonstrate Energy Control Procedures or General Lockout Procedure as appropriate. List Energy Control Procedures demonstrated.
5. Are department Lockout Authorized Employees familiar with and follow the General Lockout Procedure?
6. Does the department conduct Group Lockout? Review procedure.
7. Does the department conduct lockout work across shift/personnel changes? Review procedure.
8. Does the department have an Emergency Lock Removal procedure? Review key security method and list persons who will implement the Emergency Lock Removal procedure/form.

For Facilities Management return form Messenger Mail – Attn: Brian Shifflett, FM, Safety Mgr, Box 400726

For Other Departments return form Messenger Mail – Attn: Michelle Whitlock, EHS, Box 400322

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