Lockout - Tagout Program

Purpose
Control of Hazardous energy is the purpose of the Lockout- Tagout Program.
This program establishes the requirements for isolation of both kinetic and
potential electrical, chemical, thermal, hydraulic and pneumatic and
gravitational energy prior to equipment repair, adjustment or removal.
Reference: OSHA Standard 29 CFR 1910. 147, the control of hazardous
energy.

Definitions
Authorized (Qualified) Employees are the only ones certified to lock and
tagout equipment or machinery. Whether an employee is considered to be
qualified will depend upon various circumstances in the workplace. It is likely
for an individual to 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.
Other Employees are identified as those that do not fall into the
authorized, affected or qualified employee category. Essentially, it will
include all other employees. These employees will be provided instruction in
what the program is and not to touch any machine or equipment when they
see that it has been locked or tagged out.

Training
Authorized Employees Training
All Maintenance Employees, Department Supervisors and Janitorial
employees will be trained to use the Lock and Tag Out Procedures. The
training will be conducted by the Maintenance Supervisor or Safety
Coordinator at time of initial hire. Retraining shall be held at least annually.
The training will consist of the following:
1. Review of General Procedures
2. Review of Specific Procedures for machinery, equipment and processes
3. Location and use of Specific Procedures

4. Procedures when questions arise

Affected Employee Training

Only trained and authorized Employees will repair, replace or adjust

machinery, equipment or processes
Affected Employees may not remove Locks, locking devices or tags
from machinery, equipment or circuits.
Purpose and use of the lockout procedures.

Other Employee Training

Only trained and authorized Employees will repair, replace or adjust

machinery or Equipment.
Other Employees may not remove Locks, locking devices or tags from
machinery, equipment or circuits

Preparation for Lock and Tag Out

Procedures
A Lockout - Tagout survey has been conducted to locate and identify all
energy sources to verify which switches or valves supply energy to
machinery and equipment. Dual or redundant controls have been removed.
A Tagout Schedule has been developed for each piece of equipment and
machinery. This schedule describes the energy sources, location of
disconnects, type of disconnect, special hazards and special safety
procedures. The schedule will be reviewed each time to ensure employees
properly lock and tag out equipment and machinery. If a Tagout Schedule
does not exist for a particular piece of equipment, machinery and process,
one must be developed prior to conducting a Lockout - Tagout. As repairs
and/or renovations of existing electrical systems are made, standardized
controls will be used.

Routine Maintenance & Machine

Adjustments
Lock and Tag Out procedures are not required if equipment must be
operating for proper adjustment. This rare exception may be used only by
trained and authorized Employees when specific procedures have been
developed to safely avoid hazards with proper training. All consideration
shall be made to prevent the need for an employee to break the plane of a
normally guarded area of the equipment by use of tools and other devices.

Locks, Hasps and Tags

All Qualified Maintenance Personnel will be assigned a lock with one key,
hasp and tag. All locks will be keyed differently, except when a specific
individual is issues a series of locks for complex lockout-tagout tasks. In
some cases, more than one lock, hasp and tag are needed to completely deenergize equipment and machinery. Additional locks may be checked out
from the Department or Maintenance Supervisor on a shift-by-shift basis. All
locks and hasps shall be uniquely identifiable to a specific employee.

SOP: General Lock and Tag Out

Procedures
Before working on, repairing, adjusting or replacing machinery and
equipment, the following procedures will be utilized 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 have knowledge of the type
and magnitude of the energy, the hazards of the energy to be
controlled, and the means to control the energy.
Notify all affected Employees that the machinery, equipment or
process will be out of service

Machine or Equipment Shutdown.

The machine or equipment will be turned or shut down using the

specific procedures for that specific machine. An orderly shutdown will
be utilized to avoid any additional or increased hazards to employees
as a result of equipment de-energization.
If the machinery, equipment or process is in operation, follow normal
stopping procedures (depress stop button, open toggle switch, etc.).
Move switch or panel arms to "Off" or "Open" positions and close all
valves or other energy isolating devices so that the energy source(s) is
disconnected or isolated from the machinery or equipment.

Machine or Equipment Isolation.

All energy control devices that are needed to control the energy to the
machine or equipment will be physically located and operated in such
a manner as to isolate the machine or equipment from the energy
source.

Lockout or Tagout Device Application.

Lockout or tagout devices will be affixed to energy isolating devices by

authorized employees. Lockout devices will be affixed in a manner that
will hold the energy isolating devices from the "safe" or "off" position.
Where tagout devices are used they will be affixed in such a manner
that will clearly state that the operation or the movement of energy
isolating devices from the "safe" or "off" positions is prohibited.
The tagout devices will be attached to the same point a lock would be
attached. If the tag cannot be affixed at that point, the tag will be
located as close as possible to the device in a position that will be
immediately obvious to anyone attempting to operate the device.
Lock and tag out all energy devices by use of hasps, chains and valve
covers with an assigned individual locks.

Stored Energy

Following the application of the lockout or tagout devices to the energy

isolating devices, 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, verification of isolation will be continued 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 employees will verify that isolation or deenergization of the machine or equipment have been accomplished.
After assuring that no Employee will be placed in danger, test all lock
and tag outs by following the normal start up procedures (depress start
button, etc.).

Caution: After Test, place controls in neutral position.

Extended Lockout - Tagout
Should the shift change before the machinery or equipment can be restored to service, the
lock and tag out must remain. If the task is reassigned to the next shift, those Employees
must lock and tag out before the previous shift may remove their lock and tag.

SOP: Release from LOCKOUT/TAGOUT

Before lockout or tagout devices are removed and the energy restored to the machine or
equipment, the following actions will be taken:
1. The work area will be thoroughly inspected to ensure that nonessential items have been
removed and that machine or equipment components are operational.
2. The work are will be checked to ensure that all employees have been safely positioned
or removed. Before the lockout or tagout devices are removed, the affected employees
will be notified that the lockout or tagout devices are being removed.
3. Each lockout or tagout device will be removed from each energy isolating device by
the employee who applied the device.

SOP: LOTO 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.
When working on, repairing, or adjusting the above equipment, the following procedures must
be utilized 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.
An exception is granted to not lock & tag the plug is the cord & plug remain in the
exclusive control of the 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. Any
defects must be repaired before placing the equipment back in service.
NOTE: Occasionally used equipment may be unplugged from power source when not in use.

SOP: LOTO Procedures Involving More Than One Employee

In the preceding SOPs, if more than one 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).

SOP: Management's Removal of Lock and Tag Out

Only the Employee that locks and tags out machinery, equipment or processes may remove
his/her lock and tag. However, should the Employee leave the facility before removing his/her
lock and tag, the Maintenance Manager may remove the lock and tag. The Maintenance Manager
must be assured that all tools have been removed, all guards have been replaced and all
Employees are free from any hazard before the lock and tag are removed and the machinery,
equipment or process are returned to service. Notification of the employee who placed the lock is
required prior to lock removal.

Contractors
Contractors, working on company property and equipment must use this Lockout - Tagout
procedure while servicing or maintaining equipment, machinery or processes.