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1 The purpose of the lockout/tagout (LOTO) program is to define protection from the potential Hazards associated with the unexpected release of hazardous energy for employee performing equipment maintenance. This program establishes the minimum requirements for the use of LOTO procedures and energy isolating devices. 1.2 To ensure that machinery or equipment is isolated from all potential hazardous energy sources and locked or tagged out before employees perform any servicing or maintenance activities where the unexpected energization, start-up, or release of stored energy could cause injury or release of stored energy that could cause injury. This program describes: 2. Scope 2.1 This program and its associated procedures apply to MAB employees or contractors performing maintenance, service work, or unscheduled repairs on machines or equipment including: Installing, setting up, adjusting, inspecting, modifying, maintaining, servicing, and removing equipment from service. Bypassing any guard or safety device. Requiring an employee to place any part of the body into the “point of operation” or danger zone of a machine. 2.2 An exception to LOTO may be made by the (INSERT RESPONSIBLE PARTY HERE) under the limited circumstances listed below. The exception can be made only if work is performed using alternative measures that provide effective protection such as guards, personal protective equipment, or other provisions that prevent the employee from being exposed to the hazard. Exceptions may apply to: Minor adjustments and other servicing activities that take place during normal production operations if they are routine, repetitive, and integral to the use of the equipment for production. Cord and plug type of equipment where the employee performing the maintenance has “control” of the power cord and all sources of hazardous energy are removed by disconnecting the plug. If absolute control of the plug cannot be assured, an appropriate lockout device shall be used. The responsibilities of MAB employees, contractors, and client`s representatives. The equipment to be used to isolate energy sources and lock and tag the energy isolation devices. The template of procedures to be used for shutting down, isolating energy sources, and restarting equipment. Training requirements. Records and documentation requirements
1. 3. Operations Manager is responsible for defining the process and procedures outline in this document and for the changes to this document. DM-TG05 “Guidelines for electrical Safety at Work”. Responsibilities 3.1 Absolute control of the plug shall be defined as: The plug is disconnected from the supply by the person in control. Only one piece of equipment is being maintained at a time per individual. The FM Managers.1. Equipment 5. The FM Manager. QHSE Officer shall assure that adequate general training is available on their site. Only one key is issued in each lock. LOTO Devices Locks and tags are issued to all authorized employees Locks must be durable. 4. only the MEP supervisor/coordinator or any MAB representative assign by the FM manager is authorized to physically removed a lock . Electrical Safety Guide 4.5.3. 3. HSE Planning HSE-02 Procedure 4. MEP Supervisors/Coordinator. All Contractors/vendors shall be informed of the requirement to provide LOTO protection equivalent to the MAB LOTO program before beginning of any work. The FM manager is responsible for providing continual input. MEP Supervisor/Coordinator shall ensure that employees and other contracted personnel comply with the restrictions and prohibitions of the outside contractor`s hazardous energy control procedure. Safe Use of work Equipment 5. The plug is in the direct line of sight of the person in control The plug is within reach of the person in control during maintenance activities.2. 4. distributing appropriate LOTO devices to all authorized personnel and auditing and enforcing compliance with LOTO procedure. Only one person is performing the maintenance or service task.5. specification. MEP Supervisor/coordinator is responsible for having knowledge of the LOTO specification. The FM Manager is responsible for ensuring that all authorized MAB staff are trained in this procedure. identifiable and standardized.3.6. Operations Manager. 3. 126.96.36.199.1.4. Reference Document 4. Electrical Test Equipment 4.2. resources and tool specific information to the QHSE Officer at site. 3. 3.
5. Locks are issued only for LOTO purposes and must not be used in any other usage. radio frequency energy. hazardous chemicals. 6.5. laser light or radiant heat. damage and cracked timely and shall be stored in dry and staging location at site. This includes. Records of assign locks are maintained by the authorized employee`s or MEP admin/Supervisor/Coordinator consolidated on the masters list. testing. in situ. Hazardous Energy 6.3. All locks.4. or exhaust/effluent by-products Any nonhazardous liquid at a temperature above 115oF Any surface at a temperature above 115oF Any cold surface at 32oF or less Any compressed gas at a pressure greater than 29 psig . the following examples: Any hazardous chemicals including. Also contact with hazardous levels of radiant energy such as ultraviolet light. Exposure/Exposed Physical contact with.1. bulk feed.or tag and start up equipment if the authorized employee is unable or unavailable. hazardous energy such as electric currents. or the discharge point of a gas at pressures greater than 29 psig. 6. stored energy. 6. but not limited to. moving parts that create pinch points.1. and restart of the equipment. Authorized Employee Designated workers who are trained and permitted to perform LOTO and start up procedures. 6. Definitions 6. high temperatures. isolation. 6. adapters and locking devices shall be inventoried and check for wear.2. Affected Employees Workers who operate or used the equipment that is going to be locked or tagged out. Control of Hazardous Energy Procedure A written guideline that details the sources of hazardous energy associated with a specific piece of equipment and the steps to be followed during the shutdown. but not limited to. Any potential or kinetic energy to which an employee may be exposed that can cause injury to the employee. but is not limited to.
Gravity Any other energy that can reasonably be expected to cause an injury 6. The hazards of the energy to be controlled iv. or verbally at the location of the work to be performed. the authorized employee must know and understand: i. 7. Methods/procedures to verify a “zero energy” state vi. or hazards associated with the maintenance task(s). Follow warning labels and manufacturer’s recommendations or consult INSERT RESPONSIBLE PARTY.1.1. The authorized employee must notify all affected employees (or other workers) that a lockout or tagout procedure will be implemented and why.6. Notification shall be timely and effective to protect affected workers and authorized workers from risk associated with the shutdown. Working Instruction to Control of Hazardous Energy 7.4. Lockout Locking an energy isolation device so that only the authorized employee placing the lock can restore the energy. by written notification. The lockout procedures to control all energy sources v. Preparation (STEP 1) 7.3. Any exposed electrical component at a potential greater than 49 volts g) Any magnetic field at a strength greater than 600 gauss Ultraviolet (or high intensity light) radiation exposures must be evaluated according to calculations depending on frequency. The specific equipment ii. 7. Before shutdown. 7.1.2. 188.8.131.52. INSERT OTHER SPECIFIC MEANS OF NOTIFICATION HERE . unintentional startup of equipment. The types of energy involved iii. Notification may be made during group meetings. Zero Energy State – All sources of hazardous energy in a system are isolated and locked or tagged out.
or other sources of energy are moved to the “off” position or otherwise rendered inoperative.7.4. Warning tags are securely applied with each lock.).2. 7. Tagout – For hazardous energy sources that cannot be locked out.3.1..e.3.3. or otherwise made safe. or water pressure. LOTO (STEP 4) 7. The QHSE Officer/MEP Supervisor must approve all “tagout only” operations individually on a case -by-case basis. blocking.1. During a group lockout. tagout alone will not satisfy the requirements of this standard. pneumatics. 7.4. Isolation (STEP 3) 7. gravity.3.1. The main power switches. . In most situations.4. For equipment that cannot be “totally” powered down. flip toggle switch. and verified to be in a “zero-energy” state.) are relieved. 7. etc. circuits. etc.4. electrical systems. place an approved tag on the energy-isolating device. Shutdown (STEP 2) 7.3. restrained. The tag also includes the name of the authorized employee and the date applied. If there is a possibility that stored energy could accumulate to a hazardous level. and air. disconnected. All energy sources needing isolation are located. flammable.3..5. bleeding down. disconnected.4.2. All tags will be attached with self-locking.1.4. valves will be closed and lines disconnected or purged to remove the contents. 7. 7. or other energy sources in the “safe” or “off” position. hydraulic systems. a multi-lock hasp is used and all members of the group must place their own lock on the hasp.5. etc. 7. rotating flywheels. verification of isolation and dissipation continues until servicing or maintenance is completed or until the possibility of such accumulation no longer exists. pneumatic or hydraulic is stored in lines of pipes. elevated parts. Where energy such as thermal. springs. The authorized employee shuts down the equipment by the normal stopping procedure (depress stop button. Stored Energy (STEP 5) 7. All stored or residual energy is to be relieved. 7. non-resealable nylon ties (or equivalent). gas. 7. or otherwise made safe by repositioning.184.108.40.206. 7. circuits.5. Warning tags indicate the energy isolating device and the equipment being controlled may not be operated until the tag is removed. Lockout – Locks are placed on switches. All potentially hazardous stored energy or residual energy (i. chemical. locate the switch or isolation mechanism that isolates energy to the area to be serviced. 7.4.
The machine or equipment is now restarted by the authorized employee only. and all interlocks and guards are reinstalled.220.127.116.11. machine/equipment components are fully reassembled.9.9. Then the authorized employee ensures that all affected employees are safely positioned clear of danger zones during restart procedures.1. or verbally at the location of the work that has been performed. Inspection (STEP 7) 7. return the operating switch(s) to the “neutral” or “off” position. Notification shall be timely and effective to protect affected workers and authorized workers from risk associated with the restart or energization of the equipment.1.2. 7. After ensuring no personnel are exposed. After inspecting the equipment and work area.2. Restart Procedures 7. 7. The authorized employee inspects the work area. Remove and Restart (STEP 9) 7.10.7. 7.8.9. Notification (STEP 8) 7.3. Caution: After testing the equipment. the authorized employee notifies all affected employees that service and/or maintenance of the equipment is complete.10.1.2. 7. or verbally a the location of the work to be performed. 7.7.7. ensuring tools and other items are removed from the hazard zone. 7.6. The following procedures outline the three general steps for restarting equipment that is locked/tagged out.6. 7. 7. 7.8.1. Locks. .10. by written notification.10. the authorized employee confirms the equipment cannot be started or powered up by pressing the piece of equipment’s “on” button or other normal operating control. by written notification. d) Notification may be made during group meetings. Testing (STEP 6) 7. tags and isolation devices are removed from each energy source by the authorized employee(s) who applied them. Notification may be made during group meetings. The authorized employee notifies affected employees that the equipment is operational.
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