ENERGY CONTROL PROCEDURE

(LOCKOUT/TAGOUT)

College of DuPage
Glen Ellyn, IL

March 2020
 TABLE OF CONTENTS

Topic Page
Objective 3
Purpose and Scope 3
Workplace Responsibilities 4

Energy control Program 5

LOTO Procedure 5
Restoring to Service 6
Full Employee Protection 6
Energy control Exception 7
Protective Materials & Hardware 7

Periodic Inspection of Procedure 8

Training and Communication 9
Application of Control 10
Release from LOTO 11
Additional Requirements 12
Outside Personnel 12
Group LOTO 12
Missing or Unreachable Employee 13
Shift or Personnel Change 13
Specific Procedures for Equipment & Areas 13

Appendix A LOTO Definitions 15

Appendix B LOTO Procedure Checklist 18

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 Energy Control Procedure (Lockout/Tagout)

Objective
This Lockout/Tagout (LOTO) plan has been developed with the objective to protect workers
performing service or maintenance on machinery and equipment, from injuries related to
unexpected energization, startup of the machinery or equipment, or release of stored energy in
the equipment. The LOTO program shall consist of energy control procedures, employee
training, and periodic inspections to ensure that units that have the potential to become
energized, or release stored energy, are rendered safe to service. Information found within this
plan is based on the requirements set forth by OSHA’s Control of Hazardous Energy
(Lockout/Tagout) standard 29CFR1910.147. Definitions of terms used within this procedure are
available in Attachment A.

This procedure applies to all Facilities Services, other College of DuPage employees, and on-site
contractors who may be required to work on this type of equipment or otherwise be exposed to
the unexpected energization of this equipment.

All COD safety plans and procedures are made available to employees through the EH&S
website and shall be reviewed annually. Employees may review or print them out them by going
to the Inside.cod.edu portal and clicking on the COD Links tab to the right to access the EH&S
website. If at any time an employee of College of DuPage has a question or concern regarding
their safety in the workplace, they should contact their supervisor, or EH&S, immediately.

Purpose and Scope

The purpose of this procedure is to establish minimum guidelines to ensure the safety and health
of personnel who may be required to work on any type of equipment capable of being energized
or harboring stored energy. This program will be used to ensure that a machine, or equipment,
has been shut down, isolated from all potentially hazardous energy sources, and locked out
before employees are allowed to perform any service or maintenance related activities.

This procedure applies to any source of electrical, mechanical, hydraulic, pneumatic, chemical,
thermal or other types of hazardous energy. Hazardous energy can be stored in the machinery or
equipment after the unit has been turned off and release through:

 Heat
 The force of gravity that could cause machinery to continue to move
 Electricity, where the flow of electrical current can cause an unsafe condition
 Pressure of fluids or air, as with pneumatic or hydraulic equipment;
 Steam, such as when it remains in a pipe after shutoff
 Chemical reactions that might generate pressure or be subject to the force of gravity

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This procedure will also apply to any employees required to remove or bypass a guard or other
safety device during normal operations. As well as, if an employee is required to place any part
of their body into a point of operation, into an area on the machine where work is being
performed, or into the danger zone associated with the machine’s operation.

This procedure is not intended to cover machines or equipment where the only source of energy
is from a connection to an electrical outlet. Employees servicing or maintaining this type of
equipment shall be considered in compliance with this program if the following conditions are
met:

 All affected employees are notified of the equipment being serviced

 The plug is removed from the electrical source
 The person servicing the equipment is in control of the cord and plug at all times, or a
plug cap device is properly attached

Workplace Responsibilities
Management

Departmental Management shall assume ownership and responsibility for implementation of this
procedure. Management personnel are to be cognizant of the requirements established for
implementation of this procedure.

Departmental Management will assure that the locks, tags and other devices required for
compliance with lockout/tagout procedures are available to their employees.

Supervisors are to ensure that personnel assigned to perform work requiring LOTO are formally
trained to do so and strictly comply with all requirements established in this procedure.

Employees

Employees performing work assignments covered in this LOTO procedure are required to
comply with the requirements set forth in this procedure. Training shall be completed according
to the following classifications:

Authorized employee: An employee who is specially trained to recognize sources of

hazardous energy and is authorized to perform LOTO procedures. They are familiar with
the equipment, how to service it, and ensure that all sources of energy are locked out.
This is the only class of employee that can attach or remove locks and tags.

Affected employee: An employee who operates machinery or equipment, but is not

responsible for servicing or repairing it. They will notice when equipment needs to be
repaired or serviced and should verify that the equipment is safe to operate after work has
been completed. Affected employees must be trained to know the purpose and use of

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 energy control procedures so that the equipment is not inadvertently energized when
under LOTO.

Other employees: Employees who are, or may be, in an area where energy control
procedures or devices may be utilized.

Environmental, Health & Safety (EH&S)

EH&S shall perform an annual audit of the College of DuPage Energy Control procedure. A
written report shall be distributed to affected parties, outlining identified deficiencies or
modifications. If a job site is found to be in non-compliance of this procedure, it will be shut
down until action is taken to bring it back into compliance is completed.

Energy Control Program

This procedure lists the specific information that an authorized employee must know in order to
safely accomplish the LOTO sequence available in Attachment B. Periodic review of this
energy control procedure should be conducted by all employees to ensure that the requirements
of the standard are being met and that they apply to all current types of equipment being
serviced.

Any machinery or equipment that contains or stores hazardous energy is subject to LOTO.
Examples include:

 Presses
 Power saws
 Electrical Panels & disconnected switches
 Air handling units
 Conveyors
 Pumps
 Production equipment
 Trash compactors

Energy Control (LOTO) Procedure

An authorized employee shall review and complete the procedure checklist available in
Attachment B. Additional steps outlined below shall also be completed:

Lockout

 The authorized employee shall notify all affected employees that servicing or
maintenance is required on the equipment and that the machine must be shut down and
locked out.

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  The authorized employee shall review the LOTO procedure for that particular machine
and will follow each step carefully.
 If the machine or equipment is operating, the authorized employee will shut it down by
the normal stopping procedure.
 The energy isolating device(s) will be deactivated.
 The energy isolating device(s) will be locked out with locks that identify each individual
employee. Tags shall be applied, if necessary, to warn others not to re-energize the
equipment.
 Stored or residual energy will be dissipated or restrained.
 Test equipment; verify the energy isolation by operating the normal start up sequence, or
by testing, to ensure that the machine will not operate. Turn machine off again.

Tagout

If the energy isolating devices are not lockable, tagout devices may be used. The authorized
employee must comply will all of the lockout provisions outlined above. Utilizing only tagout
identification will require more periodic inspections than when a lockout/tagout system is used.

Restoring to Service

 Once service is complete, check around the machine to make sure that all maintenance
items and tools have been removed and that all equipment components are operationally
intact.
 Check the work area to make sure that employees are removed from the area and cannot
enter during the restart phase.
 Verify that the controls are in neutral.
 Remove the lockout and/or tagout devices and reenergize the machine
 Notify the affected employees that the servicing is completed and the machine is ready
for use.

Full employee protection

Employers may use a tagout system on an energy isolating device which is capable of being
locked out if they can show that it will provide a level of safety equivalent to that obtained by
using the lockout program. The tagout device shall be attached at the same location that the
lockout device by the authorized employee after receiving approval from management. It is
recommended that additional safety controls be considered to ensure full employee protection.
Additional safety measures may include:

 Removal of isolating circuit elements

 Blocking of controlling switches
 Opening of extra disconnecting devices
 Removal of valve handles to reduce the likelihood of inadvertent energization.

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Energy control Exceptions:

Under 29CFR1910.147(c )(4)(i) OSHA has provided an exception which eliminates the
requirement for a written procedure if all of the following conditions are met:

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

Protective materials & hardware

Appropriate lockout devices such as; locks, tags, chains, wedges, key blocks, adapter
pins, self-locking fasteners, or other hardware shall be provided by the employer for
isolating, securing, or blocking energy sources during maintenance or servicing of
equipment. General requirements, outlined in 29CFR1910.147(c )(5), of LOTO devices
include:

 Must be durable, so that they are capable of withstanding the environment to

which they are exposed for the maximum period of time that exposure is
expected.
 Must be easily identified as the device used for controlling energy.
 Must not be used for other purposes.
 Must be standardized within the department in at least one of the following
criteria: color, shape, or size. Additionally, tagout devices must be standardized
as to print and format.
 Must identify the employee who has applied the device
 Must be substantial enough to prevent removal without the use of excessive force
or unusual techniques such as with the use of bolt cutters or other tools.
 Must not deteriorate when used in corrosive environments such as areas where
acid or alkali chemicals are handled and stored.

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Locks

 Locks used for the purpose of isolating an energy source shall not be used for any other
purpose. Locks must be individually keyed, and while in use, the key shall remain in the
possession of the individual who placed the lock.
 A lock-out system should be utilized by the issuing department to identify the location of
a lock-out lock while it is in use.

Tags

 Each tag must contain the name and department of employee tagging out the equipment,
time and date the disconnection took place, what type of work is being done, and the
estimated duration of lockout.
 Only the authorized tag holder may apply and remove their tag.
 Individualized tags are to be requested from the employee’s supervisor.
 Tagout device attachments shall be of a non-reusable type, attachable by hand, self-
locking, and non-releasable with a minimum unlocking strength of no less than 50 lbs.
and having the general design and basic characteristics of being at least equivalent to a
one-piece, all environment-tolerant nylon cable tie.

Periodic inspection of Procedure

The department managers shall conduct a periodic inspection of the energy control procedure at
least annually to ensure that employees are meeting the requirements. This periodic inspection
shall be performed by an authorized employee other than the ones(s) utilizing the energy control
procedure being inspected. This inspection shall be conducted to correct any deviations or
inadequacies which are identified.

Where lockout is used for energy control, the periodic inspection shall include a review, between
the inspector and each authorized employee, of that employee's responsibilities under the energy
control procedure being inspected.

Where tagout is used for energy control, the periodic inspection shall include a review, between
the inspector and each authorized and affected employee, of that employee's responsibilities
under the energy control procedure being inspected.

The department manager shall certify that the periodic inspections have been performed. The
certification shall identify the machine or equipment on which the energy control procedure was
being utilized, the date of the inspection, the employees included in the inspection, and the
person performing the inspection.

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Training & Communication
The College shall provide training to ensure that the purpose and function of the energy control
program is understood by employees and that the knowledge and skills required for the safe
application, usage, and removal of the energy controls are acquired by employees. The OSHA
standard requires different levels of training based on the classification of the employee which
are outlined below.

Training records shall be maintained by the employees department with copies being forwarded
to the Teaching and Learning Center to be placed in the employees file. This documentation
shall include the employee’s names, dates of training and who provided the training.

Retraining shall be provided for all authorized and affected employees whenever there is a
change in their job assignments, a change in machines, equipment or processes that presents a
new hazard, or when there is a change to the Energy Control Procedure. Retraining shall also be
provided when an inspection reveals, or whenever there is reason to believe, that there are
inadequacies in employees’ knowledge or use of the energy control procedures.

Authorized Employees

Each authorized employee shall 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. Training will include:

 How to recognize energy sources, the type and magnitude of the energy available in the
workplace.
 How to perform an equipment shutdown
 How to isolate equipment.
 How to safely release stored energy to reach a zero energy state.
 How to apply and remove lockout/tagout devices.
 Procedures and requirements for over-ride removal of lockout/tagout devices.

Affected Employees

Each affected employee shall be instructed in the purpose and use of the energy control
procedure. Employees must be able to demonstrate a clear understanding of the importance of
energy control devices and that they are not to be removed or altered in any way.

Other Employees

All other employees whose work operations are or may be in an area where energy control
procedures may be utilized, 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.

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When tagout systems are used, all employees shall also be trained in the following limitations of
tags:

 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.
 When a tag is attached to an energy isolating means, it is not to be removed without
authorization and it is never to be bypassed, ignored, or otherwise defeated.
 Tags must be legible and understandable by all employees.
 Tags and their means of attachment must be made of materials which will withstand the
environmental conditions encountered in the workplace.
 Tags must be securely attached to energy isolating devices so that they cannot be
inadvertently or accidently detached during use.

Application of Control
The lockout or tagout procedure shall cover the following elements and actions and shall be done
in the following sequence:

1. Preparation for shutdown. Work orders shall indicate the need for LOTO when work
is assigned to employees. Before an authorized or affected employee turns off a machine
or equipment, the authorized employee shall have knowledge of the type and magnitude
of the energy, the hazards of the energy to be controlled, and the method or means to
control the energy.

2. Machine or equipment shutdown. The machine or equipment shall be turned off or shut
down using the procedures established for the machine or equipment. An orderly
shutdown must be utilized to avoid any additional or increased hazard(s) to employees as
a result of the equipment stoppage.

Live parts to which an employee may be exposed must be de-energized before the
authorized employee can work on or near them. Only qualified employees may work
on or in close proximity to electric circuits or equipment that has not been de-
energized. Such persons must be capable of working on energized circuits and will be
familiar with the proper use of special precautionary techniques, personal protective
equipment, insulating and shielding materials and insulated tools.

3. Machine or equipment isolation. All energy isolating devices that are needed to control
the energy to the machine or equipment shall be physically located and operated in such a
manner as to isolate the machine or equipment from the energy source(s).

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 Lockout device application:

 Lockout or tagout devices shall be affixed to each energy isolating device by

authorized employees.
 Lockout devices, where used, shall be affixed in a manner that will hold the
energy isolating devices in a "safe" or "off" position.

Tagout device application:

 Tagout devices, where used, shall be affixed 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 shall be fastened at the same point
at which the lock would have been attached.
 Where a tag cannot be affixed directly to the energy isolating device, the tag shall
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.

4. Release & Isolation of Stored energy. Following the application of lockout or tagout
devices to energy isolating devices, an authorized employee must verify that all
potentially hazardous stored or residual energy has been relieved, disconnected,
restrained, or otherwise rendered safe.

Equipment shall be at a “zero energy state” before servicing. Deenergization may

include, but not limited to, removing the plug, opening a disconnect switch, removing a
fuse, closing a valve, bleeding the line, or placing a block in the equipment.

If there is a possibility of re-accumulation of stored energy to a hazardous level,

verification of isolation shall be continued until the servicing or maintenance is
completed, or until the possibility of such accumulation no longer exists.

Release from LOTO

Before LOTO devices are removed and energy is restored to the machine or equipment, the
following sequence shall be followed and actions taken by the authorized employee to ensure the
safe re-energization of the unit.

1. The machine or equipment shall be inspected to ensure that nonessential items (tools,
parts, materials) have been removed and that all of the machine or equipment components
are operationally intact.

2. The work area must be checked to ensure that all employees have been safely positioned
or have cleared the area. In addition, all affected employees must be notified that the
LOTO devices have been removed before the equipment is started.

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 3. Each LOTO device must be removed from the energy isolating device by the employee
who applied the device.

4. After LOTO devices have been removed and before a machine or equipment is started,
affected employees shall be notified that the LOTO devices have been removed and the
equipment is to be re-energized.

5. The equipment is to be restarted following the standard operating procedure for that piece
of equipment.

Additional Requirements
Outside Personnel

Whenever outside contractors or service personnel perform tasks requiring energy

control procedures, they will be required to adhere to the OSHA standard
29CFR1910.147.

Contractors are to be informed that any de-energization of COD equipment is to

approved by the project manager or other responsible COD supervisory employee having
project oversight responsibilities.

The project manager is to coordinate the LOTO of equipment with the responsible
supervisor or department. The College and the contractor will inform each other
of their respective LOTO program responsibilities.

Any equipment that is required to be locked out by a contractor may also to be locked out
by the appropriate COD supervisor or department. The COD lock or tag is to be applied
first, and removed last after work is complete.

The department supervisor must ensure that COD employees understand the restrictions
and prohibitions of the outside contractor’s energy control program.

Group LOTO

When service or maintenance is performed by a crew or shift, each person must

apply their own lock. This prevents any accidental start-ups while another
employee may still be working on the machinery. In this case, employees will
need to use a lockout hasp that accepts multiple locks.

Additional locks are to be obtained from the department supervisor. These locks will
have only one key and will be given out at that time and all will be returned at the end of
use. Check out of these additional lock(s) will be recorded and maintained by the
supervisor.

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 Missing or Unreachable Employee

In the event that an employee cannot be reached to remove his/her personal lock and it is
necessary to unlock the equipment, only the department supervisor may remove the
lock.

The following sequence of events should take place before the emergency removal of
another employees lock or tag.

 Attempt to determine the location of the employee and exhaust all reasonable
efforts to have the lockout removed via the normal process.
 If the employee is not on campus, and cannot be located or is unable to report to
the campus, the supervisor should check the machine or process to be sure it is
clear before removing the lock.
 The supervisor who removes the lock(s) is responsible for following all of the
requirements for restoring power. (See “Release from LOTO”)
 The supervisor will be responsible for contacting the employee ASAP to advise
them of the removal of their lock & tag.

Shift or Personnel Change

If the piece of equipment is locked out at shift change, the person on the next shift or
supervisor must apply their lock or tag before the employee who is leaving can remove
their lock or tag from the locking device.

Specific Procedures for Individual Equipment and Areas

Each COD department should develop internal procedures for the isolation of specific
equipment in order to perform work. These procedures should be updated continuously
and checked against drawings/prints each time a LOTO is performed to incorporate
system modifications that may affect the isolation process.

If work is to be performed near overhead power lines, the lines must be de-energized and
grounded, or other protective measures shall be provided before work is started. The
following procedures will be utilized:

Only qualified persons may perform this type of work. If work is to be performed within
10’ of overhead power lines, a supervisor or designee is required to be on location and
directly overseeing the work.

The local electric utility company should be contacted to perform work on or near lines
under their control. Note: A minimum safe working distance of 10’ is to be maintained
away from any overhead power lines.

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 If lines are to be de-energized, arrangements will have to be made with the person, shop,
or department that operates or controls the electric circuits to de-energize and ground
them.

If protective measures are provided, such as guarding, isolation, or insulating, these

precautions must prevent an employee from directly contacting such lines with any part
of his/her body and from indirect contact though conductive materials, tools, or
equipment.

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 APPENDIX A
LOTO Definitions

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 Lockout Tagout Common Definitions

Affected employee.
An employee whose job requires him/her to operate or use a machine or
equipment on which servicing or maintenance is being performed under lockout or tagout, or
whose job requires him/her to work in an area in which such servicing or maintenance is being
performed.

Authorized employee.
A person who locks out or tags out machines or equipment in order to
perform servicing or maintenance on that machine or equipment. An affected employee becomes
an authorized employee when that employee's duties include performing servicing or
maintenance covered under this section.

Capable of being locked out.

An energy isolating device is capable of being locked out if it has a
hasp or other means of attachment to which, or through which, a lock can be affixed, or it has a
locking mechanism built into it. Other energy isolating devices are capable of being locked out,
if lockout can be achieved without the need to dismantle, rebuild, or replace the energy isolating
device or permanently alter its energy control capability.

Energized. Connected to an energy source or containing residual or stored energy.

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.

Energy source. Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or
other energy.

Hot tap.A procedure used in the repair, maintenance and services activities which involves
welding on a piece of equipment (pipelines, vessels or tanks) under pressure, in order to install
connections or appurtenances. it is commonly used to replace or add sections of pipeline without
the interruption of service for air, gas, water, steam, and petrochemical distribution systems.

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.

Lockout device.A device that utilizes a positive means such as a lock, either key or combination
type, to hold an energy isolating device in the safe position and prevent the energizing of a
machine or equipment. Included are blank flanges and bolted slip blinds.

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Normal production operations. The utilization of a machine or equipment to perform its intended
production function.

Servicing and/or maintenance.Workplace activities such as constructing, installing, setting up,

adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment.
These activities include lubrication, cleaning or unjamming of machines or equipment and
making adjustments or tool changes, where the employee may be exposed to the unexpected
energization or startup of the equipment or release of hazardous energy.

Setting up.
Any work performed to prepare a machine or equipment to perform its normal
production operation.

Tagout. The placement of a tagout device on an energy isolating device, in accordance with an
established procedure, to indicate that the energy isolating device and the equipment being
controlled may not be operated until the tagout device is removed.

Tagout device.A prominent warning device, such as a tag and a means of attachment, which can
be securely fastened to an energy isolating device in accordance with an established procedure,
to indicate that the energy isolating device and the equipment being controlled may not be
operated until the tagout device is removed.

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 APPENDIX B
LOTO Procedure checklist

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 COD LOTO PROCEDURE CHECKLIST
Date and Time Building & Location

Specify equipment to be worked on or task to be performed:

Lockout/Tagout Isolation Control Log

Equipment/machine to be locked out Lock # Type of Signature of Authorized Time LOTO
/color/ID Energy Employee device removed

Transfer of Lock Ownership

Former Authorized Employee Lock # Type of Signature of NEW Time device
/color/ID Energy Authorized Employee switched

Equipment Isolation Yes No

Power feed located and turned off?

Locking device, locks and tags attached?
Locks and tags identify the authorized employee who attached it?
The tag indicates the date and time it was applied?
The authorized employee is the only person who has a key to the lock?
Shutdown was completed following normal practices?
Isolation confirmed by activation of remote start/circuit load?
Residual energy dissipated or restrained as described in the COD LOTO
procedure?
Isolation integrity was double checked using a multi-meter or pressure gauge?
If more than one employee will be working Yes No
Has a multiple lock-hasp be used?
Have all authorized employees been informed and have their lock attached?
Does every lock have a different color or number?
Release from LOTO Yes No

LOTO devices have been removed by the authorized employee who attached
them?
If the authorized person is not on site have reasonable efforts been made to contact them?
Is the Supervisor present where forceful removal is necessary or in case of
emergency?
Area has been checked to verify all tools and supplies have been removed?
Affected employees have been notified about the re-start?
Power feed is switched to the on position?
Equipment is started by following normal practices?
Equipment is tested to ensure that it is operating safely?
Signature of Supervisor verifying that all Signature Date & Time
LOTO conditions were met and the
equipment is safe to operate.

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