PARTICIPANT HANDBOOK Blueprints ee. aT a aa = es aLockout/Tagout ~ Employee Handbook Every workplace has the need for ongoing maintenance. Installation, repair and servicing of machines and equipment may seem routine butean he dangerous to the employees performing the work. Serious injury can be caused by the sudden and unexpeeted startup of the machinery or equipment, contact with live electrical cireuits or the unexpected release of stored energy. Equipment that has been shut down may inadvertently be restarted or re-energized by a e0- worker, or equipment that was thought to be shut down may be controlled by eutomatie processors, timers ‘or computers and may restart automatically and without warning. Fortunately, these hazards ean be avoided through the use of lockout /tagout procedures, in which the employee performing the work plaes a lock and a ag at any point where the equipment can be turned on or where any stored -mergy can be released. This keeps the equipment from being started during repair or maintenanee, Lackout/tagout procedures isolate energy and control machinery and ‘equipment. Doing so helps ta proteet the employees servicing the equipment, the equipment itself and any equipment operators and bystanders It’s important for you to understand lockout/tagout procedures, how and ‘when to use them and how to safely restart equipment and machinery. ‘That's the best way to ensure that everyone will stay safe. (©2005 Comprehensive Lass Management, IncLockout'Tagout Definitions ‘Th help you understand lockoutagout and the requirements of the OSHA standard, here are some basic definitions: Affected Employee: An employee whose job requires him or her to operate ‘or use a machine or equipment an which service or maintenance is being performed under lockout/tagout or whose job requires him or her to work in ‘an area in which such servioe or maintenance is being performed. Affected ‘employees must be informed when lockoutitagout is being performed. Authorized Employee: A person who locks and tags machines or ‘equipment in order to perform service or maintenance on it. Blanks: Typically, a metal disk that is inserted into the space between two pipe flanges, The blank is bolted in place and forms a solid block to prevent the passage of liquids or gases through the pipe. Blanking (the insertion of blanks) is an important siep to assure the safe entry into tanks or vessels if the materials inthe pipes pose a hazard to employees working inside. Bleed: To release stored hydraulic, electrical or pneumatic energy. Block-Out: To physically prevent the movement of machinery or equipment, ‘using mechanical devices such as blocks, chains, cribbing or timbers. Capable Of Being Locked Out: An energy-isolating devioe is enpable of being locked out if has a hasp or other means of attachment to which or through which a lock can be affixed or iit 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 to permanently alter its energy control capability, Energized: Connected to an energy source or containing residual or stored energy. Energy: All sourees of power to a given piece of machinery or equipment. ‘These can be electrical, pneumatic, hydraulic, mechanical, potential, thermal or gravity.Energy Control: The use of energy isolating device to block or isolate energy sourees a8 wel as lockout/tagout procedures to prevent the _~tnespected startup or release of stored energy during maintenance or installation, Energy-Isolating Device: A mechanical device that physically prevents the transmission or release of energy, including a manually operated electrical circuit breaker, a disconnect switch, a line valve, a block or any similar device used to block or isolate energy. Energy Source: Any source of electrical, pneumatic, hydraulic, mechanical, potential, thermal, gravity or other energy. Lockout: The process used to identify, ent off and secure all energy sources before beginning repair, adjustment or maintenance, A lockout device is used to secure equipment or machinery in the ‘of position, ensuring that iteannot be operated, Lockout Device: A lock (ether key or combination type) that holds an energy isolating device in a safe position and prevents the machine or equipment from energizing. Lockout/Tagout Written Program: This is the main requirement of the OSHA standard. The written program provides details about the following: + Tho hazards of uncontrolled energy + Energy control and lockout!tagout procedures in the workplace + Employee training * Inspections * Complete records of all inspection and training that applies to energy control and lockouttagout Normal Production Operations: The use of a machine or piece of equipment to perform its intended production funetion. Servicing And/Or Maintenance: Workplace activities that require lockout) tagout on the equipment before beginning the activity beeause employees ‘may be exposed tothe unexpected energization or startup ofthe equipment or the release of hazardous energy. Servicing andlor maintenance inchudes constructing, installing, seiting up, adjusting, inspecting, modifying, Jubrieating,clezning oF unjamming and making tool changes.Setting Up: Any work performed to prepare a machine or piece of ‘equipment to perform its normal production operation, ‘Tagout: Attaching a tag to the lock on the power source that has been shot off, indicating the time and reason forthe lockout and the name of the person doing the work. The tag acts as a warning not to restore energy to the equipment or machinery. ‘Tagout Device: A prominent warning tag that can be securely fastened to an energy-isolating device to indicate that the energy isolating device and ‘the equipment being controlled may not be operated until the tagout device has been removed. ‘Zero-Energy State: All energy has been controlled in the machinery or equipment, ‘Sources Of Energy + Blectrical ‘+ Mechanical * Thermal * Pheumatie * Potential * Gravity + Hydraulic Energy refers to the movement or possibility of movement in equipment or machinery. Whether the power switch is Yon" o “off,” enorgy is always: present in any powered equipment, Here are the common types of energy: Electrical: The flow of electrons through a conductor ‘The force caused by compressed air Hydraulic:"The force caused by a pressured fluid, especially water ‘Mechanical (or kinetie)The foree eaused by moving parts Potential (or stored): The foree stored in an object that isn’t moving ‘Thermal: The increased heat of fluid or abject Gravity: The force of an object that falls or is knocked over ‘An example of mechanical energy is the energy released by a spinning shaft asit turns, An example of potential energy is a suspended load, The lad is not moving but its under tension, which rsults in energy being stored.‘Its important to identify and isolate al types of energy. Equipment needs to be hoth shut off and prevented from releasing stored energy, tthe energy source isnot isolated, a release of energy can occur, This could cause an unexpected startup, movement caused by the release of stored energy o electrical shock. Each could result in serious injury or even death, By understanding and identifying the type and amount of energy source, ‘you can make sure that equipment or machinery has no mechanical (kinetic) or potential (stored) energy that could eause injury. Engineering Safety Devices Accidental startup and/or release of stored energy can sometimes be controled with engineering safety devices, such a these: * Machine guards * Bleetrical disconnects * Mechanical stops * Point-of operation guards All ofthese devices are designed to provide additional safety to employees ‘working on a piece of equipment or machinery, in addition to the power shutoff. However, no safety device is 100% effective if someone wants to bypass it ‘This means that employees should never rely totally on engineering safety _~ devices as their only protection while working on equipment,‘Types Of Employees + Authorized employees * Affected employees Before discussing specific procedures it's important to identify the two types of employees involved in lockouttagout: + Authorized employees are those individuals who are sanctioned to shut down, lock out and tag out, equipment in order to perform service oor maintenanee on it, «Affected employees are those individuals who operate or work near equipment that’s being serviced or maintained according to lockout/tagout procedures, Even though affected employees don't actually perform service or maintenanee, their work may be influenced by those employees who do perform such work—that is, authorized employees. Thus, acritieal part oflockout/tagout procedures is to keep affected employees informed. Specifically, affeeted employees must be notified when equipment is being locked out and tagged out for service and when it is being restored to normal working order, (Well return to these points later in this handbook.) Its also helpful for affected employees tobe given some advance notice of equipment being locked out so they can plan ahead for the interruption in their work. In fact, affected employees should initiate repair or servicing by letting their co-workers in the maintenance department know when equipment needs work. Teamwork between authorized and affected employees will go a long way toward ensuring that work will be done efficiently and safely. Once equipment has been locked out and tagged out, the general rule is for affected employees to stay clear of it. They should not attempt to remove a lock or restart equipment, even if it looks as though work has ‘been completed.Lockout!Tagout Procedures Prepare and notify, Shut down the equipment Tslate the equipment. Attach the lock and tag. Release any stored energy ‘Test equipment to verify that all energy has been released or controlled, pomeme Lockouttagout must be performed in the following situations: * When service or maintenance is being performed on or around any machine where injury could result from an unexpected startup or the release of stored energy + When new equipment or machinery is being installed ‘+ When a guard or other safety device must be bypassed or removed + When an employee must place any part ofhis or her body where it could be caught by moving machinery I. Prepare And Notify Before servicing or installing equipment, you must be able to answer the following questions: * What is the type and amount of energy source in the equipment? /~* What are the potential hazards related to the energy source? What steps will be necessary to control the energy source? ‘+ Who needs to be notified that the equipment will be shut down, locked out and tagged out? Once you have answered these questions, you should notify all affected employees that a lockout procedure is about to begin and thet the equipment will be shut down for servic.2, Shut Down The Equipment Follow the company’ safety procedures and/or the manufacturer's instructions, Be aware that some equipment has special shutdown ‘procedures (for exemple, computer-controlled equipment). ‘Make sure all energy sources have been located and shut down. (Some machines have more than one power souree—all must be shut down.) 3, Isolate The Equipment ‘Two types of devices are used during lockouttagout to isolate equipment. ‘The first is called an energy-isolating device. ‘An energy-isolating device is a mechanical instrument that’s used to physically prevent energy from being transmitted or released. Examples include the following: * Blectrical cireuit breakers * Disconnect switches * Line valves * Mechanical blocks It’s very common for a single piece of equipment to have multiple energy sourees or backup systems. Each source of energy must be identified and isolated accordingly. For complex machines or equipment, refer to the manufacturer's control diagram detailing the locations of al isolation points, including breaker panels, switches, valves and so on. Keep the following in mind when working with electricity: + Never poll an electrical switch while itis under load, + Never remove a fuse instead of disconnecting. + HEworking on electrical components, always use a voltage indicator to test all exposed components for voltage before starting any work4, Attach The Lock And Tag ‘The second type of device involved ia ‘isolating energy is the lackout device, 1's used to hold an energy isolating device in place, thus ensuring that energy can't be restored to a pioce of equipment, Locks and tags are examples of lockout devices. Placing a lock on a disconnect switch or valve will physically prevent anyone from re-energizing or restarting equipment during ‘maintenance or service. Different types of lockout devices are available for use with electricity, gases, water and liquid chemicals. Chains and blocks are sometimes used, as well, to keep parts of equipment from moving during maintenanee or service, ‘Bach lockout device must be tagyed individually, and the tag must include ‘this information: * When and why the equipment was locked out ‘© Who placed the lock on the equipment (either a name or employee ‘identification number) In addition, a tag serves as a visual reminder that the equipment has been shut down. In this sense, it acts as a warning not to restore energy to or otherwise tampor with the equipment. Given this important safety factor, ‘each tag must be securely attached soit can't be easily removed. ‘Authorized employees who perform maintenance and service are responsible for locking and tagging equipment. Bach employee whose duties require him orher to work on equipment must be provided with hs or her own lock and ey Ifmore than one authorized employee is involved in maintenance or service, ‘multiple locking devices must be used to allow each employee to lock and tag. Doing so prevents one emplayee from accidentally starting up the ‘equipment while another employee is still working. Following the rule of “One lock; one key" is critical to ensuring safety. Authorized employees should never use one anothers locks or lend out, their own locks. In fact, employees should not even share or exchange keys,10 Allemployees—authorized and affected—should be familiar with the tags sed in the workplace and what they mean, Lockout Devices '* Must be provided to each authorized employee * Must only he used for the purposes of loekont/tagout. * Must he able to withstand the environment that they are exposed to for aslong as they are in plave * Must be standardized by color, shape and size Tagout Devices + Must be standardized by color, shape, size and format or print *+ Must contain warnings such as “DANGER -DO NOT OPERATE ‘THIS MACHINE” + Must have space forthe name ofthe lock or tag owner andthe date and purpose of the lockout/tagout ‘Tagout Only A tagout system can be used instead of a lockout system only in the following situations: ‘+ When an energy-isolating device cannot be locked out ‘+ When the employer can prove that tagout system provides the same amount of protection as a Jockout system Ifa tagout-only system is used, the tags must be placed at all isolation points and the employer must follow all safety procedures,5, Release Any Stored Energy After locking and tagging equipment, make sure that any stored energy on the equipment is released. You can do this ina number of ways: + Inspect equipment to make sure all parts have stopped moving. + Bleed elecirial capacitance (stored charge), + Vent or isolate pressure or hydraulic lines from the work area, leaving ‘the vent valves open. «Drain tanks and valves. + Release the tension on springs or block the movement of springsdriven parts. + Block or brace parts that could fall because of gravity. «Block, clamp or chain any switches or levers that could be moved into the “start” position + Clear lines containing process materials that are toxic, ht, cold, corrosive or asphysiating, “+ Monitor the process to make sue that the work you are doing will nt result in an accumulation of stored energy. 6, Test Equipment To Verify That Alt Energy Has Been Released Or Controlled ‘To make sure that al kinetic and stored energy has been released or controlled, do the following: ‘Clear personnel from danger areas. + Test the ‘start switehes on the equipment (> to confirm that all power sources have been shut down and switches can't be moved tothe “on” ‘or “start” position. * Check pressure gauges to sake sure that all lines have bbeen dopressurized and stored energy has been released. * Secure all blocks, lamps, chains and eribs. * Cheek electrical circuits to make sure that voltage is at 0, + Secure blanks (used to block feed lines) and make sure they are not leaking u2 Because some machinery and equipment can be controlled via a remote, ‘you must consider equipment to be energized and in motion at all times. ‘The only exception is when you have personally locked it out of operation and tested equipment to verify that it is at a zero-enengy state. Once you have confirmed that all energy sources have been controlled and Jocks and tags are in plac it is safe to begin the maintenance work. While ‘working, you should avoid any actions that could reactivate the equipment, ‘When installing new piping or wiring, make sure the lockout is not bypassed. Safe Startup Procedures Once the maintenance or installation has been completed, the equipm 1. Prepare. 2. Remove lockout devices and tags. 3. Notify affected employees. can be restarted. Follow these procedures for safe startup. 1. Prepare ‘To make sure the area is safe for restart, you must do these things: Verify that all equipment components are fully assembled and operational. Verify that all safety guards are in place. ‘Make sure all controls are in “neutral” to prevent an unintended startup ‘when the power eomes back on. Remove all tools from the equipment and the work area. Remove all braces, pins blocks, cribs and chains, Reconnect all pressure tubing, pipes and hoses and close all valves, Clear the work area ofall personnel12, Remove Lockout Devices And Tags Exeept in emergencies, each lockout —4evice must be removed by the .uthorized employee who put it on. If more than one employee worked on. the equipment, the removal of devices should be coordinated with everyone involved in the shutdown. 3. Notify Affected Employees Notify all personne! in the area that maintenance, servicing or installation has been completed, that lockouttagout has been removed and that the rmachinclequipment is ready to be restarted, Once all three steps have been completed, it will be safe to start up the ‘equipment, Special Situations ‘Removing someone else's Jock. Shift changes Outside contractors ‘Temporary reactivation (© Yor some situations in the workplace, you must perform additional procedures for safe lockoul/tagout: + Removing someone else's lock: A lock may be removed by someone other than the employee who placed the lock only under the following conditions = The employee whose lock is t he removed is not available to remove the lock after servicing has been completed. — All reasonable efforts have been made to contact the employee to inform him or her that the lock has been removed. ~ The employee is contacted and informed that the lock is removed prior to his or her starting the next work shift.u * Shift changes: f maintenance ona piece of equipment will extend beyond one shift, provisions must be made to have employees from the new shift place their locks onthe lockout device before they begin work an the ‘equipment. This must be done without any interruption in lockout/tagout protection. * Outside contractors: I outside contractors willbe working on equipment inside the facility or workplace, provisions must be made to inform them ofthe lckout/tagout procedures followed in that facility or workplace. Ifthe contractor's procedures are different, agreement must be reached as to which procedures will be followed, All employees working on the project must be notified of any changes in their own procedures + Temporary reactivation: If he equipment being serviced must be temporarily reactivated (for example, to test the equipment as part of installation) all startup and lockout/tagout procedures must be followed. Lockout Boxes In situations invelving a lange number of employees, a Targe number of energy-igolating devices and thus a large number of locks, its good idea to use a lockout bor. With this devie, a single lock and tag are placed on each energy-isolating device. All ofthe keys forthe locks on the various energy- isolating devices on the equipment are kept safely in the lockout box until the job has been completed, Using a lockout box can help avoid the potential confusion and danger involved in complicated situations—for instance, when new employees are brought into a job, when a job extends across different shifts and when employees from different organizations are working on the same job.