SAFETY POLICY

Lockout/Tagout SP# 1910.147 


Quick Reference

1.0 Purpose
2.0 Scope and Applicability
3.0 References
4.0 Policy
5.0 General Responsibilities
6.0 Procedure
6.1 Definitions
6.2 General Provisions
6.2.1 General Training Requirements
6.2.2 Authorized Employee Training
6.2.3 Affected Employee Training
6.2.4 Supervisor Training
6.2.5 Equipment Survey
6.3 Specific Responsibilities
6.3.1 Managers
6.3.2 Supervisors
6.3.3 Authorized Employees
6.3.4 Affected Employees
6.3.5 Safety Risk Management
6.3.6  Additional Resources

Lockout/Tagout Flowchart
APPENDIX A: Certification Training Form for Authorized Employees
APPENDIX B: Certification Training Form for Affected Employees
APPENDIX C: Lockout/Tagout Procedure
APPENDIX D: Lockout/Tagout Equipment and Energy Source Survey Form
APPENDIX E: Tagout System Justification
1.0 Purpose

The purpose of this safety policy is to establish methods for isolating machines or equipment from energy sources to permit routine maintenance and servicing of those machines and equipment by North Carolina Department of Environment and Natural Resources (NCDENR) employees.


2.0 Scope and Applicability

Uncontrolled energy is a hazard to operators and other employees in the area of the machinery, equipment, or processes. Those who service and maintain machinery or equipment are especially vulnerable because the machinery or equipment might become energized while being serviced or stored energy might be unexpectedly released.
A lockout is a method of keeping equipment from being set in motion and endangering employees. This safety policy provides guidelines for isolating machines or equipment from energy sources. It emphasizes the two major components of the lockout/tagout requirements of training and equipment surveys. The training component is organized into:

The training component addresses all the procedural details of an effective lockout/tagout program. The equipment survey component addresses the identifications of energy sources and the assignment of lockout/tagout devices for those energy sources.

This document also details the areas of responsibility for managers, supervisors, employees, and Safety Risk Management.

This safety policy affects employees who service, maintain, and operate stationery equipment and machines.


3.0 Reference

This safety policy is established in accordance with Occupational Safety and Health Standards for General Industry (29 CFR 1910.147).


4.0 Policy

It is the policy of the North Carolina Department of Environmental and Natural Resources (NCDENR) to provide a place of employment free from recognized hazards that cause or are likely to cause death or serious physical harm to employees or the public. Therefore, all energized machines and equipment must be locked out and/or tagged out before any maintenance or servicing is performed.
When hazards exist that cannot be eliminated, then engineering practices, administrative practices, safe work practices, Personal Protective Equipment (PPE), and proper training regarding Lockout/Tagout will be implemented. These measures will be implemented to minimize those hazards to ensure the safety of employees and the public.


5.0 General Responsibilities

It is the responsibility of each manager, supervisor and employee to ensure implementation of NCDENR's safety policy on Lockout/Tagout. It is also the responsibility of each NCDENR employee to report immediately any unsafe act or condition to his or her supervisor. Specific responsibilities are found in Section 6.3.


6.0 Procedure

This section provides applicable definitions, establishes general provisions, and identifies specific responsibilities required by NCDENR's Lockout/Tagout Program.


6.1 Definitions

Affected Employee
An employee whose job duties require operation or use of a machine or piece of equipment in a location in which servicing or maintenance is being performed under Lockout/Tagout Procedures.

Authorized Employee
An employee who lockouts or tagouts a machine or piece of equipment in order to perform servicing or maintenance on that machine or piece of equipment. An affected employee becomes the authorized employee when that employee's duties require him or her to perform the service or maintenance covered under this policy.

Capable of Being Locked Out
An energy isolating device capable of being locked out if it has a hasp or other means of attachment through which a lock can be affixed to the equipment or machine.

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 additionally by which no pole can be operated independently; a line valve; a blind; or 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.

Hasp
Multiple lockout or tagout device. (See Figure 1.)

LO/TO multi tag examples
Figure 1
 
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 a safe position to prevent the energizing of a machine or piece of equipment. (See Figure 2.)

loto examples.gif
Figure 2

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 lubricating, cleaning, or unjamming of machines or equipment and making adjustments or tool changes, where the employee may be exposed to 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 or 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.


6.2 General Provisions

This section details the provisions of this safety policy with each provision discussed in a separate subsection. These provisions are:


6.2.1 General Training Requirements

General training requirements for the Lockout/Tagout program shall consist of:

Basic lockout/tagout training shall communicate a basic awareness of the procedures and skills that employees are required to possess. This training shall ensure that: Training on the limitations of tags must be provided to the identified employees. Tagout systems are not completely foolproof. Instructions should include, among others, the following examples of tag limitations: Authorized and affected employee retraining is required when: This retraining shall establish employee proficiency and introduce new or revised control, methods and procedures, as necessary.

Certification of lockout/tagout training must be accomplished and updated when such training has taken place. The certification shall contain each employee's name, job title, division/unit, and dates of training.
Appendices A and B provide Lockout/Tagout training certification forms for authorized and affected employees, respectively.

A standard DENR sign-in sheet may be used to document training.


6.2.2 Authorized Employee Training

Authorized employees are those who use lockout/tagout devices. This training will be the responsibility of the supervisor.

Training requirements for authorized employees will include the following:

Appendix C lists NCDENR's lockout/tagout procedure for authorized employees.
6.2.3 Affected Employee Training

Affected employees are those who operate, but do not service or maintain equipment subject to being locked or tagged out, or employees who work in the area where the devices are in use. Affected employee training should cover:


6.2.4 Supervisor Training

In addition to the employee training mentioned above, supervisors will receive additional training to include the following elements:


6.2.5 Equipment Survey

A survey is required to identify all isolating devices prior to a lockout/tagout event. The purpose of the survey is to determine which switch(es), valve(s), or other energy isolating devices applies to the equipment to be locked out or tagged out.
Appendix D
contains forms for performing an equipment survey for a facility.


6.3 Specific Responsibilities
6.3.1 Managers

Managers shall ensure that completion of a survey of machinery and equipment by supervisors is conducted within their area to determine which machinery and equipment should be included in the Lockout/Tagout Equipment Inventory Program.

Managers shall be responsible for identifying all affected and authorized employees. Managers shall ensure that the necessary funding is available for the purchase of any required lockout/tagout safety equipment. Managers will also ensure annual compliance with this safety policy through their inspection and auditing processes.

Managers are responsible for ensuring that supervisors obtain any required training for their direct reports.


6.3.2 Supervisors

Supervisors shall be responsible for ensuring that this safety policy is implemented in their areas.
They shall complete a survey of machinery and equipment within their area to determine which machinery and equipment shall be included in the Lockout/Tagout Equipment Inventory Program. (See appendix D)

Supervisors will ensure that all newly purchased Locks and Tags comply with this safety policy

Supervisors shall be responsible for ensuring that an adequate supply of locks, tags, and other safety equipment is available and is utilized in accordance with this safety policy.

Supervisors will ensure that monitoring of the Lockout/Tagout Program and any changes in the machinery and equipment that may require modification of the Program takes place for their work area.

Supervisors shall be responsible for obtaining or providing  training of the employees and for ensuring that the training meets the requirements of this safety policy.

Supervisors shall be responsible for maintaining training needs in accordance with this safety policy.


6.3.3 Authorized Employees

Authorized employees shall be responsible for following NCDENR's lockout/tagout procedures before any maintenance or servicing activities are begun.

Authorized employees will be responsible for notifying affected employees before beginning a lockout/tagout procedure on a piece of equipment or machinery.

Authorized employees shall report to their supervisors any changes in the machinery or equipment that would require a change in the lockout/tagout procedure.


6.3.4 Affected Employees

Affected employees shall attend the required training. This training will be given at least annually or when new employees or equipment are introduced into the work environment. Records for training will be maintained by the office in which the equipment and employees are located. This training will include electrical, hydraulic, chemical, thermal, and any other energy sources that have the ability to release without warning. Affected employees shall ensure that all precautions required by this safety policy be observed.

Affected employees shall report to their supervisors any changes in the machinery or equipment that would require a change in the lockout/tagout procedure.


6.3.5 Safety Risk Management

Safety Risk Management will provide prompt assistance to managers, supervisors, or others as necessary on any matter concerning this safety policy. Safety Risk Management will assist in developing or securing required training.

To ensure effective implementation of this safety policy, Division/Office/Program Safety Consultants and Safety Officers shall be responsible to provide consultative, training and audit assistance on this safety policy for their Division/Office/Program.  This includes monitoring the Lockout/Tagout Program and any changes in the machinery and equipment that may require modification of the Program.


6.3.6 Additional Resources

The NC Department of Labor produces an industry guide that also has lockout/tagout information for your use. Click here to see the guide.


Lockout/Tagout Flowchart

Lockout Tagout flow


APPENDIX A: Certification Training Form for Authorized Employees
 
Facility: Location:
AUTHORIZED EMPLOYEE TRAINING
 

Lockout/tagout for Authorized employees includes special instructions concerning scope, purpose, rules, and techniques for lockout/tagout of hazard energy sources including, but not limited to:

Intended use of the procedure
Steps for shutting down, isolating, holding, and securing
Steps for placement, removal, and transfer of lockout/tagout devices
Requirements for testing to determine and verify effectiveness of lockout/tagout devices
Other measures__________________________________________________________

Click here to print a sign-in roster for use.

Employee's Name Job
Title
Division       
Comments AUTHORIZED
Date Supervisor
           
           
           
           
           
           
           
           
           
           
           
           
           
Training Conducted by:   Date:   Reviewed by:   Date:


APPENDIX B: Certification Training Form for Affected Employees
Click here to print a sign-in roster for use.
 
Facility: Location:
AFFECTED and OTHER EMPLOYEE TRAINING

Lockout/tagout for AFFECTED and OTHER employees includes special instructions concerning scope, purpose, rules, and techniques for lockout/tagout of hazard energy sources including, but not limited to:

Intended use of the procedure
Steps for shutting down, isolating, holding, and securing
Steps for placement, removal, and transfer of lockout/tagout devices
Requirements for testing to determine and verify effectiveness of lockout/tagout devices
Other measures__________________________________________________________

Employee's Name Job
Title
Division  
Comments AUTHORIZED
Date Supervisor
           
           
           
           
           
           
           
           
           
           
           
           
           
           
           
           
           
           
           
           
           
           
Training Conducted by:   Date:   Reviewed by:   Date:


APPENDIX C: Lockout/Tagout Procedure

Sequence of Lockout or Tagout

  • Complete survey and identify all isolating devices to determine which switch(s), valve(s), or other energy isolating devices applies to the equipment to be locked out or tagged out.(See Appendix D for sample survey forms.)
  • Notify all affected employees that a lockout or tagout system is being implemented and the reason why.
  • Shut down machine or equipment by normal stopping procedure.
  • Position the ON switch, valve, or other energy isolating device(s) so that the equipment is isolated from its energy source(s). Stored energy (such as that in springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, etc.
  • Lockout and/or tagout the energy isolating devices with assigned individual lock(s) or tag(s). If tags are to be used, tag justification forms (Appendix E) must be completed.
  •     

    To verify that the energy sources are disconnected:

    Restoring Machines or Equipment to Normal Production Operations Procedure Involving More Than One Person

    In the preceding steps, if more than one individual is required to lockout or tagout equipment, each shall place his or her own personal lockout device or tagout device on the energy isolating device(s).

    When an energy isolating device cannot accept multiple locks or tags, a multiple lockout or tagout device (hasp) may be used.

    <>If lockout is used, a single lock may be used to lockout the machine or equipment with the key being placed in a lockout box or cabinet which allows the use of multiple locks to secure it. Each employee will then use his or her own lock to secure the box or cabinet. As each person no longer needs to maintain his or her lockout protection that person will remove his or her lock from the box or cabinet.
    APPENDIX D: Lockout/Tagout Equipment and Energy Source Survey Form
     (NOTE: You may need to adjust your printer settings to get the form on one page.)
     
    TYPES OF HAZARDOUS ENERGY AT THIS FACILITY: 
    Facility Name________________________________________________________

    Yes No General Description and Location
    Electrical: ____________________________________________________
    Pneumatic: ____________________________________________________
    Hydraulic:  ____________________________________________________
    Stored: ____________________________________________________

    ELECTRICAL EQUIPMENT
    PNEUMATIC EQUIPMENT
    Equipment
    Name
    Service Panel
    Disconnect
    Identification
    Number
    Lockout/Tagout
    Device Needed
    Equipment
    Name
    Service Panel
    Disconnect
    Identification
    Number
    Lockout/Tagout
    Device Needed
           



           



           



           



           



           



           



           



           



           



           



           



           



           



           



           



           



           



    Comments Comments
     
     
     
     
    HYDRAULIC EQUIPMENT STORED ENERGY EQUIPMENT
    Equipment
    Name
    Service Panel
    Disconnect
    Identification
    Number
    Lockout/Tagout
    Device Needed
    Equipment
    Name
    Service Panel
    Disconnect
    Identification
    Number
    Lockout/Tagout
    Device Needed
           



           



           



           



           



           



           



           



           



           



    Comments Comments











    APPENDIX E: Tagout System Justification

    Location:
    FULL EMPLOYEE PROTECTION:If you cannot indicate a "yes" answer to all of the following items, do not use the tagout system.
    Yes No
    Yes No
    Tagout system provides full employee protection Tagout system provides equivalent safety to the lockout program.
    Tagout devices placed at the same location where the lockout device would have been placed.  Employees fully comply with all tagout-related provisions.
    ADDITIONAL SAFETY MEASURES: Check measure(s) used to provide equivalent employee protection.
    Isolating circuit element removal
    Control switches blocked
    Extra disconnecting device opened
    Removal of valve handles
    Other________________________
    TAGOUT DEVICES:The tagout device must satisfy each of the following criterion:
    Singularly identified Exposure does not cause deterioration
    Only devices used for controlling energy Does not deteriorate in corrosive environment
    Not used for other purposes Standardized 
    Durable/Substantial Color 
    Withstand environment Shape and Size
    Non-reusable Print and Format
    Attachable by hand Minimum unlocking strength of no less than 50 pounds.
    Self-locking Equivalent to a one-piece, all environment-tolerant, nylon cable tie
    Indicates employee identity 
    Warning:The tagout device must:
    Warn against hazardous conditions
    Include Do Not Start, Open, Close, Energize, Operate, etc.
    Tag Limitations:Employees should be trained to know that:
    Tags are warning devices Tags are part of the overall security
    Tags do not provide physical restraint Tags must be securely attached
    Tags must never be removed without authorization Tags must never be bypassed, ignored,or defeated
    Tags may evoke false sense of security 

     
    EMPLOYEE TRAINING ON LOCKOUT/TAGOUT
    DATES: LOCATION:
    DESCRIPTION:
    REASON(S) FOR USING TAGOUT SYSTEM
    HOW EQUIVALENT EMPLOYEE PROTECTION IS PROVIDED
    OTHER COMMENTS
    Conducted by: Date: Authorized By: Date: