Each year thousands of workers are injured on the job due to the accidental release of energy. These injuries range from electrical shock to severe amputation and even death in some tragic incidents. The Occupational Safety and Health Administration (OSHA) believes that the Lockout/Tagout standard will prevent nearly 122 deaths and 28,400 lost workday injuries annually.

A written lockout/tagout program should provide policies, procedures and practices that protect your workers from harm. The written program, when implemented, will reduce the hazard from the unexpected start-up of machines and equipment.

When the OSHA compliance officer requests to see your written lockout/tagout program, will you be able to provide it? If you do not have, or cannot show the OSHA inspector, a written lockout/tagout program, you face an administrative headache of violations, penalties, and citations. It is better to have the program in the first place than dealing with the consequences, and then writing your program.

The major parts of a written lockout/tagout program (also known as "Control of Hazardous Energy Sources") are the establishment of written procedures for energy control, employee training on lockout/tagout practices and periodic inspections to see that the program is being implemented. The written program must indicate how the hazards from potential and actual energy are controlled. The written program must include affected employees, maintenance employees and types of energy being controlled.

Maintenance or service work on machines must be done with the machine or equipment stopped, and all sources of energy disconnected to prevent accidental start-up. The written program must indicate how the hazards from potential and actual energy are controlled. This way when a maintenance person is working on a machine, it will not be started up accidentally by the operator or any other person.

Lockout and tag is the preferred method where the main disconnect is locked in the off position and a tag is placed indicating that the machine is being serviced by an identified service person. If locking out is not possible because of the configuration of the disconnect, then tagout is acceptable. This is where there is a tag by the disconnect indicating the machine should not be turned on because it is being serviced. The tag should also identify the person doing the service. In both cases all operators of the machine should be notified when not to use the machine and also when the machine can be brought back into service.

To help you write your own Lockout/Tagout Program, you can use the following template. Fill in the information as it applies to your äcompany and you will have a basic program that will bring your company into compliance with the OSHA requirements for a written program:

Lockout/Tagout Procedures Used At (name of company)

Scope:

This procedure covers the servicing and maintenance of machines and equipment in which the unexpected energization or start up of the machines or equipment, or release of stored energy, could cause injury to employees. This procedure establishes minimum performance requirements for the control of such hazardous energy.

Purpose:

The purpose of this lockout procedure is to ensure the protection of all employees who could be exposed to the danger of hazardous energy sources during the servicing and maintenance of machines and equipment as described in OSHA 29 CFR 1910.147. This procedures must be followed to ensure that the machines or equipment are isolated from all potentially hazardous energy, and locked out before employees perform any service or maintenance activities where the unexpected energization, start-up or release of stored energy could cause injury.

Authorization/Responsibility

• All maintenance repairmen and/or maintenance foremen (names and title) are authorized to lockout or tagout.
• Appropriate employees shall be instructed in the safety significance of the lockout (or tagout) procedure. (Names and title of employees authorized to lockout or tagout)
• Each new or transferred affected employee and other employees whose work operations are or may be in the area shall be instructed in the purpose and use of the lockout or tagout procedure. (Name & titles of employees authorized to lockout or tagout)
• Each new or transferred affected employee and other employees whose work operation are or may be in the area shall be instructed in the purpose and use of the lockout or tagout procedure. (Name and title) are affected by the lockout because they are involved with the operation of the machine. They will be notified by (radio, alarm, memo, other notification means) that the machine has been locked out and is being serviced and not to work on it, or start it up.
  

Rules

• Locks, tags, chains, wedges and other hardware used for lockout will be provided by (name of company).
• Lockout devices shall be singularly identified. They shall be the only devices used for controlling energy and shall not be used for other purposes.
• Lockout devices and tagout devices shall indicate the identity of the employee applying the devices.
• All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation could cause injury to personnel.
• No employee shall attempt to operate any switch, valve, or other energy isolating devices where it is locked out or tagged out.
• Each lockout or tagout device shall be removed by the employee who applied the device. When the authorized employee who applied the lockout or tagout device is not in the plant to remove it, that device may be removed under the direction of the Maintenance Supervisor, providing that he verifies that the authorized employee who applied the device is not in the plant. He must make all reasonable efforts to contact the said employee to inform him that his lockout or tagout device has been removed, and if unable to contact employee, he must ensure that the employee has this knowledge before he resumes work.
• In situations in which lockout or tagout devices must be temporarily removed from the energy isolating device and the machine or equipment energized to perform testing, the authorized employee must clear the machine or equipment of all tools and material and remove or safely position all employees prior to removing the devices.
• Outside contractors and the Maintenance Supervisor or Foreman shall inform each other of their respective lockout or tagout procedures.
• At shift or personnel changes the off-going and oncoming employees shall transfer their lockout or tagout devices in an orderly manner to minimize exposure to hazards of unexpected energization, start-up of the machine or equipment.
  

Disciplinary Action

No employee shall willfully, deliberately, or continually violate or disregard the rules of this procedure. Penalties for violations will be:

• First Offense -- Written warning and three days suspension.
• Second Offense -- Written warning and five days suspension.
  

Lockout/Tagout Procedures and Techniques

1. Preparation for Shutdown

Determine the energy sources and how to disconnect and control them. In preparation for a lockout or tagout, an initial survey must be made to locate and identify all isolating devices to be certain äwhich switch, valve or other energy isolating devices apply to the equipment to be locked or tagged out. More than one energy source such as electrical, hydraulic, pneumatic, chemical, thermal, etc. may be involved. Before an authorized or affected employee turns off a machine or equipment, the authorized or affected employee shall have knowledge of the type and magnitude of the energy to be controlled and the methods or means to control the energy.

2. Machine or Equipment Shutdown:

2-1 Employee Notification. Before the controls are applied, all affected employees must be notified that a lockout or tagout system is going to be used and the reason for it. Affected employees are defined as employees whose job requires them to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires them to work in an area in which such servicing or maintenance is performed. It is imperative that the authorized employee know the type and understands its hazards and methods of control.

2-2 Machine or Equipment Shutdown. If the machine or equipment is operating, shut it down by the normal stopping procedure such as depress stop button, open toggle switch, etc.

3. Machine or Equipment Isolation

Physically locate and operate the switch, valve, or other energy isolating device so that the equipment is isolated from its energy source and apply adequate hardware such as locks, tags, chains, wedge key blocks, adapter pins, self locking fasteners, etc.

4. Lockout or Tagout Device Application

Authorized employees must lockout or tagout the energy isolating devices with assigned individual locks or tags. When lockout devices are used they will be applied so that they will hold the energy isolating devices in a "safe" or "off" position is prohibited. When tags cannot be attached directly to the energy isolating device, they will be located as close as safely possible to the device and immediately obvious to anyone attempting to operate the device. After the lockout or tagout device has been applied, all potentially stored or residual energy must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, etc. Residual energy would be the potential energy from springs, elevated machine parts, rotating flywheels, hydraulic pressure systems, and air, gas, steam or water pressure.

5. Verification of Isolation

Prior to starting work on machines or equipment that have been locked or tagged out and after ensuring that no personnel are exposed, the authorized employee must operate the push button or other normal operating controls to verify the equipment or machine has been de-energized and make certain it will not operate.

CAUTION: After Verification Return Operating Control To Neutral Or Off Position
The machine or equipment is now locked or tagged out. Service or maintenance may now occur.

Removal of Lockout/Tagout Device

1. After the servicing or maintenance is completed and before the lockout or tagout devices are removed and energy is restored the following sequence of activities must be completed by authorized employees:

1.-1. Machine or Equipment. Check the work area to be sure the machine is intact, unnecessary items such as tools and spare parts have been removed, and guards have been reinstalled.

1.-2. Employees. Check to be sure all employees around the machine or equipment are safely positioned or moved from the area. Additionally affected employees must be notified before the removal of the lockout or tagout devices and the energizing of the machine or equipment.

1.-3. Lockout or Tagout Devices Removal. The authorized employee who applied the device will remove each lockout and tagout from every energy source and restore energy to the machine or equipment.

When it has been verified that the authorized employee who applied the device is not available for removal, the program administrator will select another authorized employee trained for that specific procedure to complete the removal task. All reasonable efforts to contact the employee who initially applied the device will be made to inform him that the device has been removed. Additionally, that employee will be informed of the removal of the device before he resumes work at the facility.

1.-4 Temporary Removal of Lockout/Tagout Devices. In situations in which lockout or tagout devices must be temporarily removed from the isolating device and the machine or equipment energized to test or position the machine, equipment or component hereof, the following sequence of actions will be followed:

• Clear the machine or equipment of tools and materials.
• Remove employees from the machine or equipment area and make sure that they are in a safe position.
• Removal of the lockout/tagout device by the employee who installed it.
• Energize and proceed with testing or positioning.
• De-energize all systems and reapply energy control measures in accordance with procedures set forth in this written procedure.
  

Group Lockout/Tagout

In most cases there will be only one individual required to lockout the equipment. In the rare case that more than one individual is required to lockout equipment, the following procedure will be implemented to provide protection to all employees. The authorized employee will be responsible for the number of people working under the protection of the group lockout device. The authorized employee will ascertain the exposure status of the individual member participating in the group lockout.
When there is more than one crew, craft or department, to ensure continuity of protection for each participating individual, the authorized employee will be assigned to control the job related lockout procedure. Each authorized employee will place their own personal lockout device on the energy isolating device. When an energy isolating device cannot accept multiple locks, a multiple lockout device may be used. If a 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 their own lock to secure the box or cabinet. As each person no longer needs to maintain their lockout protection, that person will remove their lock from the box or cabinet.

Shift Personnel Changes

If a lockout procedure will extend into the following shift, the authorized employee who originally placed the lock will remove it, and it will immediately be replaced with a lock by the authorized employee who is to continue the repair or maintenance on that equipment or machine for the following shift.

Outside Contractors

The lockout procedure applies to all employees, contractors, subcontractors and any other company representatives while on the premises. The general procedure will be made aware to outside contractors, and this written program will be made available to them if they request to see a copy. It will be ascertained if the contract has a lockout procedure. This program will be used and all affected employees will be notified that the contractor will be locking out equipment and notifying them.

Training

Training of authorized and affected employees will be done on a periodic basis. There will be written certification of the attendees at the lockout training. The objectives of the training is to provide employees with principles and procedures of the lockout program necessary to eliminate injuries caused by accidental release of energy.

The attending employees will know when to lockout, notification of lockout equipment, lockout procedure, dissipation of stored energy, equipment start-up and operation after the lockout procedure maintenance.

Periodic Inspection Of Equipment

There will be periodic inspection of energy control procedures. This will ensure that the lockout devices are functional and can be put into place during routine and non routine maintenance and repair.

Specific List Of Machinery And Equipment

Each piece of equipment that is subject to lockout or tagout should have a sheet using the following information:

• Name of machine or equipment
• Energy source and location
• Type of disconnect and lockout device used.
• Authorized employees -- those that are authorized to lockout and will service
• Affected employees, those that operate the machine and those affected by a lockout procedure.
  

This template is similar to the one that was left by an OSHA compliance officer at a plating shop that did not have a lockout/tagout program. By following the format and filling in the blanks, you will be able to have a lockout/tagout program specific to your company that meets the requirements of OSHA. If additional help is needed, it is available from Great Tracers at 847/255-0436.

About the Author: David Blustein is an industrial hygienist working for Great Tracers, an environmental consulting firm. David has over 22 years environmental experience, 14 of which were spent working at OSHA as a compliance officer and trainer at the OSHA National Training Institute. He has served as a safety and health consultant to industry, performing internal safety and health audits, representing employers at informal hearings and assisting in compliance activities.