POWERCARE & SERVICE SOLUTIONS, INC.
DECEMBER, 2010
FROM:
MANAGER
TO:
ALL TEAM MEMBERS
SUBJECT:
LOCKOUT/TAGOUT PROCEDURE
I. PURPOSE
The purpose of this procedure is to protect team members from unexpected release of hazardous
energy during maintenance (per OSHA Standard 1910.147). Energy in this context includes, but is
not limited to, electrical, hydraulic, pneumatic, chemical, mechanical and thermal.
This policy covers the servicing and maintenance of machines and equipment in which the
unexpected energization or start up of the machine or equipment, or release of stored energy could
cause injury to team members. This policy establishes minimum performance requirements for the
control of such hazardous energy.
This procedure defines the minimum requirements for controlling energy sources when opening or
working on any machinery, process equipment or piping system at POWERCARE & SERVICE
SOLUTIONS, INC. (PowerCare) location.
II. PROGRAM ADMINISTRATOR:
Manager of Operations has been assigned the administrative responsibility for the Lockout/Tagout
procedure.
A. GENERAL
Electrical power sources and electrically-powered equipment will be isolated before any work can be
done. All electrical powered equipment must be disconnected or electrical power source must be
removed. If circuit breakers are used to remove source, the breaker must be locked out (if possible)
and tagged. Additional checks must be made prior to working on the equipment (such as trying the
switch, voltage check to ensure no power source). Any system that has an energy source that could
be released must be blinded or piping removed prior to working on the system. A Master Isolation
Tag system is used to assure all team members assigned to work on a job understands all energy
isolation devices and their locations.
B. RESPONSIBILITIES
The OSHA Standard defines three classifications of responsibilities associated with the
lockout/tagout program. The three classifications are:
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1. Affected Team members – Team members who normally operate or use a machine or equipment
on which servicing or maintenance work is being performed under lockout or tagout, or whose job
requires them to work in an area in which such servicing or maintenance work is being performed.
For the most part, this designated team member classification represents team members at
PowerCare.
2. Authorized Team members – PowerCare team members or contract team members who require the
protection afforded by the lockout/tagout system to perform servicing of maintenance work on
machines, equipment or systems. The authorized team member classification represents supervisors,
foreman and contract maintenance. It can also be PowerCare personnel performing work on their
own equipment or anyone requiring lockout/tagout protection. A Designated Authorized Team
member may serve as the communications link with Outside contractor for permitting and energy
isolation. In this role, the Designated Authorized Team member is responsible for communicating all
pertinent information to the maintenance crew (outside contractors) for assuring that all crew
members sign-on the Master Isolation Tag before the job begins. The Designated Authorized Team
member shall assure that all crew members sign-off the Master Isolation Tag prior to returning it to
their supervisor.
See Attachment 1 for list of equipment that fall under the Lockout/Tagout procedure.
3. Other Team members – PowerCare team members or contract team members whose job may place
them in the area where machinery or equipment is under lockout/tagout. Typically, these persons
include field support staff managers who neither implement nor perform work under lockout/tagout
situations. Exceptions would include inspectors/technical support or troubleshooting during
maintenance where lockout/tagout protection is required.
Contractors are responsible for total compliance with this procedure (including training and
application). Contractors will use tags provided by PowerCare. However, they must provide their
own individually keyed locks. Each lock installed by a contractor’s team member must be marked
with the required identification (name of company, name of individual).
C. STEPS IN PERFORMING A PROPER LOCKOUT/TAGOUT
All isolation control points must be visited jointly by PowerCare and maintenance representative
(outside contractor) prior to start of job.
III. LOCKOUT/TAGOUT PROCEDURE
ALL ELECTRICAL EQUIPMENT (CIRCUIT BREAKERS, J-BOX, TRANSFORMERS,
ETC) WILL BE CHECKED WITH AN INSTRUMENT PRIOR TO TOUCHING THE
APPARATUS. – NEVER USE THE BACK OF YOUR HAND TO CHECK FOR ANY
ELECTRICAL CURRENT.
If an energy isolating device is not capable of being locked out, then PowerCare will utilize a tagout
system. If the energy isolating device is capable of being locked out,
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PowerCare will utilize lockout, unless we can demonstrate that the utilization of a tagout system will
provide full team member protection as set forth by 29 CFR 1910.147.
1. POWERCARE SERVICE & SOLUTIONS, INC. ACTIVITIES:
All team members are required to comply with the restrictions and limitations imposed upon
them during the use of lockout. The authorized team members are required to perform the
lockout in accordance with this procedure. All team members, upon observing a machine or
piece of equipment which is locked out to perform service or maintenance shall not attempt to
start, energize, or use that machine or equipment. Any team member who violates this
procedure is subject to disciplinary action.
(1) Sequence of Lockout:
Notify all affected team members that service or maintenance is required on a machine or
equipment and the machine or equipment must be shut down and locked out to perform the
service or maintenance. AFFECTED TEAM MEMBER the operator of the machine or equipment.
(2) The authorized team member shall refer to the company procedure to identify the type and
magnitude of the energy that the machine or equipment utilizes and understand the hazards of the
energy and shall know the methods to control the energy. See Attachment VI.
(3) If the machine or equipment is operating, shut down by normal stopping procedures.
Refer to the above Attachment VI.
(4) De-activate the energy isolating device(s) so that the machine or equipment is isolated from the
energy source(s).
(5) Lock out the energy isolating device(s) and tag.
(6) Stored or residual energy. Refer to III A Stored Energy of this section
(7) Ensure that the equipment is disconnected.
a. Identify all points where a hazard exist from unexpected release of energy and the isolation
points from these energy sources. All isolation points ( i.e. electrical lockouts, blinds, etc.)
must be listed on either a permit, Equipment Isolation List, or a sketch.
b. Shutdown, depressure, drain and decontaminate the equipment in preparation for the
maintenance. Utilize electrical lockout procedure as appropriate to control electrical
energy source.
c. In stall properly completed “DANGER – DO NOT REMOVE” tags on all process isolation
valves and bleeder valves previously identified.
d. When blinds are used to control energy sources, they must be tagged.
e. Verify that all pressure or other energy sources are relieved by checking appropriate
bleeders or other test points and that all electrical equipment is de-energized by testing the
switches/start button and any other test devices (all switches/buttons must be returned to
the “Neutral” or “Off” position after testing).
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f. Assure isolation integrity on all re-issued permits (if work is not completed during a shift
the next shift personnel must check to assure the team members doing the work are safe).
g. Conduct joint job visit with the craftsman or craft foreman. Review the job scope and
isolation precautions with the craftsman or foreman prior to start of work.
h. Assume that the craftsman installs lock(s) (when needed), tags, and sign on as appropriate
on the Master Isolation Tag that is posted at the job site.
i. Accept signed- off Master Isolation Tag from the craftsman or foreman at the end of work
or end of shift. When the work is completed, review all isolation points for tags or locks left
in place (should do this with an Authorized Team member or Designated Authorized
Team member).
j. Inspect job for completion and remove all PowerCare lock and tags.
k. Communicate equipment status to other Affected Team members prior to returning
equipment to service.
l. PowerCare (supervisor) shall retain and file the Master Isolation Tag when the job is
completed the Equipment Isolation List or sketch will be retained and Filed with the Master
Isolation Tag.
m. Additional Requirements (Temporarily Removal of LOTO)
(1) “Testing or positioning of machines, equipment or components thereof” in
situations in which lockout or tagout devices must be temporarily removed from
the energy isolating devices and the machine or equipment energized to test or
position the machine, equipment or component thereof, the following sequence
of actions shall be followed:
(2) Clear the machine or equipment of tools and materials. Inspect the work area to
ensure that nonessential items have been removed and to ensure that machine or
equipment components are operationally intact.
(3) Remove team members from machine or equipment area. The work area shall be
checked to ensure that all team members have been safely positioned or removed.
(4) Remove the lockout or tagout devices. Each lockout or tagout device shall be
removed from each energy isolating device by the team member who applied the
device. Exception: When the authorized team member who applied the lockout
or tagout device is not available to remove it, that device may be removed under
the direction of the job supervisor, provided that the training and procedure for
such removal is followed and the job site supervisor.
Energize and proceed with testing or positioning.
Deenergize all systems and reapply energy control measures in accordance procedure to continue
servicing and/or maintenance.
The supervisor will fill out: 1) Equipment Isolation List, 2) Master Isolation Tag, prior to starting to
work after it has been reenergized.
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A. STORED ENERGY
Following the application of lockout or tagout devices to energy isolating devices, all potentially
hazardous stored or residual energy shall be relieved, disconnected, restrained, and otherwise
rendered safe.
If there is a possibilities of re-accumulation of stored energy to a hazardous level, verification of
isolation shall be continued until the servicing of maintenance is completed, or until the possibility of
such accumulation no longer exists.
Prior to working on any PowerCare equipment the supervisor must inspect the work site and ensure
that all sources of energy are removed.
See attached list of equipment that fall under the Lockout/Tagout policy.
2. MAINTENANCE ACTIVITIES
Maintenance work by any team member (PowerCare or outside contractor) will check all isolated
energy sources prior to start of job.
a. Apply lock and/or tags.
b. Test all switches, bleeders, and other appropriate test point to assure the equipment and
machinery will not start and all energy is relieved.
c. Assure that all workers sign-on the Master Isolation Tag.
d. Perform required maintenance work on equipment.
e. Remove locks and tags (maintenance only) when job is completed.
f. All crew members must “Sign-Off” the Master Isolation Tag when the job is completed.
g. Return equipment to PowerCare.
3. GROUP LOCKOUT OR TAGOUT
Primary responsibility is vested in an authorized team member for a set number of team members
working under the protection of the group lockout or tagout device.
a. When more than one crew, craft, department, etc is involved, an authorized team member
will
be designated to coordinate affected work forces and ensure continuity of protection.
b. If more than on craft or contractor on the job site, each will apply their own lock and tag.
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A. PROPER USE OF THE EQUIPMENT ISOLATION LIST
The Equipment Isolation List is an isolation reference document which will aid the Designated
Authorized Team member and workers in understanding and locating all of the isolation points
identified by PowerCare personnel prior to signing of the Master Isolation Tag. When used, the
Equipment Isolation List will be attached and posted with the Master Isolation Tag. Upon
completion, and after all isolation devices are removed, the Equipment Isolation List shall be retained
with the Master Isolation Tag for filing. As an alternative to the Equipment Isolation List, a sketch of
the system to be isolated may be attached to the permit and Master Isolation Tag. This sketch must
include the equipment nomenclature, number (if assigned) and isolation points to control hazardous
energy sources.
B. PROPER USE OF THE MASTER ISOLATION TAG
The purpose of the Master Isolation Tag is to assure that all Authorized Team members assigned to
the job understand the isolation devices and their location. In situations where more than one permit
(contractors) is issued for the same job, a Master Isolation Tag will be issued to each contractor.
Prior to commencing work on a job, all Authorized Team members will sign the Master Isolation Tag
posted at the job site. When Authorized Team members leave the job due to re-assignment,
completion of task, or completion of the work shift, they will sign-off on the tag. Entries are not
required for breaks, lunch and etc. This tag will be returned to PowerCare when the job is completed.
C. TAGS
Tags and their means of attachment shall be substantial enough to prevent accidental or inadvertent
removal. The means of attachment should be with string or wire. The tags used for maintenance
should be a different color than PowerCare operations tag. The “DANGER-DO NOT REMOVE”
tags used by PowerCare shall be completed by PowerCare team members installing them. These tags
must be properly completed, including name of person installing tag, date, time, equipment ID, and
reason for tag.
D. LOCKOUT DEVICE
A device that utilize 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.
Lockout device shall be substantial enough to prevent removal without the use of excessive force or
unusual techniques, such as with the use of a bolt cutter or other metal cutting tools.
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E. TAGOUT DEVICE
A warning tag (weather and chemical resistant) standardized in size and color, with wording warning
of hazardous energy (Do Not Open), (Do Not Close), (Do Not Energize), (Do Not Operate). The tags
used by PowerCare shall be completed by PowerCare team members installing them. These tags
must be properly completed, including name of person installing tag, date, time, equipment ID and
reason for tag.
Tagout devices, including their means of attachment, shall be substantial enough to prevent
inadvertent or accidental removal. Tagout device attachment means shall be non-reusable type,
attachable by hand, self-locking, and non-releasable with minimum unlocking strength of no less than
50 pounds and having the general design and basic characteristics of being at least equivalent to a
one-piece, all environment-tolerant nylon cable tie.
F. TRAINING
Training for each authorized team member will be conducted to ensure that the purpose and function
of the energy control program are understood by team members and that the knowledge and skills
required for the safe application, usage, and removal of the energy controls are acquired by team
members. The training shall include the following:
(A) Each authorized team member 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.
(B) Each affected team member shall be instructed in the purpose and use of the energy
control procedure.
(C) All other team members whose work operations are or may be in an area where energy
controls 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.
(ii) When tagout systems are used, team members shall also be trained in the following
limitations of tags.
(a) 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.
(b) When a tag is attached to an energy isolating means, it is not to be removed
without authorization of the authorized person responsible for it and it is never
to be bypassed, ignored, or otherwise defeated.
(c) Tags must be legible and understandable by all authorized team members, and all other
team members whose work operations are or may be in the area, in order to be
effective.
(d) Tags and their means of attachment must be made of materials which will withstand
the environmental conditions encountered in the workplace.
(e) Tags may invoke a false sense of security, and their meaning need to be understood
as part of the overall energy control program.
(f) Tags must be securely attached to energy isolating devices so that they cannot be
inadvertently or accidentally detached during use.
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(iii) Team member retraining.
(A) Retraining shall be provided for all authorized and affected team members whenever
There is a change in their job assignments, a change in machines, equipment or
processes that present a new hazard, or when there is a change in the energy control
procedures.
(B) Additional retraining shall also be conducted whenever a periodic inspection under
paragraph 29 CFR-1910.147 (c)(6) reveals, or whenever the employer has reason to
believe, that there are deviations from or inadequacies in the team member’s
knowledge or use of the energy control procedure.
(C) The retraining shall establish team member proficiency and introduce new or revised
control methods and procedures, as necessary.
(D) PowerCare will certify that team member training has been accomplished and is being
kept up to date. The certification shall contain each team member’s name and dates
of training.
See attached list of Affected/Authorized team members.
G. PERIODIC INSPECTION
PowerCare will conduct a periodic inspection of the energy control procedure annually to ensure that
the procedure and the requirements of this standard are being followed.
(A) The periodic inspection will be conducted by the Manager or other qualified individuals.
(B) The periodic inspection shall be conducted to correct any deviations or inadequacies
identified.
(C) Where lockout is used for energy control, the periodic inspection shall include a review,
between the inspector and each authorized team member, of that team member’s
responsibilities under the energy control procedure being inspected.
(ii) PowerCare shall certify that the periodic inspections have been performed. The
certification shall identify the machine or equipped on which the energy control
procedure was being utilized, the date of inspection, the team members included in the
inspection, and the person performing the inspection.
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ATTACHMENT I
EQUIPMENT ISOLATION VERIFICATION
EQUIPMENT IDENTIFICATION_________________________________________
The current signature below verifies that the above equipment has been checked for proper isolation.
This verification must be made prior to work on the equipment.
DATE
TIME
SIGNATURE
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ATTACHMENT II
MASTER ISOLATION TAG
EQUIPMENT
DATE ______________
IDENTIFICATION_________________________ TIME_______________
JOB DESCRIPTION______________________________________________
DESIGNATED AUTHORIZED TEAM MEMBER__________________________
Your signature on this sheet verifies that you are aware of energy control devices installed, the reason
for installing them and that the devices will stay in place until all personnel sign-off.
This is a Master Isolation Tag only. PowerCare tags must be installed on all energy control devices
for this job. All personnel working on the equipment listed below will sign-on this sheet before
performing repairs and sign-off when the job is completed, upon re-assignment, or the end of the
shift.
SIGN-IN BEFORE WORK BEGINS
SIGN OFF
NAME
TIME IN
TIME OUT
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ATTACHMENT III A
LOCKOUT/TAGOUT
SITE-SPECIFIC EQUIPMENT
Site Lockout/Tagout Coordinator_____John Smith________________________________________
Site Lock/Key/Tag Coordinator_____ Sam Doe__________________________________________
Type of Machine
Manufacturer
Power
Source
Lockable or
Tag Only
Location
of Lock/Tag
__Welder__________Lincoln__________240V__________Lockable__________Circuit Breaker___
__Air Compressor___Sulair____________480V__________Lockable__________Circuit Breaker__
_________________________________________________________________________________
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EXAMPLE_____________________
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ATTACHMENT III
LOCKOUT/TAGOUT
SITE-SPECIFIC EQUIPMENT
Site Lockout/Tagout Coordinator______________________________________________________
Site Lock/ Key Tag Coordinator_______________________________________________________
Type of Machine
Manufacturer
Power Source
Lockable or
Tag Only
Location
of Lock/Tag
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ATTACHMENT IV
AUTHORIZED AND AFFECTED TEAM MEMBERS
The following team members are trained to perform the functions designated:
Affected Team members
Manager
Supervisors
Helpers
Technicians
Lead Tech
Authorized Team members:
Manager
Supervisors
Helpers
Technicians
Lead Tech
Manager of Operations is responsible for ensuring these job positions are current in training for the
assigned jobs.
Field Supervisors on the job will ensure their team members are current and demonstrate their
knowledge of Lockout/Tagout Procedure.
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ATTACHMENT V A
ANNUAL PERIODIC INSPECTION
SAMPLE
POWERCARE SERVICE & SOLUTIONS, INC. will conduct a periodic inspection of the energy
control procedure at least annually to ensure that the procedure and requirements of this standard are
being followed for machines and equipment that fall under lockout/tagout.
The periodic inspection will be conducted to correct any deviations or inadequacies identified.
PowerCare will use this form to certify that the periodic inspection has been performed.
MACHINE or EQUIPMENT;___ BORING MILL, SN 123454_____________________________
DATE OF INSPECTION: 10/12/2003__________________________________________________
TEAM MEMBERS INCLUDED INSPECTION: Sam Jones, Bill Smith, Hector
Lopez,______________
_________________________________________________________________________________
_________________________________________________________________________________
(List all affected team members)
TEAM MEMBER PERFORMING INSPECTION:__John
Smith_________________________________
INSPECTION REPORT:
_______ NO NON-CONFORMANCE
___X___ CORRECTIVE ACTION REQUIRED
___X___ ADDITIONAL TRAINING REQUIRED
___X___ WAS IMMEDIATE ACTION REQUIRED
WHAT ACTION WAS REQUIRED: Step 4 of the Lockout/Tagout procedure for this machine was
not required any more, due to equipment modification.
All affected team members were instructed of the change and a new Lockout/Tagout procedure was
posted on the machine._______________________________________________________________
_________________________________________________________________________________
DID THE INSPECTION REQUIRE THE POLICY/PROCEDURE TO BE REVISED:
__X__YES _____ NO
IF YES WHAT ACTION DID YOU DO: __New Lockout/Tagout Policy for this machine was
written and posted at the machine. All Affected and Authorized team members were
trained.__________
________________________________
(Signature of Inspector)
When complete this form will be on file for review.
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ATTACHMENT V
ANNUAL PERIODIC INSPECTION
POWERCARE & SERVICE SOLUTIONS, INC. will conduct a periodic inspection of the energy
control procedure at least annually to ensure that the procedure and requirements of this standard are
being followed for machines and equipment that fall under lockout/tagout.
The periodic inspection will be conducted to correct any deviations or inadequacies identified.
PowerCare will use this form to certify that the periodic inspection has been performed.
MACHINE or EQUIPMENT:_________________________________________________________
DATE OF INSPECTION:____________________________________________________________
TEAM MEMBERS INCLUDED IN
INSPECTION:___________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
(List all affected team members)
TEAM MEMBER PERFORMING
INSPECTION:____________________________________________
INSPECTION REPORT:
_____ NO NON-CONFORMANCE
_____ CORRECTIVE ACTION REQUIRED
_____ ADDITIONAL TRAINING REQUIRED
_____WAS IMMEDIATE ACTION REQUIRED
WHAT ACTION WAS
REQUIRED:______________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
DID THE INSPECTION REQUIRE THE POLICY/PROCEDURE TO BE REVISED:
_____YES _____ NO IF YES WHAT ACTION DID YOU _______________________________
_________________________________________________________________________________
______________________________________
(Signature of Inspector)
When completed this form will be on file for review.
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ATTACHMENT VI
POWERCARE & SERVICE SOLUTIONS, INC.
DECEMBER, 2006
FROM:
MANAGER
TO:
MACHINIST
SUBJECT: LOCKOUT/TAGOUT FOR LATHES
PURPOSE:
The purpose of this procedure is to ensure all lathes are lockout and tagout prior to any maintenance
being performed. The procedure will cover all potential energy sources.
PROCEDURE:
1. Shut off switch (at machine).
2. Throw switch on circuit breaker (this will open the circuit).
3. Install lockout device, and install your lock.
4. Tagout the circuit with "Do Not Operate" tag. Make sure you fill out the tag and sign your name.
5. Try the "ON/OFF" switch on the lathe to make sure it will not operate.
6. Unplug any electrical accessory attached to the machine.
7. Turn off air line valve and disconnect the quick release air connection.
8. Tag the air connection after you have disconnected the air line.
9. Issue work permit.
10. Inform the maintenance person about the coolant oil in the sump, and any other hazard that may
be present.
11. When all maintenance is completed check the lathe to insure all guards and other parts have been
replaced. Make sure all maintenance tags and locks have been removed. Check to see the
"ON/OFF" switch is in the off position.
12. Connect air quick connection, remove tag, warn anyone around the lathe to move back, unlock
circuit breaker, remove tag, and close the breaker switch.
13. Bump test the lathe, to ensure the correct rotation.
14. The lathe is ready for operation
15. Turn in any forms to your supervisor.
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EXAMPLE
LOCKOUT PROCEDURE FOR A LATHE.
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