Control of Hazardous Energy (Lockout/Tagout) --- 29 CFR 1910



HAZARDOUS ENERGY CONTROL (LOCKOUT / TAGOUT) PROGRAMUNIVERSITY OF WASHINGTON – DEPARTMENT SPECIFIC PROGRAMDepartment: School of FORMTEXT ?????, FORMTEXT ????? ShopLocation: FORMTEXT ?????Date Prepared: FORMTEXT ?????TABLE OF CONTENTSPurpose Scope Responsibility Basic Lockout Principles Training Lockout Procedures Program Inspection and Review Outside Contractors ATTACHMENTSTraining Record Lockout Equipment Listing Lockout Program Inspection Annual Lockout/Tagout Administrative Review Lockout/Tagout Schedule Authorized Employee Training Certificate Authorized Employee Annual CertificationPURPOSEThe purpose of this program is to protect employees of the University of Washington School of FORMTEXT ?????Shop from injuries while servicing and maintaining equipment. SCOPE The program establishes requirements for hazardous energy control. It is to be used to ensure that machines and equipment are isolated from all potentially hazardous energy sources whenever servicing or maintenance activities are in progress. RESPONSIBILITY FORMTEXT ?????, Shop Manager, is designated as the Program Coordinator for this Shop. Specific responsibilities include: Provide Hazardous Energy Control training to employees. Maintain a current listing of employees who have completed lockout training. Maintain a current list of all equipment/machines that fall under the Hazardous Energy Control program. Listing is to be updated each time a change occurs. Implement and enforce this program. Maintain an adequate supply of padlocks and DANGER tags for use each time a lockout process is performed. Padlocks are located (location where locks are stored). Conduct the annual inspection and review as required by section VII.Each supervisor is responsible for the effective use of this program in the work group and to see that all required procedures are followed in every instance. Each employee is responsible for learning and following the procedures and practices developed under this program. Notify the Program Coordinator prior to a lockout process. BASIC LOCKOUT PRINCIPLESAll equipment must be locked out to protect against accidental or inadvertent operation, when operation could cause injury to personnel. Locks are to be applied and removed only by the authorized employee who is performing the servicing or maintenance. No one should attempt to operate locked-out equipment. Disciplinary action will be applied if any employee violates these procedures, regardless of whether or not physical harm or equipment damage results. Lockout devices (padlocks) with an appropriate DANGER warning tag shall be used only for energy control. Prior to the servicing or maintenance of equipment a padlock and DANGER warning tag will be obtained from the Program Coordinator. Each padlock will be keyed differently with no master key or duplicate keys available. TRAINING Each authorized employee will be trained 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. Each affected employee shall be instructed in the purpose and use of the energy control procedure.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 the standard. All other employees who do not work in areas where lockout may be used will be provided a brief overview of the lockout program. Training in lockout will be given to all new employees as a part of their orientation. Retraining will be conducted whenever there is a change in job assignment, a change in machinery or equipment or process change that presents a new hazard. Training records will be kept for all employees covered under the standard.LOCKOUT PROCEDURESSEQUENCE OF LOCKOUT: The following are specific procedures to be followed for lockout.Notify the Program Coordinator FORMTEXT ?????, Shop Manager, Phone: FORMTEXT ?????. Notify all affected employees that lockout is going to be utilized, and the reason why. If the machine/equipment is in operation, shut it down by the normal shutdown procedure. Operate the appropriate switch, valve, etc., so that the machine/equipment is isolated from the energy source. Lock the energy isolating devices, using assigned locks and danger tags. Release, restrain, or dissipate any stored energy. Verify that energy isolation is complete, by attempting to start the affected machinery or equipment in the normal manner. After testing, return all operation controls to the "neutral" or "off" positions.RESTORATION TO NORMAL: After service or maintenance is complete, check the area to ensure that no employees are exposed. Remove all tools and repair equipment. Ensure that all guards have been replaced and all safety interlocks reactivated (if so equipped). Verify that the operating controls are in the "off" or neutral position. Remove all lockout and tag devices and activate the energy isolation devices to restore energy.PROGRAM INSPECTION AND REVIEW At least annually, the Program Coordinator will verify the effectiveness of the energy control procedures. These inspections shall provide for a demonstration of the procedures and may be carried out through random audits and observations. The inspector will review the Hazardous Energy Control Procedure with all authorized employees and actually observe the use of the procedure. This inspection will be certified and documented by the inspector using a Hazardous Energy Control Lockout Procedure Inspection Review Form (Appendix B).These inspections are to ensure that the energy control procedures are being properly used and to provide a check on the continued adherence to the procedures. (Name of person or title) will certify that the prescribed inspections have been performed. Any deficiencies will be corrected immediately, either by modification of the procedure, retraining of employees, or a combination of both. Annual Lockout/Tagout Program Review Form (Appendix C).OUTSIDE CONTRACTORS Outside personnel or contractors involved in lockout of equipment or machinery that affects our employees must submit their energy control procedures, in writing, to the Program Coordinator. All affected employees must be trained in and familiar with the contractor's submitted procedure. In order to protect our employees, the contractor's work area will be isolated, and access by our employees will be restricted. If this is impractical or cannot be accomplished, the Program Coordinator must assure the contractor's compliance with proper work procedures, energy isolation procedures and contractor employee compliance. Contractors failing to adhere to the provisions of the OSHA Hazardous Energy Control standard will be asked to terminate their work until their program is brought into compliance. Appendix A:Inventory of Equipment for Lockout/TagoutEquipment NameEnergy SourcesControl MechanismsEnergy Isolating DevicesAppendix B:Equipment Specific Energy Control ProceduresSample Lockout ProcedureInstructionsUse with Lockout/Tagout (Control of Hazardous Energy), Chapter 296-803 WACThe following sample lockout procedure contains the minimum information necessary to help you develop an energy control procedure that meets the requirements of Lockout/Tagout (Control of Hazardous Energy), Chapter 296-803 WAC. Complex systems may require you to develop, document, and use more comprehensive procedures. You can use this fill-in-the-blank template, or develop your own form. Note:If you develop your own form, remember to include the necessary information from this template. Fill-in-the-Blank TemplateSCOPE: This lockout procedure is for: Department Name if you only use a single procedure (one machine or type of machine) OrSpecific machine or equipment that this procedure applies to, if you use multiple procedures. For additional information, see WAC 296-803-20005) _______________________________________________________________________________________________________________________________________________________________________________________PURPOSE:This procedure establishes the minimum requirements necessary to protect employees from injury caused by the unexpected energization, start up, or release of stored energy during service or maintenance. Use this procedure to make sure the machine or equipment is stopped, isolated from all potentially hazardous energy sources, and locked out before any employee begins work. AUTHORIZATION: The following persons are authorized to lock out the machine or equipment using this procedure: (List the names of authorized employees you want to use this procedure) _______________________________________________________________________________________________________________________________________________________________________________________COMPLIANCE WITH THIS PROGRAM:All employees are required to comply with the restrictions and limitations imposed upon them during the use of lockout. Authorized employees will perform lockout as described in this procedure. No employee will attempt to start, energize or use any machine or equipment that is locked out.Failure to comply with this procedure will result in the following action:(List the actions that will be taken if employees violate the procedure) ____________________________________________________________________________________________________________________________________________________________________________________INTENDED USE:This procedure will be used for the following service or maintenance actions:(List the service and maintenance activities that require using the procedure)____________________________________________________________________________________________________________________________________________________________________________________SPECIFIC PROCEDURAL STEPS:Step 1:The authorized employee will identify the type and magnitude of the energy that the machine or equipment uses, understand the hazards of the energy, and the methods to control the energy before using this procedure. (List the type and magnitude of the energy, its hazards, and the methods to control the energy. For additional information, see WAC 296-803-50010)____________________________________________________________________________________________________________________________________________________________________________________Step 2:Notify all affected employees that the machine or equipment is to be shut down and locked out for service or maintenance. (List the names or job titles of affected employees and how to notify them. For additional information, see WAC 296-803-50010)____________________________________________________________________________________________________________________________________________________________________________________Step 3:Shut down the machine or equipment by the normal stopping procedure (such as depressing a stop button, opening switches, or closing valves). (List types and locations of machine or equipment operating controls. For additional information, see WAC 296-803-50010) ____________________________________________________________________________________________________________________________________________________________________________________Step 4:Completely isolate the machine or equipment from its energy sources by using the appropriate energy-isolating devices. (List types and locations of energy isolating devices. For additional information, see WAC 296-803-50010)________________________________________________________________________________________________________________________SPECIFIC PROCEDURAL STEPS: (continued)Step 5:Lock out the energy isolating devices with assigned individual locks. (List any additional procedural requirements, such as putting on a tag with amplifying information, necessary for the authorized employee to know. For additional information, see WAC 296-803-50010)____________________________________________________________________________________________________________________________________________________________________________________Step 6:Dissipate or restrain stored and residual energy, such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, using methods such as grounding, repositioning, blocking, or bleeding down. (List the types of stored and residual energy and the methods to dissipate or restrain them. For additional information, see WAC 296-803-50025)____________________________________________________________________________________________________________________________________________________________________________________(List any actions necessary to prevent stored energy from accumulating to a hazardous level. For additional information, see WAC 296-803-50025)____________________________________________________________________________________________________________________________________________________________________________________Step 7:Make sure the equipment is disconnected from the energy sources and stored and residual energy has been made safe. Check that no personnel are exposed, then verify the isolation of the equipment by doing the following: (List the method of verifying machine or equipment isolation, such as operating the push button or other normal operating controls or by testing to make certain the equipment will not operate. For additional information, see WAC 296-803-5003)____________________________________________________________________________________________________________________________________________________________________________________CAUTION: Return the operating controls to the safe, neutral, or off position, after verifying the equipment is isolated from its energy sources.THE MACHINE OR EQUIPMENT IS NOW LOCKED OUTRestore the machine or equipment to service after the service or maintenance is completed and the machine or equipment is ready to return to its normal operating condition by doing the following steps: (For additional information, see WAC 296-803-50035)Step 1:Check the machine or equipment and the immediate area around it to make sure all nonessential items have been removed and that the machine or equipment is in operating condition and ready to energize.Step 2:Make sure all employees are safely positioned for starting or energizing the machine or equipment.Step 3:Verify that the controls are in neutral.Step 4:Remove the lockout devices and reenergize the machine or equipment.Note: Some forms of blocking may require re-energization of the machine before they can be safely removed.Step 5:Notify affected employees that the servicing or maintenance is completed and the machine or equipment is ready to use. Appendix C:Lockout/Tagout Inspection Procedure Review FormNote to employers: Use this form to document an inspection of a written lockout or tagout procedure.Department: FORMTEXT ????? Equipment type and serial number: FORMTEXT ?????Inspection conducted by: FORMTEXT ?????Equipment location: FORMTEXT ?????Inspection date: FORMTEXT ?????List authorized employees using this procedure. Has the employee been trained in the procedure?Employee name: FORMTEXT ????? FORMCHECKBOX Yes FORMCHECKBOX NoEmployee name: FORMTEXT ????? FORMCHECKBOX Yes FORMCHECKBOX NoEmployee name: FORMTEXT ????? FORMCHECKBOX Yes FORMCHECKBOX NoEmployee name: FORMTEXT ????? FORMCHECKBOX Yes FORMCHECKBOX NoDo authorized employees know the location of the written procedure? FORMCHECKBOX Yes FORMCHECKBOX NoDo authorized employees have access to the procedure? FORMCHECKBOX Yes FORMCHECKBOX NoAre affected employees notified when the procedure is being used? FORMCHECKBOX Yes FORMCHECKBOX NoHave affected employees been trained to recognize when the procedure is being used and instructed not to remove lockout/tagout devices or start de-energized equipment? FORMCHECKBOX Yes FORMCHECKBOX NoCan energy-isolating devices be locked out? Note: When you replace, renovate, or modify machines and equipment, ensure that the energy-isolating devices will accept lockout devices. New equipment and equipment renovated or modified after January 2, 1990, must be capable of being locked out. FORMCHECKBOX Yes FORMCHECKBOX NoDid each authorized employee lock out all energy sources? FORMCHECKBOX Yes FORMCHECKBOX NoDoes this procedure involve group lockout/tagout? FORMCHECKBOX Yes FORMCHECKBOX NoDid the authorized employees verify that the equipment was de-energized? FORMCHECKBOX Yes FORMCHECKBOX NoDid the authorized employees follow the lockout/tagout procedure? FORMCHECKBOX Yes FORMCHECKBOX NoDoes the lockout/tagout procedure adequately protect employees? FORMCHECKBOX Yes FORMCHECKBOX NoIf not, list and describe the deficiencies requiring corrective action. FORMTEXT ????? FORMTEXT ????? FORMTEXT ????? FORMTEXT ????? FORMTEXT ?????If this is a lockout procedure, did the inspector review with all authorized and employees their responsibilities under the procedure? Note: A review can be accomplished by meeting with employees individually or in a group. FORMCHECKBOX Yes FORMCHECKBOX No FORMCHECKBOX Not applicable FORMCHECKBOX If this is a tagout procedure, did the inspector review with all authorized and affected employees their responsibilities under the procedure? Note: A review can be accomplished by meeting with employees individually or in a group. FORMCHECKBOX Yes FORMCHECKBOX No FORMCHECKBOX Not applicable FORMCHECKBOX Appendix D:Lockout - Tagout (LOTO) Program ReviewAnnual Review and Training Assessment ChecklistDepartment:Shop:Location:Equipment: YesNoA) Has there been a change in job assignments, machines, equipment or processes?B) If so, have employees been re-trained when job assignments, machines, equipment or processes have changed? Are the locks uniquely identified, uniquely keyed, and only used for the purpose of LOTO?Does the tag used with the lock identify the worker servicing the machine or equipment?Has equipment and machine-specific LOTO procedures been documented in writing?Does the employee know where the written LOTO procedures are located?Does the employee notify affected employees and all other employees in the area before starting the LOTO procedure?Can the employee identify all hazardous energy sources and associated hazards for the equipment or machine to be locked out? Does the employee follow the proper LOTO procedures for de-energizing the equipment or machine?Does the employee demonstrate the proper steps for the placement, removal and transfer of LOTO devices?Does the employee use the proper methods to verify the equipment or machine was de-energized? Before releasing the machine or equipment from LOTO, does the employee do the following:Inspect the machine or equipment to ensure it is operationally intact? Ensure that all employees are safely positioned?C) Notify affected employees and all other employees in the area that the LOTO devices have been removed?If you answered “No” to questions 2-11, has the employee been re-trained?Appendix C:Lockout - Tagout (LOTO) Program ReviewAuthorized Employees Observed(Print Name, Job Title and Employee ID)NAMEJob TitleEID Deficiencies Observed & Corrective Actions:Reviewed By: Job Title: ________________ Date Reviewed: ................
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