LOCK AND TAG PROGRAM FOR THE CONTROL OF HAZARDOUS ENERGY

1
LOCK AND TAG PROGRAM FOR THE CONTROL OF HAZARDOUS
ENERGY

• (Version August 99)
• INSTRUCTOR
• Tom Tamshen
• Certified Safety Professional
• Risk Management Department

2
OUTLINE

• Training file on CD Rom
• Introduction
• Video
• LT Program
• General (1-4)
• Procedures ELP, GLP (5-7)
• Additional requirements and hardware (8-9)
• Training inspection (10, 11)
• Caution tags (12)
• Documentation (13-15)
• Most Frequently asked questions
• Quiz

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INTRODUCTION

• What is Lock and Tag Program?
• Program consists of
• Basic rules
• General Lock and Tag Procedure (GLP)
• Guide for making Equipment Specific Lock and Tag
  Procedure.
• Training and Inspection Requirements.
• Caution Tags.

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INTRODUCTION
What is NOT included?

• The program does not include Equipment Specific
  LT Procedures. The departments have to prepare
  them for their equipment and train the authorized
  employee. All LT procedures must be submitted
  to Safety for review.

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SCOPE (1)

• Covered
• Locking out of all hazardous energy sources such
  as electrical, mechanical, hydraulic, pneumatic,
  chemical, or thermal.

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SCOPE (1)

• Not covered (1.2)
• Operation locks
• PPS locks to prevent operation
• Locks to block entry
• Locks for administrative control
• Construction
• Permanently disconnected

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APPLICABILITY
OSHA Required by OSHA as follows - 1910.147
(covers all Hazardous. Energy sources) - 1910.33
3 (covers electrical only) This is for personnel
safety and not an operational lock out.
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APPLICABILITY (2)

• Site-wide (all OTC)
• 50 V and above
• Below 50 V if hazardous
• Moving/rotating equipment
• Service and Maintenance (includes modifications,
  etc.) of any system involving hazardous energy.

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EXCEPTIONS (3)

• Energized Circuits (3.1)
• 3.1 May work on energized circuits without lock
  and tag provided
• Safe work practices (OSHA Subpart S)
• AND approval obtained
• AND safety watch provided (Chapter 8)

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EXCEPTIONS (Contd)

• And only in following situations
• Increases hazard (fire protection, life support,
  etc.),
• Or infeasible,
• Or testing which requires energizing.

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EXCEPTIONS (Contd)
HOT TAP OPERATIONS (3.2) See manual.
12
EXCEPTIONS (Contd)
CORD AND PLUG (3.4) If the plug is in exclusive
control of the worker, no LT required. Use plug
hugger or lock-a-plug device, if not in sight or
in arms reach.
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INTERLOCKS
RESTRICTION ON INTERLOCKS (4) Interlocks not to
be used in place of lock and tag on the energy
source as per OSHA.
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ACRONYMS

• Refer to Appendix C.
• CLL Crew Lockout Leader
• ELC Equipment (specific) Lockout
  Coordinator
• ELP Equipment Lock and Tag Procedure
• GLP General Lock and Tag Procedure

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LOCK TAG PROCEDURES (5)
Two types of equipment 1) Equipment which needs
ELP. ELP Equipment (specific) Lock and Tag
Procedure. Note All equipment needs ELP unless
meets exceptions (See 6.3) 2) Equipment which
needs GLP. GLP General Lock and Tag
Procedure. If Equipment meets exceptions (see
6.3) ELP is not required. Use GLP.
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ELP (6)
Similar equipment may be covered by a single
procedure. RESPONSIBILITY (6.1) Dept. or shop in
control of the equipment is responsible for ELP.
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ELP (6)
PREPARATION OF ELP (6.2) STEP 1 Make
inventory STEP 2 Fill out forms for each
equip. 1. Equip. identification 2. Controls 3.
Energy Sources 4. Shutdown verify 5. Release
from LT 6. List Authorized affected
employees 7. Title sheet, approval, etc.
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ELP (Contd)
Which equipment needs ELP? ALL except those which
meet all 8 exceptions (6.3) 1. No stored
energy 2. Single energy source, readily
identified and isolated. 3. Lockout will
completely deactivate machine. 4. Machine
remains isolated. 5. A single lockout will do
it. 6. In exclusive control of the worker. 7.
No hazard for other personnel. 8. No accident in
the past. (All above are as per OSHA)
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GLP (7)
Which equipment may be locked out by GLP? - Meets
exceptions (6.3) - And does not have
ELP. Responsibility Dept. or Shop in control of
equipment is responsible for checking the
equipment for exceptions (7.1).
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GLP (7)
GLP STEPS FOR APPLICATION Check - are you
authorized for the equip? If yes, proceed. STEP
1 Prepare and notify. STEP 2 Shutdown use
normal procedure. STEP 3 Isolate from energy
source. (note interlock is not a substitute
for LT) STEP 4 Apply lock and dated tag.
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GLP (7) (Contd)
STEP 5 Verification of isolation. Electrical
1) Verify it cannot be started. 2) Check
voltage, by a qualified person. Non-electrical
Verify machine is isolated and deenergized. STEP
6 Keep lock and tag on till finished. Every
person must have his/her lock and tag
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GLP (Contd)
RELEASE FROM LOCKOUT (7.3) When finished, do the
following STEP 1 Clear personnel and
tools. STEP 2 Check for mechanical hazards. STEP
3 Notify operators and affected
employees. STEP 4 Remove your own lock and
tag. (To remove other persons lock, see
section 8.6)
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ADDITIONAL REQUIREMENTS (8)
SHIFT OR PERSONNEL CHANGE (8.1) Supervisors lock
may be used as a bridge lock. Exchange locks at
shift change. Continuity of protection is
essential. GROUP LOCKOUT (8.2/8.3) One crew
versus multiple crews.
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ADDITIONAL REQUIREMENTS (8)
GROUP L/O FOR ONE CREW (8.2) Choice - Each
employee applies LT or use this procedure as a
short cut. STEP 1 Lockout by an Authorized
Employee. STEP 2 Select a CLL. CLL shall (CLL
Crew Lockout Leader must be part of
crew) 1) Apply personal Lock/Tag. 2) Verify
isolation.
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ADDITIONAL REQUIREMENTS (8)
3) Each worker applies his/her personal tag
(lock is not necessary). 4) Each worker removes
his/her tag when done and safe. 5) CLL
removes LT last. Follows appropriate release
procedure. E.g., check for clearance of
tools, etc.
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ADDITIONAL REQUIREMENTS (Contd)
GROUP L/O FOR MULTIPLE CREWS (8.3) Select a CLL
and a ELC (ELC Equipment Lockout
Coordinator) ELC is typically an Area Manager or
a Supervisor. He does not have to be in crew.
(Remember, CLL must be a member of crew).
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ADDITIONAL REQUIREMENTS (Contd)
ELC does the following STEP 1 Applies LT to
Equip. or Lock Box. Use experts as
necessary. STEP 2 Coordinates CLLs. STEP 3 When
finished, removes LT last after thorough
checkout.
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ADDITIONAL REQUIREMENTS (Contd)
If already locked out (8.4) You must apply your
personal lock and tag in addition to existing
lockout after notifying the owner of existing
lockout. ENERGIZING FOR TESTING, ETC. (8.5) STEP
1 Remove LT, use appropriate release
procedure. STEP 2 After testing, reapply LT.
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ADDITIONAL REQUIREMENTS (Contd)
UNLOCING BY OTHERS (8.6) Only if A. Authorized
by the owner of the LT, OR B. In absence of
the owner, use 5 steps 1) Verify not on site
2) Try to contact 3) Record 4) Safe? 5)
Inform owner when he comes back to site for
his/her safety (Very Very Important)
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ADDITIONAL REQUIREMENTS (Contd)
CONTRACTOR PERSONNEL (8.7) Contractor uses
his/her Procedures. Affected employees shall be
informed. Contract personnel supervised by
USOC Project Manager.
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ADDITIONAL REQUIREMENTS (Contd)
IF NOT LOCKABLE (8.8) Use additional safety
measures. 7 choices (see 8.8) such as LT
Upstream (if practical). Remove fuse or
disconnect (tag wires). Operate two breakers in
series. Remove valve handle. Blank or blind
pipe line or duct. Block or lock a control
switch. Post a safety guard.
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ADDITIONAL REQUIREMENTS (Contd)
NEW EQUIPMENT (8.9) Must be lockable as per
OSHA. VERIFICATION OF ISOLATION
(8.10) ELECTRICAL 1) check, cannot
start. 2) check voltage. NON ELECTRICAL
check deenergized.
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ADDITIONAL REQUIREMENTS (Contd)
STORED ENERGY (8.11) ELECTRICAL Ground and short
capacitors. Restrain from reenergizing. NON
ELECTRICAL Relieve, restrain or disconnect to
make it safe.
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LOCK AND TAG DEVICES (9)
PADLOCKS (9.1) Use only designated RED
lock 1) Identify lock 2) Must attach a
tag 3) Dept. may keep a duplicate
Key. 4) Exclusive for Energy Lockout use.
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LOCK AND TAG DEVICES (9)
TAGS (9.3) Two types of tags 1. Personal
Tag 2. Special Tag - supervisor tag, ELC tag,
shop tag
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LOCK AND TAG DEVICES (9)
TAGS SHALL BE 1) Only designated photo
tags 2) Place photo 3) Laminate to protect from
environment. 4) Front Name, dept., phone,
pager. Back Date, equipment affected. 5) Numbere
d to help you manage your tags. 6) Exclusive for
energy lockout. 7) Attach by cable tie, 50 pounds
rule. May apply directly on lock.
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LOCK AND TAG DEVICES (9)
SPECIAL TAGS To be used as 1) ELC or Supervisor
Tag 2) Group (Shop/Dept) Tag ELC or Supervisor
Tag Front - Identify ELC or Supervisor. - Name,
Dept., phone/pager. Back - Date, affected
equipment.
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LOCK AND TAG DEVICES (9)
Group Tag Front - Name of Group/Shop/ Dept
Phone/Pager of the Group Back - Date,
affected equipment. Signed by the person who
applies it. See Appendix A for sample.
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Tag A illustrates a personal tag to be used by
individuals. Tag B illustrates a special tag to
be used as Supervisor or Equipment Lockout
Coordinator (ELC) tag. Group, shop, or
department tag.
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Appendix A Tags
Tags shall include the following minimal
information Personal Tag Front Name,
department, phone and/or pager
number. Back Write the date of application and
identification of affected equipment or
circuit.
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Appendix A Tags
Special Tag Front ELC or Supervisor Tag - Write
the words Equipment Lockout Coordinator or
Supervisor (as applicable) I the area marked
with a dotted box. Additionally, write the
name, department, phone and/or pager number of
the ELC or supervisor. Back Write the date of
application of affected equipment or circuit.
The group/shop/department department tag shall
be signed by the person who applies it.
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Training (10)
RESPONSIBILITY The supervisor of the
employee PURPOSE (10.2) - Provide skill and
uniformity in application. - Regulatory
requirement by OSHA.
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Training (10)
TYPES OF TRAINING (10.3) - Authorized - Affected
- Other TRAINING IN LIMITATION OF TAGS
(10.4) 1. Warning devices only 2. Do not remove
except your own. 3. Must be legible.
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Training (Contd)
TIMING OF TRAINING (10.5) Affected and other -
time of orientation Authorized - prior to use of
LT. For new hires, supervisor. May give informal
training to start. Formal training within 3
months. RETRAINING (10.6) Required if - Change
in job assignment or equipment with new
hazards. - Change in procedures. - Inadequacies
found.
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Training (Contd)
TRAINING RECORD (10.7) Supervisor shall maintain
the record of training. TRAINING IN ELPs This
training is a basic training or LT program
training. One must have training in ELPs as
needed, provided by department.