a) The purpose of this procedure is to establish safeguards for the protection of employees and others, to prevent the unexpected, energization or start-up of machines or equipment, or release of stored energy which could cause injury to employees or others. To ensure whenever maintenance and serving is done, that all machines or equipment are stopped, isolated from all potentially hazardous energy sources and locked and tagged out.
a) Each foreman/supervisor in charge of a job shall have the overall responsibility for the implementation and coordination of the Energy Control/Lockout-Tagout Program. Each employee has the responsibility of performing our Energy Control Procedure as set forth in our program.
a) Each employee who will be involved in the Energy Control/Lockout-Tagout Procedure shall be trained prior to performing work on any mechanical, electrical system, etc. Only employees trained in ESCO Group’s procedure, and the facility where the work is being performed, are authorized employees. Retraining will be required when there is a change in the ESCO procedures, customer procedures, job assignments, new machinery/equipment, hazards, disciplinary action utilized, or where an annual inspection indicates a gap.
b) All training will be documented and records maintained by the safety department for a minimum of three years. Records will indicate name, date of employee and trainer’s name.
c) An electrically safe work condition shall be achieved when performed in accordance with and verified by the following process:
i. Determine all possible sources of electrical supply to the specific equipment. Check applicable up-to-date drawings, diagrams, and identification tags.
ii. After properly interrupting the load current, open the disconnecting device(s) for each source.
iii. Wherever possible, visually verify that all blades of the disconnecting devices are fully open or that draw out type circuit breakers is withdrawn to the fully disconnected position.
iv. Apply lockout/tagout devices in accordance with a documented and established policy.
v. Use an adequately rated voltage detector to test each phase conductor or circuit part to verify they are de-energized. Test each phase conductor or circuit part both phase-to-phase and phase-to-ground. Before and after each test, determine that the voltage detector is operating satisfactorily.
vi. Where the possibility of induced voltages or stored electrical energy exists, ground the phase conductors or circuit parts before touching them. Where it could be reasonably anticipated that the conductors or circuit parts being de-energized could contact other exposed energized conductors or circuit parts, apply ground connecting devices rated for the available fault duty.
4. Operating Procedures
a) When ESCO Group is engaged in activities which require the use of Lockout/Tagout in customer’s facilities, the employee in charge shall conduct a meeting with the on-site employer and other outside employers to inform each other of their respective lockout/tagout procedures. This coordination meeting will be documented using ESCO Group’s Safety Acknowledgement Sheet in our Safety Manual in the Appendix 2 or on page 7 of this program.
b) ESCO Group employees will not be permitted to remove lockout tagout devices placed by customer employees or other contractor employer. If a specific Energy Control Procedure requires an ESCO Group employee to remove lockout devices owned by the customer or another contractor employer, the specific procedure must include written authorization from the customer to remove the lockout device.
c) Each piece of equipment, machinery, or other sources of energy from electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or potential energy stored in lifts, cranes, etc. must be locked and tagged out to protect all employees during servicing, employee shall follow our “Energy Control Procedure” on page 4 and 5 of this program. Please refer to ESCO Group’s Electrical Safety Work Practices Program on page DD-1 in our Safety Manual, where employees are working on or near exposed energized electrical conductors or circuits parts that are not placed in an electrical safe work condition for reasons of increased or additional hazards, or is infeasible due to the equipment design or operational limitations.
d) A complex lockout/tagout plan shall be permitted where one or more of the following exist:
i. Multiple energy sources
ii. Multiple crews
iii. Multiple crafts
iv. Multiple locations
v. Multiple employers
vi. Different disconnecting means
vii. Particular sequences
viii. A job or task that continues for more than one work period
e) In situations where multiple lockout devices are needed and multiple authorized employees are performing installation, servicing or maintenance on equipment/system, a group lockout box shall be used. An authorized employee shall print, sign and date out “Lock Box Complex Lockout/Tagout Procedure Worksheet”
f) Such authorized employee shall be a qualified individual who is specifically appointed with overall responsibility to ensure that all energy sources are under lockout/tagout and to account for all persons working on the job/task. Each employee under control of the complex lockout/tagout lock box must sign in on the bottom of our “Lock Box Complex Lockout/Tagout Procedure Worksheet” on page 6 of this program.
g) Each box will hold the keys from all the lockout devices and the employee in charge of the complex Lockout/Tagout, shall list out the following on the Lock Box Complex Lockout/Tagout Procedure Worksheet”.
i. Location of lockout devices
ii. Lock and key number
iii. Date/time of prior application notification for all persons under the control of lockbox
h) The authorized employee shall then place their personal lock on the end of the lockbox. The group lockout box is then locked with each authorized employees lock providing each employee with equivalent protection to locking each device by themselves.
i) When each employee has completed the job/task under control of the group lockout box, each employee shall initial beside their name after notification of lock removal at the bottom of our “Lockbox Complex Lockout/Tagout Procedure Worksheet”.
j) When all jobs/tasks are completed and each employee has removed their personal locks from the group lock box, and initialed the bottom of our worksheet, the employee in charge of the complex lockout/tagout procedure shall follow steps 1, 2, and 3 on page 5 of this program “Releasing Energy Controls”.
k) All check out sheets shall be retained and sent to the Safety Department.
l) Shift Change – When work must continue over a shift change, the following requirements apply:
i. Group lockout keys shall remain in the lockout box and shift ending employees shall remove their locks and on coming shift employees shall install their locks. All authorized employees shall initial the “Group Lock Box Complex Lockout/Tagout Procedure Worksheet,” that their personal locks have been removed and/or all employees shall be accounted for, before turning control over to the next shift.
ii. Shift change foreman/supervisor or person in charge of the job shall communicate the status of lockout devices by reviewing the Group Lock Box Worksheet from our Group Lock Box and complete a new “Group Lock Box Complex Lockout/Tagout Procedure Worksheet.” All equipment or systems must be locked out before foreman or supervisor makes shift change.
iii. All personal locks and tags must be removed at the end of each shift or if an employee is no longer working on the job. Replacement personnel on the next shift in which the jobs is worked, must install their personal lock as outlined in the above requirements before beginning work.
iv. No employee may remove the lock of another employee or a lock of another company’s employee.
v. When an authorized employee is not available to remove their personal lock, the following procedure must be followed:
1. If facility we are working in has a lock removal procedure, it must be followed first.
2. The foreman/supervisor will try to contact the person at work or at home to remove their lock.
3. If the person cannot be contacted, the foreman/supervisor will conduct a detailed review of the equipment or systems to determine that the removal is safe.
4. Any lock removal, shall be documented and documentation reviewed with the employee whose lock was removed, then sent to the Safety Department and filed.
m) Cargill Site Specific Complex Long Term Lockout Procedure
i. Lockouts performed for durations greater than the time an individual employee performs work on equipment will become “long term equipment maintenance” lockouts. Any lock left in place longer than one working shift will also become a “long term equipment maintenance” lockout. The lock shall be changed to the designated site specific color for “long term equipment maintenance”. This lock shall be a color other than ESCO Blue locks or client colored locks. Only one color of lock shall be utilized for “long term equipment maintenance” for each site. The lockout key is to be placed in the group key control box in the ESCO office area and is no longer the individual’s lockout, but considered a maintenance lock. 100% use of multi-person lockout (multi-hasps) required for all lockouts, including long term lockouts.
ii. Individuals must change the lock to the designated maintenance lock color and change the tag to long term maintenance equipment tag with the following description: lock applier name, date applied, key box tag number, lock key number, reason for lockout and expected completion date.
iii. Individuals must take maintenance lockout key, new “long term equipment” lockout key, to the ESCO Group office area to place in control box, assign a key tag ID number and record on the designated legend for maintenance locks.
iv. Employee servicing previously locked out equipment, “long term maintenance locks”, must attain key from key control box. They shall apply their own personal ESCO blue lock and tag prior to beginning work on locked out equipment, leaving designated color maintenance lock in place as well.
v. Employee removing “long term maintenance” lock must be trained in current site procedures and must follow steps 1-3 of “Releasing Energy Controls” found in the Energy Control Procedure in The ESCO Group Safety Manual.
vi. Employee removing “long term maintenance” lockouts shall update the legend for key control box located in the ESCO office area and return key identification tag to the proper location in the control box for future use.
*Long term maintenance lockouts: any lock that must remain on equipment longer than an individual is working on equipment (or for more than one shift) in order to keep equipment in an electrically safe position
5. Program Review and Auditing
a) The Safety Department shall review and document each year our Energy Control/Lockout Tagout Program to verify the program is being complied with, and employees can demonstrate that the training they receive is adequate.
b) The Employee Field Lockout/Tagout Verification Form will be used to document field audits.
a) Step 1 – Preparation
i. Lockout and tagout procedures should only be carried out by “authorized employees”. Before implementing the lockout/tagout procedure, you must fully understand:
1. The type and magnitude of the energy to be controlled
2. The methods of controlling the hazardous energy
3. The means of controlling the hazardous energy
b) Step 2 – Notification
i. Before the application of lockout or tagout devices, notify all affected personnel. Tell workers that the Energy Control Procedure is going to be used and the reasons why.
c) Step 3 – Shutdown
i. Shut down equipment in an orderly manner. This may simply mean to turn off the equipment. When the equipment is part of a production or manufacturing process, all parts of the operation must be considered. An orderly shutdown will avoid increase hazards when the equipment is de-energized.
d) Step 4 – Isolation
i. Locate all of the energy isolating devices. Operate the energy isolating devices so that equipment is completely isolated from the energy source.
e) Step 5 – Application of locks and tags
i. Attach locks and or tags to the energy-isolating device so the device is held in the “safe” or “off” position. Separate locks or tags must be used for each authorized employee. Applied locks and tags must contain the name of the authorized employee placing the device.
f) Step 6 – Control Stored and Residual Energy
i. Relieve, disconnect and restrain all stored or residual energy. Remember, hazardous energy can be found in springs, elevated machine members, capacitors, rotating flywheels, hydraulic systems, air, gas steam and water pressure. This energy must be dissipated or restrained. The operators and service manuals can assist you in safely controlling the specific energy hazards. Some common methods to restrain or dissipate stored energy are repositioning, blocking and bleeding down systems. Know in advance the tools and equipment needed to control each hazard. Be sure they are in proper working order and able to perform the tasks you expect of them.
g) Step 7 – Verification
i. Check to be sure that all personnel are in a safe location. Verify that the equipment is properly isolated and all hazardous energy is safely controlled. Operate push buttons and other controls to verify isolation. Check circuits with electrical meters. Inspect springs, pressure gauges, and the location of moving parts and other sources of stored energy. Return operating controls to the neutral or off position after the test. Each machine and piece of equipment is different. Follow the instructions found in the operators and service manuals. Once you are absolutely sure the energy is isolated and controlled, proceed with maintenance and service activities.
h) Step 8 – Peer Review
i. The application process will be reviewed by a second authorized employee. This review will consist of verifying the application process was executed successfully. The second authorized employee will be familiar with the energy control procedure involved and capable of performing any electrical testing needed for verification. A typical peer review may include such items as; walking the system down, reviewing single line diagrams, visual observations of applied locks and tags, visual observations of protective grounds, and/or electrical testing.
Some machinery and equipment can re-accumulate stored energy even after the system has been de-energized. If there is a possibility of stored energy building to a hazardous level, continue verification until maintenance or service is completed or until the possibility of accumulation no longer exists.
7. Releasing Energy Controls
a) Step 1 – Inspection
i. Inspect the work area. Be sure all non-essential items such as tools, parts, and cleaning supplies have been removed. Check to be sure that all machine and equipment components are ready for operation. Be certain all affected employees have been safely positioned or removed.
b) Step 2 – Notification
i. Notify all employees that the lockout/tagout devices are being removed.
c) Step 3 – Remove locks and tags
i. Remove locks and tags. The lockout or tagout devices should only be removed by the authorized employee who applied it. Inspect and remove from the area all service tools and notify employees.