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ITHACA COLLEGE

LOCKOUT/TAGOUT PROGRAM

Prepared By:

Office of Public Safety

Environmental Health & Safety

Rev.: July 2010

Table of Contents Table of Contents ...................................................................................................................................... 1

1.0 Purpose ......................................................................................................................................... 2

2.0 Policy ............................................................................................................................................. 3

3.0 Definitions .................................................................................................................................... 4

4.0 Applicable Equipment & Machinery ............................................................................................ 6

4.1 Energy Hazards .............................................................................................................................. 6

5.0 Energy Control Program ............................................................................................................... 7

5.1 General Rules for Lockout/Tagout ................................................................................................ 7

5.2 Lockout/Tagout Procedures .......................................................................................................... 7

5.2.1 Department-Specific Procedures .......................................................................................... 8

5.2.2 Cord and Plug Equipment ..................................................................................................... 9

5.2.3 Tagout-Only Procedures ....................................................................................................... 9

5.2.3.1 Re-Energizing for Testing/Troubleshooting ........................................................................ 10

5.2.4 Employee Notification............................................................................................................. 10

5.3 Restoring Equipment/Machinery to Service ............................................................................... 10

5.4 Lockout/Tagout Hardware .......................................................................................................... 11

5.4.1 Assignment of Lockout/Tagout Hardware .......................................................................... 11

5.5 Contractors ................................................................................................................................. 12

5.6 Group Lockout/Tagout ................................................................................................................ 12

5.6.1 Shift & Personnel Changes .................................................................................................. 12

5.7 Removal of lockout/Tagout Devices ........................................................................................... 13

6.0 Employee Training ...................................................................................................................... 14

6.1 Authorized Employees ................................................................................................................ 14

6.2 Affected Employees .................................................................................................................... 14

6.3 Tagout Training ........................................................................................................................... 14

7.0 Periodic Inspections ................................................................................................................... 15

Appendices

Appendix

A OSHA Lockout/Tagout Standard (29 CFR 1910.147)

B Lockout/Tagout Procedures Template Form

C Department-Specific Lockout/Tagout Procedures

D Affected Employee Lockout/Tagout Device Removal Notification Form

E Ithaca College Lockout/Tagout Training Program

F Lockout/Tagout Annual Review & Periodic Inspection Forms

1.0 Purpose

The Ithaca College Lockout/Tagout Program is intended to establish procedures for isolation of

potentially hazardous energy sources to prevent injuries to employees engaged in service or

maintenance activities associated with machines, equipment, or other systems where the

unexpected start-up could cause personal injury. This program is designed to meet the criteria

specified by the federal Occupational Health and Safety Administration (OSHA) Lockout/Tagout

Standard – 29 CFR Part 1910.147 (Appendix A) for protection Ithaca College workers against

hazardous energy sources

2.0 Policy

All machines, equipment, and other systems with potentially hazardous electrical, hydraulic,

pneumatic, chemical, thermal, and mechanical energy, shall be properly isolated using specific

lockout/tagout procedures to prevent unexpected energization that could lead to human injury.

Where lockout is not possible, energy sources may be tagged out-of-service or otherwise made

inoperable to protect against possible operation that could cause personal injury. Employees

must never attempt to operate any switch, valve, or other energy control device that is locked

and/or tagged out.

3.0 Definitions

This section contains a list of OSHA definitions of terms referenced throughout the Ithaca

College Lockout/Tagout Program.

"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 this section.

"Capable of being locked out." An energy isolating device is capable of being locked out if it

has a hasp or other means of attachment to which, or through which, a lock can be affixed, or it

has a locking mechanism built into it. Other energy isolating devices are capable of being locked

out, if lockout can be achieved without the need to dismantle, rebuild, or replace the energy

isolating device or permanently alter its energy control capability.

"Energized." Connected to an energy source or containing residual or stored energy.

"Energy isolating device." A mechanical device that physically prevents the transmission or

release of energy, including but not limited to the following: A manually operated electrical

circuit breaker, a disconnect switch, a manually operated switch by which the conductors of a

circuit can be disconnected from all ungrounded supply conductors and, in addition, no pole can

be operated independently; a line valve; a block; and any similar device used to block or isolate

energy. Push buttons, selector switches and other control circuit type devices are not energy

isolating devices.

"Energy source." Any source of electrical, mechanical, hydraulic, pneumatic, chemical,

thermal, or other energy.

"Hot tap." A procedure used in the repair, maintenance and service activities that involves

welding on a piece of equipment (pipelines, vessels or tanks) under pressure, in order to install

connections or appurtenances. It is commonly used to replace or add sections of pipeline without

the interruption of service for air, gas, water, steam, and petrochemical distribution systems.

"Lockout." The placement of a lockout device on an energy isolating device, in accordance with

an established procedure, ensuring that the energy isolating device and the equipment being

controlled cannot be operated until the lockout device is removed.

"Lockout device." A device that utilizes 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.

"Normal production operations." The utilization of a machine or equipment to perform its

intended production function.

“Qualified person.” An employee who has training in avoiding the electrical hazards of

working on or near exposed energized circuits.

"Servicing and/or maintenance." Workplace activities such as constructing, installing, setting

up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment.

These activities include lubrication, cleaning or unjamming of machines or equipment and

making adjustments or tool changes, where the employee may be exposed to the unexpected

energization or startup of the equipment or release of hazardous energy.

"Setting up." Any work performed to prepare a machine or equipment to perform its normal

production operation.

"Tagout." The placement of a tagout device on an energy isolating device, in accordance with

an established procedure, to indicate that the energy isolating device and the equipment being

controlled may not be operated until the tagout device is removed.

"Tagout device." A prominent warning device, such as a tag and a means of attachment, which

can be securely fastened to an energy isolating device in accordance with an established

procedure, to indicate that the energy isolating device and the equipment being controlled may

not be operated until the tagout device is removed.

4.0 Applicable Equipment & Machinery

Lockout/tagout procedures must be followed for any equipment, machinery, or other system

where its unexpected start-up or other energization could cause personal injury. Any machine,

equipment, or other system with potentially hazardous electrical, hydraulic, pneumatic, chemical,

thermal, and mechanical energy, that could cause personal injury due to unexpected energization

is subject to the Ithaca College Lockout/Tagout Program.

Lockout/tagout procedures do not apply to minor service and maintenance such as lubrication,

cleaning, minor adjustments, etc., except when an employee is required to place any part of

his/her body into an area on a machine or piece of equipment where work is actually performed

on materials (i.e., point of operation) or where an associated danger zone exists during a machine

operating cycle.

Below is a partial list of the types of machinery and equipment at Ithaca College that require

lockout/tagout prior to maintenance and servicing. The list is not all-inclusive, but is intended to

provide the user with an understanding of the general types of machines and equipment that

typically require energy control procedures before maintenance and servicing activities can

safely be performed by Ithaca College employees and/or contractors.

Air Handling Units

Automotive Lifts

Boilers and their controls

Capacitors

Circuit breaker panels

Duplicating Center Machines

Elevators

Fans

Fire Alarm Panels

Fume Hoods

Grounds Equipment &

Vehicles

Lighting

Motors

Overhead Doors

Powertools

Printshop Machines

Radio Transmitter

Switchgear

Sub-Station

Transformers

Vehicles (engine work)

Woodshop Machines

4.1 Energy Hazards

Energy hazards that must be controlled include (but may not be limited to):

a) Electrical

b) Mechanical (moving parts)

c) Hydraulic (liquid under pressure)

d) Pneumatic (steam or gas under pressure)

e) Thermal (heat/cold)

f) Chemical (pipes/systems containing harmful materials)

5.0 Energy Control Program

5.1 General Rules for Lockout/Tagout

a) When working on machines, equipment, or systems that could accidentally be

activated causing the release of harmful energy (e.g., electricity, moving parts,

etc.), lockout procedures must be used. Additionally, a tag shall be used to

identify the purpose of the shutdown, the employee involved, and the date & time

the unit was removed from service.

b) If the system has more than one energy source (e.g., electricity and pneumatic

pressure) present, each individual source must be isolated using lockout/tagout.

c) Lockout /Tagout shall be performed only by authorized employee(s) performing

the service or maintenance

d) No person shall attempt to bypass a lockout/tagout device under any

circumstances.

e) If machinery, equipment, and systems are capable of being locked out, then

lockout must be used to isolate all energy sources.

f) Only the person who installed a lockout device is authorized to remove it.

g) Authorized employees must also be instructed in the limitation of tags when they

are used as the only means of energy isolation.

h) Each authorized employee must use his/her assigned lockout/tagout equipment

only.

5.2 Lockout/Tagout Procedures

This section is the general sequence to be followed by authorized employees for

controlling hazardous energy sources that could cause personal injury due to the

unexpected start-up of a system. Lockout/tagout shall only be performed by the

authorized employee performing the service or maintenance on the system(s) to be

isolated.

The basic procedure for lockout/tagout is as follows:

Step 1: Notify all affected employees that servicing or maintenance is required on the

equipment/machinery and that it will be shut down and locked out to perform work.

Step 2: Identify the type and magnitude of energy sources that the equipment/machinery

uses (refer to operating manual, department procedures, supervisor, etc.). Make sure you

know the methods to control the energy source(s).

Step 3: If the equipment/machinery is operating, shut it down by the normal stopping

procedure.

Step 4: Follow the system specific sequential procedure for de-activating the energy

isolating device(s) applicable to the equipment/machinery, including controlling

stored/residual energy.

Step 5: Install lockout/tagout device(s) on all energy isolating devices specified in Step 4.

Step 6: Visually confirm the release and/or restraint of all stored or residual energy (e.g.,

in capacitors, springs, elevated parts, hydraulic systems, and air, gas, steam, or water

pressure, etc.)

Step 7: Make sure that no people are working on or in the equipment/machinery; and that

all are clear.

Step 8: Verify that the equipment/machinery is fully isolated from all energy sources by

activating the normal operating control(s) to make sure that the equipment/machinery

will not operate.

Step 9: Return the operating control(s) activated during the isolation verification in Step 8

to the “off” or neutral position.

Step 10: The equipment/machinery is now locked out. Do not attempt to operate any

switch, valve, or other energy isolating device where it is locked or tagged out.

5.2.1 Department-Specific Procedures

The energy control procedure outlined in Section 5.2 is only a general sequence to

be followed. Department supervisors must ensure that a written Lockout/Tagout

procedure is developed to provide specific instructions for isolating each

machine, equipment, or other system on which their employees may need to

perform service or maintenance.

A “Lock/Tagout Procedure” form (Appendix B) must be used to create a system-

specific procedure. Copies of the system specific procedure must be kept in the

Department’s copy of the Ithaca College Lockout/Tagout Program (Appendix C)

and be readily accessible at the actual system location. Copies of the specific

procedure must also be sent to EH&S so they can kept in a master file.

5.2.2 Cord and Plug Equipment

Any work on cord and plug equipment for which exposure to the hazards of

unexpected energization is controlled by unplugging the system is exempt

from full lockout/tagout procedures under the following circumstances:

Unplugging the equipment/machinery is the only control necessary to

isolate all energy hazards.

The equipment/machinery is unplugged prior to and throughout servicing

and maintenance.

The plug is kept under the exclusive control of the employee performing

the servicing/maintenance.

For systems in which the plug cannot be kept under one’s exclusive

control, a lockable plug cover device must be used to prevent unexpected

energization. Regardless of the energy control method used, the

authorized employee must always test the equipment to assure the power

source has been removed by depressing the "Start" or On" switch, and that

any stored energy has been released.

5.2.3 Tagout-Only Procedures

If machinery, equipment and system are capable of being locked

out, then lockout must be used to isolate all energy sources. There

may be circumstances such as trouble shooting or testing , where

the energy source(s) must remain “on” or must be re-energized to

perform the service or maintenance. In these cases, tagout

procedures must be followed. Tagout –only procedures must

provide a level of safety that is equivalent to lockout.

Department Supervisors are responsible for ensuring that detailed

procedures associated with isolating energy sources for operations

where the system need to be fully or partially energized to perform

the service or maintenance.

When using tagout only, on an energy isolated device that is

capable of being locked out , the tagout device shall be attached at

the same location that the lockout device would have been

attached.

Note: If a tag is used without a lockout device to isolate an

electrical circuit or other energy source, then it must be

supplemented by one additional safety measure, such as the

removal of an isolating circuit element, blocking of a controlling

switch, opening an extra disconnecting device, using a “watch

person,” etc.

5.2.3.1 Re-Energizing for Testing/Troubleshooting

Testing, trouble shooting, positioning, etc. of locked out machines,

equipment, or components thereof may be necessary to confirm

that repairs and maintenance have been successful. In situations

where lockout devices must be temporarily removed from the

energy isolating device and the unit/system or a component thereof

must be re-energized to test, etc. the following sequence must be

followed:

a. Clear the unit/system of equipment, tools and materials.

b. Make sure all employees are clear of the unit/system.

c. Inform all affected employees that the unit/system is being

re-energized.

d. Remove the lockout device(s)

e. Re-energize and proceed with testing, troubleshooting, etc.

f. De-energize again and reapply the lockout device(s) in

accordance with the procedure established for the

init/system.

5.2.4 Employee Notification

Affected employees must be notified by the authorized employee(s) performing

the energy isolation, of the application and removal of lockout/tagout devices.

Notification shall be given before the energy controls are applied and after they

are removed from the machine or equipment.

5.3 Restoring Equipment/Machinery to Service

When the servicing or maintenance is completed and the machinery/equipment is ready

to return to normal operating condition, the following steps shall be taken:

1) Check the machine/equipment and the immediate area around the system to ensure

that nonessential items have been removed and that the machinery/equipment

components are operationally intact.

2) Check the work area to ensure that all employees have been safely positioned or

removed from the area.

3) Notify workers that the lockout/tagout hardware is about to be removed.

4) Verify that the controls are in neutral.

5) Remove the lockout devices and re-energize the machine or equipment. Note: The

removal of some forms of blocking may require re-energizing of the

equipment/machinery before safe removal. Use extra caution.

6) Notify affected employees that the servicing or maintenance is completed and the

machine or equipment is ready for use.

5.4 Lockout/Tagout Hardware

Each department shall provide an adequate supply and variety of devices necessary for

their employees to safely perform maintenance and service on energized systems.

Lockout/tagout equipment may include, but is not limited to:

Locks

Tags

Chains

Breaker clips

Valve covers

Hasps

Self-locking fasteners

Key blocks

Plug buckets

Any other hardware that will

allow for securing or

blocking of machines and

equipment from energy.

Lockout/tagout devices are required to be durable and capable of withstanding the

environment to which they are exposed for the maximum time that exposure is expected.

All lockout hardware must also be substantial enough to prevent removal without the use

of excessive force or tools. The lockout/tagout device must indicate the identity of the

employee applying the device.

Tagout devices, including their means of attachment, shall be substantial enough to

prevent inadvertent or accidental removal. The attachment mechanisms must be of a

non-reusable type, attachable by hand, self-locking, and non-releasable, with a minimum

unlocking strength of 50 pounds.

Lockout/tagout hardware must be standardized (e.g., color). Tagout devices must also be

standardized

EH&S is available for assistance in selecting the appropriate lockout/tagout hardware.

5.4.1 Assignment of Lockout/Tagout Hardware

Authorized employees shall be individually assigned lockout/tagout hardware

and must not share his/her devices with other employees. All authorized

employees will be assigned a lock with one key, hasp, and tag. All locks will

be keyed differently, except when a specific individual is issued a series of

locks for complex lockout/tagout tasks. In some cases, more than one lock,

hasp, and tag are needed to completely de-energize equipment and machinery.

Additional locks should be obtained from your department supervisor. All

locks and hasps shall be uniquely identifiable to a specific employee.

5.5 Contractors

Outside vendors and contractors working on Ithaca College property are required to

follow the Ithaca College Lockout/Tagout Program, or provide a similar program that is

in compliance with the OSHA Lockout/Tagout Standard (29 CFR Part 1910.147).

Contractors and vendors wishing to use their own program must submit copies of the

written procedures to the Ithaca College Supervisor in charge of the work and the Office

of Public Safety – EH&S at least one full work-day in advance of the project.

All affected employees must be notified of the provisions of the outside contractor’s

lockout/tagout procedures and must comply with its restrictions and prohibitions. The

Ithaca College Supervisor must also inform the contractor of the applicable Ithaca

College lockout procedures to be followed.

Under no circumstances are outside vendors and contractors authorized to remove an

Ithaca College lockout/tagout device, nor are they allowed to re-energize a locked

out/tagged out system.

Ithaca College Supervisors must inform contractors of the requirements of this section.

5.6 Group Lockout/Tagout

Whenever maintenance or service on energized equipment is performed by more than one

person, including contractor personnel, they must use a procedure that provides all

personnel a level of protection equivalent to that provided by the implementation of a

personal lockout/tagout device. Group lockout/tagout devices (e.g., multi-lock hasps)

must be used for all group work on energized systems.

The Ithaca College Supervisor in charge of the work is responsible to ensure that the

exposure status of individual group members has been assessed and that the proper

procedures are used to protect all employees in group work situations.

Each authorized employee involved in a group work project shall affix his/her personal

lockout/tagout devices to the group lockout device when he/she begins work, and shall be

the only person to remove their lockout/tagout devices when he/she stops working on the

machine or equipment being serviced or maintained.

5.6.1 Shift & Personnel Changes

For work on energized equipment that extends beyond one shift, procedures must

be used to ensure that the continuity of lockout/tagout protection is maintained.

This includes the orderly transfer of lockout/tagout device protection between off-

going and oncoming employees. The off-going employee(s) must inform the

oncoming workers regarding the status of the work, including the energy isolation

procedures in-place. Re-testing must be done by the oncoming shift personnel to

ensure the de-energized state of the equipment has been maintained.

Important: The off-going employee must not remove his/her energy isolating

device until the on-coming employee has installed theirs.

5.7 Removal of lockout/Tagout Devices

In accordance with the Ithaca College Lockout/Tagout Program, each lockout and tagout

device shall only be removed from the energy isolating mechanism by the authorized

employee(s) who applied the device(s)

When the authorized employee is not available to remove their device (e.g. out sick, on

vacation, etc.) that device may be removed only under the direction of the applicable

Supervisor provided that a minimum of the following measures are taken first:

a. Verify that the authorized employee is not on campus.

b. Make all reasonable effort to contact the authorized to inform him/her that their

lockout/tagout device(s) will be removed.

c. Confirm that the authorized employee knows that his/her lockout/tagout devices

have been removed before they resume work.

The measures taken to inform the affected employees should be documented. A

sample form is in Appendix D of this program.

6.0 Employee Training

EH&S will provide training to applicable employees in the Ithaca College Lockout/Tagout

Program as required by OSHA regulations. A copy of the training program is provided in

Appendix D. The training will ensure that employees understand the purpose of the energy

control program and that the knowledge and skills required for the safe application, usage, and

removal of energy controls are acquired.

In addition to the training in the Ithaca College Lockout/Tagout Program, department

supervisors must provide further instruction applicable to the system specific procedures

applicable to their areas. Retraining shall be provided periodically and whenever there is a

change in job assignments, machinery, equipment, or processes that present a new hazard, or

when there is a change in the energy control procedures. Retraining shall also be completed

whenever deviations from or inadequacies in the employee’s knowledge or use of energy control

procedures are noted.

Department supervisors shall provide lists of applicable employees that are to receive

lockout/tagout training to EH&S. The level of training will vary depending upon the employees’

job responsibilities.

6.1 Authorized Employees

Each authorized employee will be trained in the recognition of applicable hazardous

energy sources, the type and magnitude of energy available in the workplace, and the

methods and means necessary for energy isolation and control. Authorized employees

will be instructed in the purpose and use of energy control procedures.

6.2 Affected Employees

All employees whose work operations are or may be in an area where energy control

procedures may be used, will be instructed about the procedure, and about the prohibition

relating to removing lockout/tagout hardware, and attempts to restart or re-energize

machines or equipment that are locked/tagged out.

6.3 Tagout Training

For applicable employees who must use tagout-only energy controlling procedures,

training will be provided in the proper use and associated limitations of the tag.

7.0 Periodic Inspections

OSHA requires employers to conduct a periodic inspection of the energy control procedure at

least annually to ensure that the program and its requirements are being followed. The periodic

inspection must be performed by an “authorized employee” (i.e., Department Supervisor) other

than the one(s) actually using the lockout/tagout procedure under inspection. The purpose of the

inspection is to identify and correct any deviations or inadequacies.

Where lockout and tagout is used for energy control, the periodic inspection will include a

review between the inspector and each authorized employee, of that supervisor’s responsibilities

under the energy control procedure being inspected. Where tagout only is used for energy

control, the periodic inspection will also include a review of the limitations of tagout-only

procedures with all applicable authorized employees.

The periodic inspections must be documented to certify that they have been performed. A

“Lockout/Tagout Periodic Inspection” form is in Appendix E. Completed inspection forms must

be sent to EH&S, and a copy should be kept in the Department’s Lockout/Tagout program

binder.

Appendix A OSHA Lockout/Tagout Standard (29 CFR 1910.147)

483

Occupational Safety and Health Admin., Labor § 1910.147

service should perform a critique of the prac-tice rescue, or have another qualified party perform the critique, so that deficiencies in procedures, equipment, training, or number of personnel can be identified and corrected. The results of the critique, and the correc-tions made to respond to the deficiencies identified, should be given to the employer to enable it to determine whether the rescue service can quickly be upgraded to meet the employer’s rescue needs or whether another service must be selected. The following ques-tions will assist employers and rescue teams and services evaluate their performance.

1. Have all members of the service been trained as permit space entrants, at a min-imum, including training in the potential hazards of all permit spaces, or of represent-ative permit spaces, from which rescue may be needed? Can team members recognize the signs, symptoms, and consequences of expo-sure to any hazardous atmospheres that may be present in those permit spaces?

2. Is every team member provided with, and properly trained in, the use and need for PPE, such as SCBA or fall arrest equipment, which may be required to perform permit space rescues in the facility? Is every team member properly trained to perform his or her functions and make rescues, and to use any rescue equipment, such as ropes and backboards, that may be needed in a rescue attempt?

3. Are team members trained in the first aid and medical skills needed to treat vic-tims overcome or injured by the types of hazards that may be encountered in the per-mit spaces at the facility?

4. Do all team members perform their func-tions safely and efficiently? Do rescue serv-ice personnel focus on their own safety be-fore considering the safety of the victim?

5. If necessary, can the rescue service prop-erly test the atmosphere to determine if it is IDLH?

6. Can the rescue personnel identify infor-mation pertinent to the rescue from entry permits, hot work permits, and MSDSs?

7. Has the rescue service been informed of any hazards to personnel that may arise from outside the space, such as those that may be caused by future work near the space?

8. If necessary, can the rescue service prop-erly package and retrieve victims from a permit space that has a limited size opening (less than 24 inches (60.9 cm) in diameter), limited internal space, or internal obstacles or hazards?

9. If necessary, can the rescue service safe-ly perform an elevated (high angle) rescue?

10. Does the rescue service have a plan for each of the kinds of permit space rescue op-erations at the facility? Is the plan adequate for all types of rescue operations that may be needed at the facility? Teams may prac-tice in representative spaces, or in spaces

that are ‘‘worst-case’’ or most restrictive with respect to internal configuration, ele-vation, and portal size. The following charac-teristics of a practice space should be consid-ered when deciding whether a space is truly representative of an actual permit space:

(1) Internal configuration. (a) Open—there are no obstacles, barriers,

or obstructions within the space. One exam-ple is a water tank.

(b) Obstructed—the permit space contains some type of obstruction that a rescuer would need to maneuver around. An example would be a baffle or mixing blade. Large equipment, such as a ladder or scaffold, brought into a space for work purposes would be considered an obstruction if the po-sitioning or size of the equipment would make rescue more difficult.

(2) Elevation. (a) Elevated—a permit space where the en-

trance portal or opening is above grade by 4 feet or more. This type of space usually re-quires knowledge of high angle rescue proce-dures because of the difficulty in packaging and transporting a patient to the ground from the portal.

(b) Non-elevated—a permit space with the entrance portal located less than 4 feet above grade. This type of space will allow the res-cue team to transport an injured employee normally.

(3) Portal size. (a) Restricted—A portal of 24 inches or less

in the least dimension. Portals of this size are too small to allow a rescuer to simply enter the space while using SCBA. The por-tal size is also too small to allow normal spi-nal immobilization of an injured employee.

(b) Unrestricted—A portal of greater than 24 inches in the least dimension. These por-tals allow relatively free movement into and out of the permit space.

(4) Space access. (a) Horizontal—The portal is located on

the side of the permit space. Use of retrieval lines could be difficult.

(b) Vertical—The portal is located on the top of the permit space, so that rescuers must climb down, or the bottom of the per-mit space, so that rescuers must climb up to enter the space. Vertical portals may require knowledge of rope techniques, or special pa-tient packaging to safely retrieve a downed entrant.

[58 FR 4549, Jan. 14, 1993; 58 FR 34845, 34846, June 29, 1993, as amended at 59 FR 26114, May 19, 1994; 63 FR 66038, 66039, Dec. 1, 1998]

§ 1910.147 The control of hazardous energy (lockout/tagout).

(a) Scope, application and purpose—(1) Scope. (i) This standard covers the serv-icing and maintenance of machines and equipment in which the unexpected

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484

29 CFR Ch. XVII (7–1–08 Edition) § 1910.147

energization or start up of the ma-chines or equipment, or release of stored energy could cause injury to em-ployees. This standard establishes min-imum performance requirements for the control of such hazardous energy.

(ii) This standard does not cover the following:

(A) Construction, agriculture and maritime employment;

(B) Installations under the exclusive control of electric utilities for the pur-pose of power generation, transmission and distribution, including related equipment for communication or me-tering; and

(C) Exposure to electrical hazards from work on, near, or with conductors or equipment in electric utilization in-stallations, which is covered by sub-part S of this part; and

(D) Oil and gas well drilling and serv-icing.

(2) Application. (i) This standard ap-plies to the control of energy during servicing and/or maintenance of ma-chines and equipment.

(ii) Normal production operations are not covered by this standard (See sub-part 0 of this part). Servicing and/or maintenance which takes place during normal production operations is cov-ered by this standard only if;:

(A) An employee is required to re-move or bypass a guard or other safety device; or

(B) An employee is required to place any part of his or her body into an area on a machine or piece of equipment where work is actually performed upon the material being processed (point of operation) or where an associated dan-ger zone exists during a machine oper-ating cycle.

NOTE: Exception to paragraph (a)(2)(ii): Minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations, are not covered by this standard if they are routine, repetitive, and integral to the use of the equipment for production, provided that the work is performed using alternative measures which provide effective protection (See subpart 0 of this part).

(iii) This standard does not apply to the following.

(A) Work on cord and plug connected electric equipment for which exposure to the hazards of unexpected energization or start up of the equip-

ment is controlled by the unplugging of the equipment from the energy source and by the plug being under the exclu-sive control of the employee per-forming the servicing or maintenance.

(B) Hot tap operations involving transmission and distribution systems for substances such as gas, steam, water or petroleum products when they are performed on pressurized pipelines, provided that the employer dem-onstrates that (1) continuity of service is essential; (2) shutdown of the system is impractical; and (3) documented pro-cedures are followed, and special equip-ment is used which will provide proven effective protection for employees.

(3) Purpose. (i) This section requires employers to establish a program and utilize procedures for affixing appro-priate lockout devices or tagout de-vices to energy isolating devices, and to otherwise disable machines or equip-ment to prevent unexpected energization, start-up or release of stored energy in order to prevent in-jury to employees.

(ii) When other standards in this part require the use of lockout or tagout, they shall be used and supplemented by the procedural and training require-ments of this section.

(b) Definitions applicable to this sec-tion.

Affected employee. An employee whose job requires him/her to operate or use a machine or equipment on which serv-icing or maintenance is being per-formed 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 serv-icing or maintenance on that machine or equipment. An affected employee be-comes an authorized employee when that employee’s duties include per-forming servicing or maintenance cov-ered under this section.

Capable of being locked out. An energy isolating device is capable of being locked out if it has a hasp or other means of attachment to which, or through which, a lock can be affixed, or it has a locking mechanism built into it. Other energy isolating devices are capable of being locked out, if lockout


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can be achieved without the need to dismantle, rebuild, or replace the en-ergy isolating device or permanently alter its energy control capability.

Energized. Connected to an energy source or containing residual or stored energy.

Energy isolating device. A mechanical device that physically prevents the transmission or release of energy, in-cluding but not limited to the fol-lowing: A manually operated electrical circuit breaker; a disconnect switch; a manually operated switch by which the conductors of a circuit can be discon-nected from all ungrounded supply con-ductors, and, in addition, no pole can be operated independently; a line valve; a block; and any similar device used to block or isolate energy. Push buttons, selector switches and other control circuit type devices are not en-ergy isolating devices.

Energy source. Any source of elec-trical, mechanical, hydraulic, pneu-matic, chemical, thermal, or other en-ergy.

Hot tap. A procedure used in the re-pair, maintenance and services activi-ties which involves welding on a piece of equipment (pipelines, vessels or tanks) under pressure, in order to in-stall connections or appurtenances. It is commonly used to replace or add sections of pipeline without the inter-ruption of service for air, gas, water, steam, and petrochemical distribution systems.

Lockout. The placement of a lockout device on an energy isolating device, in accordance with an established proce-dure, ensuring that the energy iso-lating device and the equipment being controlled cannot be operated until the lockout device is removed.

Lockout device. A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy isolating device in a safe posi-tion and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds.

Normal production operations. The uti-lization of a machine or equipment to perform its intended production func-tion.

Servicing and/or maintenance. Work-place activities such as constructing, installing, setting up, adjusting, in-

specting, modifying, and maintaining and/or servicing machines or equip-ment. These activities include lubrica-tion, cleaning or unjamming of ma-chines or equipment and making ad-justments or tool changes, where the employee may be exposed to the unex-pected energization or startup of the equipment or release of hazardous en-ergy.

Setting up. Any work performed to prepare a machine or equipment to per-form its normal production operation.

Tagout. The placement of a tagout device on an energy isolating device, in accordance with an established proce-dure, to indicate that the energy iso-lating device and the equipment being controlled may not be operated until the tagout device is removed.

Tagout device. A prominent warning device, such as a tag and a means of at-tachment, which can be securely fas-tened to an energy isolating device in accordance with an established proce-dure, to indicate that the energy iso-lating device and the equipment being controlled may not be operated until the tagout device is removed.

(c) General—(1) Energy control pro-gram. The employer shall establish a program consisting of energy control procedures, employee training and periodic inspections to ensure that be-fore any employee performs any serv-icing or maintenance on a machine or equipment where the unexpected ener-gizing, start up or release of stored en-ergy could occur and cause injury, the machine or equipment shall be isolated from the energy source, and rendered inoperative.

(2) Lockout/tagout. (i) If an energy iso-lating device is not capable of being locked out, the employer’s energy con-trol program under paragraph (c)(1) of this section shall utilize a tagout sys-tem.

(ii) If an energy isolating device is capable of being locked out, the em-ployer’s energy control program under paragraph (c)(1) of this section shall utilize lockout, unless the employer can demonstrate that the utilization of a tagout system will provide full em-ployee protection as set forth in para-graph (c)(3) of this section.


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(iii) After January 2, 1990, whenever replacement or major repair, renova-tion or modification of a machine or equipment is performed, and whenever new machines or equipment are in-stalled, energy isolating devices for such machine or equipment shall be de-signed to accept a lockout device.

(3) Full employee protection. (i) When a tagout device is used on an energy iso-lating device which is capable of being locked out, the tagout device shall be attached at the same location that the lockout device would have been at-tached, and the employer shall dem-onstrate that the tagout program will provide a level of safety equivalent to that obtained by using a lockout pro-gram.

(ii) In demonstrating that a level of safety is achieved in the tagout pro-gram which is equivalent to the level of safety obtained by using a lockout program, the employer shall dem-onstrate full compliance with all tagout-related provisions of this stand-ard together with such additional ele-ments as are necessary to provide the equivalent safety available from the use of a lockout device. Additional means to be considered as part of the demonstration of full employee protec-tion shall include the implementation of additional safety measures such as the removal of an isolating circuit ele-ment, blocking of a controlling switch, opening of an extra disconnecting de-vice, or the removal of a valve handle to reduce the likelihood of inadvertent energization.

(4) Energy control procedure. (i) Proce-dures shall be developed, documented and utilized for the control of poten-tially hazardous energy when employ-ees are engaged in the activities cov-ered by this section.

NOTE: Exception: The employer need not document the required procedure for a par-ticular machine or equipment, when all of the following elements exist: (1) The ma-chine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees; (2) the machine or equipment has a single energy source which can be readily identified and isolated; (3) the isolation and locking out of that energy source will completely deenergize and de-activate the machine or equipment; (4) the machine or equipment is isolated from that energy source and locked out during serv-

icing or maintenance; (5) a single lockout de-vice will achieve a locked-out condition; (6) the lockout device is under the exclusive control of the authorized employee per-forming the servicing or maintenance; (7) the servicing or maintenance does not create hazards for other employees; and (8) the em-ployer, in utilizing this exception, has had no accidents involving the unexpected acti-vation or reenergization of the machine or equipment during servicing or maintenance.

(ii) The procedures shall clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce com-pliance including, but not limited to, the following:

(A) A specific statement of the in-tended use of the procedure;

(B) Specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy;

(C) Specific procedural steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them; and

(D) Specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other en-ergy control measures.

(5) Protective materials and hardware. (i) Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fas-teners, or other hardware shall be pro-vided by the employer for isolating, se-curing or blocking of machines or equipment from energy sources.

(ii) Lockout devices and tagout de-vices shall be singularly identified; shall be the only devices(s) used for controlling energy; shall not be used for other purposes; and shall meet the following requirements:

(A) Durable. (1) Lockout and tagout devices shall be capable of with-standing the environment to which they are exposed for the maximum pe-riod of time that exposure is expected.

(2) Tagout devices shall be con-structed and printed so that exposure to weather conditions or wet and damp locations will not cause the tag to de-teriorate or the message on the tag to become illegible.

(3) Tags shall not deteriorate when used in corrosive environments such as areas where acid and alkali chemicals are handled and stored.


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(B) Standardized. Lockout and tagout devices shall be standardized within the facility in at least one of the fol-lowing criteria: Color; shape; or size; and additionally, in the case of tagout devices, print and format shall be standardized.

(C) Substantial—(1) Lockout devices. Lockout devices shall be substantial enough to prevent removal without the use of excessive force or unusual tech-niques, such as with the use of bolt cutters or other metal cutting tools.

(2) Tagout devices. Tagout devices, in-cluding and their means of attachment, shall be substantial enough to prevent inadvertent or accidental removal. Tagout device attachment means shall be of a non-reusable type, attachable by hand, self-locking, and non-releas-able with a minimum unlocking strength of no less than 50 pounds and having the general design and basic characteristics of being at least equiv-alent to a one-piece, all-environment- tolerant nylon cable tie.

(D) Identifiable. Lockout devices and tagout devices shall indicate the iden-tity of the employee applying the de-vice(s).

(iii) Tagout devices shall warn against hazardous conditions if the ma-chine or equipment is energized and shall include a legend such as the fol-lowing: Do Not Start, Do Not Open, Do Not Close, Do Not Energize, Do Not Oper-ate.

(6) Periodic inspection. (i) The em-ployer shall conduct a periodic inspec-tion of the energy control procedure at least annually to ensure that the pro-cedure and the requirements of this standard are being followed.

(A) The periodic inspection shall be perfomed by an authorized employee other than the ones(s) utilizing the en-ergy control procedure being inspected.

(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 employee, of that employee’s responsibilities under the energy control procedure being in-spected.

(D) Where tagout is used for energy control, the periodic inspection shall

include a review, between the inspector and each authorized and affected em-ployee, of that employee’s responsibil-ities under the energy control proce-dure being inspected, and the elements set forth in paragraph (c)(7)(ii) of this section.

(ii) The employer shall certify that the periodic inspections have been per-formed. The certification shall identify the machine or equipment on which the energy control procedure was being utilized, the date of the inspection, the employees included in the inspection, and the person performing the inspec-tion.

(7) Training and communication. (i) The employer shall provide training to ensure that the purpose and function of the energy control program are under-stood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees. The training shall include the following:

(A) Each authorized employee 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 en-ergy isolation and control.

(B) Each affected employee shall be instructed in the purpose and use of the energy control procedure.

(C) All other employees whose work operations are or may be in an area where energy control procedures may be utilized, shall be instructed about the procedure, and about the prohibi-tion relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out.

(ii) When tagout systems are used, employees shall also be trained in the following limitations of tags:

(A) Tags are essentially warning de-vices affixed to energy isolating de-vices, and do not provide the physical restraint on those devices that is pro-vided by a lock.

(B) When a tag is attached to an en-ergy isolating means, it is not to be re-moved without authorization of the au-thorized person responsible for it, and it is never to be bypassed, ignored, or otherwise defeated.


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(C) Tags must be legible and under-standable by all authorized employees, affected employees, and all other em-ployees whose work operations are or may be in the area, in order to be effec-tive.

(D) Tags and their means of attach-ment must be made of materials which will withstand the environmental con-ditions encountered in the workplace.

(E) Tags may evoke a false sense of security, and their meaning needs to be understood as part of the overall en-ergy control program.

(F) Tags must be securely attached to energy isolating devices so that they cannot be inadvertently or acciden-tally detached during use.

(iii) Employee retraining. (A) Retraining shall be provided for

all authorized and affected employees 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 in-spection under paragraph (c)(6) of this section reveals, or whenever the em-ployer has reason to believe, that there are deviations from or inadequacies in the employee’s knowledge or use of the energy control procedures.

(C) The retraining shall reestablish employee proficiency and introduce new or revised control methods and procedures, as necessary.

(iv) The employer shall certify that employee training has been accom-plished and is being kept up to date. The certification shall contain each employee’s name and dates of training.

(8) Energy isolation. Lockout or tagout shall be performed only bythe authorized employees who are per-forming the servicing or maintenance.

(9) Notification of employees. Affected employees shall be notified by the em-ployer or authorized employee of the application and removal of lockout de-vices or tagout devices. Notification shall be given before the controls are applied, and after they are removed from the machine or equipment.

(d) Application of control. The estab-lished procedures for the application of energy control (the lockout or tagout procedures) shall cover the following

elements and actions and shall be done in the following sequence:

(1) Preparation for shutdown. Before an authorized or affected employee turns off a machine or equipment, the authorized employee shall have knowl-edge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy.

(2) Machine or equipment shutdown. The machine or equipment shall be turned off or shut down using the pro-cedures established for the machine or equipment. An orderly shutdown must be utilized to avoid any additional or increased hazard(s) to employees as a result of the equipment stoppage.

(3) Machine or equipment isolation. All energy isolating devices that are need-ed to control the energy to the ma-chine or equipment shall be physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s).

(4) Lockout or tagout device applica-tion. (i) Lockout or tagout devices shall be affixed to each energy isolating de-vice by authorized employees.

(ii) Lockout devices, where used, shall be affixed in a manner to that will hold the energy isolating devices in a ‘‘safe’’ or ‘‘off’’ position.

(iii) Tagout devices, where used, shall be affixed in such a manner as will clearly indicate that the operation or movement of energy isolating devices from the ‘‘safe’’ or ‘‘off’’ position is prohibited.

(A) Where tagout devices are used with energy isolating devices designed with the capability of being locked, the tag attachment shall be fastened at the same point at which the lock would have been attached.

(B) Where a tag cannot be affixed di-rectly to the energy isolating device, the tag shall be located as close as safely possible to the device, in a posi-tion that will be immediately obvious to anyone attempting to operate the device.

(5) Stored energy. (i) Following the ap-plication of lockout or tagout devices to energy isolating devices, all poten-tially hazardous stored or residual en-ergy shall be relieved, disconnected, re-strained, and otherwise rendered safe.


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(ii) If there is a possibility of re-accumulation of stored energy to a hazardous level, verification of isola-tion shall be continued until the serv-icing or maintenance is completed, or until the possibility of such accumula-tion no longer exists.

(6) Verification of isolation. Prior to starting work on machines or equip-ment that have been locked out or tagged out, the authorized employee shall verify that isolation and deenergization of the machine or equipment have been accomplished.

(e) Release from lockout or tagout. Be-fore lockout or tagout devices are re-moved and energy is restored to the machine or equipment, procedures shall be followed and actions taken by the authorized employee(s) to ensure the following:

(1) The machine or equipment. The work area shall be inspected to ensure that nonessential items have been re-moved and to ensure that machine or equipment components are operation-ally intact.

(2) Employees. (i) The work area shall be checked to ensure that all employ-ees have been safely positioned or re-moved.

(ii) After lockout or tagout devices have been removed and before a ma-chine or equipment is started, affected employees shall be notified that the lockout or tagout device(s) have been removed.

(3) Lockout or tagout devices removal. Each lockout or tagout device shall be removed from each energy isolating de-vice by the employee who applied the device. Exception to paragraph (e)(3): When the authorized employee who ap-plied the lockout or tagout device is not available to remove it, that device may be removed under the direction of the employer, provided that specific procedures and training for such re-moval have been developed, docu-mented and incorporated into the em-ployer’s energy control program. The employer shall demonstrate that the specific procedure provides equivalent safety to the removal of the device by the authorized employee who applied it. The specific procedure shall include at least the following elements:

(i) Verfication by the employer that the authorized employee who applied the device is not at the facility;

(ii) Making all reasonable efforts to contact the authorized employee to in-form him/her that his/her lockout or tagout device has been removed; and

(iii) Ensuring that the authorized employee has this knowledge before he/ she resumes work at that facility.

(f) Additional requirements—(1) Testing or positioning of machines, equipment or components thereof. In situations in which lockout or tagout devices must be temporarily removed from the en-ergy isolating device and the machine or equipment energized to test or posi-tion the machine, equipment or compo-nent thereof, the following sequence of actions shall be followed:

(i) Clear the machine or equipment of tools and materials in accordance with paragraph (e)(1) of this section;

(ii) Remove employees from the ma-chine or equipment area in accordance with paragraph (e)(2) of this section;

(iii) Remove the lockout or tagout devices as specified in paragraph (e)(3) of this section;

(iv) Energize and proceed with test-ing or positioning;

(v) Deenergize all systems and re-apply energy control measures in ac-cordance with paragraph (d) of this sec-tion to continue the servicing and/or maintenance.

(2) Outside personnel (contractors, etc.). (i) Whenever outside servicing per-sonnel are to be engaged in activities covered by the scope and application of this standard, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures.

(ii) The on-site employer shall ensure that his/her employees understand and comply with the restrictions and prohi-bitions of the outside employer’s en-ergy control program.

(3) Group lockout or tagout. (i) When servicing and/or maintenance is per-formed by a crew, craft, department or other group, they shall utilize a proce-dure which affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device.

(ii) Group lockout or tagout devices shall be used in accordance with the


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procedures required by paragraph (c)(4) of this section including, but not nec-essarily limited to, the following spe-cific requirements:

(A) Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device (such as an operations lock);

(B) Provision for the authorized em-ployee to ascertain the exposure status of individual group members with re-gard to the lockout or tagout of the machine or equipment and

(C) When more than one crew, craft, department, etc. is involved, assign-ment of overall job-associated lockout or tagout control responsibility to an authorized employee designated to co-ordinate affected work forces and en-sure continuity of protection; and

(D) Each authorized employee shall affix a personal lockout or tagout de-vice to the group lockout device, group lockbox, or comparable mechanism when he or she begins work, and shall remove those devices when he or she stops working on the machine or equip-ment being serviced or maintained.

(4) Shift or personnel changes. Specific procedures shall be utilized during shift or personnel changes to ensure the continuity of lockout or tagout protection, including provision for the orderly transfer of lockout or tagout device protection between off-going and oncoming employees, to minimize exposure to hazards from the unex-pected energization or start-up of the machine or equipment, or the release of stored energy.

NOTE: The following appendix to § 1910.147 services as a non-mandatory guideline to as-sist employers and employees in complying with the requirements of this section, as well as to provide other helpful information. Nothing in the appendix adds to or detracts from any of the requirements of this section.

APPENDIX A TO § 1910.147—TYPICAL MINIMAL LOCKOUT PROCEDURE

General

The following simple lockout procedure is provided to assist employers in developing their procedures so they meet the require-ments of this standard. When the energy iso-lating devices are not lockable, tagout may be used, provided the employer complies with the provisions of the standard which re-

quire additional training and more rigorous periodic inspections. When tagout is used and the energy isolating devices are lock-able, the employer must provide full em-ployee protection (see paragraph (c)(3)) and additional training and more rigorous peri-odic inspections are required. For more com-plex systems, more comprehensive proce-dures may need to be developed, documented and utilized.

Lockout Procedure

Lockout procedure for

llllllllllllllllllllllll

(Name of Company for single procedure or identification of equipment if multiple pro-cedures are used)

Purpose

This procedure establishes the minimum requirements for the lockout of energy iso-lating devices whenever maintenance or servicing is done on machines or equipment. It shall be used to ensure that the machine or equipment is stopped, isolated from all potentially hazardous energy sources and locked out before employees perform any servicing or maintenance where the unex-pected energization or start-up of the ma-chine or equipment or release of stored en-ergy could cause injury.

Compliance With This Program

All employees are required to comply with the restrictions and limitations imposed upon them during the use of lockout. The au-thorized employees are required to perform the lockout in accordance with this proce-dure. All employees, upon observing a ma-chine or piece of equipment which is locked out to perform servicing or maintenance shall not attempt to start, energize or use that machine or equipment.


Type of compliance enforcement to be taken for violation of the above.

Sequence of Lockout

(1) Notify all affected employees that serv-icing or maintenance is required on a ma-chine or equipment and that the machine or equipment must be shut down and locked out to perform the servicing or maintenance.


Name(s)/Job Title(s) of affected employees and how to notify.

(2) The authorized employee shall refer to the company procedure to identify the type and magnitude of the energy that the ma-chine or equipment utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy.



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Type(s) and magnitude(s) of energy, its haz-ards and the methods to control the energy.

(3) If the machine or equipment is oper-ating, shut it down by the normal stopping procedure (depress stop button, open switch, close valve, etc.).


Type(s) and location(s) of machine or equip-ment operating controls.

(4) De-activate the energy isolating de-vice(s) so that the machine or equipment is isolated from the energy source(s).


Type(s) and location(s) of energy isolating devices.

(5) Lock out the energy isolating device(s) with assigned individual lock(s).

(6) Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic sys-tems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc.


Type(s) of stored energy—methods to dis-sipate or restrain.

(7) Ensure that the equipment is discon-nected from the energy source(s) by first checking that no personnel are exposed, then verify the isolation of the equipment by op-erating the push button or other normal op-erating control(s) or by testing to make cer-tain the equipment will not operate.

CAUTION: Return operating control(s) to neutral or ‘‘off’’ position after verifying the isolation of the equipment.


Method of verifying the isolation of the equipment.

(8) The machine or equipment is now locked out.

Restoring Equipment to Service. When the servicing or maintenance is completed and the machine or equipment is ready to return to normal operating condition, the following steps shall be taken.

(1) Check the machine or equipment and the immediate area around the machine or equipment to ensure that nonessential items have been removed and that the machine or equipment components are operationally in-tact.

(2) Check the work area to ensure that all employees have been safely positioned or re-moved from the area.

(3) Verify that the controls are in neutral. (4) Remove the lockout devices and reener-

gize the machine or equipment. NOTE: The removal of some forms of block-

ing may require reenergization of the ma-chine before safe removal.

(5) Notify affected employees that the serv-icing or maintenance is completed and the machine or equipment is ready for use.

[54 FR 36687, Sept. 1, 1989, as amended at 54 FR 42498, Oct. 17, 1989; 55 FR 38685, 38686, Sept. 20, 1990]

Subpart K—Medical and First Aid

AUTHORITY: Sections 4, 6, and 8 of the Occu-pational Safety and Health Act of 1970, 29 U.S.C. 653, 655, and 657; Secretary of Labor’s Order No. 12–71 (36 FR 8754), 8–76 (41 FR 25059), 9–83 (48 FR 35736), 1–90 (55 FR 9033), 6– 96 (62 FR 111), or 3–2000 (65 FR 50017), as ap-plicable, and 29 CFR part 1911.

§ 1910.151 Medical services and first aid.

(a) The employer shall ensure the ready availability of medical personnel for advice and consultation on matters of plant health.

(b) In the absence of an infirmary, clinic, or hospital in near proximity to the workplace which is used for the treatment of all injured employees, a person or persons shall be adequately trained to render first aid. Adequate first aid supplies shall be readily avail-able.

(c) Where the eyes or body of any per-son may be exposed to injurious corro-sive materials, suitable facilities for quick drenching or flushing of the eyes and body shall be provided within the work area for immediate emergency use.

APPENDIX A TO § 1910.151—FIRST AID KITS (NON-MANDATORY)

First aid supplies are required to be readily available under paragraph § 1910.151(b). An example of the minimal contents of a generic first aid kit is described in American Na-tional Standard (ANSI) Z308.1–1998 ‘‘Min-imum Requirements for Workplace First-aid Kits.’’ The contents of the kit listed in the ANSI standard should be adequate for small worksites. When larger operations or mul-tiple operations are being conducted at the same location, employers should determine the need for additional first aid kits at the worksite, additional types of first aid equip-ment and supplies and additional quantities and types of supplies and equipment in the first aid kits.

In a similar fashion, employers who have unique or changing first-aid needs in their workplace may need to enhance their first- aid kits. The employer can use the OSHA 200 log, OSHA 101’s or other reports to identify


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Appendix B

Lockout/Tagout Procedures Template Form

Ithaca College Lockout/Tagout Procedure Form

Building:

Room/Location: Equipment/Machinery:

Purpose: This procedure establishes the minimum requirements for the control of energy isolating devices whenever maintenance or servicing is performed on the equipment/machinery specified above. The authorized employee must always follow the procedures specified on this form before performing any maintenance/servicing where the unexpected energization or start-up of the equipment/machinery or release of stored energy could cause injury. Compliance: All employees are required to comply with the restrictions and limitations imposed upon them during the use of lockout. The authorized employees are required to perform the lockout in accordance with the specific procedure below. All employees, upon observing a machine or piece of equipment that is locked out to perform servicing or maintenance shall not attempt to start, energize, or use that machine or equipment. Employees failing to observe the lockout/tagout procedures may be subject to disciplinary actions in accordance with Ithaca College human resources policies.

TYPE OF ENERGY SPECIFIC ISOLATION LOCATION(S)(1) TYPE OF LOCKOUT DEVICE(S)(2)

Electrical

Potential (stored)

Mechanical (moving parts)

Pneumatic (air/gas pressure)

Hydraulic (liquid under pressure)

Thermal

Chemical

Other Special Hazard(s)

(1) Identify the exact breaker, valve, switch, disconnect, blocking device, etc., to be locked and tagged to isolate the

source of energy from the work area. Be as descriptive as possible (e.g., “Electrical Panel #PP3 behind emergency generator).

(2) Specifically name the exact type(s) of locking device(s) needed to ensure the disconnect or blocking device stays in the isolated condition/position (e.g., circuit breaker clip, valve cover, blank flange, etc.)

The specific energy control procedures are described on the reverse side of this form.

Date: __________________________ The following is the sequence to be followed by authorized employees for controlling energy sources applicable to the equipment/machinery being worked on: Step 1: Notify all affected employees that servicing or maintenance is required on ____________________

and that it will be shut down and locked out to perform work. Step 2: Identify the type and magnitude of energy sources that the equipment/machinery uses (e.g.,

operating manual, department procedures, supervisor, etc.). Make sure you know the methods to control the energy.

Step 3: If the equipment/machinery is operating, shut it down by the normal stopping procedure. The exact operating controls (e.g., button, switch, valve, etc.) for the equipment/machinery are: ______________________________________________________________________________ Step 4: The sequential procedure for de-activating the energy isolating device(s) listed in the table on the

reverse side of this form, including controlling stored/residual energy, is described below: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Step 5: Install lockout/tagout device(s) on all energy isolating devices specified in Step 4. Step 6: Visually confirm the release and/or restraint of all stored or residual energy (e.g., in capacitors,

springs, elevated parts, hydraulic systems, and air, gas, steam, or water pressure, etc.) Step 7: Make sure that no people are working on or in the equipment/machinery; and that all are clear. Step 8: Verify that the equipment/machinery is fully isolated from all energy sources by activating the

normal operating control(s) to make sure that the equipment/machinery will not operate. Step 9: Return the operating control(s) activated during the isolation verification in Step 8 are returned to

the “off” or neutral position. Step 10: The equipment/machinery is now locked out.

Restoring Equipment/Machinery To Service: When the servicing or maintenance is completed and the machinery/equipment is ready to return to normal operating condition, the following steps shall be taken:

1) Check the machine/equipment and the immediate area around the machine to ensure that nonessential items have been removed and that the machinery/equipment components are operationally intact.

2) Check the work area to ensure that all employees have been safely positioned or removed from the area. 3) Verify that the controls are in neutral. 4) Remove the lockout devices and re-energize the machine or equipment. Note: The removal of some forms of

blocking may require re-energizing of the equipment/machinery before safe removal. Use extra caution. 5) Notify affected employees that the servicing or maintenance is completed and the machine or equipment is ready.

Appendix C

Department Specific Lockout/Tagout Procedures

Appendix D

Affected Employee Lockout/Tagout Device

Removal Notification Form

LOCKOUT/TAGOUT

DEVICE REMOVAL NOTIFICATION FORM

As required by Section 5.7 of the Ithaca College Lockout/Tagout Program, each lockout and tagout device shall

only be removed from the energy isolating mechanism by the authorized employee(s) who applied the device(s).

When the authorized employee is not available to remove their device (e.g., out sick, on vacation, etc.) that device

may be removed only under the direction of the applicable Supervisor provided that a minimum of the following

measures are taken first:

a) Verify that the authorized employee is not on campus.

b) Make all reasonable efforts to contact the authorized employee to inform him/her that their lockout/tagout

device(s) will be removed.

c) Confirm that the authorized employee knows that his/her lockout/tagout devices have been removed before

they resume work.

All actions taken to notify the employee that his/her lockout/tagout device(s) were removed shall

be documented on this form below:

Employee Name: ___________________________________________________

How has it been verified that the employee is not on-campus? ________________________

______________________________________________________________________________

Building Where Lockout/Tagout Devices Are To Be Removed:

______________________________________________________________________________

Equipment/Facility/System Where Lockout/Tagout Devices Are To Be Removed:

______________________________________________________________________________

Date of Contact: _____________________________

Method of Contact: (telephone, email, etc.): _______________________________________

Has the employee confirmed that they are aware that his/her lockout/tagout device(s) have

been removed?

Yes _____ No _____

If no, describe follow-up actions to be taken to ensure the employee knows that

his/her lockout/tagout device(s) have been removed before they return to work.

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

________________________________________________________________________

Appendix E

Ithaca College Lockout/Tagout Training Program

1

Lockout / Tagout

Safety Training for the Control of Hazardous Energy at Ithaca College

Training Overview:

Recognition of Hazardous Energy SourcesPurpose of Lockout-Tagout (LO-TO)Types and Magnitude of Hazardous EnergyProcedures for Energy Isolation and Control

PURPOSEInform you of the hazards associated

with uncontrolled energy sources and the required procedures for isolating

equipment and systems to prevent injury to employees from the unexpected

energization, start-up, or release of stored energy.

LO-TO Safety Facts…• Approx. 600 workplace

fatalities (10% of all) due to uncontrolled energy sourcesuncontrolled energy sources each year.• 285 = contact with electrical current• 265 = caught in or compressed by

equipment• 35 contact with temp. extremes.

Types of Hazardous Energy

• Electrical • Mechanical • Chemical • Thermal • Hydraulic • Pneumatic

Q: When is LO/TO Necessary?

A: Whenever you are performing service or maintenance on any equipment where the unexpected start-up or release of stored energy could cause injury.

Examples:• Constructing• Installing• Setting up• Adjusting (e.g., clearing a jam)• Inspecting• Modifying• Maintenance (e.g., replacing, cleaning, lubing, etc.)

2

Mechanical Energy Hazards:

2 Types:1)Kinetic – moving1)Kinetic moving

parts2)Potential – stored

or built up energy.

Kinetic Energy Hazards

• Energy of moving machinery can cause:

LacerationsLacerations Fractures AmputationsLoss of life

Examples: fan blades, printing machines, shops equipment, etc.

Potential Energy HazardsStored potential energy can be releasedduring work causing injury or death

Examples: • Energy stored in machinery (e.g., elevated parts,

motors, capacitors, compressed air, etc.)• Weights & springs • Hydraulic controls (e.g., elevators, garbage truck,

bailers, etc.)

Thermal Energy Hazards• Hot equipment & gases or fluids will burn

you. • Cold fluids can cause injury also

• Quick release of compressed gases (e.g., nitrogen) can freeze skin

Allow equipment and their contents to reach a safe temperature before starting work.

Hydraulic Energy Hazards

• Energy of equipment containing liquids under pressure.

pressure can cause equipment to movepressure can cause equipment to move forcefully and rapidly rapid release can cause injury or ejection of

system parts

Relieve pressure slowly into a proper container.

Pneumatic Energy Hazards

• Energy of Compressed Gases or Steam • uncontrolled release can cause injury • rapid de-pressurization creates extreme lowrapid de pressurization creates extreme low

temperature

Properly vent all systems before starting work.

3

Chemical Energy Hazards

• Chemicals have energy that can: start fires burn skin or eyesburn skin or eyes generate harmful gases or vapors

• Before working – release, drain, and/or vent chemicals safely.

Magnitude of Electrical Hazards

•as little as 30 volts can carry enough current to kill a person•80 kV = “Stun Gun”

•1 amp = approx. current needed for auto dome light•15 amp = typical household current

• 1 milli-amp “faint tingle”• 5 milli-amps “slight shock, disturbing”• 9-30 milli-amps “painful, loss of muscular control, let-

go range”• 50-150 milli-amps “extreme pain; respiratory arrest;

cannot let go; death is possible”• 1,000-4,300 milli-amps “stops heart; nerve damage; likely

death”• 10,000 milli-amps “cardiac arrest, severe purns; death

probable”

Magnitude of Electrical Hazards – contd.

Example: “LOW VOLTAGE” does NOT imply “low hazard.”100 milli-amp current @ 3 seconds = same as 900 milli-amp for .03 seconds …. causing fibrillation.

Current is the culprit that kills; voltage determines how much will flow.AC voltage as low as 60 volts can kill.

Therefore, all factors being equal, the degree of injury is a function of the length of time the body is in the circuit.

Other Hazard Sources:• Moving parts• Pinch, nip, and crush points• Elevated componentsp• Blades• Loose clothing, long hair,

dangling jewelry

“Lockout” and “Lockout Devices:”

Lockout: The placement of a lockout device on an energy isolation device to ensure that the equipment being controlled cannot be operatedequipment being controlled cannot be operated until the lockout device is removed.Lockout Device: A device that uses a positive means

such as a lock to hold an energy isolation device in a safe position and prevent energizing the equipment.

Who Can Lockout Equipment?

• Only “authorized employees” who have been trained and designated bybeen trained and designated by management, and who will be performing the service or maintenance.

4

“Tagout” and “Tagout Devices:”

• Tagout: the placement of a tagout device on an energy isolation device to indicate that the equipment being controlled may not be

d il h d i i doperated until the tagout device is removed.• Tagout device: a prominent warning device

such as a tag that can be securely fastened to an energy isolation device with a warning that the equipment may not be used until the tagout device is removed.

Tagout Limitations:• Tags only provide warning• Tags do not provide the physical restraint that is

provided by a lockout deviceprovided by a lockout device.• Tags must never be ignored, removed, or bypassed• Must be securely attached• Must be legible and understandable• False sense of security?

• Always use L.O. & T.O. whenever possible.

Types of LO-TO Equipment:• Locks & Tags - specific to the

worker • Hasps - for placing locks &

tags • Circuit Breaker ClipsCircuit Breaker Clips• Threaded Pipe Caps & Plugs• Blank Flanges (“pancakes”) -

for fluid lines• Valve Covers• Handwheel Caps• Plug Buckets - for electrical

plugs

Lockout Devices:• Shall be affixed in a manner that will hold

the energy isolation devices in a safe or “off” position.

Tagout Devices:• Shall be affixed in a manner that clearly

indicates that the operation or movement of the energy isolation device from the safe or off position is prohibited.o pos t o s p o b ted.

• Must warn against hazards caused by energization:

e.g., “Do Not Start”

“Do Not Open”

“Do Not Operate”

Tagout devices - contd.• Where tagout devices cannot be affixed directly

to the energy isolation device • tag shall be located as close as possible to the device• in a position that will be immediately obvious to

anyone attempting to operate device• Securely fastened so it cannot be inadvertently

removed.• Procedure must provide same level of safety as full

LO/TO.

• Tags - means of attachment must be non-reusable, attached by hand, self-locking and non-releasable with a minimum unlocking strength of no less than 50 lbs.

5

TAGOUT (without Lockout)• Attach tag where lockout device(s) would be

installed.• Procedure must provide same level of safety

as lockout.EXAMPLESEXAMPLES:• Removal of isolating circuit element• Blocking of control switch• Opening of an extra disconnecting device• Removal of a valve handle

Energy Isolation Devices• A mechanical device

that physically prevents the transmission or release of energy.• Examples: disconnect

switch, manually operated circuit breaker, line valve, blank flange

• Push buttons, selector switches, and other control circuit types are not energy isolation devices

Use of Locks & Tags• Use only locks and tags

issued to you • Never use another worker’s

lock or taglock or tag • Ask your supervisor or

EH&S if you need more LO/TO equipment

• Never try to remove someone else’s lock or tag.

• Never ignore or bypass equipment that is locked-and/or tagged-out

Requirements for LO/TO Devices:

• Must be singularly identified• Be the only devices used for controlling

energy• N t d f th• Not used for any other purpose• Meet the following requirements

• Durable• Standardized• Substantial• Identifiable

6-Step LO-TO Procedure:1. Prepare for Shutdown 2. Shutdown Equipment 3. Isolate All Energy Sources 4. Place Locks & Tags5. Release Stored Energy 6. Verify Equipment Isolation

6

1. Prepare for Shutdown

• Understand: • Type and magnitude of energy source(s)

H d f th t b t ll d• Hazards of the energy to be controlled• Method(s) to be used to control the

energy – use written procedure• Notify other workers of shutdown

2. Shutdown Equipment

• Use normal shutdown procedure.• Orderly manner to avoid additional

hazards resulting from equipment g q pstoppage.

• Turn all energy controlling devices to “OFF.”

• Disable all other sources of energy.

3. Isolate All Energy Sources

All energy isolating devices that control the energy source(s) to the machine or equipment that

could cause injury whilecould cause injury while working on it, must be

physically located and isolated.Examples:• Open breakers & disconnects.• Close all control valves. • Pull fuses.

4. Apply Locks & TagsLockout and tagout devices shall

be affixed to each energy isolation device by authorized

employees performing the service/maintenance.

Examples:• Valves• Breakers / electrical disconnects• Block or disconnect all lines• Blank flanges

Lock(s) must be affixed in a manner that will hold the energy isolating device(s)

in a “safe” or “off” position.

5. Release or Block ALL Stored EnergyAll potentially hazardous stored or residual energy

must be relieved, disconnected, restrained, or otherwise rendered safe.

Examples:All i t d d t d?• All moving parts secured and stopped?

• Block or release springs • Block elevated parts • Stop rotating flywheels • Relieve trapped system pressure • Drain fluids • Vent gases • Discharge capacitors• Allow system to cool

6. Verify Equipment Isolation

• Confirm that all other workers are clear• Notify them of test

• Check locking devices securely placed g y p• Check isolation• Attempt normal startup

• REMEMBER: Return Controls to OFF/Neutral after start-up test

NOTE: Continue verification throughout servicing operation if there is possibility of reaccumulation of stored energy to a

hazardous level.

7

Q: Who Can Remove Locks & Tags?

A: Only the employee who y p yapplied the lock and tag.

Release from LO-TO:1) Inspect area and equipment.

a) Ensure all machine guards in place b) Move tools away from equipment c) Make sure all employees safely positioned/removed

2) Inform others of LO/TO device removal.)3) Restore system connections, guards, access panels, etc. 4) Removal of Locks & Tags by the employee who

applied them.5) Notify affected employees of start-up6) Restore equipment to normal. 7) Conduct normal startup.

Release from LOTO - contd.

If employee who applied device is not available to remove it, that device may be removed under the direction of the employer if all of the following are met:

1. Employer verifies employee is not at the facility2. Makes all reasonable effort to contact employee

to inform them of removal3. Ensure employee is aware that device was

removed before work resumes at facility

ContractorsAll contractor employees must follow Ithaca College

Lockout-Tagout procedures.

I.C. supervisors must coordinate with contractors to make sure I.C. and contractor employees understand each other’s LO/TO procedures.

Use Safe Electrical Practices• Use non-conducting tools and ladders.• Check that circuits are dead before working.• Lock & Tag source breakers not switches.g• Ensure all control power is de-energized.• Discharge all capacitors after lockout.• Don’t reach blindly into areas that may contain

energized parts.• Remove watches, rings, belt buckles, etc., when

working on exposed energized parts.

Q: A piece of equipment already has a lock and tag. Do I have to place my

own locks & tags if I will be working on

Group Lockout/Tagout:

it?YES. Each person working on the equipment must place his/her own locks and tags to ensure personal safety.

Supervisor must coordinate the LO/TO of group.

8

Lockout-Tagout Protects YOU!

************Protect YourselfProtect Yourself

By ALWAYSusing Proper

Lockout - TagoutProcedures

************

Cable Lockout

Gate Valve Lockout/Tagout Breaker Box Lockout

9

Emergency Stop & Fuse Lockouts

Hasps Ball Valve Lockouts

Pneumatic Disconnect Lockouts

Appendix F

Lockout/Tagout Annual Review & Periodic Inspection Form

Annual Lockout - Tagout Administrative Review

Department ______________ Date ____________

The Lockout/Tagout procedures for this facility have been reviewed for necessary changes. Each piece of equipment is listed and the required Lockout/Tagout isolation points (e.g., valves, breakers, disconnects, etc.) are properly identified.

Responsible Manager ___________________________________

The following changes have been made: (if no changes write "None")

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

_______________________________________________________________

______________________________________________________________

Lockout/Tagout Periodic Inspection

Equipment/System: ______________________ Department: ______________

Manager/Supervisor: __________________ Date/Time: _________ ________

Inspector(s): _______________________________________________________

Yes No NA Corr Date Area Inspected

1 All hazardous energy sources required to be de-energized, disengaged, blocked or locked-out during cleaning, servicing, adjusting, setting-up operations, or as required?

2. When electrical control circuit cannot be disconnected, are the appropriate electrical enclosures identified?

3. When electrical control circuit cannot be disconnected, is a means provided to assure control circuit can also be disconnected and locked-out?

4. Lockout of control circuits in lieu of locking-out main power disconnects prohibited?

5. All equipment control valve handles provided with a means for lockout?

6. Lockout procedure require stored energy be released or blocked?

7. Appropriate employees provided with individually keyed personal safety locks?

8. Employees required to keep personal control of their key(s) while they have safety locks in use?

9. Required that only employee exposed to the hazard, place or remove the safety lock?

10. Required that employees verify equipment lockout by attempting a start-up after making sure no one is exposed?

11. Employees instructed to always push the control circuit stop button prior to re-energizing the main power switch?

12 Means established to identify any/all employees who are working on locked-out equipment by their locks or accompanying tags?

13. In the event that equipment or lines cannot be shutdown, locked and tagged out, is a safe job procedure established and rigidly followed?

Periodic – Annual Observation of Lockout/Tagout Program

EMPLOYEE BEING OBSERVED: DEPT. : DATE:

BLDG.: MACHINE/EQUIPMENT/PROCESS: EQUIP. :

OBSERVATION QUESTION YES NO COMMENTS 1. Has all energy-isolating device been located? 2. Does the plant provide devices specifically for

lockout/tagout procedures?

3. Are lockout/tagout devices durable enough to withstand plant conditions?

4. When only tagout devices are used, are attachments non-reusable, attachable by hand, self-locking and non-releasable with minimum unlocking strength of 50 lbs.?

5. Can the person using a lockout/tagout device be easily identified?

Authorization:

6. Is an authorized person performing the lockout/tagout?

Preparation:

7. Are affected employees notified when there is an application or removal of lockout/tagout devices?

Shutdown:

8. Are normal “shutdown” procedures followed?

Energy Isolation:

9. Are energy isolating device(s) located and energy source(s) separated from the machine?

Lockout/Tagout Device Application:

10. Are lockout/tagout devices placed on each energy-isolating device?

OBSERVATION QUESTION Stored Energy:

11. Are potentially hazardous, stored or residual energy relieved, disconnected or restrained?

Verification of Isolation:

12. Does the authorized employee verify that de-energization of the equipment has been accomplished?

Inspection:

13. Prior to removing locks/tags, has the work area been inspected, nonessential items removed and the machine components including guards, made operationally intact?

Employee Notification:

14. Prior to removing locks/tags, have affected employees been notified and the work area inspected to ensure all employees are in a safe position?

Lockout/Tagout Device Removal:

15. Have Lockout/Tagout devices been removed by the person who applied them?

COMMENTS:

OBSERVER INFORMATION

OBSERVER EMPLOYEE

OBSERVER SIGNATURE TITLE DEPT. DATE

EMPLOYEE

EMPLOYEE SIGNATURE TITLE DEPT. DATE

***A COPY OF THIS COMPLETED FORM MUST BE FILED WITH

ITHACA COLLEGE – EH&S ***

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