1.0 PURPOSE
The purpose of this procedure is to provide written instructions to prevent accidental exposure to hazardous energy sources.
2.0 RESPONSIBILITY
It is the responsibility of the site manager to control and implement the requirements of this procedure. An “Authorized LOTO Supervisor” will have the primary responsibility for a set number of employees working under the protection of a group lockout/tag out device. On sites where the customer has a LOTO procedure in place, that procedure may be used in lieu of this procedure, provided it provides equal or stricter protection.
3.0 REFERENCES
29 CFR 1910.147
29 CFR 1926.416
29 FR 1926.417
4.0 DEFINITIONS
4.1 Affected Employee – An employee whose job requires him to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tag out.
4.2 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. (See Sec. 4.0 Responsibility)
4.3 Authorized LOTO Supervisor – An employee who is in charge of the lockout/tag out program for a specified group of authorized lockout/tag out participants.
4.4 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.
4.5 Energized – Connected to an energy source or containing residual or stored energy.
4.6 Energy Isolating Device – A mechanical device (switch, valve, etc.) that physically prevents the transmission or release of energy.
4.7 Energy Source – Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, kinetic, or other energy.
4.8 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.
4.9 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 position and prevent the energizing of a machine or equipment.
4.10 Qualified Person – A person designated by the employer as capable, by education and/or training, of anticipating, recognizing, and evaluating employee exposure to hazardous energy or other unsafe condition working on/or around equipment and/or machinery.
4.11 Tagout – The act of placing a tag out device on an energy-isolating device, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tag out device is removed.
4.12 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 to indicate that the energy-isolating device and the equipment being controlled may not be operated until the tag out device is removed.
5.0 REQUIREMENTS
Employees shall not be allowed to work in proximity to hazardous energy sources in which during the course of work the employee could contact the energy source unless the source is de-energized or effectively guarded.
Servicing and/or maintenance of or around machines, equipment, lighting, or piping that could cause injury if accidentally started, energized, pressurized, etc. shall not be allowed until lockout/tag out has been completed to ensure employee safety.
6.0 COMPLIANCE WITH THIS PROGRAM
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 this procedure unless superseded by the site procedure. All employees, upon observing a machine or piece of equipment, which is locked out to perform service and maintenance, shall not attempt to start, energize, or use that machine or equipment.
The program will be enforced through the job site disciplinary program. The initial training will be performed at new hire and the strict adherence to the policy from that point will be required. The penalty for deviation from the policy will include disciplinary action up to and including termination.
7.0 PROCEDURE
The following procedures shall be used to assure that the machine, equipment, lighting, or piping is stopped or de-energized, isolated from all potentially hazardous energy sources, and locked out before employees perform any servicing or maintenance. This applies where the unexpected energization or start-up of the machine or equipment, or release of stored energy could cause injury and/or equipment damage. If it can be locked out, it must be locked out, unless the client’s procedure supersedes the Nitro Construction Services procedure contractually.
7.1 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 this procedure. 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.
7.2 Sequence of Lockout
7.2.1 Notify all affected employees that servicing, or maintenance is required on a machine, equipment, lighting, or piping and that the machine or equipment must be shut down and locked out to perform the servicing or maintenance.
7.2.2 The authorized LOTO Supervisor shall refer to the machine, equipment, lighting, or piping data sheets to identify the type and magnitude of energy that the machine or equipment utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy. The attached sample form (NCS Form 019) or similar local form with equal information shall be used and transferred to all authorized employees for information and instructional purposes. If an item on the LOTO form is not applicable to the job being done, document it as “N/A”.
7.2.3 If the machine, equipment, lighting, or piping is operating, the authorized employees shall then shut it down by the normal stopping procedure. (Depress stop button, open switch, close valve, etc.)
7.2.4 Deactivate the energy isolating device(s) so that the machine or equipment is isolated from the energy source.
7.2.5 Lockout the energy-isolating device with assigned individual lock(s) and/or tag(s). Each affected employee (regardless of craft) shall apply a lockout device at the energy isolating device or group lockbox. LOTO devices shall indicate the name of the individual applying the tag as well as the Nitro Construction Services name.
7.2.6 Stored up residual energy (such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam or water pressure, etc.) must be dissipated or restrained by methods such as grounding, blocking, bleeding down, etc. If there is a possibility of re-accumulation of stored energy level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists.
7.2.7 Ensure that the equipment is disconnected from the energy source(s) by first checking that no personnel is exposed, and then verify the isolation of equipment by operating the push button or other normal operating control(s) or by testing to make certain the equipment will not operate. Note: Return operating control(s) to neutral or “off” position after verifying the isolation of the equipment.
7.2.8 The machine or equipment is now locked out.
7.3 Restoring Equipment to Service / Temporary Removal of LOTO (See NCS Form 019)
7.3.1 Check the machine or equipment and the immediate area around the machine or equipment to ensure that non-essential items have been removed and the machine or equipment components are operationally intact.
7.3.2 Check the work area to ensure that all employees have been safely positioned or removed from the area.
7.3.3 Verify that the control(s) is/are in neutral.
7.3.4 Remove the lockout devices and re-energize the machine or equipment.
7.3.5 Notify affected employees that the servicing or maintenance is completed and the machine or equipment is ready for use.
7.3.6 If the machine is being tested: De-energize and re-apply control measures. Authorized LOTO Supervisor is to perform and verify LOTO procedures
7.3.7 Return the Energy Control Inspection form to the Authorized LOTO Supervisor where it can be attached to the crew timesheet.
7.4 If an energy-isolating device is not capable of being locked out, the employer’s energy control program shall utilize a tag-out system.
7.4.1 Tagout devices, including their means of attachment, shall be substantial enough to prevent inadvertent or accidental removal. Tagout device attachment means shall be of the non-reusable type, attachable by hand, self-locking, and non-releasable with a minimum unlocking strength of no less than 50 pounds and having the general design and basic characteristics of being at least equivalent to a one-piece, all environment-tolerant nylon cable tie.
7.4.2 Tagout devices shall warn against hazardous conditions if the machine or equipment is energized, and shall include a legend, such as the following:
Do Not Start Do Not Open Do Not Close
Do Not Energize Do Not Operate
The tag should also identify the appropriate Nitro Construction Services entity as the contractor implementing the lockout/tag-out and the date implemented.
7.4.3 When a tag is attached to an energy isolating means, it is not to be removed without authorization of the authorized person responsible for it, and it is never to be bypassed, ignored, or otherwise defected.
7.5 Examples of Equipment/Machines with Energy Sources:
7.5.1 Electrically driven equipment:
Pumps, compressors, blowers, fans
Motor-operated valves Conveyor belts
Electric heaters Desalter and precipitator grids
Rotary feeders Bin activators
Screw conveyors Ignitors
Elevators Oxygen analyzers Mixers
7.5.2 Scraper drives for double-pipe chillers and API separators
• Steam-driven equipment: Pumps, compressors, blowers, fans, educators, jets on condensing turbines
• Pneumatically-driven equipment: Control valves, Drier switching valves, Portable pumps, Chemical injection pumps, Barring over compressors (on compressors)
• Hydraulically operated equipment: Slide valves, Trip and throttle valves, Power recovery turbines, Firewater system, Mainline block valves, Hydrant/monitor block valves, Compressed gas cylinders, Heavy equipment (crane booms, dozer blades, etc.)
7.6 Safety Testing Machines Temporary LOTO Removal
7.6.1 The written requirements must be in this order: Clear away tools; remove employees; remove the LOTO device; energize and proceed with testing; de-energize & reapply control measures.
7.6.2 This procedure shall be documented (i.e., who performs & verifies).
7.7 Shift Change
7.7.1 During shift change or personnel changes, the LOTO Supervisor shall leave his/her LOTO device in place to ensure the continuity of lockout or tag out procedures (each employee shall attach a personal lockout device to the group’s device while he/she is working & then remove it when finished.)
7.7.2 The LOTO Supervisor shall pass his / her key on to the LOTO Supervisor of the following shift.
8.0 TRAINING
8.1 Each authorized employee shall be trained in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control.
8.2 Each affected employee shall be instructed in the purpose and use of the energy control procedure.
8.3 All other employees whose work operations are or maybe in an area where energy control procedures may be utilized shall be instructed about the procedure, and about the prohibition relating to attempts to restart or re-energize machines or equipment which are locked out or tagged out.
8.4 When tag out systems are used; employees will also be trained in the following limitations of tags:
8.4.1 Tags are essentially warning devices affixed to energy isolating devices, and do not provide the physical restraint on those devices that is provided by a lock.
8.4.2 Tags must be legible and understandable by all authorized employees, affected employees and all other employees whose work operations are or maybe in the area, to be effective.
8.4.3 Tags and their means of attachment must be made of materials that will withstand the environmental conditions encountered in the workplace.
8.4.4 Tags may evoke a false sense of security, and their meaning needs to be understood as part of the overall energy control program.
8.4.5 Tags must be securely attached to energy isolating devices so that they cannot be inadvertently or accidentally detached during use.
8.5 Employee retraining shall be provided whenever job conditions change, machinery changes, or equipment processes change that present a new hazard. Also, whenever there is a change in energy control procedures or when a periodic inspection reveals inadequate knowledge of employees.
8.6 Certification of Training / Retraining
8.6.1 The certification shall contain each employee’s name, social security number, and date of the training.
9.0 DOCUMENTATION
All documentation generated because of training shall be maintained in secure storage throughout the life of the contract and transmitted to the Nitro Construction Services office for storage when the job is completed.
10.0 POLICY REVIEW AND INSPECTION
Nitro Construction Services shall conduct a periodic review of the energy control procedure at least annually and periodic inspections in the workplace to assure that the requirements of this procedure are being followed.
10.1 The corporate safety office will review, maintain, and update this policy manual and this LOTO procedure.
10.2 A periodic inspection shall be conducted to correct any deviations or inadequacies identified. The site manager shall be responsible for performing the periodic inspections for his site.
10.3 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 inspected.
10.4 Where tag out is used for energy control, the periodic inspection shall include a review between the inspector and each authorized and affected employee of that employee’s responsibilities under the energy control procedure being inspected, and the elements set forth in section 9.0 TRAINING of this policy.
10.5 The site manager shall certify that the periodic inspections have been performed. The certification shall identify the types of machines 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 inspection.
11.0 APPENDICES
11.1 NCS Form 019 – Nitro Lockout/Tagout Sheet
11.2 NCS Form 020 – Nitro LOTO Audit Form