LOCK AND TAG PROGRAM FOR THE CONTROL OF HAZARDOUS ENERGY

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

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

INTRODUCTION What is NOT included? The program does not include Equipment Specific L&T Procedures. The departments have to prepare them for their equipment and train the authorized employee. All L&T procedures must be submitted to Safety for review. Lock & Tag

SCOPE (1) Covered: Locking out of all hazardous energy sources such as electrical, mechanical, hydraulic, pneumatic, chemical, or thermal. Lock & Tag

SCOPE (1) Not covered (1.2): Operation locks PPS locks to prevent operation Locks to block entry Locks for administrative control Construction Permanently disconnected Lock & Tag

APPLICABILITY OSHA: Required by OSHA as follows: - 1910.147 (covers all Hazardous. Energy sources) - 1910.333 (covers electrical only) This is for personnel safety and not an operational lock out. Lock & Tag

APPLICABILITY (2) Site-wide (all OTC) 50 V and above Below 50 V if hazardous Moving/rotating equipment Service and Maintenance (includes modifications, etc.) of any system involving hazardous energy. Lock & Tag

EXCEPTIONS (3) Energized Circuits (3.1): 3.1 May work on energized circuits without lock and tag provided: Safe work practices (OSHA Subpart S) AND approval obtained AND safety watch provided (Chapter 8) Lock & Tag

EXCEPTIONS (Cont’d) And only in following situations: Increases hazard (fire protection, life support, etc.), Or infeasible, Or testing which requires energizing. Lock & Tag

EXCEPTIONS (Cont’d) HOT TAP OPERATIONS (3.2): See manual. Lock & Tag

EXCEPTIONS (Cont’d) CORD AND PLUG (3.4) If the plug is in exclusive control of the worker, no L&T required. Use plug hugger or lock-a-plug device, if not in sight or in arm’s reach. Lock & Tag

INTERLOCKS RESTRICTION ON INTERLOCKS (4): Interlocks not to be used in place of lock and tag on the energy source as per OSHA. Lock & Tag

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

LOCK & TAG PROCEDURES (5) Two types of equipment: 1) Equipment which needs ELP. ELP = Equipment (specific) Lock and Tag Procedure. Note: All equipment needs ELP unless meets exceptions (See 6.3) 2) Equipment which needs GLP. GLP = General Lock and Tag Procedure. If Equipment meets exceptions (see 6.3) ELP is not required. Use GLP. Lock & Tag

ELP (6) Similar equipment may be covered by a single procedure. RESPONSIBILITY (6.1): Dept. or shop in control of the equipment is responsible for ELP. Lock & Tag

ELP (6) PREPARATION OF ELP: (6.2): STEP 1: Make inventory STEP 2: Fill out forms for each equip. 1. Equip. identification 2. Controls 3. Energy Sources 4. Shutdown & verify 5. Release from L&T 6. List Authorized & affected employees 7. Title sheet, approval, etc. Lock & Tag

ELP (Cont’d) Which equipment needs ELP? ALL except those which meet all 8 exceptions (6.3): 1. No stored energy 2. Single energy source, readily identified and isolated. 3. Lockout will completely deactivate machine. 4. Machine remains isolated. 5. A single lockout will do it. 6. In exclusive control of the worker. 7. No hazard for other personnel. 8. No accident in the past. (All above are as per OSHA) Lock & Tag

GLP (7) Which equipment may be locked out by GLP? - Meets exceptions (6.3) - And does not have ELP. Responsibility: Dept. or Shop in control of equipment is responsible for checking the equipment for exceptions (7.1). Lock & Tag

GLP (7) GLP STEPS FOR APPLICATION: Check - are you authorized for the equip? If yes, proceed. STEP 1: Prepare and notify. STEP 2: Shutdown: use normal procedure. STEP 3: Isolate from energy source. (note interlock is not a substitute for L&T) STEP 4: Apply lock and dated tag. Lock & Tag

GLP (7) (Cont’d) STEP 5: Verification of isolation. Electrical: 1) Verify it cannot be started. 2) Check voltage, by a qualified person. Non-electrical: Verify machine is isolated and deenergized. STEP 6: Keep lock and tag on till finished. Every person must have his/her lock and tag Lock & Tag

GLP (Cont’d) RELEASE FROM LOCKOUT (7.3): When finished, do the following: STEP 1: Clear personnel and tools. STEP 2: Check for mechanical hazards. STEP 3: Notify operators and affected employees. STEP 4: Remove your own lock and tag. (To remove other person’s lock, see section 8.6) Lock & Tag

ADDITIONAL REQUIREMENTS (8) SHIFT OR PERSONNEL CHANGE (8.1) Supervisor’s lock may be used as a bridge lock. Exchange locks at shift change. Continuity of protection is essential. GROUP LOCKOUT (8.2/8.3) One crew versus multiple crews. Lock & Tag

ADDITIONAL REQUIREMENTS (8) GROUP L/O FOR ONE CREW (8.2) Choice - Each employee applies L&T or use this procedure as a short cut. STEP 1: Lockout by an Authorized Employee. STEP 2: Select a CLL. CLL shall: (CLL = Crew Lockout Leader; must be part of crew) 1) Apply personal Lock/Tag. 2) Verify isolation. Lock & Tag

ADDITIONAL REQUIREMENTS (8) 3) Each worker applies his/her personal tag (lock is not necessary). 4) Each worker removes his/her tag when done and safe. 5) CLL removes L&T last. Follows appropriate release procedure. E.g., check for clearance of tools, etc. Lock & Tag

ADDITIONAL REQUIREMENTS (Cont’d) GROUP L/O FOR MULTIPLE CREWS (8.3): Select a CLL and a ELC (ELC = Equipment Lockout Coordinator) ELC is typically an Area Manager or a Supervisor. He does not have to be in crew. (Remember, CLL must be a member of crew). Lock & Tag

ADDITIONAL REQUIREMENTS (Cont’d) ELC does the following: STEP 1: Applies L&T to Equip. or Lock Box. Use experts as necessary. STEP 2: Coordinates CLLs. STEP 3: When finished, removes L&T last after thorough checkout. Lock & Tag

ADDITIONAL REQUIREMENTS (Cont’d) If already locked out (8.4): You must apply your personal lock and tag in addition to existing lockout after notifying the owner of existing lockout. ENERGIZING FOR TESTING, ETC. (8.5): STEP 1: Remove L&T, use appropriate release procedure. STEP 2: After testing, reapply L&T. Lock & Tag

ADDITIONAL REQUIREMENTS (Cont’d) UNLOCING BY OTHERS (8.6): Only if: A. Authorized by the owner of the L&T, OR B. In absence of the owner, use 5 steps: 1) Verify not on site; 2) Try to contact; 3) Record; 4) Safe? 5) Inform owner when he comes back to site for his/her safety (Very Very Important) Lock & Tag

ADDITIONAL REQUIREMENTS (Cont’d) CONTRACTOR PERSONNEL (8.7): • Contractor uses his/her Procedures. • Affected employees shall be informed. • Contract personnel supervised by USOC Project Manager. Lock & Tag

ADDITIONAL REQUIREMENTS (Cont’d) IF NOT LOCKABLE (8.8) Use additional safety measures. 7 choices (see 8.8) such as: • L&T Upstream (if practical). • Remove fuse or disconnect (tag wires). • Operate two breakers in series. • Remove valve handle. • Blank or blind pipe line or duct. • Block or lock a control switch. • Post a safety guard. Lock & Tag

ADDITIONAL REQUIREMENTS (Cont’d) NEW EQUIPMENT (8.9) Must be lockable as per OSHA. VERIFICATION OF ISOLATION (8.10) ELECTRICAL: 1) check, cannot start. 2) check voltage. NON ELECTRICAL: check deenergized. Lock & Tag

ADDITIONAL REQUIREMENTS (Cont’d) STORED ENERGY (8.11) ELECTRICAL: Ground and short capacitors. Restrain from reenergizing. NON ELECTRICAL: Relieve, restrain or disconnect to make it safe. Lock & Tag

LOCK AND TAG DEVICES (9) PADLOCKS (9.1) Use only designated RED lock 1) Identify lock 2) Must attach a tag 3) Dept. may keep a duplicate Key. 4) Exclusive for Energy Lockout use. Lock & Tag

LOCK AND TAG DEVICES (9) TAGS (9.3) Two types of tags: 1. Personal Tag 2. Special Tag - supervisor tag, ELC tag, shop tag Lock & Tag

LOCK AND TAG DEVICES (9) TAGS SHALL BE: 1) Only designated photo tags 2) Place photo 3) Laminate to protect from environment. 4) Front: Name, dept., phone, pager. Back: Date, equipment affected. 5) Numbered to help you manage your tags. 6) Exclusive for energy lockout. 7) Attach by cable tie, 50 pounds rule. May apply directly on lock. Lock & Tag

LOCK AND TAG DEVICES (9) SPECIAL TAGS: To be used as 1) ELC or Supervisor Tag 2) Group (Shop/Dept) Tag ELC or Supervisor Tag: Front - Identify ELC or Supervisor. - Name, Dept., phone/pager. Back - Date, affected equipment. Lock & Tag

LOCK AND TAG DEVICES (9) Group Tag: Front - Name of Group/Shop/ Dept Phone/Pager of the Group Back - Date, affected equipment. Signed by the person who applies it. See Appendix A for sample. Lock & Tag

• Supervisor or Equipment Lockout Coordinator (ELC) tag. Tag A illustrates a personal tag to be used by individuals. Tag B illustrates a special tag to be used as: • Supervisor or Equipment Lockout Coordinator (ELC) tag. • Group, shop, or department tag. Lock & Tag

Appendix A: Tags Tags shall include the following minimal information: Personal Tag Front: Name, department, phone and/or pager number. Back: Write the date of application and identification of affected equipment or circuit. Lock & Tag

Appendix A: Tags Special Tag Front: ELC or Supervisor Tag - Write the words Equipment Lockout Coordinator or Supervisor (as applicable) I the area marked with a dotted box. Additionally, write the name, department, phone and/or pager number of the ELC or supervisor. Back: Write the date of application of affected equipment or circuit. The group/shop/department department tag shall be signed by the person who applies it. Lock & Tag

Training (10) RESPONSIBILITY: The supervisor of the employee PURPOSE (10.2): - Provide skill and uniformity in application. - Regulatory requirement by OSHA. Lock & Tag

Training (10) TYPES OF TRAINING (10.3) - Authorized - Affected - Other TRAINING IN LIMITATION OF TAGS (10.4) 1. Warning devices only 2. Do not remove except your own. 3. Must be legible. Lock & Tag

Training (Cont’d) TIMING OF TRAINING (10.5) RETRAINING (10.6) Affected and other - time of orientation Authorized - prior to use of L&T. For new hires, supervisor. May give informal training to start. Formal training within 3 months. RETRAINING (10.6) Required if: - Change in job assignment or equipment with new hazards. - Change in procedures. - Inadequacies found. Lock & Tag

Training (Cont’d) TRAINING RECORD (10.7) Supervisor shall maintain the record of training. TRAINING IN ELPs This training is a basic training or L&T program training. One must have training in ELPs as needed, provided by department. Lock & Tag