Table of Contents

• Purpose
  
• Definitions
  
• Responsibility
  
• Training
  
• Sequence of Lockout/Tagout Procedures
  
• Group Lockout/Tagout
  
• Shift or Personnel Changes
  
• Contractors
  
• References
  

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Purpose

It is the intent of The Florida State University (FSU) to provide every employee with a safe and healthful working environment. The administration at FSU feels that any faculty or staff members who, during the course of their employment activities, are required to service and maintain machines/equipment should be protected.

This procedure establishes the minimum requirements for the lockout or tagout of energy isolating devices. It shall be used to ensure that the machines or equipment are isolated from all potentially hazardous energy, and locked out or tagged out before employees perform any servicing or maintenance activities where the unexpected energization, start-up or release of stored energy could cause injury.

This Lockout/Tagout Program, as set forth in the following manual, applies to activities such as, but not limited to: erecting, installing, constructing, repairing, adjusting, inspecting, cleaning, operating, or maintaining the machine/equipment/process.

This Program applies to energy sources such as, but not limited to: electrical, mechanical, hydraulic, pneumatic, chemical, radiation, thermal, compressed air/gas, stored energy (such as in springs), and potential energy from suspended parts (gravity).

This manual has been developed by the Department of Environmental Health & Safety (EH&S). The Coordinator, EH&S, Industrial Hygiene is charged with administering the Program for FSU. The Industrial Hygiene Coordinator is also responsible for reviewing the Program on an annual basis to ensure the effectiveness of the Program. The results of the evaluation will be presented in a written report that lists plans to correct any faults, if discovered, and the target dates for their implementation.

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Definitions

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: An employee 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 by this Program.

Principal authorized employee: An authorized employee who has been assigned the responsibility for a set number of authorized employees in a crew, department, or other group, who are working under the protection of a group lockout/tagout device.

Primary authorized employee: An authorized employee who has been assigned the responsibility of coordinating the overall lockout/tagout control when more than one crew, department or other group is involved; coordinates the affected work forces and ensures the continuity of protection. For example, a Project Manager.

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 services activities which 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 in the safe position and prevent the energizing of a machine or equipment. Included are blank flanges, bolted slip blinds and chains.

Normal production operations: The utilization of a machine or equipment to perform its intended production function.

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/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.

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Responsibility

The lockout/tagout procedure applies to all employees whose job requires servicing and/or maintenance of machines/equipment; and employees working in areas where servicing and/or maintenance is performed. All employees who use lockout/tagout procedures must be authorized by supervision. The authorization requires special lockout/tagout instructions, rules, and techniques including, but not limited to:

• intended use of the procedure;
• steps for shutting down, isolating, blocking and securing;
• steps for placement, removal and transfer of lockout/tagout devices and responsibility; and
• requirements for testing to determine and verify the effectiveness of the lockout/tagout devices.

The following departments/agencies have been recognized as having personnel who service and maintain equipment and will use lockout/tagout procedures. Others may be added as they become known:

• Environmental Health and Safety
• Facilities Operations and Maintenance
• Housing Maintenance
• Alumni Village Maintenance
• Central Utilities Plant
• National High Magnetic Field Laboratory
• Campus Recreation
• Academic Diving
• Ogelsby Student Union
• WFSU-FM
• Laboratory Animal Resources
• Panama City Campus, Maintenance

FSU Departments/Agencies

Departments/Agencies are responsible for the following:

• Selecting a designated person to oversee that department's/agency's lockout/tagout procedures (Lockout/Tagout Supervisor).
• Selecting authorized employees
• Each authorized employee is responsible for learning and following the procedures and practices under this program.
• Maintain, at no cost to employees, a lockout/tagout station to be at a central location(s) in that department/agency. Each station shall have an adequate supply of padlocks, DANGER tags, group lockout/tagout devices, chains, wedges, adapter pins, fasteners and other necessary equipment for use each time a lockout/tagout process is performed.
• Develop written lockout/tagout policy/procedures, which incorporate the following elements:
• All personnel shall comply with the provision of the lockout/tagout program. Supervisors must enforce the use of personal locks/tags to ensure protection when personnel performing tasks where exposure to unexpected energization may occur.
• The locks/tags shall be standardized throughout the department/agency and the only authorized method for the lockout/tagout of energy sources. Locks and tags shall not be used for any purpose other than personal protection.
• Individual locks/tags shall be applied and removed by each person exposed to the unexpected release of energy, other than in those special situations where specific facility procedures have been developed.
• Where equipment is lockable, use of a lock is required by all exposed personnel.
• Where equipment is not lockable, tagout application or special lockout/tagout procedures shall be utilized.
  Note: As of January 2, 1990, whenever replacement, major repair, renovation, or modification of a machine or equipment is performed, and whenever new machines or equipment are installed, energy isolating devices for such machine or equipment shall be designed to accept a lockout device.
• When locks are used in the lockout/tagout application, tags shall always accompany them.
• Energy isolation devices shall be clearly labeled or identified to indicate their function unless located and arranged so their purpose is evident.
• The lockout/tagout of electrical energy sources shall occur at the circuit disconnect switch. Identify any situations where the circuit cannot be positively interrupted and develop procedures providing equivalent protection.
• The use of electrical control circuitry to accomplish lockout/tagout is prohibited since it does not offer positive personnel protection.
• The specific procedures to lockout/tagout machinery/equipment under control of that department/agency, including:
• Department/Agency name
• Equipment description
• Energy source(s)
• Type(s) and location(s) of energy isolating means
• Stored or residual energy
• Intended use of the procedure
• Steps for shutting down, isolating, blocking, and securing
• Steps for placement, removal, and transfer of lockout/tagout devices and responsibility
• Requirements for testing to determine and verify the effectiveness of the lockout/tagout devices and other measures.

The EH&S Department is responsible for the following:

• Developing and Administering the Lockout/Tagout Program
• Monitoring Program compliance
• Assisting with specific lockout/tagout procedures
• Maintaining a current list of employees who have completed lockout/tagout training.
• Giving final approval for cutting or removal of a lock when it is not done by the employee who installed the lock.

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Training

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 energy isolation and control.

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

All other employees who do not work in areas where lockout/tagout may be used will be provided a brief overview of the lockout/tagout program.

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

• Tags are essentially warning devices affixed to energy isolation devices. They do not provide the physical restraint on those devices that is provided by a lock.
• When a tag is attached to an energy isolation device, it is only to be removed by the authorized employee responsible for it, and it is never to be bypassed or ignored.
• Tags must be legible and understandable by all employees.
• Tags and their means of attachment must be made of materials that will withstand the environmental conditions encountered in the workplace.
• Tags may evoke a false sense of security, and their meaning needs to be understood as part of the overall energy control program.
• Tags must be securely attached to energy isolation devices so that they cannot be inadvertently or accidentally detached during use.

Employee retraining:

• Retraining shall be provided for all authorized 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.
• Additional retraining shall also be conducted whenever a periodic inspection reveals, or when the department/agency/supervisor believes that there are deviations from or inadequacies in the employee's knowledge or use of the energy control procedures.
• The retraining shall reestablish employee proficiency and introduce new or revised control methods and procedures, as necessary.

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Sequence of Lockout/Tagout Procedures

The lockout/tagout sequence is as follows:

1. Notify all affected employees that a lockout/tagout system is going to be utilized and the reason why.

2. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress stop button, open toggle switch, open or close valve, etc.).

3. Operate the switch, valve, or other energy isolating device(s) so that the equipment is isolated from its energy source(s). Stored energy (such as that in springs, elevated machine parts, rotating flywheels or fan blades, hydraulic systems, and gas, air, steam or water pressure, etc.) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, venting, etc. If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall be continued until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists.

4. Lockout and/or tagout the energy isolating devices with assigned individual lock(s) and/or tag(s).

5. After ensuring that no personnel are exposed, one or more of the following actions must be taken:

   • Operate the equipment/process control(s) (push buttons, switches, etc.) to verify that energy isolation has been accomplished.
     Caution:Return operation control(s) to "neutral" or "off" position after the test.

   • Check the equipment/process by the use of test instruments and/or visual inspection to verify that energy isolation has been accomplished.

6. The equipment/process has now been locked/tagged out.

Release from lockout/tagout:

Before lockout/tagout devices are removed and energy is restored to the equipment/process, procedures shall be followed and actions taken by the authorized employee(s) to ensure the following:

1. Tools, debris and other items have been removed from the equipment/process.

2. All employees have been safely positioned or removed.

3. All guards have been replaced.

Lockout/tagout device (s) removal:

Each lockout/tagout device shall be removed from each energy isolating device by the employee who applied the device.

When the authorized employee who applied the lockout/tagout device is not available to remove it, that device may be removed under the direction of that department's/agency's Lockout/Tagout Supervisor, provided that specific procedures for such removal have been developed, documented and incorporated into the department's/agency's energy control program. Specific procedures include at least the following elements:

• Verification by the department/agency supervisor that the authorized employee who applied the device is not at the facility.

• Make all reasonable efforts to contact the authorized employee to inform him/her that his/her lockout/tagout device has been removed. If the employee cannot be contacted and the lock must be removed, the Primary Authorized Employee shall contact EH&S at 644-6895 for final approval to remove the lock. If it is after hours, contact FSUPD at 644-1234; they will contact EH&S.

• Ensure that the authorized employee has this knowledge before he/she resumes work at that facility.

Lockout/tagout interruption (energized testing):

In situations where the energy isolating device(s) is locked/tagged and there is a need for testing or positioning of the equipment/process, the following sequence shall apply:

1. Clear equipment/process of tools and materials.

2. Clear all personnel.

3. Remove locks/tags from the energy isolating device(s) according to established procedure.

4. Proceed with test/positioning.

5. De-energize and re-lock/tag energy isolation device(s) to continue work.

6. Operate controls or use test instruments to verify energy isolation.

7. Return controls to "off" or "neutral" position, if applicable.

High voltage work

Special written procedures shall be developed by the department/agency to describe the lockout/tagout measures necessary when employees are required to work on high voltage circuits or equipment (above 600 volts).

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Group Lockout/Tagout

When servicing and/or maintenance is performed by a crew, department, or other group, they shall utilize a written procedure which gives the employees a level or protection equivalent to that provided by the implementation of a personal lockout/tagout device.

Group lockout/tagout devices shall be used in accordance with the procedures required by paragraph III, A of this Section including, but not limited to, the following specific requirements:

• Responsibility is vested in an authorized employee (Principal Authorized Employee) for a set number of employees working under the protection of a group lockout/tagout device.

• Provision for the authorized employee to ascertain the exposure status of individual group members with regard to the lockout/tagout of the equipment/process.

When more than one crew, department, or other group is involved, overall job-associated lockout/tagout control responsibility shall be assigned to an authorized employee (Primary Authorized Employee) designated to coordinate affected work forces and ensure continuity of protection.

Each authorized employee shall affix a personal lockout/tagout device to the group lockout/tagout 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 equipment/process being serviced or maintained.

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Shift or Personnel Changes

Specific procedures shall be implemented, documented, and utilized during shift or personnel changes to ensure the continuity of lockout/tagout protection, including provisions for the orderly transfer of lockout/tagout device protection between off-going and oncoming employees to minimize exposure to hazards from the unexpected energization or start-up of the equipment/process, or the release of stored energy.

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Contractors

Whenever outside Contractors are to be engaged with lockout/tagout procedures, the FSU on-site department/agency/Project Manager and the Contractor shall inform each other of their respective lockout/tagout procedures.

FSU personnel that observe Contractors not complying with a Lockout/Tagout Program or procedures shall contact EH&S at 644-6895.

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References

1. Occupational Safety and Health Administration (OSHA) 29 CFR 1910.147-1995, The control of hazardous energy (lockout/tagout)

2. Lockout/Tagout The Process of Controlling Hazardous Energy, Edward V. Grund, 1995

3. Florida Administrative Code 38I-20, Safety and Health Standards

4. Florida Department of Labor and Employment Security, Division of Safety, Sample Lockout/Tagout Program

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