Illinois State University
Lockout Tagout Procedure
Illinois State University
Facilities Management
Revision Date: May 2016
Illinois State University Facilities Management
Lockout Tagout Procedure
1.0
Purpose and Scope
The purpose of this procedure is to establish minimum guidelines to ensure the safety and health
of personnel who may be required to work on any type of equipment capable of being energized
or harboring stored energy. This program will be used to ensure that a machine or equipment is
stopped and isolated from all potentially hazardous energy sources, and locked out before
employees perform any servicing or maintenance where the unexpected energization, start-up of
the machine/equipment, or release of stored energy could cause injury.
This procedure applied to all Facilities Services, Heating Plant, and other Illinois State
University employees and on-site contractors who may be required to work on this type of
equipment or otherwise be exposed to the unexpected energization of this equipment.
2.0
References
2.1
2.2
3.0
OSHA 29CFR 1910.147: Control of Hazardous Energy; Lock-out / Tag-out
OSHA 29CFR 1926.417: Lock-out and Tagging of Circuits
Attachments
Attachment 1: List of Qualified Employee’s
Attachment 2: Lockout / Tagout Inspection Record
4.0
Definitions
Affected Employee – An employee whose job required him/her to operate of use a
machine or equipment on which servicing is being performed under the lockout/tag-out program, or whose job requires him/her to work in an area where such
servicing is being performed.
Authorized Employee – A person who locks or tags out machines or equipment in order
to perform work on that machine or equipment.
Energy Isolation Device – a mechanical device that physically prevents the transmission
or release of energy.
Lock-out – the placement of a lock-out device (usually a lock) on an energy isolating
device to ensure that the energy isolating device and the equipment being
controlled may not be operated until the lock-out device is removed.
Qualified employee – One who has skills and knowledge related to the construction and
operation of the equipment and has received safety training on the hazards
involved.
Note: It is possible and, in fact, likely for an individual to be considered “qualified” with
regard to certain equipment in the workplace, but “unqualified” as to other
equipment.
Tag-out – the placement of a tag-out 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. Note: Tag-out device attachment means shall
be of a non-reusable type, attachable by hand, self-locking, and non-relaeasable
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.
5.0
Responsibilities
5.1
5.2
5.3
Facilities Management:
5.1.1
Facilities Management shall assume ownership and responsibility for
implementation of this procedure. Facilities Management personnel are to
be cognizant of the requirements established for implementation of this
procedure.
5.1.2
Facilities Management will assure that the locks, tags and other devices
required for compliance with lockout/tagout procedures are provided to
their employees.
5.1.3
Supervisors are to ensure that personnel assigned to perform work
requiring a lock-out/tag-out are formally trained to do so and strictly
comply with all requirements established in this procedure.
The Office of Environmental Health and Safety (OEHS):
5.2.1
Will monitor implementation of this procedure for compliance.
Non-compliance will be reported to responsible supervision for
appropriate action.
5.2.2
OEHS shall perform an annual inspection of departmental energy
control programs/practices to ensure that requirements of this
procedure are being followed. Non-compliance will be noted in a
written report to the Department head.
Employee:
5.3.1
6.0
Training
6.1
6.2
6.3
7.0
Employees performing work tasks covered by this Lock-out/Tagout procedure are required to comply with the requirements set
forth in this procedure and training provided.
All affected personnel must receive training on the purpose of this procedure to
ensure they have a clear understanding of the meaning of equipment locks and
tags, and that they are not to be altered in any way. This will typically be
included in the new-hire safety orientation.
All authorized personnel must receive formal training on the requirements of this
procedure so that they can effectively lock-out / tag-out equipment as needed,
ensuring for safety of themselves and others who may be in the immediate area.
The training will include the following:
6.3.1
How to recognize energy sources, the type and magnitude of the
energy available in the workplace.
6.3.2
How to perform an equipment shutdown.
6.3.3
How to isolate equipment.
6.3.4
How to safely release stored energy to reach a zero energy state.
6.3.5
How to apply and remove lock-out/tag-out devices.
6.3.6
Procedures/requirements for over-ride removal of lock-out/tag-out
devices.
6.4
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 to the Energy
Control Procedure. Retraining shall also be provided when the annual inspection
reveals, or whenever there is reason to believe that there are inadequacies in
employees’ knowledge or use of the energy control procedures.
6.5
Documentation of all training is to be maintained by the employees’ department.
Energy Isolating Devices (Locks & Tags)
7.1
Locks
7.1.1
7.2
8.0
Locks used for the purpose of isolating an energy source shall not be used
for any other purpose. Locks must be individually keyed, and while in
use, the key shall remain in the possession of the individual who placed
the lock.
Tags
7.2.1
Each tag must contain the name, picture, and department of employee
locking out the equipment.
7.2.2
Only the individual tag holder may apply and remove his/her tag. [Note:
In special cases, a non-picture tag may be utilized, and is to be requested
by a Facilities supervisor.]
7.2.3
Individualized tags are to be requested from the employee’s supervisor.
7.2.4
Tagout device attachment means shall be of a non-reusable type,
attachable by hand, self-locking, and non-releasable with a minimum
unlocking strength of no less than 50 lbs. and having the general design
and basic characteristics of being at least equivalent to a one-piece, all
environment-tolerant nylon cable tie.
Isolation
8.1
The supervisor should discuss the need for a lock-out/tag-out when special
isolation conditions apply.
8.2
The machine or equipment to be isolated shall be turned off or shut down using
the procedures established for the machine or equipment.
8.3
All energy sources that energize the piece of equipment to be serviced are to be
identified and physically located. [Note: Shop drawings/prints should be
reviewed and/or the appropriate shop foreman consulted to perform this task.
8.4
The employee is to lock out all energy sources involved by applying his/her lock
and personal tag. De-energization may include, but not limited to, pulling a plug,
opening a disconnect switch, removing a fuse, closing a valve, bleeding the line,
or placing a block in the equipment.
8.5
If an energy isolating device is not capable of being locked out, a tagout (alone)
may be utilized. In these cases, additional safety measures should be used, such
as the removal of an isolating circuit element, blocking of a controlling switch,
opening of an extra disconnecting device, or the removal of a valve handle to
reduce the likelihood of inadvertent energization are required to be taken.
Note : In the event an electrical system is required to be locked out, the Electrical
Foreman is to be contacted. The Electrical Foreman will advise the foreman
overseeing the work to be performed of the electrical source(s) of energy that
would required a lockout.
8.6
If several people are needed to work on a piece of equipment, each person must
apply their own lock/locks. This prevents any accidental start-ups while another
employee may still be working on the machinery. In this case, employees will
need to use a lockout hasp that accepts multiple locks.
8.7
Each employee’s lockout devices will be individually keyed, and a master key set
will be maintained by the carpenters shop and accessible to only a foreman or
designee.
8.8
Live parts to which an employee may be exposed must be de-energized before the
employee works on or near them.
Note: Only qualified employees may work on or in close proximity to electric
circuits or equipment that has not been de-energized. Such persons must be
capable of working on energized circuits and will be familiar with the proper use
of special precautionary techniques, personal protective equipment, insulating and
shielding materials and insulated tools. Facilities Management will maintain a list
of qualified employees.
9.0
10.0
Safe Release of Stored Energy
9.1
Equipment is to be at “zero energy state” before servicing. All potentially
hazardous stored or residual energy shall be relieved, disconnected, restrained,
and otherwise rendered safe i.e. drain all valves, bleed off air from a system, and
eliminate stored hydraulic pressure. In addition, you may need to use other safe
method to release existing energy.
9.2
Follow the equipment’s maintenance manual where guidance is provided
regarding release of stored energy.
Verification of Isolation
10.1
11.0
Following de-energization of the power source(s) and application of lock and tag,
one should attempt to activate/operate the equipment to confirm that it has been
de-energized. (Ensure all employees are secured away from equipment.)
Removing Lockout and Tagout Devices
11.1
After servicing is finished, tools & material are to be cleared away and guards
replaced.
12.0
11.2
The area is to be cleared, as warranted, in case re-energization does not go as
planned.
11.3
All locks & tags and other isolation devices are to be removed.
11.4
After lockout devices have been removed and before a machine or equipment is
started, affected employees shall be notified that the lockout device(s) have been
removed and the equipment is to be re-energized.
11.5
The equipment is to be restarted, following the standard operating procedure for
that piece of equipment.
Equipment Connected via Cord & Plug
12.1
Machinery/equipment where the only source of energy is from connection to an
electrical outlet cord and plug shall be considered to be in compliance with
lockout/tagout procedure if the following conditions are met:
12.1.1 The plug is removed from the electrical source.
12.1.2 The person servicing the equipment can be in control of the cord and plug,
at all times during the servicing.
12.1.3 All affected employees shall be notified of the equipment being serviced.
12.2
13.0
An alternative means of compliance is to have a plug cap device in which
lockout/tagout devices are affixed to the plug.
Over-ride Safety Lock/Tag Removal
13.1 In the event that an employee cannot be reached to remove his/her personal lock
and it is necessary to unlock the equipment, only the Electrical Shop Foreman
and/or the appropriate supervisor may remove the lock.
13.2 The following sequence of events should take place before the emergency
removal of someone else’s lock/tag.
13.2.1 Attempt to determine the location of the employee and exhaust all
reasonable efforts to have the lockout removed via the normal process.
13.2.2 If the employee is not on-campus, and can not be located or is unable to
report to the campus, the shop foreman should check the machine or
process to be sure it is clear before removing the lock.
13.2.3 The supervisor [who removes the lock(s)] is responsible for following all
of the requirements for restoring power. (See “Removing Lockout and
Tagout Devices”)
13.2.4 The supervisor will be responsible for contacting the employee ASAP to
advise him of the removal of his lock & tag.
14.0
Shift Change
14.1
15.0
16.0
If the piece of equipment is locked out at shift change and the person on the next
shift needs to service the piece of equipment, he/she must apply their lockout and
tag before the employee leaves.
Outside Contractors
15.1
Contractors are to follow a lock-out / tag-out procedure in full compliance with
OSHA 1910.147.
15.2
Each outside contractor working in areas on campus have been contractually
informed that they are responsible for the safety of their employees.
15.3
Contractors are to be informed that any de-energization of Illinois State
University equipment is to approved by the project manager or other responsible
Illinois State University supervisory employee having project oversight
responsibilities.
15.4
The project manager or designee is to coordinate the lock-out / tag-out of
equipment with the responsible shop foreman.
15.5
Any equipment under control of Illinois State University that is required to be
locked out by a contractor must also be locked out by the appropriate shop
foreman. The ISU lock/tag is to be applied first, and removed last after work is
complete.
Specific Procedures for Individual Equipment and Areas
16.1
Shift Change
16.1.1 If work is to be performed on equipment by multiple different shifts (Heat
Plant and Electricians only) the following procedure will be utilized:
16.1.1.1 The Foreman/Ass. Chief will lockout the equipment using a
multiple lockout hasp, lockout, and his/her tag.
16.1.1.2 Anyone performing work on the equipment is required to
lockout the equipment using their lock/tag and attaching it to
the multiple lockout hasp.
16.1.1.3 Once work is completed, the lockout and tag are removed by
the individual who installed it.
16.1.1.4 The Foreman/Ass. Chief will be notified and will remove the
multiple lockout hasp. See attachment III.
16.2
Overhead Power Lines
16.2.1 If work is to be performed near overhead power lines, the lines must be
de-energized and grounded, or other protective measures shall be provided
before work is started. The following procedures will be utilized:
16.2.2 Only qualified persons may perform this type of work. (A list of qualified
people will be maintained by Facilities Management). If work is to be
performed within 10’ of overhead power lines, a supervisor is required to
be on location and directly overseeing the work.
16.2.3 Only lines owned and controlled by Illinois State University may be
worked on by Illinois State University employees. The local electric
utility company should be contacted to perform work on or near lines
under their control. [Note: A minimum safe working distance of 10’ is
to be maintained away from any overhead power lines.]
16.2.4 If lines are to be de-energized, arrangements will have to be made with
the person/shop or department that operates or controls the electric
circuits to de-energize and ground them.
16.2.5 If protective measures are provided, such as guarding, isolation, or
insulating, these precautions must prevent an employee from directly
contacting such lines with any part of his/her body and from indirect
contact though conductive materials, tools, or equipment.
16.3
Heat Plant Boilers
16.3.1 Only Chief Engineers or designees may lockout/tagout boilers in the
Heating Plant.
16.3.2 Only color coded locks will be used for the boilers.
16.3.3 Boilers will be shut down as outlined in procedures located in the water
test room
16.4
17.0
Steam
16.4.1
If work is to be perform on any main steam line (115 psi or higher) the
Environmental Health and Safety Office must be notified prior to any work.
16.4.2
When performing work on steam lines 25psi – 15psi a double valve lockout
must be used whenever feasible.
Annual Program Audit
17.1
The Office of Environmental, Health & Safety shall perform an annual audit of
the Facilities Energy Control procedure. A written report shall be distributed to
affected parties, outlining identified deficiencies.
17.2
Supervisors/Foreman will conduct periodic audits of their employees. The
Periodic Inspection Form will be used. Anyone found not complying with this
procedure will be required to go through retraining.
Attachment 1
List of Qualified Employee’s
Building Operating Engineer’s
Electricians
Refrigeration Mechanics
Heating Plant
Pipefitters
Water Operators
Plumbers
Lockout/Tagout Periodic Inspection Form
Shop/Department
Name of Equipment and
Location
Date of Inspection
Inspection Items
Yes
No
1. Are the steps in the Energy Control Procedure being followed?
2. Do the involved employees understand their responsibilities?
3. Are there any inadequacies in the employee’s knowledge and
abilities?
Name of Employee(s) Being Reviewed
1.
2.
3.
4.
5.
6.
Corrective Action- Use the space provided below to describe any problems
identified during the inspection, along with a description of any corrective action
needed. Appropriate action must be taken to ensure that the deficiencies are corrected.
This may involve making changes to the procedure, providing retraining to
employees, and/or taking additional steps to ensure compliance.
Inspected By
Name ___________________________
Signature ________________________
Title ______________________________
Facilities Services Lock Removal Form
General Information:
Date & time of request to remove lock:
Name of lock owner whose lock/tag is to
be removed:
Work Unit or Department of lock owner:
Name of lock owner’s supervisor:
Equipment & Location:
Is it absolutely necessary for the equipment to be reenergized before the lock owner
can return to personally remove the lock?
Yes
No
If “Yes”, explain why:
Document Reason for Removing Lock:
(Lock owner called in sick, lock owner forgot to remove lock before leaving site,
etc)
Document attempts to contact lock owner prior to removal:
Date & Time
Method of Attempted
Contact
@
Result
@
@
Lock Removal:
Verify that the lock will be removed by the supervisor of the lock owner or the
supervisor’s direct designee.
Verify that the supervisor of the lock owner or the supervisor’s direct designee has
reviewed the equipment to ensure that it can be safely reenergized.
Lock removed by:
Date & Time of removal:
Notifications:
Verify that the OPP Safety Coordinator has been notified (i.e. via e-mail or phone
call/message) of lock removal within 24 hours of removal.
Verify that the lock owner has been informed of lock removal prior to beginning their
next shift.
Supervisor Signature: __________________________________ Date: _______________