Trinity Operating Procedures - TOPs

TOP-LOKTG: Lock-Out/Tag-Out

Rev: 12/06/2017

Scope: This procedure covers the Trinity Forge lock-out/tag-out policy, prescribing minimum requirements for the lock-out/tag-out of energy sources that could cause injury to personnel. These procedures must be followed before employees perform any servicing or maintenance activities to ensure that employees are protected from potential hazards caused by unexpected equipment activation or the release of stored energy. These procedures are posted at some pieces of equipment and are also available through manuals on lock-out/tag-out at the following locations:

1. Warehouse, Lock-out Tag-out station, and will be used for reference and training,
2. VP-Manufacturing's office, and will be used for reference and instruction,
3. Human resources office, and will be used for reference and training.

RESPONSIBILITY: Each employee must be instructed by management in the safety significance of the lock-out/tag-out procedure. Each new or transferred affected employee and other employees whose work operations are or may be in the area shall be instructed in the purpose and use of the lock-out/tag-out procedure.

DEFINITIONS: As used in this policy, certain important terms and concepts are defined as follow:

1. Affected Employee: An employee whose job involves working with or in the vicinity of equipment involved in a covered activity.
2. Authorized Employee: An employee responsible for performing any covered activity.
3. Covered Activity: Any activity performed in the workplace during which the unexpected activation of equipment or the release of stored energy could cause injury. This policy includes, but is not limited to, the following types of covered activities: installation, maintenance, inspection, repair, adjustment, etc. Only normal operational activities are excluded from this policy, including repetitive, routine minor equipment adjustments and maintenance work, work on cord- and plug-connected electric equipment when it is unplugged.
4. Energy Isolating Device: Any physical device that prevents the transmission or release of energy (e.g., circuit breakers, disconnect switches, valves, etc.).
5. Energy Source: Any energy source that could cause injury to personnel. This term includes, but is not limited to, the following types of energy: electrical, mechanical, hydraulic, pneumatic, etc.
6. Lock-Out Device: Consists of individually assigned key-operated padlock(s) used when necessary in conjunction with a multiple lock adapter for use in locking out an energy source. Padlocks must be identifiable and sufficiently durable to require considerable force when removed by any means other than the regular key. Padlocks and other lock out devices are provided by management and are the only devices authorized for use in equipment lock outs. These padlocks must not be used for any purpose other than lock outs.
7. Tag-Out System: Lock-out procedures may be supplemented by standardized safety tags describing the equipment being de-energized and the reason for the lock out. Standardized safety tags must be of sufficient quality and durability to ensure their effectiveness. Such tags are to be used only as substitutes for lock-out devices when specific equipment cannot be locked out using key-operated lock out devices. Additional means to ensure safety are to be utilized when employing safety tags. The use of safety tags must be approved by management.
8. Troubleshoot: To locate and diagnose equipment breakdown or malfunction.

PREPARATION FOR LOCK-OUT/TAG-OUT ACTIVITY: Placement of a lock out/tag out device is the responsibility of the authorized employee(s) performing a covered activity. Employees authorized to perform lock out/tag outs must make a survey to locate and be certain which switch, valve or other energy isolating device(s) apply to the equipment being locked out. More than one energy source may be involved. All potentially hazardous energy sources must be isolated and locked out. When uncertainty exists concerning which energy sources should be locked out, clearance must first be obtained from the Maintenance Manager.

LOCK OUT/TAG OUT PROCEDURE SEQUENCE: The following steps must be taken when any covered activity is to be performed:

1. Notify all affected employees that a lock-out is required and the reason for the lock-out.
2. If the equipment to be locked out is operating, shut it down by the normal stopping procedure. (Please refer to posted instructions or manual on Lock out Tag out in the warehouse.)
3. Identify the appropriate energy isolating device(s) for the equipment to be locked out.
4. Operate the switch, valve or other energy isolating device(s) so that the energy source(s) is/are disconnected or isolated from the equipment. Stored energy (e.g., springs, rotating flywheels, hydraulic systems or pneumatic lines) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, etc.
5. Lock out and/or tag out the energy isolating device(s). Each individual who will perform a covered activity must place his lock-out/tag-out device on the energy isolating device.
6. After ensuring that no personnel are exposed, operate the normal equipment operating controls to verify that the equipment will not operate. (Note: After making this test, return the operating controls to the neutral or off position.) If it is possible to verify the lock-out in this way, test or visually inspect the equipment to ensure that lock-out has been achieved.
7. Check the equipment for the presence of stored energy (e.g., springs, hydraulic or pneumatic lines under pressure, parts under compression or subject to gravity, etc.). Release or block appropriately.
8. The equipment is now locked out.

When the covered activity is completed and the equipment is ready for testing or normal service, check the area surrounding the equipment to verify that no one will be endangered by removal of the lock-out device.

9. When the equipment is all clear, all tools removed, guards reinstalled and all employees are in the clear, remove the lock out/tag out device(s). Individual locks/tags may normally be removed only by the employees who installed them.

SPECIAL CIRCUMSTANCES: In situations where a lock-out device must be removed by someone other than the person who installed it, the following steps must be taken:

1. The Maintenance Supervisor or senior maintenance employee on site must personally verify that no employee is exposed to danger from re-energizing or reactivating equipment.
2. Only after the above person has verified that no employee exposure exits may the lock-out device(s) be removed by cutting or similar method. (Note: The removal of lock out device(s) under these conditions is expected to occur very rarely.)
3. When equipment requires troubleshooting: Lock or tag with open lock to alert people you are troubleshooting the equipment and not to operate any of the controls. The open lock allows you to quickly have access to disconnect, in case you need to turn machine off. If after troubleshooting you find that you need to work on the machine, proceed with regular lock-out/tag-out procedures.

OUTSIDE CONTRACTORS, ETC.: The above Lock-Out/Tag-Out Policy is applicable to all outside contractors, et cetera, performing work on the premises. It will be the responsibility of the Maintenance Manager to ensure compliance. Failure to comply may result in immediate termination of such outside contractor's services.

All shop employees of Trinity Forge are to be notified of the existence of this Lock-Out/Tag-Out Policy and are required to be familiar with its requirements. Failure to comply with the Lock-Out/Tag-Out Policy may result in disciplinary action, up to and including discharge.

REF: Department of Labor - OSHA 29 CFR Part 1910

Revision history: