The document provides definitions and procedures for lockout/tagout at Spark Science Centre. It defines key terms like lockout, tagout, and affected/authorized employees. Procedures include shutting down equipment, placing tags on controls, installing locks, blocking energy sources, and verifying isolation before work. Group lockout procedures and forms are described. Responsibilities include preparing equipment for lockout by operations and verifying isolation before work by other workers. Procedures must be documented for each piece of equipment.
3. Objective, Application and
Purpose
Objective:
• To provide procedures for locking, tagging and trying
of equipment prior to installation of new equipment
or shutdown for servicing, repairs, tests or
adjustments of existing equipment such that
equipment may be repaired, cleaned, adjusted or
inspected safely.
Application:
• All areas where a source of energy could result in
accidental movement of equipment or other energy
source which could result in injury to persons,
property or process.
5. DEFINITIONS
• Affected employee - Assigned to or operating a device.
• Authorized employee - Responsible for the LO/TO of
equipment.
• Capable of being locked out - has a built in LO/TO
mechanism or can be affixed.
• Energized - Contains stored/residual energy.
6. DEFINITIONS (continued)
• Energy Isolation Devices - Mechanical device that physically prevents
transmission or release of energy such as:
• Manually operated electrical circuit
breakers
• Disconnect switches
• Line valves
• Blocks
7. DEFINITIONS (continued)
• Energy sources -
• Electrical Power - Current
• Mechanical Power - Gears
• Fluid Power - Pressurized Fluids
• Gravity Power - Suspended Objects
• Pneumatic Power
• Chemical Power
• Thermal Power
8. DEFINITIONS (continued)
• Lockout - Placing a locking device on an energy isolation
device.
• Lockout device - A positive means (such as a lock) to hold
an energy isolation device in safe position. Locks used for
lock outs must be designated only for the purpose of lock
outs. Locks must be of appropriate size and design such
that it cannot be broken or tampered with.
9. DEFINITIONS (continued)
• Servicing / Maintenance - Construction, installation,
adjustment, inspecting, modification, maintenance,
servicing, cleaning, etc.
• Set-Up - Preparing a machine/equipment for normal
operation.
10. DEFINITIONS (continued)
•Tagout - Placement of Tagout device on an energy isolating
device.
•Tagout Device - Prominent warning such as a tag. Must be
used with lock or 1 additional safety measure.
12. Purpose:
• To protect employees from injury caused by the sudden
start up of machines or other equipment during
maintenance or servicing
• To ensure that hazardous energy is isolated before an
employee performs an activity where unexpected
energizing could cause injury
13. Responsibilities
• Where lockout and tag out is being performed in order for a
contractor or other group to complete work on the piece of
equipment, it is the responsibility of operations personnel
to complete the initial lockout and tag out of the equipment
and properly isolate / de-energize the equipment and
communicate the purpose and status of the disconnecting
and locking out.
• Others that will perform work on the equipment have the
responsibility to review the lockout, tag out isolation and
de-energization with the operations personnel who
performed the work in order to ensure for themselves that
the equipment is safe. At that time, the contractor should
install their own locks.
14. Lockout/Tagout shall be used
when:
• A task requires an employee to bypass or remove or defeat a
safety device
• A task requires an employee to place any part of his or her
body anywhere equipment may be energized
• Authority to work on equipment must first be obtained from
the H&S Lead or his designate who will then take the
following steps to ensure that the equipment or machinery is
properly prepared for repair or maintenance.
15. Hazard Assessment
• Spark Science Centre shall identify and assess the hazards, or the
potential hazards of lockout tag out in accordance with the Hazard
Assessment Program
• The hazard assessment must include isolation and de-energization
hazards including:
1. Electrical Energy– live circuits, charged capacitors, etc.
2. Pressure Energy – pressure within piping, vessels and cavities with pieces
of equipment, etc.
3. Mechanical Energy – energy stored in springs, levers, etc.
4. Static Energy – equipment that could fall, suspended equipment, etc.
5. Dynamic Energy – energy stored in equipment that spins or rotates, Etc.
6. Chemical Energy – energy that may be released from chemicals (i.e.
chemicals that may be water or air reactive, etc.)
• SOPs shall be developed for compliance with lock-out tag out.
16. Lockout/Tagout Procedures
1. Shut down equipment as required.
2. Place "DO NOT OPERATE" tags on all necessary controls.
3. Install locks as required.
4. Block in, de-pressure and purge as required.
5. Lock control devices in the inoperative position and attach a
supplemental tag describing the work to be done and the name of
the person who installed the lock out device. Only the person who
installed the device or the operations supervisor may remove it.
6. Ensure that all hazards, pressure conditions, tension or toxic
substances have been removed or rendered safe.
7. Before starting any work, the workers who will be performing the
actual work must physically check all potential sources where
energy can be released and verify that they have been successfully
isolated (locked out, blocked, etc.). This check should be
documented on the LOTO form. Lockout locations must also be
documented on the LOTO form.
17. Lockout And Tagout Procedures
• A lockout and tagout procedure must be written for
every piece of equipment.
• That lockout tagout procedure must have an annual
review to ensure accuracy.
• Locking Out is Part of the Occupational Health and
Safety Act in all jurisdictions.
18. Group Lockout
• Each trade or group of workers must install their own locks on the
mechanical lock out device prior to the commencement of work. Such
locks shall be removed only by the worker who installed the lockout
device or in the case of an emergency, by the Manager of Operations &
H&S or their designate. In the case where a worker's lock is removed in
their absence, the worker will be informed before they start work again.
• Where group lock out is undertaken, the H&S Specialist must develop a
group lock out procedure and post it to make it readily available to
workers. The procedures must include designation of responsibilities for
two competent workers for
• Independently locking out the energy isolating devices,
• securing the keys for the locks to a key securing systems (i.e., a lock
box or other multiple lock device),
• completing the lock-out/Tag-out logbook, and
• determining that it is safe to end the group lock out after all
personal locks have been removed from the key securing system.
19. STANDARD SPARK LOCK OUT TAG
• These tags must accompany a lock out lock.
• Person applying lock must sign and date and fill in remark section.
20. Return to Operating Position
• It is the responsibility of the Locking out Employee or his/her
designate to ensure that all equipment and machinery is
ready for service and all locks, tools, etc., have been
removed before placing the equipment back into service.
Where an employee who installed the lock is unavailable
(i.e. off-shift), every reasonable effort must be made to
contact the employee (or the employee the responsibility
was transferred to) and to ensure that the
machinery/equipment can be operated safely before
removing the lock.
21. When Employee is Not There
Make every effort to find that individual.
Another employee and the Manager of Operations & H&S
must look at the situation separately and agree that
equipment is safe to operate.
Editor's Notes
There are several instances where machines and equipment are required to be locked out or tagged out, such as when an employee has removed or bypassed a guard or safety device. This usually occurs when performing maintenance to a machine, and the safety device limits access to the machine. By disabling the guard or safety device, the worker has no protection from the machine if another worker inadvertently starts the machine. Many times safety devices must be disabled in order to get to the site of repairs. Other examples are when setting up machines (usually code changes or change overs in production equipment), or when adding or installing new components.
Another example requiring lockout / tagout of the equipment is when an employee puts his or her body into the point of operation, where the work is actually being performed. If the employee is in a danger zone, the equipment should be secured to ensure that there is no risk of unexpected start up. The penalties issued for this violation in 1996 were $867,6753. Many organizations didn’t realize the importance, or were blatantly indifferent.
ONE issue not covered in detail in books, is the removal of jam-ups or ball-ups. Common to manufacturing environments where conveyors move parts along a designated pathway. When removing ball-ups, Lockout/Tagout procedures must be followed.
The next area that we will focus on is key terms that need to be defined. It is vital to comprehend these terms if this standard is to be clearly understood. All terms will be explained as they apply to this law:
Affected employee - is an employee that is either assigned to an area where a lockout / tagout is being performed; or an employee whose job requires him/her to operate or use a machine that has been locked or tagged out. Again, this is usually done during servicing or maintenance.
Authorized employee - is the person that will lock or tag out the equipment in order to perform the maintenance. Usually, authorized employees must undergo extensive training to possess the knowledge and skill necessary to repair such machinery. Also, an affected employee whose duties include servicing or repairs, such as preventive maintenance, will become an authorized person when in the act of servicing the equipment.
Capable of being locked out - refers to the ability of a power source having a mechanism (hasp) which a lock can be affixed; or a built in locking mechanism.
Energized - is when there is residual or stored energy; or being connected to an energy source.
Have hardware (lockout devices to pass around as they are discussed. It is wise to take students on a “field trip” to a shop or location where these can be demonstrated as where they would be applied.
It is important to note that push buttons, selector switches, and other such types of devices are not considered energy isolation devices. In other words, pushing the red stop button, or putting a machine in the off position (selector switch), does not mean the machine has been locked out.
Make sure to cover items like lockouts for light switches, circuit breakers, etc...
Most of the energy sources can be found in every home and industrial setting.
Give examples of various types of power components. I.e.…Gravity power could be weight-actuated accumulators, pulleys, . Mechanical energy could be springs, gears, …… Fluid power - hydraulic or pneumatic cylinders.
Energy source - below is a list of the different types of power sources found in industry:
Electrical power (electrical current)
Mechanical power (gears)
Fluid power (either pneumatic or hydraulic pressurized fluid)
Gravity power (heavy objects released to deliver power)
Chemical power (reactive materials that can deliver force such as chemical cartridges in nail guns)
Thermal power (steam can be channeled through ducts and pipes to deliver force)
Hot tap - a procedure used in maintenance and servicing which involves welding on a piece of equipment under pressure, in order to install connections or add-ons. This is common when adding sections of pipeline without interrupting service.
Lockout - is the placement of a locking device on an energy isolation device. This is to ensure that the equipment being controlled cannot be operated until the hardware is removed.
Lockout device - a device that utilizes a positive means such as a lock (either key or combination type) to hold an energy isolation device in the safe position and prevent the energizing of a machine or equipment.
Normal production operations - machinery or equipment performing its intended production function.
Servicing and/or maintenance - includes constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machinery and equipment. Other items that will fall into this definition will be lubricating, cleaning, or un-jamming ball ups of material caught in the equipment. If you must make tool changes or adjustments, that too would be considered maintenance / servicing.
Setting up - many times work areas must be set up for production. Large industrial presses must have set up work done when changing to run a different product. It is defined as any work performed to prepare a machine or equipment to perform its normal production operation.
Tagout - is 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 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.
A tag used without a lock shall be supplemented by at least one additional safety measure that provides a level of safety equivalent to that obtained by the use of a lock, such as opening an additional disconnecting device, removal of an isolating circuit element, blocking of a controlling switch or the removal of a valve handle to reduce the likelihood of inadvertent energization.
After the repairs have been made, the authorized employee can prepare for the release of the lockout or tagout devices. Again there is a procedure that must be followed to ensure worker safety.
FROM GOODYEAR LOTO MANUAL
1) First the work area must be inspected to make sure that any tools or supplies are removed. Screwdrivers and other items left on the floor could create tripping / falling hazards. The authorized employee should also ensure that the machine components are intact. Make Sure that all guards have been replaced.
2) Next, the work area must be checked to confirm that all employees are in a safe position. Associates must be clear of machinery and cautious of parts of the machine that may cycle upon energization.
3) All affected or other employees in the area shall be notified before the lockout or tagout devices are removed.
4) After the employees have been notified, then the authorized employee can begin to physically remove the hardware.
5) Restore all energy to the machine.
We’ve stressed that the only person that should remove locks or tags is the person that applied them. However, sometimes emergencies or other unforeseen circumstances might require authorized employees to be gone when maintenance is completed.
1) Verify that the employee is gone. Page them on intercom system, yell out to the shop, or whatever it takes to ensure they are gone.
2) Make every effort to contact the employee. Call them on their mobile phone, pager, at home, etc. Remember that each worker must have their own locks and tags.
3) The Maintenance tech may physically remove the lock or tag after obtaining permission (see slide). This should require bolt cutter or other means to remove. Remember it should withstand 50 lbs. of force - minimum.