Lockout / Tagout

1. Lockout / Tagout Hershey Entertainment and Resorts Company Revised 2006 29 CFR 1910.147

2. Scope • Covers servicing and maintenance of machines when UNEXPECTED start-up or release of stored energy could cause injury

3. Purpose • Requires employers to: • Establish a program and use procedures for affixing lockout or tagout devices to energy isolating devices, and • To otherwise disable machines or product • To prevent unexpected energization, start-up or release of stored energy in order to prevent injury to employees

4. Application • Standard applies to control of energy during servicing and/or maintenance of machines and equipment

5. Application • The standard does not apply to • Servicing or maintaining cord and plug connected electrical equipment • Hot tap operations that involve transmission and distribution systems for gas, steam, water or petroleum products when they are performed on pressurized pipelines; when continuity of service is essential, and shutdown of the system is impractical; and employees are provided with an alternative type of protection that is equally effective.

6. Definitions • Authorized Employee – person who locks or tags machines/equipment to perform servicing • Affected Employee – One who is required to use machines/equipment on which servicing is performed under lockout/tagout or who must work in such an area

7. Definitions • Capable of being locked out • Designed with hasp or attachment to which lock can be affixed; or • Has locking mechanism built in; or • Lockout can be achieved without need to dismantle, rebuild, replace or permanently alter

8. Definitions • 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 • Energy Source – any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal or other energy

9. Definitions • Lockout – the placement of a lockout device on an energy isolating device, in accordance with an established procedure, ensuring that the device and the equipment being controlled cannot be operated until the lockout device is removed • Lockout Device – a device that utilizes a positive means to hold an energy isolating device in a safe position and prevent energization

10. Definitions • Normal Production Operations – utilization of a machine or equipment to perform its intended function • Servicing/Maintenance – includes lubrication, cleaning or unjamming, making adjustments and tool changes; where employees may be exposed to unexpected energization, start-up, or release of hazardous energy

11. Definitions • Tagout – placement of a tagout device on an energy isolating device 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 which can be securely fastened to an energy isolating device to indicate that the equipment being controlled may not be operated until the tagout device is removed

12. Lockout vs. Tagout • When an energy isolating device is not capable of being locked out, tagout devices may be used • Only when tagout will provide full employee protection • If an energy isolating device is capable of being locked out it shall be unless the employer can show that tagout devices provide full employee protection

13. Lockout vs. Tagout • When tagout is used on equipment which is capable of being locked out • Tags shall be attached where lockout devices would be; and • Employer must demonstrate that tagout will provide safety equivalent to lockout • Equivalent protection requires compliance with tagout provisions and additional measure, such as removal of isolating circuit element, blocking of a controlling switch, etc.

14. New or Modified Equipment • Machines/equipment replaced or having major repair, renovation, or modification must be capable of being locked out • Any new machine or equipment purchased after January 1, 1990 must be capable of being locked out

15. Maintenance Operations • If a servicing activity takes place during production, the employee must lockout or tagout the device • Lockout/tagout must be used when an employee is involved in • The removal or bypass of machine guards or other safety devices, resulting in exposure to hazards at the point of operation; • The placement of his or her body in contact with the point of operation of the operational machine or piece of equipment • Placing any part of his or her body into any danger zone associated with the specific machine

16. Maintenance Operations • Minor tool changes and/or adjustments during normal production operations that are routine, repetitive and integral to the use of the production equipment are not required to follow the lockout/tagout standard • Alternative measures should be taken to ensure the safety of the employee

17. Requirements for Devices • Durable • Lockout and tagout devices shall be capable of withstanding the environment for the maximum period of time that exposure is expected • Tagout devices shall be constructed and printed so that exposure to weather conditions or wet and damp locations will not cause the tag to deteriorate • Tags shall not deteriorate when used in corrosive environments such as areas where acid and alkali chemicals are handled and stored

18. Requirements for Devices • Standardized • Lockout and tagout devices shall be standardized within the facility in at least one of the following criteria: Color; shape; or size; and additionally, in the case of tagout devices, print and format shall be standardized

19. Requirements for Devices • Substantial • Lockout devices shall be substantial enough to prevent removal without the use of excessive force • Tagout devices, including their means of attachment, shall be substantial enough to prevent inadvertent or accidental removal.

20. Requirements for Devices • Identifiable • Lockout devices and tagout devices shall indicate the identity of the employee applying the device • Tagout devices shall warn against hazardous conditions if the machine or equipment is energized and shall include a legend such as the following: Do Not Start. Do Not Open. Do Not Close. Do Not Energize. Do Not Operate.

21. Procedure The following steps will provide for a successful and safe lockout/tagout: • Notify all affected employees that servicing or maintenance of some kind is required on a machine and that the machine must be shut down prior to lockout to perform the servicing or maintenance. • Before an authorized employee turns off a machine, the authorized employee shall have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy.

22. Procedure • Before any shutdowns or work of any kind can take place, a survey must take place in order to locate and identify all isolating devices. More than one energy source may be involved in the lockout/tagout procedure. • The machine or equipment shall be shut down using the procedures established for the machine or equipment.

23. Procedure • If the machine or equipment is in operation, it must be shut down by its normal halting procedure • All energy isolating devices that are needed to control the energy to the machine shall be physically located and operated in such a manner as to isolate the machine from the energy source.

24. Procedure • Prior to starting work on machines that have been locked out or tagged out, the authorized employee shall verify that isolation and de-energization of the machine or equipment have been accomplished. • Stored or residual energy must be dissipated or retrained by methods such as grounding, repositioning, blocking, bleeding down, etc.

25. Procedure • Tagout devices, where used, shall be affixed in such a manner as will clearly indicate that the operation or movement of energy isolating devices from the "off" position is prohibited. • Where tagout devices are used with energy isolating devices designed with the capability of being locked, the tag attachment shall be fastened at the same point at which the lock would have been attached.

26. Procedure • Where a tag cannot be affixed directly to the energy isolating device, the tag shall be located as close as safely possible to the device, in a position that will be immediately obvious to anyone attempting to operate the device.

27. Procedure • Lockout the energy-isolating device with assigned individual locks, the design, purpose and use of which the employee shall have been trained with prior to their use. • Lockout devices, where used, shall be affixed in a manner that will hold the energy isolating devices in a "safe" or "off" position.

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30. Tagout Limitations • Tags are essentially warning devices affixed to energy isolating devices, and do not provide the physical restraint on those devices that is provided by a lock. • When a tag is attached to an energy isolating means, it is not to be removed without authorization of the authorized person responsible for it, and it is never to be bypassed, ignored, or otherwise defeated.

31. Tagout Limitations • Tags must be legible and understandable by all authorized employees, affected employees, and all other employees whose work operations are or may be in the area, in order to be effective. • Tags and their means of attachment must be made of materials, which will withstand the environmental conditions encountered in the workplace.

32. Tagout Limitations • Tags may evoke a false sense of security, and their meaning needs to be understood. • Tags must be securely attached to the energy-isolating devices so that they cannot be detached accidentally during use.

33. Safe Work Practices • De-energize all sources of Hazardous Energy • Disconnect or shift down engines or motors • De-energize electrical circuits • Block fluid flow in hydraulic or pneumatic systems • Block machine parts against motion

34. Safe Work Practices • Block or dissipate stored energy • Discharge capacities • Release or block springs that are under compression or tension • Vent fluids from pressure valves, tanks, or accumulators BUT NEVER vent toxic, flammable or explosive substances directly into the atmosphere

35. Safe Work Practices • Lockout and tagout all forms of hazardous energy including electrical break panels and control valves • Make sure only one key exists for each assigned lock • Verify by test and observation that all energy sources are de-energized

36. Identity • The lockout and/or tagout device shall indicated the identity of the employee applying the device • The device shall warn against hazardous conditions if the machine or equipment is energized and shall include a legend such as the following: • Do not start • Do not open • Do not close • Do not energize • Do not operate

37. Restoring Equipment • The work area shall be inspected to ensure that nonessential items have been removed and to ensure that machine or equipment components are operationally intact. • The work area shall be checked to ensure that all employees have been safely positioned or removed.

38. Restoring Equipment • After lockout or tagout devices have been removed and before a machine is started, affected employees shall be notified that the lockout or tagout device(s) have been removed. • The employee who applied the device shall remove each lockout or tagout device from each energy-isolating device. If that employee is unavailable to remove the lockout or tagout devices, every effort should be made to contact them and ensure that they are aware that the energy is being restored to that specific machine or piece of equipment.

39. Restoring Equipment • In situations in which lockout or tagout devices must be temporarily removed from the energy isolating device and the machine energized to test or position the machine, equipment or component thereof, the following sequence of actions shall be followed: • Clear the machine or equipment of tools and materials • Remove employees from the machine or equipment area • Remove the lockout or tagout devices as specified earlier in this procedure • Energize and proceed with testing or positioning • De-energize all systems and reapply energy control measures to continue the servicing and/or maintenance.

40. Inspection • Inspection shall be performed: • At least annually during the operation • By an authorized employee • Used to correct deviations or inadequacies • Lockout – between supervisors and authorized personnel • Tagout – between inspector and each authorized and effected employee

41. Safe Work Practices • Inspect repair work before removing your lock and activating the equipment • Make sure the assigned worker removes his or her lock • Make sure that you or your co-workers are clear of danger points BEFORE re-energizing the system

42. Energy Isolation • Performed by an authorized employee only • Notification of Employees • The effected employees • Before being applied • Upon removal of the lockout/tagout device

43. Application and Control • Procedure for shutdown • Machine/Equipment shutdown • Machine/Equipment isolation • Lockout/Tagout device application • Stored energy • Verification of isolation • Release from lockout/tagout

44. Outside Contractors • Manager or supervisors will alert outside contractors of our policies and procedures with lockout/tagout • All contractors shall following our guidelines when working within our complex

45. Shift Changes • There shall be a change over period • Employees shall exchange locks/tags when this occurs • Personnel taking over should be fully briefed in the scope and stage of work done by those being relieved