Hazardous
Energy Control
Sample Written Program
This sample program
has been prepared to provide assistance in compliance with
USA OSHA standards and/or Best Management Practices. It
should not be used without consideration of the unique conditions
and requirements at each site. It may be necessary to
modify the program for your specific needs. You remain
under obligation to comply with all applicable standards,
and use of this program should not be considered to be a guarantee
that compliance with applicable requirements will be achieved.
It is strongly suggested that your final program be
reviewed by a qualified person. The best written program
without implementation is inadequate.
HAZARDOUS
ENERGY CONTROL
This sample hazardous energy control
program has been prepared to provide assistance in compliance
with OSHA standard 1910.147. It should not be used without
consideration of the unique conditions and requirements at
each site. It may be necessary to modify the sample
program for your specific needs. You remain under the
obligation to comply with all applicable standards, and use
of this program should not be considered to be a guarantee
that this compliance will be achieved. It is suggested that
your final program be reviewed by a qualified person.
The referenced standard is entitled,
"The Control of Hazardous Energy (lockout/tagout)", but tagout
has deliberately not been included in the sample program.
This standard requires lockout unless "the employer can demonstrate
that the utilization of a tagout system will provide full
employee protection as set forth in paragraph (c)(3) of this
section" [see 1910.147 (c)(2)(ii)].
Since there is a much greater
risk of employee injury when tagout is used and with the availability
of a variety of heavy-duty rigid plastic lockout adapter devices
available on the market, tagout is not recommended.
I.
PURPOSE
The purpose of this program is
to protect employees from injuries while servicing and maintaining
equipment.
II. SCOPE
The program establishes requirements
for hazardous energy control. It is to be used to ensure that
machines and equipment are isolated from all potentially hazardous
energy sources whenever servicing or maintenance activities
are in progress.
III. RESPONSIBILITY
1. The _____________________________
is designated as the Program Coordinator for this company.
Specific responsibilities include:
a. Provide Hazardous Energy Control
training to employees.
b. Maintain a current listing
of employees who have completed lockout training (Attachment
1).
c. Maintain a current listing
of all equipment/machines which fall under the Hazardous Energy
Control program (Attachment 2). Listing is to be updated each
time a change occurs.
d. Implementation and enforcement
of this program.
e. Maintain an adequate supply
of padlocks and DANGER tags for use each time a lockout process
is performed. Padlocks and tags are located _________________________________.
f. Conduct the annual inspection
& review as required by section VII of this program.
2. Each supervisor is responsible
for the effective use of this program in the work group and
to see that all required procedures are followed in every
instance.
3. Each employee is responsible
for learning and following the procedures and practices developed
under this program. Notify the Program Coordinator prior to
a lockout process.
IV.
BASIC LOCKOUT PRINCIPLES
All equipment must be locked out
to protect against accidental or inadvertent operation, when
operation could cause injury to personnel. Locks are to be
applied and removed only by the authorized employee who is
performing the servicing or maintenance.
No one should attempt to operate
locked out equipment.
Disciplinary action will be applied
if any employee violates these procedures, regardless of whether
or not physical harm or equipment damage results.
Lockout devices (padlocks) with
an appropriate DANGER warning tag shall be used only for energy
control. Prior to the servicing or maintenance of equipment
a padlock and DANGER warning tag will be obtained from the
Program Coordinator. Each padlock will be keyed differently
with no master key or duplicate keys available.
V.
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 may be used will be provided a
brief overview of the lockout program.
Training in lockout will be given
to all new employees as a part of their orientation. Retraining
will be conducted whenever there is a change in job assignment,
a change in machinery or equipment or process change that
presents a new hazard.
Names of authorized employees
who have received appropriate lockout training will be identified
on the Hazardous Energy Control Training Record (Attachment
1).
VI. LOCKOUT
A. SEQUENCE OF LOCKOUT:
The following are specific procedures
to be followed for lockout.
1. Notify the Program Coordinator.
2. Notify all affected employees
that lockout is going to be utilized, and the reason why.
3. If the machine/equipment is
in operation, shut it down by the normal shutdown procedure.
4. Operate the appropriate switch,
valve, etc., so that the machine/equipment is isolated from
the energy source.
5. Lock the energy isolating devices,
using assigned locks and danger tags.
6. Release, restrain, or dissipate
any stored energy.
7. Verify that energy isolation
is complete, by attempting to start the affected machinery
or equipment in the normal manner.
8. After testing, return all operation
controls to the "neutral" or "off" positions.
B. RESTORATION TO NORMAL:
1. After service or maintenance
is complete, check the area to ensure that no employees are
exposed.
2. Remove all tools and repair
equipment.
3. Ensure that all guards have
been replaced and all safety interlocks reactivated (if so
equipped).
4. Verify that the operating controls
are in the "off" or neutral position.
5. Remove all lockout and tag
devices and activate the energy isolation devices to restore
energy.
VII. PROGRAM INSPECTION
AND REVIEW
At least annually, a designated
representative will verify the effectiveness of the energy
control procedures. These inspections shall provide for a
demonstration of the procedures and may be carried out through
random audits and observations.
The inspector must review the
Hazardous Energy Control Procedure with all authorized employees,
and actually observe the use of the Hazardous Energy Control
Procedure. This inspection must be certified and documented
by the inspector using a Hazardous Energy Control Lockout
Program Inspection form. (Attachment 3).
These inspections are to ensure
that the energy control procedures are being properly used,
and to provide a check on the continued adherence to the procedures.
Management must certify that the prescribed inspections have
been performed. Any deficiencies must be corrected immediately,
either by modification of the procedure, retraining of employees,
or a combination of both.
VIII. OUTSIDE CONTRACTORS
Outside personnel or contractors
involved in lockout of equipment or machinery that affects
our employees must submit their energy control procedures,
in writing, to the Program Coordinator. All affected employees
must be trained in and familiar with the contractor's submitted
procedure.
In order to protect our employees,
the contractor's work area will be isolated, and access by
our employees will be restricted. If this is impractical or
cannot be accomplished, the Program Coordinator must assure
the contractor's compliance with proper work procedures, energy
isolation procedures and contractor employee compliance.
Contractors failing to adhere
to the provisions of the OSHA Hazardous Energy Control standard
will be asked to terminate their work until their program
is brought into compliance.
Attachment 1
HAZARDOUS ENERGY CONTROL
PROGRAM TRAINING RECORD
The following company employees
have received Hazardous Energy Control (Lockout) training.
NAME DEPT
TYPE OF TRAINING
DATE
-----------------------------------------------------------
Attachment 2
HAZARDOUS ENERGY CONTROL
LOCKOUT EQUIPMENT LISTING
The following machines and equipment
fall under the requirements of 29 CFR 1910.147, the Control
of Hazardous Energy (Lockout/Tagout). For this reason appropriate
lockout procedures must be performed each time servicing or
maintenance is performed.
EQUIPMENT/MACHINE IDENTIFICATION
LOCATION DATE LISTED
-----------------------------------------------------------
Attachment 3
HAZARDOUS ENERGY CONTROL
LOCKOUT PROGRAM INSPECTION
DATE: _______________
EQUIPMENT IDENTIFICATION:
INSPECTION:
AUTHORIZED EMPLOYEES (JOB TITLES)
1. ___________________________________________
4. __________________________________________
2. ___________________________________________
5. __________________________________________
3. ___________________________________________
6. __________________________________________
PROCEDURES BEING FOLLOWED: Y /
N
COMMENTS/DEFICIENCIES
DEFICIENCY FOLLOW-UP: COMPLETED
________________________ N/A
DATE
COMMENTS
REVIEWED BY:_____________________________________________
DATE: __________________
_____________________________________________
DATE: __________________
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