LOCKOUT TAGOUT. Document Number: HSE April 9, Author: A Holland

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1 Dcument Number: HSE April 9, 2013 Authr: A Hlland MAPP Cnstructin - Crprate 344 Third Street Batn Ruge, LA (225) MAPP Cnstructin - Hustn 1511 Katy Freeway, Suite 145 Hustn, TX (281) MAPP Cnstructin New Orleans 601 Pydras St., Suite 1715 New Orleans, LA (504) MAPP Cnstructin - Dallas 3131 Turtle Creek Blvd, Suite 1300 Dallas, TX (214) Rev Date Rev Seq Descriptin Revised By 04/09/13 1 Refrmat A. Hlland

2 MAPPcnsructin.cm MAPP emplyees d nt perfrm wrk n energized electrical systems, and any subcntractr perfrming this type f wrk shall be required t submit fr apprval a Lckut/ Tagut Prgram meeting r exceeding regulatry guidelines. If a client has a Lckut/Tagut Prgram - MAPP and all subcntractrs shall fllw that plicy. In the absence f any subcntractr r client plicies, all wrkers shall cmply with the fllw plicy. 1. PURPOSE AND SCOPE 1.1. The purpse f this plicy is t establish minimum prcedures t ensure the safety and health f persnnel wh may wrk n any type f equipment capable f being energized r string energy. This plicy applies t all emplyees and subcntractrs, wh may be required t wrk n this type f equipment r therwise be expsed t the unexpected energizatin f this equipment. 2. RESPONSIBILITIES 2.1. MAPP Superintendent - The MAPP superintendent shall verify that all requirements specified in this wrk instructin have been met prir t authrizing a supervisr t remve an authrized persn s lckut device. The MAPP Superintendent shall assure that annual and pst-incident reviews, as defined belw, have been perfrmed. The MAPP Superintendent shall maintain a spare r multiple spare keys fr lcks used in the lckut prgram in a safe, secure manner Wrk Supervisr -It is the respnsibility f each persn, wh supervises emplyees that perfrm wrk cvered by this prcedure, t: 3. DEFINITIONS Train emplyees in the recgnitin f hazardus energy surces and the methd and means f islating such surces. Mnitr the wrk t verify cmpliance with this prcedure. Ensure that adequate supplies f energy islating devices and lckut devices, i.e., lcks, tags, etc., are readily available. Cnfirm that each jb is prperly prepared by Operatins and/r client persnnel prir t implementing lckut and tagut prcedures. Determine the best lckut methd (individual r grup) fr each lckut and tagut peratin. Supervise all grup lckut activities. Affected Emplyee Authrized Emplyee Electrical Plug and Cnnectr Lckut Bx Energy Surces Energy Islatin Device A persn whse jb requires him/her t perate r use machines, equipment, r prcess n which service is being perfrmed under the lckut and tagut prgram, r whse jb requires him/her t wrk in an area where such service is perfrmed A persn wh is authrized t lck ut and tag ut machines, equipment, r prcess in rder t perfrm service r maintenance wrk n that machine, equipment, r prcess. A bx specifically designed t lck ut electrical plug assemblies r, in the case f engine driven equipment, its battery cables Electrical, mechanical, hydraulic, pneumatic, chemical, thermal, r ther surce. A mechanical device that prvides a psitive means f cntrl t prevent the transmissin r release f energy. Examples f these devices include circuit breakers, discnnects, pins, blinds, blanks, valves, blcks, and duble blck and bleed. They d nt include secndary cntrls such as start buttns r cntrls that regulate valves. HSE f 8

3 MAPPcnsructin.cm Grup Lckbx Grup Lckut Lckut Lckut Device Pint(s) f Prtectin Specific Energy Cntrl Prcedure Tagut Verificatin A bx r similar device prvided fr the placement and safekeeping f keys used t secure energy islatin devices in a grup lckut. Grup lckbxes are generally clearly labeled as t their purpse, are tamper prf and are capable f being lcked by ne lckut lck r a multiple gang attachment. A prcedure which prvides a level f prtectin equivalent t that prvided by a persnal lckut r tagut device, when servicing and/r maintenance is perfrmed by a crew, department, r ther grup. The placement f a lckut device usually a lck n an energy islatin device t ensure that the energy islating device and the equipment being cntrlled may nt be perated until the lckut device is remved. A device used t secure an energy islatin device in a particular psitin (valve handle cvers, switch cvers, r circuit breaker devices) in such a way that the psitin f the energy islatin device cannt be changed withut the remval f the lck ut device. Pint r place where a lckut device has been placed n an energy islatin device t prtect emplyees frm the hazardus release f energy. A written prcedure that details specific actins t be taken t cntrl hazardus energy during servicing r maintenance. A specific lckut written prcedure, a jb safety analysis specific t the machine, equipment, r prcess being wrked n are examples f acceptable specific energy cntrl prcedures. The placement f a tagut device usually a tag n an energy islatin device t indicate that the energy islating device and the equipment being cntrlled may nt be perated until the tagut device is remved. Verificatin (try-ut) f machines, equipment, r prcesses t assure that energy surces have been islated 4. PROCEDURE Specific Energy Cntrl Plans 4.1. Specific Energy Cntrl Plans must be develped in writing fr each peratin cvered under the purpse and scpe f this plicy. These specific Energy Cntrl Plans must cntain the fllwing steps: Step 1 Preparing T Shut Dwn The Machine, Equipment, Or Prcess Examples f Step 1 issues t be addressed fllw. Identify all surces f energy and ptential fr stred and residual energy. Identify methds that will be used t islate and lckut these energy surces. Hw will Operatins r the client prepare the machine r equipment fr shutdwn and servicing? D prcess pumps, r ther equipment need t be drained and flushed t eliminate a chemical expsure? Hw will the affected persns be ntified f the impending shut dwn f the machine, equipment, r prcess? Hw will the machine, equipment, r prcess be shut dwn? Hw will stred and/r residual energy be relieved, cled, blcked, r islated? Hw will all surces f energy t the machine, equipment, r prcess be islated, lcked, and tagged ut? Identify the prper type and placement fr lcks, tags, and lckut devices at all pints f prtectin where an energy islatin device is used. Determine if and where temprary blcking r supprts will be needed and hw t lck them in place. Will the individual r grup lckut methd be used fr the lckut and/r tagut? All f this infrmatin shall be placed in a written prcedure specific t the peratin, and this infrmatin will be cnveyed t the persnnel wh will perfrm the servicing and/r maintenance f the equipment. Step 2 Shutting Dwn The Machine and/r Equipment HSE f 8

4 MAPPcnsructin.cm. Examples f issues t be addressed and actins t be taken include the fllwing. Prir t shutting dwn the equipment, verify that the client is aware f and apprves f the deactivatin f the machine, equipment, r prcess. Obtain permits. Ntify all affected persns that the machine, equipment, r prcess will be shut dwn and shall nt be reactivated until further ntice. Shut dwn the machine, equipment, r prcess in accrdance with the written plan. Step 3 Islating The Machine, Equipment, Or Prcess Frm The Energy Surces Examples f issues t be addressed and actins t be taken in this phase are the islatin f all electrical, mechanical, pneumatic, chemical, thermal, r ther energy surces by the applicatin f apprpriate energy islatin devices, lckut devices, lcks, and tags. Step 4 Applying The Lckut And Tagut Devices Examples f issues t be addressed and actins t be taken in this phase fllw. If using the individual lckut methd, verify that all authrized persns place a lck and tag n each energy surce. If using the grup lckut methd, the supervisr must place a lck and tag n each energy surce, verify that the key fr each lck is placed in the grup lck bx, and that the grup lck bx is secured by placing their lck and tag n the lck bx. Then each individual invlved with the lcked ut equipment shall apply a lck n the grup lck bx, including subcntractrs Step 5 Safely Releasing All Ptentially Hazardus Stred Or Residual Energy Examples f issues t be addressed and actins t be taken in this phase are: Placing temprary energy islating devices r supprts, as needed. The energy islating devices shall be lcked in place and clearly identify as t their purpse. Safely releasing any stred r residual electrical energy by a qualified electrician. Safely releasing any stred r residual hydraulic r pneumatic energy by remving and/r bleeding lines and equipment r utilizing anther, equivalent safe methd. Safely releasing any stred r residual thermal r chemical energy by draining and flushing lines, pumps, r ther equipment that may cntain chemicals, steam, ht water, etc. Safely releasing any mechanical energy by allwing the equipment t cycle, r ther safe means. Step 6 Verifying (Trying Out) The Islatin Of The Machine, Equipment, r Prcess Befre starting the maintenance r servicing f the machine, equipment, r prcess, prper islatin must be verified. Examples f issues t be addressed and actins t be taken in this phase fllw. A qualified electrician shall test all electrical cnductrs with an apprved meter. The meter shall be tested n a knwn surce, the lcked ut equipment is then tested, and afterwards the meter is tested n the knwn surce again. Attempt t restart the equipment by pushing the start buttn, manual cntrls, etc., t verify that the machine, equipment, r prcess cannt be inadvertently started during servicing. If the machine, equipment, prcess, r a cmpnent theref des start during the verificatin phase, stp the prcess and ntify the supervisr. Additinal steps shall be taken t identify, islate, lckut, and tagut the energy surce. If necessary, the Specific Energy Cntrl Prcedure shall be revised befre wrk resumptin. 5. ENERGY ISOLATION 5.1. General Requirements N attempt shall be made t perate equipment n which a lckut device has been placed. N ne shall remve anther persn s lckut device, except as described belw. All lcks shall have identificatin as t the wner f the device. Lckut devices must be inspected befre each use t ensure they are wrking prperly. Lcks fr energy surce islatin must have a means f identificatin that HSE f 8

5 MAPPcnsructin.cm 5.2. Lcks 5.3. Tags distinguishes them frm any ther lcking device n the prject. A particular clr, shape, r size may be used as the means f identificatin. Lcks shuld als be numbered. Lckut devices shall nt be used fr any ther purpse ther than t lckut equipment. When a machine, equipment, r prcess must be islated and lcked ut fr a lng perid f time, peridic inspectins shuld be perfrmed t verify that lcks and tags are still in place. The frequency f these inspectins will vary depending upn the circumstances, e.g., inspect prir t each shift fr an active peratin r weekly fr an inactive peratin. Lcks used fr islating an energy surce, shall nt be used fr any ther purpse. Lcks used as part f an energy islatin device must be individually keyed. While in use, the key shall remain in the pssessin f the individual wh placed the lck(s) r in the grup lck bx. Spare keys fr lcks must be placed in a lck bx in the pssessin f the Superintendent. A Lckut Lg shuld be used t identify the lcatin f lcks while in use. Lcks must be durable and able t withstand the envirnment t which they are expsed. Tags used in cnjunctin with lckut devices fr the purpse f islating an energy surce shall be standardized in such a way as t serve as a prminent warning, e.g., DANGER DO NOT OPERATE. The tag must have spaces available fr date, identificatin f energy surce, and name f the individual placing the tag. The cnstructin, markings, and written infrmatin n the tag shall be such that deteriratin will nt ccur when expsed t weather and/r crrsive envirnments. Tags and tag attachment devices shuld nt be re-used and are t be apprpriately dispsed after remval. The means f attachment shall be: Of a nn-reusable type, Attachable by hand, Self-lcking and nn-releasable with a strength t withstand at least 50 punds f pull, and Resistant t weather and crrsive envirnments Remval f Lcks and Tags Only the persn wh applied the lck and/r tag shall remve that lck and/r tag except as prvided in this sectin. In cases where the persn wh applied the lck and/r tag is nt available t remve it, the Site Manager may authrize the supervisr t remve the lck and/r tag nly in accrdance with the fllwing prcedure. This prcedure shuld be used nly as a last resrt t remve a lckut 1. Verificatin that the persn wh applied the lck and/r tag is nt present at the facility. 2. Make all reasnable effrts t cntact the persn, wh applied the lck and/r tag t infrm him/her that the lck and/r tag will be remved. 3. The supervisr must verify that the equipment that was lcked ut is safe t return t service. All persnnel invlved in the lck ut are clear and n damage will ccur when the equipment is restarted. 4. The supervisr must dcument hw all previus steps have been met. Dcumentatin shuld be kept n file at the site. Once this has been dne, the lck may be remved, but step five shall als be cmpleted. 5. Ensure that the persn wh applied the lck and/r tag is ntified f the remval befre he/she resumes wrk at the facility Tasks Invlving Multiple Shifts HSE f 8

6 MAPPcnsructin.cm Fr tasks requiring lckut and/r tagut, which invlve multiple shifts, the supervisr must ensure the cntinuity f the lckut and/r tagut as fllws: The ff ging supervisr will remve his/her lck and tag nly after the incming supervisr has placed his lck and tag n the lck bx. The incming supervisr will ensure that the incming craft wrkers verify islatin and place their lcks and tags n the lck bx Energy Islatin Methds There are three methds f energy islatin: individual lckut, grup lckut, and tagut nly. The methd t be used in each situatin will depend n. The cmplexity f the system, The number f persns wh will place lcks, The number f lcks t be placed t effectively lck ut the machine, equipment, r prcess, and Whether r nt the system is designed t accept a lck. The supervisr shall determine which methd is apprpriate fr each situatin and will identify the methd in Step 1 f the Specific Energy Cntrl Prcedures Individual Lckut Methd The individual lckut methd is nrmally used when the number f persns and lcks that will be required n energy islatin devices is small When using the individual lckut methd, each persn invlved in the service r repair f the machine, equipment, r prcess shall: Place a lck n each apprpriate energy islatin device. Place a cmpleted tag n each lck. Remve his/her lckut devices and tags after verificatin that all f his/her Wrk is cmpleted, Tls and materials are cleared, and Blcks r temprary energy islatin devices have been remved Grup Lckut Methd The grup lckut methd is nrmally used when a larger number f persns r lcks will be required t assure islatin f energy surces. When using the grup lckut methd, the fllwing prcedure shall be used. The supervisr f the authrized emplyees shall place a single lckut device n each energy islatin device. The supervisr f the authrized emplyees places a single cmpleted tag n each lckut device. The supervisr places the keys fr the single lckut device in the grup lckbx r equivalent device. Each authrized emplyee and the supervisr shall affix a lck and tag t the grup lckut device, grup lckbx, r equivalent device befre he/she begins wrk, and shall remve thse devices nly when he/she cmpletes wrk n the machine, equipment, r prcess being serviced r maintained. The supervisr shall ensure that all wrk f persnnel under their supervisin is cmpleted, and that their persnnel will n lnger be affected by the lckut prir t remval f lckut devices and tags. The supervisr shall remve his/her lckut devices and tags after verificatin that all Wrk is cmpleted, Tls and materials are cleared, and Blcks r temprary energy islatin devices have been remved Tagut Only The tagut-nly methd shall be used nly when energy surces are nt capable f being lcked ut. This shuld be very rare cnsidering the variety f lck ut devices available n the market. Use f the tagut-nly methd requires apprval f the Site Manager. All ther requirements f this wrk instructin apply. When tagut systems are used, emplyees shall als be trained in the fllwing limitatins f tags: HSE f 8

7 MAPPcnsructin.cm Tags are essentially warning devices affixed t energy islating devices, and d nt prvide the physical restraint n thse devices that is prvided by a lck and lckut device. When a tag is attached t an energy islating means, it is nt t be remved withut authrizatin f the authrized persn respnsible fr it, and it is never t be bypassed, ignred, r therwise defeated Tags must be legible and understandable by all authrized emplyees, affected emplyees, and all ther emplyees whse wrk peratins are r may be in the area, in rder t be effective. Tags and their means f attachment must be made f materials, which will withstand the envirnmental cnditins encuntered in the wrkplace. Tags may evke a false sense f security, and their meaning needs t be understd as part f the verall energy cntrl prgram. Tags must be securely attached t energy islating devices s that they cannt be inadvertently r accidentally detached during use. 5.7 Start-up Prcedures Befre lckut and energy islatin devices are remved and energy is restred t the machine, equipment, r prcess, the fllwing steps shall be taken in rder: Step 1 Step 2 Verify that machine and equipment cmpnents, guards, etc., have been replaced and are intact. Als, verify that all tls and materials such as screws, wrenches, nuts, blts, rags, etc., have been remved frm the machine, equipment, r prcess. Verify that the persn wh applied the devices remves all energy islatin and lckut devices. Step 3 Verify that all persnnel are remved frm the machine, equipment, r prcess and are safely psitined s that start-up will nt expse them t hazardus energy surces. Step 4 Remve temprary blcking and structural supprts as set frth in the Specific Energy Cntrl Prcedure 5.8 Shp Equipment Specific prcedures will be required fr each piece f shp equipment unless all f the fllwing exceptins are met: The equipment must nt prduce r use any stred energy, fr example a prtable air cmpressr, a steam washer, r a chemical pump. The equipment can be and is unplugged and the plug remains under the exclusive cntrl f the peratr r it is placed in a lckut device and lcked. The service n the tl is limited t changing bits, blades, r ther such devices. The tl must be prperly lcked ut if any Operatrs f shp equipment must de-energize and lck ut their equipment t change tls, chucks, blades, and perfrm similar tasks. A pwer discnnect switch must be prvided fr this purpse at r near the equipment unless the equipment can be unplugged The activatin f push-buttn r butterfly cntrls will nt be slely relied upn fr lckut. 6 LOCKOUT AND TAGOUT PROGRAM REVIEW 6.6 Inspectins shall be cnducted t verify that the site s lckut and tagut prgram is effective. 6.7 A written review f lckut and tagut prcedures shall be perfrmed at least annually and/r after any incident invlving lckut r tagut, in rder t verify that the requirements f the prcedure are being fllwed. 6.8 A designated emplyee, ther than the ne(s) utilizing the lckut and tagut prcedure, shall HSE f 8

8 MAPPcnsructin.cm perfrm the review. 6.9 The prgram review shall include an evaluatin f emplyees cmpliance with the lckut and tagut prcedure The prgram review shall dcument the machine, equipment, r prcess n which the energy cntrl prcedure was being utilized, the date f the review, the emplyees included in the review, and the name f persn perfrming the review. See Figure 1, Lckut and Tagut Prgram Review Reprt Safety Evaluatin Reprts and ther written safety audits that include lckut and tagut prgram review may, in sme cases, fulfill the prgram review requirements The Site Manager shall assure that annual and pst-incident reviews have been perfrmed. 7 TRAINING 7.6 Authrized and affected persnnel must receive training in the cntents f this wrk instructin and the relevant HSE training mdule prir t wrk invlving lckut and tagut. N MAPP emplyee shall perfrm wrk n energized electrical systems. 7.7 The training shall be cnducted at least annually thereafter, anytime this wrk instructin is revised, and when a change in machinery, equipment, r prcess presents new ptential hazards. 7.8 Training dcumentatin will be maintained at the site and shall include cpies f quizzes and the training recrd sheet HSE f 8