(1) You must develop a formal written policy and procedure for lockout requirements. The policy must embody the principles of subsection (2) of this section and must clearly state that the procedures must be applied in all instances.
(a) The lockout policy must be posted on all required employee bulletin boards.
(b) The lockout policy and procedures must be made a part of new employee orientation and employee training programs.
(c) Supervisors and crew leadpersons must assure compliance with the published policy and procedures in all instances.
(2) Whenever the unexpected start up of machinery, the energizing of electrical circuits, the flow of material in piping systems, or the removal of guards would endanger workers, such exposure must be prevented by deactivating and locking out the controls as required by this section.
(3) Equipment requirements.
(a) You must provide and each employee must use as many padlocks, tags, chains, or devices as are necessary to implement these requirements.
(b) Provisions must be made whereby the source of power or exposure can be locked out in accordance with the requirements of this section.
(c) On electrically powered equipment, "stop/start" control switches must not be used as lockout switches. Lockout switches must be the primary circuit disconnects and must adequately separate both the power source and any auxiliary power unit from the prime mover so that accidental start up of the equipment being locked out is precluded.
(d) Keyed-alike locks, which all open with identical keys, must not be issued as personal lockout locks.
(4) Training requirements.
(a) Each person who will be given authority to implement these requirements must first be thoroughly trained in the requirements and procedures.
(b) Before being given authority to deactivate and lockout a particular system or piece of equipment, authorized personnel must be made fully aware of all power sources and/or material entry sources which may offer exposure.
(c) Checklists must be used to implement effective lockout procedures for complex systems or equipment.
(i) Complex is identified as those systems or equipment which require the locking out of four or more controls to assure isolation or which have controls remote from the immediate work area.
(ii) Checklists must identify all controls necessary to achieve isolation at the intended worksite(s).
(iii) Checklists must provide a space after each listed control to be used for the identity of the person(s) who performed the lockout and required postlockout tests of each control.
(iv) Checklists must be prepared by qualified personnel and approved by the responsible area supervisor before each use.
(5) Control procedure.
(a) Each person who could be exposed to the hazard must apply a personal padlock on each control mechanism. Padlocks must be applied in such a manner as to physically block the controls from being moved into the operating position. Each lock must be personally identified or an information tag identifying the owner must be attached to the lock.
(b) Padlocks used in lockout procedures may only be removed by the person identified on the lock, except, when it is positively determined that the owner/user of the lock has left the premises without removing a lock, the job supervisor may remove the lock in accordance with a specific procedure formulated by the local plant labor management safety committee or approved by the department.
(6) Testing after lockout or tagout. After tagging or locking out equipment, a test must be conducted to ascertain that the equipment has been made inoperative or the flow of material has been positively stopped. Precautions must be taken to ascertain that persons will not be subjected to any hazard while conducting the test if the power source or flow of material is not shut off.
(7) Temporary or alternate power to be avoided. Whenever possible, temporary or alternate sources of power to the equipment being worked on must be avoided. If the use of such power is necessary, all affected employees must be informed and the source of temporary or alternate power must be identified.
(8) Where tags or signs are required to implement the lockout and control procedures, the tag and attachment device must be constructed of such material that it will not be likely to deteriorate in the environment that it will be subjected to.
(9) Provisional exception. Electrical lighting and instrument circuits of two hundred forty volts or less on single phase systems or two hundred seventy-seven volts on three-phase systems may be exempted from the lockout requirements of subsection (5)(a) of this section provided that:
(a) An information tag meeting the requirements of subsection (8) of this section is used in lieu of a padlock.
(b) The information tag must be placed on the switch or switch cover handle in such a manner as to easily identify the deactivated switchgear.
(10) Deactivating piping systems.
(a) Hazardous material systems are defined as:
(i) Gaseous systems that are operated at more than two hundred psig;
(ii) Systems containing any liquid at more than five hundred psig;
(iii) Systems containing any material at more than 130°F;
(iv) Systems containing material which is chemically hazardous as defined by NFPA 704 M Class 3 and 4; and
(v) Systems containing material classified as flammable or explosive as defined in NFPA Class I.
(b) Lockout of piping systems must provide isolation to the worksite, including backflow where such potential exists and where the system is classified as a hazardous material system. The required method must be applied based on the content of the system as specified below:
(i) Nonhazardous systems must be deactivated by locking out either the pump or a single valve.
(ii) Hazardous material systems must be deactivated by one of the following methods:
(A) Locking out both the pump and one valve between the pump and the worksite;
(B) Locking out two valves between the hazard source and the worksite;
(C) Installing and locking out a blank flange between the hazard source and worksite.
Exception: | Aerial tramways and lifts, surface lifts and tows. It is recognized that some inspection, testing, running adjustments, and maintenance tasks cannot be accomplished on this equipment while using standard lockout procedures, particularly when using a work platform suspended from the haulrope. Management of each ski area shall therefore develop a specific written procedure to be used in any instance where any potentially exposed personnel cannot personally lock the controls. The procedure for each area shall meet the following minimum requirements: |
(I) The controls must be attended by a qualified operator at all times when personnel are in potentially exposed work positions and the controls are not padlocked out.
(II) Direct communication capability between the control operator and remote work crew must be maintained at all times.
(III) All personnel involved must be thoroughly trained in the exact procedures to be followed.
(IV) Extension tools which minimize personnel exposure must be used where possible.
(V) The equipment must be operated at the slowest speed possible consistent with the task at hand.
(VI) This exception must not be used by more than one workcrew at more than one remote location on any single piece of equipment or system.
(VII) This exception is limited to work on the haulrope, towers, and replacing bullwheel liners. For all other work on the bullwheels or drive operations, the master disconnect must be deactivated and locked out.
Note: | See Appendix 1 for illustrative example. |