Sequence of Lockout

Notify all affected employees that servicing or maintenance is required on a machine or equipment and that the machine or equipment must be shut down and locked out to perform the servicing or maintenance.

The authorized employee shall identify the type and magnitude of the energy that the machine or equipment utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy.

If the machine or equipment is operating, shut it down by the normal stopping procedure (depress the stop button, open switch, close valve, etc.).

De-activate the energy isolating device(s) so that the machine or equipment is isolated from the energy source(s).

Lock out the energy isolating device(s) with assigned individual lock(s). Group Lockout boxes may be used.

Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc.

Ensure that the equipment is disconnected from the energy source(s) by first checking that no personnel are exposed, then verify the isolation of the equipment by operating the push button or other normal operating control(s) or by testing to make certain the equipment will not operate. Return operating control(s) to neutral or "off" position after verifying the isolation of the equipment.

The machine or equipment is now locked out.

Sequence of a Line Break (Pipe Line) Lockout

Line breaks will require close cooperation between Bodine employees and the host employer. Bodine employees must review and be familiar with the host employer's procedures before proceeding with the line break.

Properly preparing a section of pipeline and/or equipment for "breaking" is particularly important when unexpected release of the contents could cause personal injury. Therefore, this lockout/ line break procedure is to be used when breaking pipelines and equipment that contain materials which are flammable, combustible, corrosive, toxic, or at elevated temperature (> 140 °F) or pressure (> 110 psig). This operation may require a permit by the host employer.

Personnel thoroughly knowledgeable of the operation, which includes the pipeline/equipment, must see that the portion of line/equipment to be worked on is completely and properly isolated.

Isolation valves must be secured in the "OFF" position and bleeder devices/valves in the "OPEN" position.

Personal lock and/or tag device must be secured to the valves. The tag must have the name of the person attaching the tag and date.

Automatic valves may never be used as a means of isolation for Confined Spaces. Automatic valves may only be used under the following conditions for line break;

• Air-operated valves (air to open, fail-close) may be used if the air has been removed from the controller, properly isolated and there is confirmation of the valve closure.
• Air-operated valves (air to close, fail-open) may be used only if there is a mechanical mechanism for securing/locking the valve in the closed position, the valve tagged, and the valve can be tested (try-out) to ensure positive closure.
• Automatic valves being used as manual valves must not be used for isolation during any line break situation. Isolate the line ahead of the automatic valve.
• All valves used for isolation are to be locked before work begins. However, in situations where hazardous materials lines/equipment are being prepared for Confined Space Entry, an additional measure of safety must be provided such as blinding, double block and bleed, misalignment of pipe, etc.

For line breaks involving thermal hazards (above 140 degrees), Hot Liquids PPE must be worn at all times during the initial line break and until the contents of the pipe/vessel have been confirmed “empty”. Required PPE for thermal line breaks include at a minimum face shield, rubber or waterproof gloves and rubber or waterproof coat or rubber or waterproof jacket and pants.

For line breaks involving chemical hazards, all appropriate PPE required by the MSDS (Material Safety Data Sheet) must be worn by the employee( s) for the duration of the exposure potential. Bodine employees must request a copy of the MSDS and review the listed hazards prior to beginning work.

The authorizing person should review the job scope, how the equipment / piping was isolated, potential hazards, and appropriate PPE with the employee(s) assigned to perform the work.

The employee(s) assigned to perform the work must attach a personal lock and/or tag to the lockout device, review the scope of the work with the authorizing employee, and sign the permit.

After personally witnessing all field inspection steps listed on the permit and filling in date, time and location, the authorizing person signs the permit.

Restoring Equipment to Service

When the servicing or maintenance is completed and the machine or equipment is ready to return to normal operating condition, the following steps shall be taken.

• Check the machine or equipment and the immediate area around the machine to ensure that nonessential items have been removed and that the machine or equipment components are operationally intact.
• Check the work area to ensure that all employees have been safely positioned or removed from the area.
• Verify that the controls are in neutral.
• Remove the lockout devices and re-energize the machine or equipment. The person who installed the Lockout/Tagout device must remove it.
• Notify affected employees that the servicing or maintenance is completed and the machine or equipment is ready for use. In the event that an employee has forgotten to remove their lock, the Supervisor must:
  • Verify that the employee who applied the locking device has left the facility.
  • Ensure that the work area is secure and that the employee has left work incomplete causing a hazardous environment.
  • Make all reasonable efforts to contact the employee to inform him that the lockout/tagout device is being removed.
  • Ensure that the employee is aware that the lock was removed prior to resuming work.

Periodic Program Review And Inspection

Periodic inspections will be performed at least annually to ensure effectiveness of this program. The inspections will be performed by the Corporate Safety Manager or assigned designee.

The inspection will include:

• A review between the inspector and the authorized employee's responsibility under this program;
• The procedure involving de-energization of machinery or equipment;
• Lockout equipment use, and;
• Procedures for releasing equipment form Lockout/Tagout.

Periodic inspections will be documented on Appendix A.

Training

Training on this procedure will be conducted during new hire training and annually.

Retraining will be performed if deviations from this procedure are identified.

Click here for Appendix A.