This document establishes procedures for lockout and tagout of energy sources that could cause injury to personnel or damage to equipment.
All types of energy sources, including electrical, mechanical, hydraulic, pneumatic,chemical, or thermal, are subject to these procedures. Electrical energy sources of less than 24 Volts AC or DC and less than 10 Amps maximum rated current do not require lockout. Equipment that can be disconnected from energy sources by standard plugs, fittings, or other connections do not require lockout if the disconnected plug is visible to workers at all times, or if the plug is removed and tagged out as specified below.
All employees, students, visitors, and contractors at the PFC must comply with these procedures. Any employee or student that is involved in the use, installation, repair, removal, or maintenance of potentially hazardous equipment must read and understand this document before beginning work. Any person issued a safety lock must be issued a copy of this document and satisfy either Bill Byford (Asst. Safety Officer) or Jim Irby (Alcator Operations Leader) that they fully understand these procedures. All visitors and contractors working with equipment connected to energy sources must either read and understand this document or rely on a designated supervisor to comply with these procedures.
Any person who violates these procedures is placing themselves and their coworkers in danger of injury or death. It is the responsibility of supervisors to ensure that all persons under their supervision are properly instructed in these procedures. It is the responsibility of all employees to understand and abide by these rules, and to report violations. Any person who knowingly violates these procedures shall be subject to immediate disciplinary action. At the least this action shall include a verbal and written reprimand, a copy of which shall be filed in the person's personnel file. Repeated violations of these procedures constitute grounds for dismissal.
No person may amend, alter, or otherwise change these procedures, in whole or in part, without the written approval of the PFC Safety Committee. Verbal changes are explicitly forbidden at all times. Temporary changes or dispensations are not allowed for any reason. Changes in these procedures require that all employees be instructed in the new procedures with particular emphasis placed on the difference between old and new procedures.
Energy Source - Any device or process that can provide energy of any form, including electrical, mechanical, chemical, hydraulic, pneumatic, and thermal energy. Examples of energy sources include utility electrical, water, or gas services, compressed gases, springs, rotating masses, steam, capacitors, hydraulic and pneumatic reservoirs (including reservoirs such as air trapped in a pipeline), furnaces, steam lines, and cryogenic fluids.
High Energy Electrical Source - Any device or process that can provide electrical energy at a voltage in excess of 600 Volts.
Energy Isolating Device - A physical (as opposed to procedural or programmable) device that prevents the transmission or release of energy. An energy isolating device must include provisions for locking the device in the state that prevents the transmission or release of energy, and prominent visual indication of the state of the device. A fused disconnect switch, a chained line valve, a locking slide gate, and similar devices are valid energy isolating devices. Molded case circuit breakers without locking provisions, micro switches, computer operated controls of any kind, interlocks, push buttons, and selector switches are not valid energy isolating devices.
Safety Lock - A sturdy mechanical lock issued with a single, numbered key to a specific individual for the sole purpose of locking energy isolating devices in the open (safe) position. Combination locks are not acceptable safety locks.
Purpose - The purpose of the lockout procedure is to ensure an individual's personal safety while working on equipment connected to energy sources of any kind.
Placement of locks - Before placement of the lock, the person placing the lock must be certain as to which switch(s), valve(s), or other energy isolating device(s) are to be locked. Special attention to be given to the possibility of multiple energy sources connected to one piece of equipment. Multiple sources might include multiple services (e.g. electric at two voltages, or electric and hydraulic), or redundant services (e.g. primary and backup electrical service via a transfer switch). After verification of the number and placement of locks, the following steps must be followed in sequence:
After service or testing of the locked-out equipment is complete, the following steps must be followed in sequence in order to remove the lock(s):
Each person working on equipment shall place their own lock(s) and tag(s). If necessary, lockout tongs may be used to allow multiple locks to be placed on the same energy isolating device. If a large group is to work on equipment that must be locked out, the supervisor or designated alternate may lock out equipment for the entire crew. In such cases, it is the responsibility of the person placing the lock to inform all members of the crew that the equipment is locked out. It is that person's further responsibility to inform and account for each member of the crew before removing the lock.
High energy electrical sources (those with a voltage greater than 600 volts) require special caution and attention to detail. Whenever equipment connected to high energy electrical sources is to be worked on, the following steps must be taken in addition to those required for a normal lockout.
Equipment without energy isolating device - All equipment installed in the PFC should be connected via appropriate energy isolating devices. If any equipment is discovered that does not meet the requirements of these procedures, it should be brought to the attention of Bill Byford or Jim Irby immediately.
Purpose - The purpose of the tagout procedure is twofold. Tagout provides a prominent visual indication of a lockout or of any potential problem or hazard associated with equipment. Tagout of locked energy isolating devices is required as part of the lockout procedure. Tagout also provides a written, permanent record of lockouts and other circumstances where lockout is not required. Any piece of equipment, including controls, energy isolating devices, or components, may be tagged out.
Examples of tag use - Tagout is required whenever the lockout procedure is used. Tags may be affixed to equipment when there is no immediate danger to personal safety. Examples of appropriate tag use that does not require lockout include:
Issue of Tags - Bill Byford or Jim Irby are the only persons authorized to issue tags. Each tag issued will have a unique serial number on it in 2 places. A log will be maintained, organized by tag serial number, showing to whom each tag was issued. Bill Byford or Jim Irby may elect to issue many tags to individuals who use them often.
Placement of tags - The Plasma Fusion Center Station Red Hold Tag with serial numbers is the only approved tag for the tagout procedure. To place a tag, all of the following information must be filled out legibly in ink on the tag;
The apparatus protected, listing the name and/or location of the apparatus being tagged out. The signature of the person placing the tag, together with the current time and date. The cause for tagout. The designation of the switch or control being tagged.
The bottom portion of the tag should be removed immediately after filling out the required information and affixing the tag. If the tag is to be left for an extended period of time (such as in example 3 above) the bottom portion of the tag should be turned over immediately to the person who issued the tag. If the tag will be removed soon, the person placing the tag may keep the bottom portion as a reminder of the location of each tag placed.
Removal of tags - Tags should normally be removed only by the person who placed them. Under no circumstances should a tag be removed without a reasonable attempt to contact the person placing the tag. The person who placed the tag may remove it whenever they are satisfied that the condition causing the tagout has been righted. Removal includes signing the tag, dating it, and turning both upper and lower parts of the tag over to Bill Byford or Jim Irby.
Bill Byford will maintain a record of all tags issued, placed, and removed. Tags that are placed for extended periods will have the reason for placement documented on the lower portion of the tag that was delivered to Bill Byford or Jim Irby by the person who placed the tag. Tags that are placed for short periods and removed by the person who placed them will have both potions of the tag turned in upon removal of the tag.
If the person who placed the tag is not available or cannot determine that the tag should be removed, the person responsible for the tagged equipment must seek the approval of Bill Byford or Jim Irby to remove the tag. Removing another's tag is a very serious responsibility. The person removing the tag assumes full and complete responsibility for the safety of the equipment and those who work with it. Tags should never be removed in haste or confusion. Before removing another's tag, the steps listed in Removal of Locks by Supervisor should be completed. Bill Byford and Jim Irby will require proof that the equipment is safe to operate, that the conditions leading to tagout have been rectified, and that the person who placed the tag is not available. The person removing the tag must sign and date it and give the removed tag to Bill Byford or Jim Irby.
Only Bill Byford or Jim Irby are allowed to issue safety locks. They will verify that each person receiving a lock understands these procedures, and will supply each person issued a lock with a copy of the procedures.
A list of all person(s) issued safety locks, with date issued and key number, shall be maintained by Bill Byford.
A duplicate key for each safety lock issued shall be kept by Bill Byford or Jim Irby. The duplicate keys shall be kept secured under lock and key at all times. The duplicate key shall be used only if the original key is lost or damaged, or if the supervisor of the employee who placed the lock and tag elects to remove the lock and tag. (See below.) If the duplicate key is required because of loss or damage to the original key, the lock and key must be destroyed after the lock is removed
There are some instances where a lock may have to be removed by someone other than the person who instituted the lockout. Contractors may complete their work and leave the premises without removing locks that they were issued. An employee may be absent due to illness or other reasons. Under such circumstances, the supervisor may elect to remove the lock. Removing someone else's lock is a very serious responsibility. Supervisors removing other's locks assume full and complete responsibility for the safety of the equipment and those who work with it. Locks should never be removed in haste or confusion. Before removing another's lock, the supervisor must perform all of the following steps, in the order listed.
This is an html version of the PSFC Lockout/Tagout Procedures, last released in May, 1995. The original version was authored by Steve Fairfax.
This page maintained by Catherine L. Fiore FIORE@PSFC.MIT.EDU