INDIANOLA FACILITY
Lockout/Tagout Program

General

OSHA requires that employers develop a written program for the safe maintenance of machinery and electrical equipment, including a detailed lock-out procedure for use during maintenance.

Employers that are covered include all employers who perform maintenance or service on hard-wired machines. Hard-wired machines are machines that cannot be disconnected by a plug.

When an employer performs its own service or maintenance on machines and equipment, it must be done with the machine or equipment stopped. All sources of energy must be disconnected. The energy device(s) for that machine or equipment must be locked-out and/or tagged-out under a documented procedure. In addition, employees must be trained and lock-out/tag-out procedures reviewed at least annually.

This program is designed to meet the OSHA requirement for a written program found in 29 CFR 1910.147. This program may also be used to meet some of the requirements of 29 CFR 1910.333 which has to do with electrical safety and related work practices.

Training

Training will be conducted on lock-out/tag-out for all equipment or machines by:
on-site safety personnel.

Authorized and affected employees will be trained in the following:

1. Review of the requirements of 29 CFR 1910.147, Control of Hazardous Energy.

2. Types of magnitudes of energy sources.

3. The limitations of tag-out.

4. Lock-out and/or procedures for the isolation of energy sources.

5. Procedures for removing lock and/or tags.

6. Procedures for restoring energy.

All authorized employees will be given training prior to any initial involvement in lock-out/tag-out procedures.

Affected employees will be given training at the time of hiring.

Retraining will be given whenever there is a change in job assignment, a change in equipment or processes that would create a new hazard, or whenever a change would occur in this company’s Hazardous Energy Control Procedures.

A list of trained employees and the dates of their training will be on file at the main office and maintained by the Safety Director. This list will designate the employee as an authorized employee or as an affected employee.

Purpose

The purpose of this policy is to provide a procedure that establishes requirements for the lock-out/tag-out of machinery and equipment to protect employees from the hazards and subsequent injuries that may occur as the result of unexpected release of a hazardous energy source during maintenance operations.

Before any inspection or repairs are made on equipment, power should be turned off at the switch box and the switch locked in the off position (locked-out). The switch or controls should be securely tagged to show that the equipment or circuits are being worked on (tagged-out).

Machinery being inspected or repaired must be isolated from all potentially hazardous energy sources, which must be locked-out and tagged-out. The machinery must also be free from all energy or accumulated energy before employees may perform any servicing or maintenance activities, if the unexpected release of stored energy could cause injury.

Employees shall be instructed in the safety procedures and the importance of the procedures by site safety personnel.

Compliance With This Program

All employees are required to comply with the restrictions and limitations imposed upon them during the use of lockout. The authorized employees are required to perform the lockout in accordance with this procedure. All employees, upon observing a machine or piece of equipment which is locked out to perform servicing or maintenance shall not attempt to start, energize, or use that machine or equipment.

Lockout Procedure

Lockout procedure for the Indianola plant is to be directed by the plant manager (Mark Richardson). Before any maintenance or service is provided to plant, the plant manager is to be notified. The plant manager is then responsible for deactivating and locking out power source and tagging. Begin by placing padlock on cover of the power box to assure no other personnel can re-energize without consent. Place tag with time and date in which service is being done and by whom. Maintenance personnel are required to wear goggles and a dust mask while performing work on the plant.

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.

When maintenance is required to be done with the Indianola plant be sure to notify the plant manager Mark Richardson beforehand. The manager is then responsible for lockout procedure.

The authorized employee shall refer to the company procedure to 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.

Plant: Has electrical, rotational and mechanical energy at all times unless de-energized at its source of power. The plant is a constant danger to all employees in and around the equipment unless precautionary measures are taken. The plant manager has the understanding and knowledge to shut down and lockout the plant for repairs. Under no circumstances is anybody to work in and around the plant without the manager’s, (Todd Bohlender, Rod Bohlender, or Mark Richardson) consent.

Vehicles: Have rotational, mechanical and sometimes stored energy unless de-energized at its source of power. Mechanical maintenance must be approved by the plant manager.

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

Plant: Before any maintenance is preformed on the Indianola plant, the power sources must be deactivated. The key to the auto-control is located on the batch panel underneath the batch computer. The key is to be pulled by the plant manager, Mark Richardson, and placed in his pocket. Auto-control is then tagged by Mark Richardson in a manner that he has to remove it in order to replace key. In order to disable the power to the plant completely, you must turn off the plant main power breaker. Go east through the north door in the dispatch down the stairs. At the end of the stairs take a left and head north down the hall. Go through the door at the end of the hall and you will then be in the shop. In the northwest corner of the shop there is a door you must go through. Immediately after going through the door you will see electrical breakers on the north wall. On the panel labeled Panel HDP you will see a breaker switch labeled Plant Main Control Box. This is the switch that controls the power to the dispatch Auto-control computer. Flip this switch to the off position and put on a breaker switch lockout on it. Tag the breaker with a Tagout card and put a lockout lock on it, placing the key in your pocket. By locking this switch in the off position you will have disabled power, rendering the dispatch computer useless. Even if for whatever reason the Auto-control key was re-inserted and turned to the on position by the dispatcher, he would still be unable to turn anything on. If you are ever in the bins doing maintenance and need the outside conveyor off, you must de-energize the power source for it. Repeat the steps for having the dispatcher remove the key to Auto-control and put it in his pocket. Go down the inside stairs out of the dispatch. Turn left and go down the hall. At the end of the hall there is a door that you must go through to get into the shop. In the northwest corner of the shop there is a door. Go through the door. In this room you will see some stairs that go down to the basement. Go down those stairs and on the south wall there is a breaker labeled Plant Main. This breaker must be switched to the off position and needs to be locked out by pad-lock located on lockout/tagout center as well as tagged with time, date and by who is performing work. After the power source has been deactivated, inform Mark Richardson and then he will run a check of the disabled plant to ensure that is in fact disabled.

Air Power Source

Plant: In order to disable any plant parts operated by air, contact the plant manager, Mark Richardson, and have him terminate the electric source to the air compressors. Once the electric is disabled the air must also be released from the lines. This is done by draining the air of the storage tank on the air compressor. Go east through the north door in the dispatch down the stairs. At the end of the stairs there is a room on the right, south, side. The plant Air compressor is located in this room. The air compressor has a switch on the wall that turns it off. There is a breaker panel on the wall behind the air compressor that needs to be locked out/tagged out. As you face the compressor on the left bottom of the tank there is a ball valve that needs to be opened to drain all the air from the lines. As you open the valve you will hear the air release. Once all the air is released, tell Mark Richardson and he will then check to make sure the air source is completely deactivated.

Shop: The air compressor in the shop is located in the northeast corner of the shop. Turn the switch off at the top center of the compressor. The main breaker for this compressor is located in the basement on the north wall labeled Shop Compressor. It needs to be locked out/tagged out. To drain this air compressor there is a pit cock valve on the left side of the compressor halfway down. Turn the pit cock valve until you hear air being released from the lines. When you are done tell the plant manager or our mechanic, Brian Schupanitz, and they will check to see that the correct procedures are in place.

Vehicles

Mixers: Engine must be shut off. Keys must be removed and placed in the pocket of individual performing maintenance. The entry doors to the cab of the vehicle must be locked. Sign a Lockout/Tagout card with name, date, and time then place the card on the handle of the door. Make sure wheels are chalked. Routine procedures such as greasing rollers do not need to be checked out by safety personnel. All other maintenance procedures must be checked by our mechanic, Brian Schupanitz, the plant manager Mark Richardson, or our on-site safety inspectors to be sure proper procedure is in place. Work levers and/or switches to ensure power has been disabled. Before truck is returned to service, make sure miscellaneous materials have been removed from working objects.

Dump Trucks: Before beginning work on a dump truck, keys must be removed from the ignition. The entry doors to the cab of the vehicle must be locked and the key placed in the pocket of the individual performing the maintenance. Sign a Lockout/Tagout card with name, date, and time then place the card on the handle of the door. Be sure to chalk the wheels of the dump truck to prevent movement. If work is required with the boxed raised, the pivot points must be blocked with 6×6 blocks to prevent the box from lowering. After box is blocked, attempt to lower box to relieve pressure off of the hydraulics ensuring all pressure is on the block. If anyone other than a mechanic is performing maintenance on a dump truck you must have our mechanic, Brian Schupanitz, or the plant manager, Mark Richardson, check to see that proper procedures are in place.

Endloader/Track Hoe: Before beginning work on the endloader or track hoe, keys must be removed from the ignition. The entry doors to the cab of the vehicle must be locked and the key placed in the pocket of the individual performing the maintenance. Sign a Lockout/Tagout card with name, date, and time then place the card on the handle of the door. If maintenance is required with the boom or bucked raised, place ram locks or pins to ensure the boom or bucket can not fall. Also place blocks under boom or bucket to prevent collapse. After boom or bucket is blocked, attempt to lower boom or bucket to relieve pressure off of the hydraulics ensuring all pressure is on the block. Be sure to chalk the wheels of the endloader or track hoe to prevent movement. If anyone other than a mechanic is performing maintenance on a endloader or track hoe you must have our mechanic, Brian Schupanitz, or the plant manager, Mark Richardson, check to see that proper procedures are in place.

NOTE: COMBINATION LOCKS ARE PROHIBITED FOR USE IN ANY LOCK-OUT OF MACHINES OR EQUIPMENT. DO NOT ATTEMPT TO OPERATE ANY SWITCH, VALVE OR ENERGY ISOLATING DEVICE WHEN IT IS LOCKED-OUT OR TAGGED-OUT. TEST EQUIPMENT TO ENSURE POWER

Lock out the energy isolating devices and entry to power sources with equipment from the Lockout/Tagout center. The Lockout/Tagout center contains sign-out cards and padlocks for locking and labeling disabled power sources. The Lockout/Tagout center is located inside the shop in the northwest corner on the right side of the door above the MSDS sheets.

Stored or residual energy (such as that in capacitators, 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.

Caution: Return operating control(s) to neutral or “off” position after verifying the isolation of the equipment.

Plant: After following lockout procedures push the conveyer start button to verify power has been disabled.

Vehicles: After following lockout procedures try operating hydraulics to verify there is no residual energy.

The machine or equipment is now locked out.

Restoring Equipment to Normal Production Operation

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.

NOTE: THE ONLY PERSON ALLOWED TO REMOVE A LOCKOUT/TAGOUT CARD IS THE PERSON WHO SIGNED IT.

Plant: To restore power to the breaker box, the person who signed the lockout tag is to remove the Lockout/Tagout card from the breaker. Next remove the padlock so that the safety lock can also be removed. The individual restoring the power can then turn the power switch to the “on” position.
To restore the auto-control unit, the person who signed the lockout tag is to remove the Lockout/Tagout card from the power switch. Mark Richardson can then place the key back into the switch and turn the key to the “on” position.

Vehicles

Mixer: To restore the concrete mixer back to normal operation, the person who signed the lockout tag is to remove the Lockout/Tagout card from the entry door. The wheel chalks can now be removed from the front and rear wheels. The mixer key can now be removed from your pocket and the entry door to the cab can be unlocked. Once door is unlocked the key can be placed in the ignition.

Dump Truck: To restore the dump truck to normal operation, the person who signed the lockout tag is to remove the Lockout/Tagout card from the entry door. The wheel chalks can now be removed from the front and rear wheels. The dump truck key can now be removed from your pocket and the entry door to the cab can be unlocked. Once door is unlocked the key can be placed in the ignition. If work was required with the box raised, start the dump truck and raise the box to re-energize the hydraulics. It is now possible to remove the 6×6 block from the pivot point.

Endloader/Track Hoe: To restore the endloader or track hoe to normal operation, the person who signed the lockout tag is to remove the Lockout/Tagout card from the entry door. The wheel chalks can now be removed from the front and rear wheels. The key can now be removed from your pocket and the entry door to the cab can be unlocked. Once door is unlocked the key can be placed in the ignition. If work was required with the boom or bucket raised, start the endloader or track hoe and raise the boom or bucket to re-energize the hydraulics. It is now possible to remove the blocks, ram locks and/or pins.

Cord and Plug: When working with equipment powered by cord and plug, to disable power you first be sure that the power switch on the equipment itself is turned to the off position. You then must be sure that the plug has been pulled out of the electrical socket. When you restore power to equipment that is powered by cord and plug, make sure that all objects are clear of the equipment then plug the cord back into the electrical socket. (Examples of equipment powered by cord and plug include but are not limited to: extension cords, drill press, table grinders etc…)

Enforcement Policy

Supervisory personnel shall effectively enforce compliance with the lockout/tagout policies and procedures as set forth in this document. The chain of command will be followed when discipline is required. Each supervisor is responsible for the actions of their subordinate employees. For accountability purposes, any employee violating these procedures or policies will be disciplined. Accordingly, that the employee’s supervisor will also be disciplined and that the supervisor’s supervisor will be disciplined.

The first action will be to verbally warn employees of their non-compliance with the program. Immediately thereafter a training session will be scheduled. The violated policy and procedure will be reviewed with the employee and certification will be made of the training.
For every disciplinary action taken subsequent to the verbal warning, the employee will receive:

1st Offense: Written Warning

2nd Offense; Indefinite Suspension

3rd Offense: Indefinite Suspension up to Termination of Employment

Please note that supervisors will be subject to the same disciplinary actions as their subordinate employees. The program incorporates many different elements that are designed to protect workers. Heavy responsibility is therefore placed on each employee to follow these established policies and procedures.

Periodic Inspections

In order to ensure that the lock-out/tag-out program is being properly utilized, random audits will be conducted in order to determine the extent of employee compliance. Specifically, three areas will be reviewed:

1. Whether the steps in the energy control procedure are being followed:

2. Whether the employee(s) involved know their responsibilities under the procedure.

3. Whether the procedure is adequate to provide the necessary protection and what changes, if any, are needed.

The inspection will be conducted when the program is initially implemented and at least annually thereafter.

All employees included in the inspection will be identified, and the name of the inspector will appear on the certification document used to certify the date, time, and who was involved in the inspection.

The inspection will be made by an authorized person other than the one implementing the energy control procedure being inspected.

If deviations are identified or if employees do not clearly understand the procedure, retraining will be conducted to the extent that the procedures are properly followed. Certification of the training will be required.

If problems with the procedures are encountered, the process will be re-evaluated and more appropriate procedures will be implemented. The inspections will be done on a one on one basis and also through meeting with the entire crew.

ANNUAL INSPECTION CERTIFICATE FORM

DATE_________________

FACILITY_____________________________________

1. MACHINE AND LOCATION
2. INSPECTOR
3. EMPLOYEES CONSULTED
4. RESULTS OF THE INSPECTION
5. MANAGERS COMMENTS

________________________________________
SIGNATURE OF INSPECTOR

________________________________________
SIGNATURE OF SAFETY DIRECTOR