Generic Program Guide

Lockout/Tagout Program F I S H E R S C I E N T I F I C Lockout/Tagout Program Program 200.05

2000 Park Lane Pittsburgh, Pennsylvania 15275 Phone 412.490.8300 • Fax 412.490.8930 R E G U L A T O R Y A F F A I R S M A N U A L S E R I E S 2 0 0 L O C K O U T / T A G O U T P R O G R A M P R O G R A M 2 0 0 . 0 5

Table of Contents

1 General 1-1 1.1 Lockout/Tagout 1-1 1.2 Lockout/Tagout Equipment 1-1 1.2.1 Group Locking Devices 1-1 1.2.2 Locking Devices 1-1 1.2.3 Locking Hardware 1-1 1.2.4 Tagout Devices 1-2 1.3 Training 1-2 1.3.1 Authorized employee training: 1-2 1.3.2 Affected employee training: 1-3 1.3.3 Outside contractors: 1-3 1.4 Procedure 1-4 1.5 Retraining 1-5 1.6 Periodic Inspections 1-5

Appendices – See Appendice Section of the Regulatory Affairs Manual Appendix 200.05.01: Guide to LOTO Appendix 200.05.02: LOTO Training Outline

Forms – See Forms Section of the Regulatory Affairs Manual Form F200.05.01 Energy Source Evaluation Form F200.05.02 Lockout Procedure Form F200.05.03 Periodic Inspection

X Mandatory Discretionary Effective Date: August 1997 Rev. # 1 Page 3 of 11 Revision Date: August 2004 R E G U L A T O R Y A F F A I R S M A N U A L S E R I E S 2 0 0 L O C K O U T / T A G O U T P R O G R A M P R O G R A M 2 0 0 . 0 5

1 GENERAL

The lockout/tagout program utilized by (your Fisher location) establishes performance and training requirements to protect employees that service and maintain machinery and equipment. This program applies to the employees that work in the vicinity of the affected machinery or equipment and protects them from injury due to unexpected energization or startup of machines or equipment, or release of stored energy. A guide is provided in Appendix 200.05.01 to assist in the implementation of this program.

1.1 Lockout/Tagout The lockout device is the primary means to control unexpected energization or startup of machines or equipment or stored energy. The tagout device will only be utilized in a situation where it would be physically impossible to utilize the lockout device. Individual locking devices will be supplied to authorized employees to be used in accordance with this program and communicated through documented training (Forms 105.07 and 200.05.03). Specific procedural training will be documented within the procedure. Recognition of the lockout/tagout devices and procedure awareness will be communicated to affected employees through documented training (Forms 105.07 and 200.05.03). A specific lockout/tagout procedure will be developed for each machine or equipment and documented on the Lockout/Tagout Procedure form (Form 200.05.02) based on the Energy Source Evaluation (Form 200.05.01).

1.2 Lockout/Tagout Equipment 1.2.1 Group Locking Devices When service or maintenance is performed by more than one authorized employee a group locking device will be utilized to accommodate each authorized employee’s locking device. Group locking device must afford the employees a level of protection equivalent to that provided by the implementation of an individual locking device.

1.2.2 Locking Devices Authorized employees will use individual locking devices dedicated solely to this program. Each locking device will bear the identity of the authorized employee applying the device. The key for the locking device will remain in the authorized employees possession throughout the procedure. Duplicate keys will remain in authorized employees possession. Locking devices will be keyed differently for each authorized employee. All locking devices will be durable enough to withstand the environment to which it is exposed for the maximum period of time that exposure is expected.

1.2.3 Locking Hardware Some machinery or equipment may contain valve handles, electric breakers or other energy source mechanisms that can not be controlled with the lock. Specialized locking hardware is available to cover, disable and protect the energy source mechanism from accidental movement. This hardware is to be used in conjunction with the locking device to protect against inadvertent removal. A supply

X Mandatory Discretionary Effective Date: August 1997 Rev. # 1 Page 4 of 11 Revision Date: August 2004 R E G U L A T O R Y A F F A I R S M A N U A L S E R I E S 2 0 0 L O C K O U T / T A G O U T P R O G R A M P R O G R A M 2 0 0 . 0 5 of specialized locking hardware will be available to authorized employees to be utilized as required within the lockout/tagout procedures.

1.2.4 Tagout Devices Authorized employees will use a tag to warn against hazardous conditions if the machine or equipment is energized. The tag will bear the identity of the authorized employee applying the device. Tagout devices will be durable enough to withstand the environment to which it is exposed for the maximum period of time that exposure is expected. All tags will contain a standard format and print throughout the facility.

Note: The means to attach a tag will be of a non-reusable type, attachable by hand, self-locking and non-releasable with a minimum unlocking strength of no less than 50 pounds.

1.3 Training Each employee that services and maintains machinery and equipment including the employees that work in the vicinity of the affected machinery or equipment will be trained on the basic awareness of the energy control program. Employees that service and maintain machinery and equipment must demonstrate an understanding of the program and possess the skills necessary to apply, use and remove energy controls. Retraining will be provided as indicated in the retraining section of this program.

1.3.1 Authorized employee training:  the purpose of the standard

 the recognition of energy sources

 the magnitude of the energy in the workplace

 the methods and means necessary to isolate and control energy

 type of hazard to be controlled

 when the standard applies

 definitions of terms used

 equipment used for lockout/tagout:

o standardized appearance

o personal identification procedures

 procedures:

o preparation for shutdown

o notification to affected employees

o shutdown

o de-energizing

o placement of devices

o release of stored energy

o testing to verify effectiveness of energy control

o release from lockout/tagout

 procedures and rules for tagout systems

 limitations of tags

o only a warning device and provide no physical restraint

o removal only by the responsible authorized employee

o never bypass, ignore or defeat tags

o tags must be legible and understandable

o tag material must withstand environmental conditions

o evoke a false sense of security

o cannot be accidentally removed during use

o tags are not foolproof

 shift and personnel changes

 group lockout/tagout

 inspection program

 communication and reporting of problems

1.3.2 Affected employee training:  overview of the training outlined above for authorized employees

 prohibition against energizing any machine or piece of equipment that is locked or tagged out.

1.3.3 Outside contractors:  outside contractor and Fisher personnel will inform each other of their respective lockout/tagout procedures

 Fisher employees will understand and comply with outside contractor’s energy control program

1.4 Procedure 1. An energy source evaluation will be performed using the Energy Source Evaluation worksheet, Form 200.05.01, for each machine and equipment within the facility to determine potential sources of energy that may require control upon maintenance or servicing.

a. List each machine and piece of equipment by name, manufacturer and location within the facility in the designated columns of the Energy Source Evaluation worksheet.

b. Analyze each machine and piece of equipment and record the potential energy source in the corresponding box of the Energy Source Evaluation worksheet.

c. The Energy Source Evaluation worksheet will be signed and dated by the person performing the evaluation.

2. A lockout/tagout procedure will be written for each specific machine or equipment listed on the Energy Source Evaluation worksheet for each identified energy source.

Exception: Work on cord and plug connected electric equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the energy source and by the plug being under the exclusive control of the employee performing the servicing or maintenance does not need a specific lockout/tagout procedure. a. The manager of maintenance is to be consulted to accurately develop a procedure to assure effectiveness of the lockout/tagout procedure.

b. The procedure will systematically disable and contain the energy sources in the manner and in the sequence identified during the consultation with maintenance.

3. Transcribe procedure onto the Lockout/Tagout Procedure form, Form 200.05.02.

a. Reference the specific machine or equipment and list the procedure date on the heading on the Lockout/Tagout Procedure form.

b. Forward completed Lockout/Tagout Procedure form to maintenance manager for final review and signature.

4. Affected and authorized employees will receive training on the items identified in the training section of this program as defined on the Lockout/Tagout Training Outline. Certification of training session will be documented on the Record of Safety & Health Training sheet, Form 105.07, with a detailed copy of the suggested Lockout/Tagout Meeting Outline attached, Appendix 200.05.02.

5. Authorized employees will be trained on each specific machine or equipment lockout/tagout procedure in which they will be performing work beyond normal production operation.

6. Trainer will document authorized employees’ understanding and demonstration of the lockout/tagout procedure through signing and dating the final page of the specific lockout/tagout procedure for each machine or piece of equipment in which they are authorized to perform work beyond normal production operation.

7. A copy of the specific lockout/tagout procedure will be secured on the specific machine/piece of equipment or in the proximate vicinity that is easily accessible to reference.

1.5 Retraining Retraining will be provided to affected and authorized employees whenever:

 there is a change in their job assignments, a change in machines, equipment or processes that present a new hazard, or when there is a change in the energy control procedures.

 a periodic inspection (Form 200.05.03) reveals, or whenever a facility manager has reason to believe, that there are deviations from or inadequacies in the employee's knowledge or use of the energy control procedures.

 there is a need to reestablish employee proficiency and introduce new or revised control methods and procedures, as necessary.

1.6 Periodic Inspections Inspections of lockout/tagout procedures will be conducted at least annually to ensure that the procedures and requirements of this program are being followed and documented on the Periodic Inspection form, Form 200.05.03. Periodic inspections will be performed:

 by an authorized employee other than the ones(s) utilizing the lockout/tagout procedure being inspected

 to correct any deviations or inadequacies identified

The lockout periodic inspection will include a review, between the inspector and each authorized employee, of that employee's responsibilities under the lockout/tagout procedure being inspected.

The tagout periodic inspection will include a review, between the inspector and each authorized and affected employee, of that employee's responsibilities under the lockout/tagout procedure being inspected, and the limitations of tags referenced in the training section of this program.

Periodic inspections will be documented through the Periodic Inspection form, Form 200.05.03, and include:

 the identity the machine or equipment on which the lockout/tagout procedure was being utilized

 the date of the inspection

 the employees included in the inspection

 the person performing the inspection

X Mandatory Discretionary Effective Date: August 1997 Rev. # 1 Page 9 of 11 Revision Date: August 2004