Document No. Sec.

Effective Date. Rev. #

Support Document Manual

Lockout/Tag out

Objective This program is to ensure all individuals are protected from unexpected
activation or release of stored energy of machinery or equipment. This could
occur during maintenance, repairing and cleaning activities.
Scope Normal equipment operations are not considered in this program. Lockout is
a first means of protection. Warning tags only supplement the use of locks.
Tags alone may be used only when the application of a lock is not practical.

Definitions
Lockout-The practice of using keyed or combination security locks to prevent the unwanted activation of
mechanical or electrical equipment.

Tag out-The practice of using tags in conjunction with locks to increase the visibility and awareness that
equipment is not to be energized or activated until such devices are removed. Tag out devices will be
non-reusable, attachable by hand, self-locking, and non-releasable with a minimum unlocking strength
of no less than 50 pounds.

Activation/Energizing-To set machinery into motion by starting, switching, pushing, moving or

otherwise engaging power sources for such equipment. To provide a flow of electricity or complete a
circuit that is the main power source for the machinery/equipment.

Energy Control Procedures-Use of lockout/tag out equipment to ensure safe work practices.

Hazardous Motion-Motion of equipment under mechanical stress or gravity that may abruptly release
and cause injury. Hazardous motion may result even after power sources are disconnected. Examples
are coiled springs, raised hydraulic equipment and any sources of potential energy that may cause
injury.

Responsibilities
VTMC Ensure procedures are developed and maintained outlining the lockout/tag out steps for all
required equipment. The file will include the location, description, power source, primary hazards of
equipment/machinery, a list of the primary operator’s maintenance personnel and a list of lockout/tag
out equipment that is used and maintained on site. They will also ensure supervisors are providing
employees with lockout/tag out training.
Supervisor/foreman
Ensure each employee engaging in work requiring lockout/tag out of energy sources understands and
adheres to adopted procedures. Assure employees have received training in energy control procedures
prior to operating the machinery or equipment. Provide and maintain necessary equipment and
resources, including accident prevention signs, tags, padlocks, seals and/or other similarly effective
means. Notify the safety department of new or revised equipment, machinery or operations that
require the use of lockout/tag out devices during servicing, maintenance or repair. Maintain all training
records for lockout/tag out employee training.

Employees
Adhere to specific procedures as outlined in this document for all tasks that require the use of
lockout/tag out procedures. Maintain lockout/tag out supplies in maintenance vehicles. Report any
hazards that would not be controlled with lockout/tag out procedures.

Lockout/Tag out Equipment

• Hardware includes locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners
and other devices used for isolating, securing or blocking machines from energy sources.
• The devices shall be singularly identified, the only device used for controlling energy and not
used for other purposes.
• The devices must be capable of withstanding the environment for the maximum period of
exposure time.
• The tag out device shall be constructed and printed so exposure to weather conditions will not
cause the tag to deteriorate and become illegible.
• The tag shall not deteriorate in a corrosive environment.
• The devices shall be standardized by one of the following criteria: color, shape or size.
• The device shall be substantial enough to prevent removal with the use of excessive force or
bolt cutters.
• The tag out device and attachment shall be substantial enough to prevent inadvertent removal.

Identification on lockout/tag out device

• Shall identify the applying employee.
• Shall warn against hazardous conditions if the machines are energized.

Lockout/Tag out Procedures.

An equipment survey will be conducted to locate and identify all isolating devices. The survey will
identify switches, valves or other energy isolating devices to be locked or tagged out. More than one
energy source (electrical, mechanical, stored energy or others) may be involved. Operators will be
trained in the equipment lockout procedures. This training will include the type and magnitude of
energy the machine or equipment utilizes.

Lockout steps
1. If the machine or equipment is operating, shut it down by the normal stopping procedure
(depress stop button, open toggle switch, etc.).
 2. Operate the switch, valve or other energy isolating device(s) so the equipment is isolated from it
energy source(s).
3. The energy source will be identified in the equipment survey. Stored energy (such as that in
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 repositioning,
blocking, bleeding down, etc.
4. Lockout/Tag out the energy isolating devices with assigned individual lock(s) or tag(s).
5. With no employees exposed, test the lockout procedure by testing the operating device.
CAUTION: Return operating controls to neutral or off position after the test.
6. The equipment is now locked out.
7. Mark the tag with name and date.

Machine Power Restoration

1. After servicing and/or maintenance is complete and equipment is ready for normal production
operations, check the area around the machines or equipment to ensure no one is exposed.
2. After all tools have been removed from the machine or equipment, guards have been reinstalled
and employees are in the clear, remove all lockout or tag out devices.
3. Operate the energy isolating devices to restore energy to the machine or equipment.

Restoration with more than one operator:

If more than one individual is required to lockout or tag out equipment, each shall place his/her own
personal lockout/tag out device on the energy isolating device(s).
1. When an energy-isolating device cannot accept multiple locks or tags, a multiple lockout or tag
out device (hasp) may be used.
2. If lockout is used, a single lock may be used to lockout the machine or equipment with the key
placed in a lockout box or cabinet, which allows the use of multiple locks to secure it.
3. Each employee will then use his or her own lock to secure the box or cabinet.
4. As each person no longer needs to maintain his or her lockout protection, that person will
remove his or her lock from the box or cabinet.

Temporary Removal of Lockout Device

If the lockout/tag out device must be temporarily removed from the energy isolating device and the
machine or equipment energized to test or position the machine, the following sequence of actions will
be followed:
1. Clear the machine of tools and materials.
2. Ensure all employees have been safely positioned or removed from the area.
3. Instruct employees to remove the lockout/tag out devices.
4. Energize and proceed with testing or positioning.
5. De-energize all systems and reapply lockout devices as previously stated.

Maintenance When Energy Source Cannot Be Locked

Maintenance, repairing, cleaning, servicing, adjusting or setting up operations that cannot be
accomplished with the energy source disconnected may be performed under the following conditions:
• The operating station (i.e.-external control panel) is under the control of a qualified operator.
 • Employees are in clear view or communication with each other.
• All employees must be out of the area of hazard.
• Machine elements are locked out separately if the operator is required to leave the control
station to install a tool.
• The machine shall be de-energized during adjustment or replacement of mechanical
components.

Employee Training
Employees will receive annual lockout/tag out training. Employees will be trained on all new equipment
prior to machinery operation. All new employees or employees who transfer jobs duties will be trained
in their equipment’s lockout/tag out procedures.
 Energy Control Procedure Form

Machine: _________________________________(type, manufacturer, model and serial number)

Location: ________________________________________________________

Energy sources and locations of energy isolating devices:

1. _____________________________________________
2. _____________________________________________
3. _____________________________________________
4. _____________________________________________

Authorized employee(s)_____________________________________________

Affected employee(s)_____________________________________________

Qualified employee(s)_____________________________________________

Specific procedure for this equipment is as follows:

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________
 Annual Inspection Certification Form

Machine: ___________________________________________

Inspector: ____________________________________________

Employees Consulted:

● ____________________________________________
● ____________________________________________
● ____________________________________________
● ____________________________________________

Date: _____________________

Results of Inspection:
______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Signature of Inspector_______________________________ Date_______________

Signature of Safety Manager__________________________ Date_______________

Specific Procedure for This Equipment Is as Follows:
1. Verbally notify Operator and Assistant that lockout will be done on the machine.
2. Electrical System Isolation--Press the red stop button at the operator's control panel. Turn
electrical disconnect switch at column P-6 to the off (open) position to de-energize all
electrical components of the machine. Insert a lockout device through the switch and panel
hasp holes and lock securely in place with one of your own personal padlocks. Press green
"on" button to verify effectiveness of lockout, then repress red stop button at operator’s
control panel.
3. Pneumatic System Isolation--Manually rotate the quick throw valve for the compressed air
located at column P-6 to the off position (with the value handle at a 90-degree angle to the
compressed air pipe) to secure the machine's compressed air source. Insert a lockout
device through the valve handle and 90-degree hasp hole and lock securely in place with
one of your own personal padlocks. Bleed the residual air pressure from the machine by
opening the petcock valve (3/4 turn) at the bottom of the water trap located under the
north side of the machine table. Close the petcock when the hissing from the escaping air
stops (approximately 40 seconds). After waiting three minutes, reopen the petcock and
listen for escaping air to verify effectiveness of lockout; then reclose petcock.
4. Hydraulic System Isolation--Primary bleed-down. Manually rotate the red handle on the
inlet side of the hydraulic lockout valve located at column P-5 90 degrees clockwise to
isolate the machine from the central hydraulic power system. Note: when the red handle is
rotated 90 degrees clockwise in this manner, function pressure is automatically bled down
to the system tank pressure of 100 PSI. Insert a lockout device through the hole in the
flange at the bottom of the red handle and the hydraulic lockout valve hasp hole and
securely in place with one of your own personal padlocks. Final Bleed-down--Place a five-
gallon bucket on the floor beneath the discharge hose connected to the red quick
disconnect valve which has been installed in the port leading to the flushing plug, on the
outlet side of the hydraulic lockout valve. Slowly reopen the quick disconnect valve,
directing the flow from the hose into the bucket until the flow stops. Close the quick
disconnect valve. Wait two minutes. Slowly reopen the quick disconnect valve, watching
discharge from the hose to ensure effectiveness of lockout then reclose quick disconnect
valve.
5. The machine is now locked out and in a zero mechanical state.

Restoring Machine to Service

1. Check the machine and the immediate area around it to ensure people and tools are clear
and the machine components are operationally intact.
2. Verify all the controls are in neutral.
3. Unlock and remove your personal padlock from the lockout device on the disconnect
switch at column P-6. Remove the lockout device from the switch and hasp holes in the
disconnect switch. Turn disconnect to on (closed position) to energize all electrical
components on the machine.
4. Make sure that petcock valve at the bottom of the water trap located under the north
side of the table is closed. Unlock and remove your personal padlock from the lockout
device on the quick throw valve handle for compressed air at column P-6. Remove the
lockout device from the valve handle and the 90-degree hasp hole. Manually rotate the
quick-throw valve to the on position (with the valve handle in the line with the
compressed air pipe) to energize all pneumatic components on the machine.
5. Make sure the red quick disconnect, installed in the port leading to the flushing plug on
the outlet side of the hydraulic lockout valve is closed. Unlock and remove your personal
padlock from the lockout device in the flange at the bottom of the red handle on the inlet
side of the hydraulic lockout valve. Remove the lockout device from the handle flange and
the hydraulic lockout valve hasp hole. Manually rotate the red handle on the hydraulic
lockout valve 90 degrees counterclockwise to energize all hydraulic components on the
machine.
6. Notify the operator that the maintenance is complete and the machine is ready for use.

Prepared by Reviewed by: Approved by

Jezreel Tolentino Demosthenes Lipura Oscar B. Saavedra

Safety Officer Shipyard Superintendent President/Owner