SINGAPORE STANDARD CP 91 : 2001 (ICS 13.110) CODE OF PRACTICE FOR Lockout procedure All rights reserved. Unless otherwise specified, no part of this Singapore ‘Standard may be reproduced or utilised in any form or by any means, electronic or mechanical, including photocopying and microfilming, without permission in writing from the Singapore Productivity and Standards Board at the address below: Director Centre for Standardisation Singapore Productivity and Standards Board 1 Science Park Drive Singapore 118221 Telephone: 2786666 Telefax: 2786665 Email: cfs@psb.gov.sg ISBN 9971-67-871-3SINGAPORE STANDARD CP 91 : 2001 (ICS 13.110) CODE OF PRACTICE FOR Lockout procedure » Published by x \ ingapore Productivity and Standards Board iseencePaKohe PSB ‘Singapore 118221 SINGAPORECP 91: 2001 a This Singapore Standard was approved by the Industria! Safety Standards Committee on behalf of the ‘Standards Council of Singapore on 4 October 2001 First published, 2001 The Industrial Safety Standards Committee appointed by the Standards Council consists of the following members: Name ' Organisation Chairman: Mr Tan Pui Guan ‘Standards Council Secretary: Ms Christina Choong Singapore Productivity and Standards Board Members: MrCheah It Cheng Institution of Engineers Singapore ‘Mr Goh Kng Yan Association of Consulting Engineers, Singapore Mr William Goh Singapore Confederation of Industries Mr Ho Heng Huat Singapore Institution of Safety Officers Mr Harry Ho Sai Kwong ‘Singapore Contractors Association Limited Mr Hoong Kee Ching Housing & Development Board Assoc Prof Kam Bool Chung ‘Nanyang Technological University Dr Lee Hock Siang Ministry of Manpower Mr Lim Keng Kuok PWD Corporation Pte Ltd ‘Assoc Prof M Rahman National University of Singapore MrP K Raveendran ‘Association of Singapore Marine Industries Mr Seah Chong An Singapore Productivity and Standards Board Mr Soh Chen Chew ‘Building and Construction Authority ‘The Technical Committee appointed by the Industrial Safety Standards Committee and responsible for the preparation of this standard consists of representatives from the following organisations: Name Organisation Chairman: Mr Ho Heng Huat Industrial Safety Standards Committee Deputy aa: MrPK Raveendran Industrial Safety Standards Committee Secretary : Ms Barbara Bok Singapore Productivity and Standards Board: Members; Mr Abu Bakar B Mohd Nor ‘Singapore Confederation of industries ‘Assoc Prof Ang Hock Eng Nanyang Technological University Mr Ho Siong Hin Occupational Safety Department Er. Thomas Lee Institution of Engineers Singapore Assoc Prof Lua Aik Chong Nanyang Technological University ‘Assoc Prof M Rahman National University of Singapore Mr Seah Liang Bing ‘Singapore Institution of Safety Officers Seep! Assoc Prof Samuel Lim Individual CapacityCP 91 : 2001 eS 2001 The Working Group appointed by the Technical Committee on General Safety to assist in the preparation of this standard comprises the following members: Name Organisation Convenor: Er. Thomas Lee Institution of Engineers Singapore Members: Mr Abu Bakar B Mohd Nor ‘Singapore Confederation of Industries Mr Mohd Alifi Ismail Association of Singapore Marine Industies Mr Ken Lim Brady Corporation Asia Pte Ltd Mr Roger Lim ‘Singapore Institution of Safety Officers Mr Low Poh Huat Occupational Safety Department Mr Gilbert Ngu Panduit Asia Pacitio Pte Lid Mr Zulkarnain b H Umar Energy Market AuthoritycP 91: 2001 Se EEE ey (blank page)CP 91 : 2001 1 2001 Contents Page Foreword 6 CODE OF PRACTICE ee 0 Application 7 1 Scope 7 2 Definitions 7 3 Lockout policy and procedure 8 4 Requirements for lockout procedure 12 5 —_ Implementation of lockout procedure 12 6 Special lockout considerations 14 ANNEXES, See A Sample lockout procedure 8g 18 B Examples of tagging devices FIGURES Ss 1 Lockout procedure for electrical energy source 10 2 Lockout procedure for hydraulic-pneumatic energy source "P91; 2001 eT Foreword ‘This Code of Practice was prepared by the Technical Committee on General Safety under the direction of the Industrial Safety Standards Committee. This code provides recommendations and guidelines for safety requirements on the control of eneray during construction, servicing of maintenance of machines. The aim is to prevent any unexpected tenergisation or start up of machines, or release of stored energy that could cause injury to employees. This code is intended for factory occupiers, factory owners, safety officers and all those concerned directly or indirectly where exposure exists due to their involvement with work in progress. This code covers the policy, requirements and implementation of lockout procedure. Special lockout considerations on group, external personnel and shiftpersonnel changes are also recommended in the guidelines. In preparing this code, reference was made to the following publications: 4. ANSIZ244.1: 1982 American National Standard for personnel protection — lockouvtagout of energy sources - minimum safety requirements 2. OSHA Regulations (Standards-29 CFR-1910.147) - The control of hazardous energy (ockouttagout) NOTE 1. Singapore Standards are subject fo periodic review to keep abreast of technolagical changes and new technical developments. The revisions of Singapore Standards are announced through the issue of either amendment sips or revised editions, 2. Compiiance.with a Singapore Standard does not exempt users from legal obligations.CP 91 : 2001 Ot! 2001, Code of practice for lockout procedure 0 Application This code applies to the control of energy during construction, servicing or maintenance of machines. 1 Scope ‘This code covers the construction, servicing or maintenance of machines where any unexpected energisation or start up of the machines, or release of stored energy could cause injury to employees. It establishes minimum performance requirements for the control of such hazardous energy. 2 Definitions 24 Affected employee An employee who is required to operate or use a machine on which construction, servicing or maintenance is being performed under lockout, or who is required to work in an area in which such construction, servicing or maintenance is being performed. 2.2 Authorised employee ‘A parson who locks out machines in order to perform construction, servicing or maintenance on that machine. An affected employee becomes an authorised ‘employee when that employee's duties include construction, servicing or maintenance covered under this code. 2.3 Construction, servicing and/or maintenance Workplace activities such as constructing, erecting, installing, setting up, commissioning, repairing, adjusting, inspecting, modifying, operating, and maintaining and/or servicing machines or equipment. ‘These activities include lubrication, cleaning or unjamming of machines or equipment and making adjustments or tool changes, where the employee may be exposed to the unexpected energisation or start-up of the equipment or release of hazardous energy. 24 Energised ‘Connected to an energy source or containing residual or stored energy. 2.5 Energy Isolating device ‘A mechanical device that physically prevents the transmission or release of energy, including but is not limited to the following: (2) acircuit breaker; (b) _anisolating switch; (©) aline valve; ~~»CP 91 : 2001 ES (d)—ablock; and (e) any similar device used to block or isolate energy. NOTE — Push buttons, solactor switches, functional switches and other control circuit type devices are not energy isolating devices. 2.6 Energy source Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other forms of energy. 2.7 Lockout The placement of a lockout device on an energy isolating device, in accordance with an established procedure, for ensuring that the energy isolating device and the machine being controlled cannot be ‘operated unti the lockout device is removed. 2.8 Lockout device A device that utlises a positive means such as a lock, either key or combination type, to hold an ‘energy isolating device in the safe position and prevent energisation of a machine. 2.9 Machine Refers to plant, machinery, equipment or its parts. 2.10 Tagging device ‘A prominent waming device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the machine being controlled may not be operated until the tagging device is removed, 3 Lockout policy and procedure 34 General It shall be the responsibility of each employer whose employees are engaged in erecting, installing, constructing, repeiting, adjusting, cleaning, inspecting, operating, or maintaining the machine, to develop, document and implement a policy and procedure for lockout. The policy and procedure shall clearly and specifically outline the purpose, responsibility, scope, authorisation, rules, definitions and measures to enforce compliance. 34.1 Policy The lockout policy shall require all personnel concerned to comply with the lockout procedure. 3.1.2 Procedure ‘The lockout procedure shall specify that prior to the performance of any of the activities listed in 3.4 where unexpected energisation, start up, or release of stored energy could occur and cause injury, all potentially hazardous energy sources shall be isolated and locked out. The procedure shall also specify the requirements for removal of such devices, transter of locks, and testing for determination of lockout effectiveness.CP 91 : 2001 rr T2007 A sample lockout procedure is given in Annex A. pneumatic energy sources are locked out. igure 1 arid 2 show how electrical and hydraulic 3.1.3. Use of locks Locks shall be provided by the employer and shall be the only authorised device(s) used for the lockout of energy sources. They shall be singularly identified and specifically approved for lockout. 3.2 Responsibility 3.2.1 Authority ‘Compliance with this code shall be the responsibility of the employer and the individuals to whom the ‘employer delegates accountability for compliance and authority to enforce compliance. 3.2.2 Perior pections It shall be the responsibility of the employer to verity, through periodic inspections, the organisation's ‘compliance with this code, 3.2.3 Joint responsibility ‘The responsibility for obtaining performance in the lockout procedure shall be collaborated between the employer and the employee. The responsibility for compliance is that of the employer, who shall establish, communicate, train in the use of and the enforcement of procedure. The employee shall be responsible for knowing and following the established procedure. 3.3. Communication and training 3.3.1 All employees All employees shall be specifically notified of the requirements for compliance with the employer's policy and made aware of the lockout procedure, 9.3.2 Affected employees The employer shall ensure that each affected employee is instructed in the purpose and use of the lockout procedure. 3.3.3 Authorised employees All authorised individuals shall receive training in recognition of the applicable hazardous energy sources and in adequate methods and means for their isolation,CP 91: 2001 port NOV] Fee Al NS -INaWdINDa HO BOLOW NO SNDIUOM JUOsIa LO 9907 W3LNV1S HOLOW any YaNvsus LINUIO. ‘913 ‘S1O¥LNOO LNaW -ESnray “SaHOLIMS OLS GNY Luvs “TaNVd TOHLNOD Figure 1 - Lockout procedure for electrical energy source ‘SNIWOONT Eero SNINOONI 10CP 91: 2001 ‘S33A014W3 SIUHL JO S¥901 GNY DVL“ 'WIISAS 31907 GNV ONOL HIM 10 39907 NOILISOd 340 NI 3ATWA DILVWNANE a04nos ASH3N FLV TOSI OL No a3901 38 N¥O 3ATVA SLLWIINANd 3NIT-NI , ~—— UBMOd ‘SNIWOONT BATA NOLLWT0st NIVHO HO a7av0 auIM 40 3sn AHL AG NOISIAOLd DNID907 ON SVH HOIHM AATWA LO 9NIN907 40 GOHLIN Figure 2" Lockout procedure for hydraulic-pneumatic energy sourceCP 91: 2001 nS 3.4 Requirements for lockout devices ‘The lockout devices used for compliance with this code shall be: (2) Durable - capable of withstanding the environment to which they are exposed for the maximum period of time that exposure is expected; (©) Unique ~ distinctive, easily recognisable, clearly visible; (©) __ Standardised - standard in one or more of the following oriteria: colour, shape, size, type, or format; (d) Identifiable - including provision for identification of the person or persons authorising the application of or applying the device; and (&) Substantial - () Looks ~ of such durability and key code complexity that removal by any means, other than the regular key, would require excessive force or unusual techniques such as metal cutting tools; and (i) Tags and attachment mechanism ~ of such design that the probability of accidental removal is minimised. 4 Requirements for lockout procedure 4.1 Survey of energy sources and Identification of all energy isolating devices identify al the energy sources as well as their respective energy isolating devices. Label these energy isolating devices to indicate their function, the machine concemed, and the type and magnitude of the energy. 4.2 Selection and procurement of protective materials and hardware Ascertain the quantity and type of locks, chains, tags etc. needed. Procure and maintain them in good condition. 4.3 Assignment of duties and responsibilities Assign the operation of energy isolating devices only to trained and knowledgeable persons. 4.4 Preparation of de-energisation and start up sequence ‘A checklist for lockout and subsequent re-energisation has to be prepared. 5 Implementation of lockout procedure 6.1 Preparation and steps for lockout Details on the types of energy that power the machinery, locations of the energy isolating devices, presence of any secondary power supplies and the correct steps to turn off the machine safely must be established in the energy control procedure. 12CP 91 : 2001 a OOF Before the machine is shut down the authorised employee must understand the type and magnitude of the energy he is working with, the hazards of the energy, the means and method to control the energy, verification of effective energy control and the purpose of the procedure to be used. The following steps shall be taken to achieve a safe energy isolation and machine lockout. The sequence established shall be followed. (a) ©) ©) @ (e) o Announce the shut down. Inform all affected employees of the purpose and duration of the lockout application. This notification must be given betore the lockout procedure is performed. Machine shut down. The machine must be shut down using the operating controls according to the shut down procedure for each individual machine to avoid any additional or increased hazard. This is a safe practice as any attempt to shut down machine under load risks damaging the machine. Machine isolation. All energy isolating devices that control the energy to the machine must be operated to isolate the machine from the energy sources. The energy control procedure must ‘also identify the location of all energy isolating devices and energy sources including ‘secondary power supplies. This will ensure the safe and complete de-energisation of the machine. Lockout and tagging device application. The authorised employee is responsible for the application of proper lockout and tagging devices to the energy isolating devices of the machine. The authorised employee must use his own locks only and nobody is allowed to apply his locks on behalf of another individual, except for group lockout protection under 6.2. The lockout devices must be sturdy and lockout the energy isolating devices in the “oft” position. They must also be designed to prevent the operation of the energy isolating devices when they are lockout. If more than one person is working on the machine, every member of the crew must attach his personal lock and tag. Secure tags directly to the energy isolating devices where the lockout devices are attached. Each tag must be clearly visible, explaining the purpose of the lockout and warning against the hazard of operating the machine. It must also identify the person who affixed the tag and the date of lockout. Control of stored energy. Any residual stored energy in the machine can be equally hazardous to the employee. The authorised employee must ensure that any stored energy is safely released before work begins, The following are examples of ways to control stored energy: () relieve trapped pressure downstream; (i) discharge capacitor and install ground wire; (ii) release tension on spring, or block movement of spring driven part; (¥) use blook to prevent fall due to gravity: and (VY) _use blank flange to block flow of hazardous materials if valve is not available, Verify the energy isolation. The authorised employee must verify the isolation and de- energisation of the machine before work begins, The following actions shall be accomplished after the lockout application to confirm the energy isolation: () Operate the machine “on/off” switch to verity that the machine is not working and return all controis to the "off" or "neutral" position. (i) Use appropriate instrument to verify that the machine is completely de-energised. 13,CP 91: 2001 ees 5.2 Steps for start-up The procedure for release of lockout is equally important after the construction, servicing or maintenance is completed. The following actions are required for safe start-up of machine to ensure the safety of employees: (a) The machine. Before restoring energy to the machine, the authorised employee must ensure that the work area is clear of all non-essential items and all necessary components are operationally intact. For a complex machine, use a checklist to verify that all essential components are operationally intact. (b) Personnel. It should be ascertained that personnel are physically clear of the machine. Multiple personnel and energy source situations demand comprehensive measures to ensure that assigned work has been completed and all personnel have cleared the machine. () Lockout and tagging devices removal. Inform all affected employees when the lockout devices are removed but before the machina is energised. Only authorised personne! who applied the lockout and tags are authorised to remove their own locks and tags. No other employee should attempt to remove another person's lockout. ‘The lockout procedure should also have a provision for the removal of another employee's lockout, in the event that the individual is not present. This provision must ensure that the procedure taken is as safe as if the individual were present to remove his locks. 6 Special lockout considerations 6.1. Protection of external personnel Established lockout procedure shail be followed for the protection of extemal personnel (i.e. service representatives, contractor's employees, and other outside personnel), where exposure exists due to their involvement with work in progress, 6.2 Group lockout protection When cleaning/inspection/repair or maintenance work is performed by a crew, craft, department or group, they shall follow a procedure which affords the employees a level of protection equivalent to that provided by the implementation of a personal lockout device. Group lockout devices shall include the following requirements: (@) Primary responsibilty is vested in an authorised employee for a sat number of employees working under the protection of a group lockout device; (b) Responsibility for the authorised employee to ascertain the exposure status of individual group members with regard to the lockout of the machine; (©) When more than one crew, craft, department, etc. is involved, assignment of overall job- associated lockout control responsibility to an authorised employee designated to co-ordinate affected work forces and ensure continuity of prot (@) Each authorised employee shall affix a personal lock to the group lockout device, group lockbox, or comparable mechanism when the employee begins work, and shall remove those devices when the employee stops working on the machine being serviced or maintained. 14CP 91 ; 2001 a 200 63 Shift or personnel changes Specific procedure shail be followed during shit or personnel changes to ensure the continuity of lockout protection, including provision for the orderly transfer of lockout protection between outgoing and incoming employees, to minimise exposure to hazards from the unexpected energisation or start- Up of the machine, or the release of stored energy. 6.4 — Repetitive minor adjustments In the case of required repetitive minor adjustments where the machine cannot be shut down and lockout, or in the case of normal production operations, these activities shall be accomplished under the protection of specially designed control circuits, control machine, and safe work procedure, that provide proven effective protection for the affected personnel. 15CP 91: 2001 a Annex A Sample lockout procedure ‘The following sample lockout procedure is provided as a guide for the development of a specific lockout procedure. Where complexity requires, a more comprehensive procedure shall be developed, documented and implemented. LockouT Lockout procedure for (Name of Company) 1 Purpose This procedure establishes the requirements for lockout of energy sources that could cause injury to personnel. All employees shall comply with the procedure. 2 Responsibi The responsibility for seeing thet this procedure is followed is binding upon all employees. All employees shall be instructed in the safety significance of the lockout procedure by designated individual(s). Each new or transferred affected employee shall be instructed by designated individual(s) in the purpose and use of the lockout procedure, 3 Preparation for lockout Employees authorised to perform lockout shall be certain as to which switch, valve or other energy Isolating device applies to the machine being locked out. More than one energy source (electrical, mechanical, or others) may be involved. The employees shall clear any questionable identification of energy sources with their supervisors, 4 Sequence of lockout procedure (a) Notify all affected employees that a lockout is required and the reason for it. () If the machine is in operation, shut it down by the normal stopping procedure (depress stop button, open toggle switch, etc), ()- Operate switches, valves, or other energy isolating devices so that the energy sources (electrical, mechanical, hydraulic, etc) are disconnected or isolated from the machine. Stored energy, such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic system, and air, gas, steam, or water pressure, ete, must also be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding-down etc. (@) Lock out the energy isolating device. 16CP 9 : 2001 nO: 2007 (@) After ensuring that no personnel is exposed and having disconnected the energy sources, operate the push button or other normal operating controls to ascertain that the machine will not operate. CAUTION: Retum operating controls to neutral posttion after the test. (f) ‘The machine is now locked out. 5 Restoring machine to service (2) When the job is completed and machine is ready for testing or normal service, check the ‘operational area to ensure all employees and tools are cleared of the machine. (©) Remove all lockout devices. The eneray isolating device may be operated to restore energy to the machine. 6 Procedure involving more than one person In the preceding steps, if more than one individual is required to lack out machine, each shall place his ‘own personal lock on the energy isolating device. Alternatively, one designated individual of a work crew or a supervisor, with the knowledge af the crew, may lock out machine for the whole crew. In such cases, it shall be the responsibilty of the designated individual to carry out all steps of the lockout Procedure and inform the crew when it is safe to work on the machine. Additionally, the designated individual shall not remove the lock unti it has been verified that all individuals are clear. 7 Rules for using lockout procedure All machines shall be locked out to protect against accidental or inadvertent operation when such operation could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy isolating device bearing a lock. 7cP 91 : 2001 a ES Annex B Examples of tagging devices The following are some examples of tagging devices. fen) DO DO NOT NOT OPEN START This lock/tag may This lock/tag may onty be removed by: only be removed by: Name Names Dept. peo Expected Completion _ jt - hers DO NOT Fe same se OPERATE . “are lp cat nergy sures + Tested sadness ew sate : a {prenatal blend This lock/tag may natty be removed by: me Depo Expected CompletionCP 91 : 2001 eT 200F ABOUT THE SINGAPORE PRODUCTIVITY AND STANDARDS BOARD. ‘The Singapore Productivity and Standards Board (PSB) was established in April 1996, Its mission Is to raise productivity so as to enhanca Singapore's competitiveness and economic growth for a better quality of life for our People. To achieve this mission, two broad thrusts are adopted — developing world-class industries and creating favourable environment for productivity improvement and innovation. The specific areas of focus are: small and ‘medium-sized enterprises (SMEs), productivity and innovation, and standardisation and metrology. ‘As th lead agency spearheading the upgrading of SMEs, PSB adopts a total approach to develop SME into vibrant and resilient enterprises. At the enterprise level, it develops promising SMEs by enhancing their capabilities. At the Sector level, it improves the productivity of domestic industries through industry-wide programmes. ‘The broad-based ‘programmes include accelerating the adoption of e-commerce amongst SMEs, developing Singapore as an SME hub and providing SMES with access to finance. PSB also gerves as the firs point of contact for SMEs that need information and assistance. Productivity and Innovation. PSB spearheads the national Productivity and Innovation Movement to cultivate a strong commitment to productivity ‘and innovation and to foster @ creative and thinking workforce that is able to translate ideas into action. As the lead agency in charge of workforce development, it works closely with employers, unions and other government agencies to build up the capabilities of the workforce and the traning infrastructure in Singapore, Financial incentives are provided {0 help employers defray the cost of training their employoas, Organisations are also encouraged to esiabish sysiome that drive continuous improvement and attain business excellence through the Singapore Quallly Award and Singapore Quality Ciass. ‘Standardisation and Metrology ‘As the nationel standards body and national metrology institute, PSB improves market access for Singapore's exports through its work on standardisation and metrology. Standardisation is also used as a major strategy to raise the Productivity of industries. PSB enforces the Weights & Measures Act and Regulations to protect both coneumors and tradars by ensuring that ‘market transactions based on weights and measurement are accurate, fair and consistent with the relevant standards. ‘As the Safaty Authority, it administers the Singapore Consumer Protection (Safety Requirements) Registration Scheme to ensure compliance by industry on the registration of controlled goods. ABOUT THE NATIONAL STANDARDISATION PROGRAMME, Under the national standardisation programme, PSB helps companies and industry to meet intemational standards and conformity requirements by creating awareness of the importance of standardisation to enhance competitiveness and Improve productivity, co-ordinating the development and use of Singapore Standards and setting up an information Infrastructure to educate companies and industy on the latest developments, PSB is vested with the autholity to appoint a Standards Council to advise on the preparation, pubkcation and promulgation of Singapore Standards and Technical References and their implementation. ‘Singapore Standards are in the form of specifications for materials and products, codes of practice, methods of test, nomenciature, services, etc. The respective standards committee will draw up the standards belore seeking final approval from the Standards Council, To ensure adequate representation of all viewpoints in the preparation of Singepore Standards, all committees appointed consist of representatives from various interest groups which include government agencies, professionel bodies, tertiary institullons and consumer, rade and manufacturing organisations. ‘Technical References are transition documents developed to help meet urgent industry demand for specifications or requirements on a particular product, process or service in an aroa where there is an absence of relerence standards. Unlike Singapore Standards, they are issued for comments over a period of two years before assesement on theit suitablity for approval as Singapore Standards. li comments ara considered when a technical reference is reviewed at the end of two years to determine the feasibilty of its transition to a Singapore Standard. Technical Relarences ean therefore become Singapore Standards after two years, continue as Technical References for further comments or be withdrawn. In the intemational arena, PSB represents Singapore in the International Organisation of Standardisation (ISO), the Intemational Elacirotechnical Commission (IEC), the Asia-Pacific Economic Co-operalion (APEC) Sub-commitiee for ‘Standards and Conformancs (SCSC) and in the ASEAN Congultative Committee for Standards and Quality (ACCSQ), 19