EHS-01 Lockout/Tagout Program

Revision 4 · Effective 2025-11-03

1 Purpose

This procedure protects people from the unexpected startup or release of stored energy while machines and equipment are serviced, repaired, cleaned or cleared of jams. It is the Tallgrass energy control program under OSHA 29 CFR 1910.147.

2 Scope

Applies to all employees and contractors at the Wichita plant who service or work near machines with electrical, pneumatic, hydraulic, mechanical, gravity or thermal energy, including CNC machining centers, grinders, saws, compressors, CMMs and assembly presses. Routine tool changes, offsets and minor adjustments done with the machine's built-in guarding and interlocks in place are not covered unless the operator must bypass a guard or place any part of the body in the point of operation.

3 Definitions

Authorized employee: A trained person who applies locks and tags and performs the servicing. Maintenance technicians, set-up machinists and designated leads are authorized after training.
Affected employee: A person who operates or works near equipment being locked out, but does not apply locks. All production, quality and shipping employees are affected employees.
LOTO placard: The machine-specific energy control procedure posted on each machine, listing every energy source, its isolation point and the verification method.
Zero energy state: All energy sources isolated, stored energy released and verified.

4 Responsibilities

EHS Coordinator (ext. 2250) owns the program, writes and updates placards, trains authorized employees, and performs the annual periodic inspection.
Department managers ensure only authorized employees perform lockout and that placards are present on their equipment.
Authorized employees follow this procedure and the placard every time.
Affected employees never attempt to start, unlock or operate locked-out equipment.
Contractor sponsors coordinate contractor lockout with EHS (section 5.6 and EHS-04).

5 Procedure

5.1 Locks and tags

Each authorized employee is issued personal red locks, keyed individually, with "Danger - Do Not Operate" tags showing the employee's name, department and date. Only the issued employee holds the key. Red locks are used for lockout only, never for toolboxes or lockers. Lock and tag stations are located in Bay 2 and Bay 5.

5.2 Machine-specific LOTO placards

Every machine with more than one energy source has a laminated LOTO placard posted at the main disconnect, identified by the machine asset number. If a placard is missing, damaged or does not match the machine, stop and contact EHS before starting work.

5.3 Lockout sequence

Prepare: Read the placard and identify every energy source.
Notify affected employees in the area that the machine will be locked out.
Shut down the machine using normal stop controls.
Isolate each energy source at the points shown on the placard.
Apply your personal red lock and tag at each isolation point.
Release stored energy: bleed air and hydraulic pressure, block or lower raised components, let spindles come to a complete stop.
Verify zero energy (try-start): clear the area, then attempt to start the machine with the normal controls. Use a meter for electrical work where the placard requires it. Return controls to OFF after the try-start.

5.4 Group lockout

When more than one person services the same equipment, the lead authorized employee locks each isolation point with a lock whose key is placed in the group lockout box. Every person working on the job places their personal red lock on the group lockout box and removes it only when their own work is done. The lead removes the isolation locks only after all personal locks are off the box. At shift change, oncoming workers apply their locks before outgoing workers remove theirs.

5.5 Restoring equipment

Remove tools, reinstall guards, confirm everyone is clear, notify affected employees, then remove locks and tags. Each person removes only their own lock.

5.6 Contractors

Contractors performing servicing use their own locks and tags and follow their own program only if it is at least as protective as this one. Before starting, the contractor, the Tallgrass sponsor and the EHS Coordinator review the work and agree which procedure applies. Tallgrass employees and contractors working on the same equipment use the group lockout box.

5.7 Removal of another person's lock

A lock may be removed by someone other than the person who installed it only with authorization from both the EHS Coordinator and the department manager, and only after documented attempts to contact the employee by phone have failed. The employee must be told before they return to work. Removal under any other circumstances is a serious safety violation handled under HR-200.

6 Training and Periodic Inspection

Authorized employees receive LOTO training at assignment and annually, plus hands-on verification of each placard type they use.
Affected employees receive LOTO awareness training at hire.
The EHS Coordinator conducts an annual periodic inspection of each energy control procedure, observing an authorized employee perform it, and certifies the inspection with the date, equipment, employee and inspector.

7 Records

Training is recorded on F-620-02 and retained per QP-6.2. Periodic inspection certifications and lock-removal records are kept by EHS on the Operations SharePoint site for 3 years.

8 Revision history

Rev	Date	Change	Approved by
2	2021-10-04	Added machine-specific placards for all CNC machines.	Carl Brandt
3	2023-11-06	Added group lockout box and shift-change rule.	Carl Brandt
4	2025-11-03	Lock removal now requires EHS Coordinator and department manager authorization; added contractor coordination; try-start verification required on every lockout.	Margaret Lindqvist