GB/T 33579-2017 English PDF (GB/T33579-2017)

GB/T 33579-2017: Safety of machinery - Control methods of hazardous energy - Lockout/Tagout
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GB/T 33579-2017
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 13.110
J 09
Safety of machinery - Control methods of hazardous energy
- Lockout/tagout
ISSUED ON: MAY 12, 2017
IMPLEMENTED ON: DECEMBER 01, 2017
Issued by: General Administration of Quality Supervision, Inspection and
Quarantine of PRC;
Standardization Administration of PRC.
Table of Contents
Foreword ... 4
Introduction ... 5
1 Scope ... 7
2 Normative references ... 7
3 Terms and definitions ... 8
4 Responsibilities ... 10
4.1 Manufacturer’s responsibilities ... 10
4.2 User responsibilities ... 10
4.3 Responsibilities of authorized individual ... 10
5 Design ... 11
5.1 Requirements for manufacturers ... 11
5.2 Energy isolation device ... 11
5.3 Special tools ... 13
5.4 Warnings and special instructions ... 13
5.5 Local component isolation ... 13
5.6 Documentation requirements ... 13
5.7 Stored energy and residual energy ... 14
5.8 Control integration ... 14
5.9 Safety protection devices ... 14
6 Hazardous energy control solutions ... 15
6.1 User responsibilities ... 15
6.2 Control methods ... 16
6.3 Lockout/tagout solution ... 16
6.4 Alternative methods ... 25
6.5 Communication and training ... 25
6.6 Review of hazardous energy control solution ... 27
Appendix A (Normative) Lockout/tagout solution ... 29
Appendix B (Normative) Universal lockout/tagout procedures ... 37
Appendix C (Informative) Example of energy control procedure ... 40
Appendix D (Informative) Sample lockout/tagout posting ... 42
Appendix E (Informative) Team lockout/tagout ... 43
Appendix F (Informative) Alternatives for printing industry ... 49
Appendix G (Informative) Alternatives for the plastics industry ... 50
Appendix H (Informative) Alternatives for robots ... 52
Appendix I (Informative) Sample of lockout/tagout checklist ... 53
References ... 56
Safety of machinery - Control methods of hazardous energy
- Lockout/tagout
1 Scope
This standard specifies requirements for the control of hazardous energy that may cause
personal injury.
This standard also specifies the protection steps, technology, design, methods,
performance indicators for controlling the accidental release of hazardous energy 1), so
as to avoid personal injury.
This standard applies to the design, manufacturing, installation, construction, repair,
adjustment, inspection, dredging, setting, fault finding, testing, cleaning, disassembly,
service, maintenance during the entire life cycle of the machine.
This standard does not apply to service or maintenance work on electrical equipment,
that is connected to the power supply by wires and plugs, AND where the plugging and
unplugging of the power plug is only under the personal control of the service or
maintenance personnel. In this case, unplugging the power cord may control the
possible injury, which is caused by accidentally energizing or accidentally starting the
machine.
This standard also does not apply to pressure pipeline transmission and distribution
systems involving water, steam, natural gas or petroleum products.
2 Normative references
The following documents are essential to the application of this document. For the dated
documents, only the versions with the dates indicated are applicable to this document;
for the undated documents, only the latest version (including all the amendments) is
applicable to this standard.
GB 5226.1-2008 Electrical safety of machinery - Electrical equipment of machines
- Part 1: General requirements
GB/T 15706-2012 Safety of machinery - General principles for design - Risk
assessment and risk reduction
1 From the perspective of the person exposed to the risk, any unexpected action, such as energization, starting and
release of stored energy, is an accidental release of hazardous energy.
5 Design
5.1 Requirements for manufacturers
5.1.1 General requirements
The design, manufacture, installation of the machine shall facilitate the user to
implement the control methods, which are specified in this standard. Any modification
affecting energy isolation shall comply with this standard. A risk assessment shall be
conducted during the design stage of the machine, to determine the requirements and
design margins for energy isolation devices and systems. See Chapter 5 of GB/T 15706-
2012 for risk assessment procedures.
5.1.2 Minimizing exposure
The manufacturer shall design the machine to be reliable, to ensure that excessive
intervention is not required. Machines shall be designed so that, to the extent possible,
personnel performing routine and recurring service and maintenance are not exposed to
hazardous energy.
Note: This can be achieved by placing the controller outside the hazardous area, adding
controllers in appropriate locations, providing external lubrication points, or providing guards.
5.1.3 Partially energized
For those functions that require partial energization, the manufacturer shall conduct a
risk assessment, in accordance with Chapter 5 of GB/T 15706-2012, to determine the
safest method of entering the machine. When it is necessary to maintain partial
energization (such as to clamp workpieces, preserve information, maintain heat, or
provide local lighting), other control methods shall be provided, to ensure the safety of
personnel.
5.2 Energy isolation device
5.2.1 General requirements
To meet the requirements of 6.3, the design, construction, and installation of machines
shall take into account energy isolation devices, according to their intended use. Energy
isolation devices shall be able to control and/or dissipate hazardous energy. Energy
isolation devices should be an integral part of the machine.
If the device is not integrated into the machine, the manufacturer shall recommend the
type and installation location of the energy isolation device in the installation
instructions.
5.2.2 Location
Energy isolation devices shall be installed in easily accessible locations. If feasible, it
shall be located so that the locking device is easy to apply during repair and
maintenance.
Note: The energy isolation device is preferably located outside the danger zone, in an adjacent
walking area, at a height that is convenient for operation (i.e., not at a high place, not on a ladder,
or under the machine).
5.2.3 Identification
All energy isolation devices shall be adequately identified or marked, unless their
location and arrangement make their purpose obvious. The identification shall include
the following:
a) The machine being served;
b) Type and magnitude of energy.
Note: The possibility of error is reduced, if the intended person does not rely on memory or
experience to determine which isolators are used for which machines. If the machine
nameplate contains the required identification of the energy isolation device, each energy
isolation device should be marked or coded on the machine nameplate.
If safety conditions can be guaranteed, coding can also be used for identification.
Examples of identification (signage, embossing, engraving, platemaking, etc.):
No.3 press main power supply (480 V); No.2 natural gas pipeline; hydraulic pump
output (5 MPa);
Compressed air (1 MPa) for No.A bracket.
5.2.4 Performance
Energy isolation devices shall be able to be locked or fixed in an effective isolation
position.
Note: Examples of effective isolating devices include handle locks [operating levers with self-
aligning locking tabs (holes)], ball valve locks, lock sleeves that only operate when the switch
is in a safe position, wheels with locking tags and position indicators, hard block with locking
tab alignment, etc.
5.2.5 Applicability
Each energy isolation device shall be evaluated to determine its applicability for its
intended use.
5.7 Stored energy and residual energy
If stored or residual energy has been determined to be hazardous, means for safely
dissipating or confining the stored or residual energy shall be integrated into the
machine. Devices used to dissipate stored energy shall be designed with means or
methods for verifying their location and status.
If it is determined that the shutdown process of the machine is dangerous, protective
devices shall be installed, to prevent the danger or to prevent approaching the danger
before the movement stops. The position of the safety protective device shall be
determined according to GB/T 19876.
Note: For stored thermal energy or residual thermal energy, if a device that dissipates or
restrains the stored energy or residual energy cannot be used, warnings and/or instructions may
be used instead. If the presence and location of hazardous thermal energy are obvious, due to
the function of the machine, warnings and instructions may be exempted.
5.8 Control integration
If other methods are used for setting up, troubleshooting or other tasks requiring de-
energization or partial energization, a protection system shall be used, to ensure that the
failure of individual components within the device or system can still stop or prevent
hazardous movement or release of hazardous energy.
Note: Typical ways to accomplish this task are:
a) A hardware-based, reliable control safety interlocking system;
b) Multi-channel safety PLC for safety purposes and used in accordance with the
manufacturer's instructions.
5.9 Safety protection devices
Safety protection devices shall be able to withstand all forces they experience multiplied
by an appropriate safety factor; comply with corresponding standards, such as
protection devices that meet GB/T 8196, interlocking devices that meet GB/T 18831,
etc.
6 Hazardous energy control solutions
6.1 User responsibilities
6.1.1 Equipment
The user's machine shall meet the requirements of Chapter 5. If the user's machine does
not meet the requirements of Chapter 5, the user shall modify and upgrade the machine,
to comply with the requirements of Chapter 5.
Note 1: Machines that may need to be upgraded may also include newly purchased second-
hand machines, machines designed to different standards, relocated original equipment.
If the user purchases components, parts of a machine or assembles multiple machines
into a production line, the user shall fulfill the manufacturer's responsibilities and meet
the requirements of Chapter 4. The user's machine shall be equipped with an energy
isolation device, to allow authorized individual to implement the hazardous energy
control solution in 6.3.
Note 2: A single isolating device, that provides energy to multiple operations or machines
simultaneously, although meeting the requirements, may still create situations that encourage
personnel not to fulfill the requirements of this standard. In this case, additional isolation
devices or other methods may be required.
6.1.2 Solution
Users shall develop a written solution for hazardous energy control; refine the
requirements of 6.3 or 6.4. The purpose of the solution is to ensure that before the
authorized individual perform the installation, construction, repair, adjustment,
inspection, unclogging, setting, troubleshooting, testing, cleaning, disassembly, service,
maintenance of machinery, that could unexpectedly energize, start, or release stored
energy and cause injury, the risk of exposure to hazard is eliminated or minimized (see
Figure 1).
Note: Users should consider warnings and special instructions provided by the manufacturer.
see Appendix B for the lockout/tagout procedure. To provide effective protection,
lockout/tagout shall include the following elements:
a) Investigation of all hazardous energies;
b) Identification of energy isolation devices;
c) Selection and procurement of protective materials and hardware;
d) Assignment of duties and responsibilities;
e) Determination of shutdown, de-energization, energization, starting sequences;
f) Written operating procedures for the machine;
g) Personnel training;
h) Review of solution elements.
If the energy isolation device can be locked, it shall be locked, unless the user can
demonstrate that effective protection of personnel can be provided by using only a
tagout solution. An energy isolation device can be locked, if it is attached with a hasp
or has a lockable accessory structure, OR if it has a built-in locking mechanism. Energy
isolation devices may also be locked, if there is no need to dismantle, rebuild or replace
the energy isolation device, or permanently alter its energy control capabilities.
If the energy isolation device cannot be locked and the risk assessment results indicate
that it is feasible, a tagout solution can be used.
If a lockable energy isolation device uses a tagout device, the tagout device shall be
attached to the same location as the lockout device; the user shall demonstrate that the
tagout solution can achieve an effective level of safety.
When demonstrating the effective level of safety achieved by the tagout solution, the
user shall demonstrate full compliance with all tagout-related provisions of this
standard. Additional protective measures shall include (but are not limited to) removing
isolating circuit components, blocking control switches, opening additional
disconnection devices, or removing the valve stem, to reduce the possibility of
accidental energization.
6.3.2 Hazardous energy control procedures
6.3.2.1 General requirements
An important element of the overall hazardous energy solution is the development of
procedures. Detailed procedures for the control of hazardous energy during service or
maintenance shall be developed and documented, for each unique machine or group of
machines. These procedures shall be posted or otherwise readily accessible for
inspection and use by authorized individual.
Note 1: See Appendix C for examples of energy control solution for complex special machines.
In addition, see Appendix D for examples of nameplates (graphical procedures).
When a workshop or factory has multiple machines of the same ty...