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6110 Hazardous
Energy Control Program |
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1.0
Purpose
The
mission of Jefferson Laboratory as a scientific and engineering research center
needs a large and diverse installed infrastructure, with facilities, equipment,
and machines that have a wide variety of hazardous energy sources. The
hazardous energy sources associated with scientific and research-related
equipment may be completely different to those of facility infrastructure
equipment. No matter what the source, mitigating hazards by isolating hazardous
energy and using Lockout/Tagout (LOTO) is part of Integrated Safety Management
at Jefferson Lab under Title 10 of the Code of Federal Regulations (CFR), Part 851, Worker Safety and Health Program, and several other CFR and
regulatory safety standards.
This manual describes the Hazardous Energy Control (HEC) program and how to
implement it. The goal of the HEC program is to prevent injury to staff or
damage to government and proprietary property that may result from an unexpected
startup of equipment and machinery, or inadvertent release of stored energy.
Refer to ES&H Manual Chapter
6111, Administrative Control Using Locks and Tags for administrative control applications.
This
program satisfies the requirements of OSHA 29 CFR1910.147 The Control of Hazardous
Energy (Lockout/Tagout);
the standard used when servicing and maintaining equipment/systems and NFPA 70E
(2015 Edition), Article 120, Establishing an Electrically Safe Work Condition.
Jefferson
Lab’s construction subcontractors follow OSHA 29 CFR1926 Safety and Health
Regulations for Construction;
which is the standard for construction work activities. Technical representatives (TR) are tasked with reviewing subcontractors’
programs for compliance.
The terms shall, should, and may, as used in this document, indicate that an action or actions are:
shall – required or mandatory
should – considered good practice in most cases, but is not considered mandatory and, in some cases, such action may not be appropriate
may – fully optional action(s)
2.0
Scope
LOTO is required whenever there is the potential for someone to be
injured by the unexpected start-up of equipment or by a release of stored
energy during maintenance and service work. ALL employees are responsible for the LOTO program and are
to work safely to control the hazardous energy potentials when performing
maintenance, repair, or modifications, or builds to any equipment.
The definition of hazardous
energy is: Any form of energy that can cause personal injury or equipment
damage. Forms and sources of energy can include:
· Electrical
· Pressure
· Vacuum
· Mechanical
· Hydraulic
· Rotation
· Pneumatic
· Gravitation
· Non-Ionizing
Radiation
· Lasers
· Chemical
· Thermal
· Cryogenic
This manual explains the Hazardous
Energy Control (HEC) program and the minimum requirements to control hazardous
energy for equipment with one or more sources of energy. This manual also
addresses alternative means to isolate equipment and systems when the isolation
is not required for maintenance or servicing (see section 4.2 and 10.13).
3.0
Applicability
The HEC program applies to ALL employees at Jefferson Lab
and ALL levels of subcontractors,
visitors (such as Open House functions which require Lock-Out Tag-Out of
systems they will be near), and users. Affected persons are those whose job
requires him/her to operate or use a machine or equipment on which servicing or
maintenance is being performed under a LOTO, or whose job requires him/her to
work in an area in which such servicing or maintenance is being performed. The
requirements will apply to the following situations:
3.1
Working on or near equipment that could
cause injury during installation, servicing, modifying, building, and/or
maintenance if the equipment unexpectedly is energized, energy has been stored
up, or there is a release of stored energy.
3.2
Work activities on or near electrical
conductors, circuits, or equipment that are or may be energized.
3.3
Work activities where there is a
significant potential for electrical shock, or other injuries from arcing,
flash burns, electrical burns, or arc blast.
3.4
Servicing or maintenance that occurs if
employees must remove or bypass a ground or other safety device (this must be
documented and approved).
3.5
Working on equipment or machines that
employees must place any part of their body into the area where work is
performed or operation of equipment is ongoing, or where an associated danger
zone exists during an equipment or machine’s operating cycle.
3.6
Working on or near equipment that can
explode due to pressure such as pressure, hydraulic, pneumatic, chemical,
thermal, and cryogenic.
3.7
Working on or near equipment that can turn
or rotate such as machines and motors that may move.
3.8
Work activities that can cause damage to a
person through suction or vacuum.
3.9
Work activities on, near, or with items or
substances that can cause burns other than electrical burns, such as freeze
burns from cryogenics, chemical burns, thermal burns from heat or hot oils, and
radiation burns.
3.10
Working on or around areas that have
lasers. Lasers can burn skin and eyes.
4.0
Exclusions
Installations and affiliate organizations excluded from requirements in the Jefferson Lab Worker Safety and Health program (Environmental, Safety, and Health (ES&H) Manual Chapter 1100 Environmental, Safety, and Health Policy) are also excluded from the requirements of the HEC program. This section explains the processes identified in 29 CFR 1910.147(a)(1)(ii) that are not applicable and therefore excluded under this program.
The
HEC program does not cover normal operations. It covers servicing and/or
maintenance which takes place during normal operations only if one of the
following applies:
4.1
Employees must remove or bypass a guard or
other safety device.
4.2
Employees must place any part of their
body into an area where work is performed on the material being processed
(point of operation), in accordance with OSHA 1910.217(c)(3), Machinery and
Machine Guarding, Point of Operation) or where an associated danger zone exists
during a machine’s operating cycle.
Excludes
a minor tool change and adjustment and other minor servicing activity that
takes place during normal production operations, if it is routine, repetitive,
and integral to using the equipment for production and if the workers use
alternative measures that provide effective protection. Workers must document
and have a modification for guard or shield removal approval as per OSHA
1910.217(e)(2), Machinery and Machine Guarding Modification.
Excludes
installations under the exclusive control of local city electric utilities for
generating, transmitting, and distributing power, and related equipment for
communication or metering.
Excludes
work that involves exposed energized electrical hazards on, near, or with
conductors or work on energized equipment that involves inspection or testing
activities. This also includes work that involves any energized work activities
that are conducted with an Energized
Electrical Work Permit (EEWP) according to the Environmental, Safety,
and Health Manual Chapter 6200.
For work
on electric equipment connected by cord and plug, see section Environmental,
Safety, and Health Manual Chapter 6200 Appendix T3 General Electrical Safety
Guidelines.
Excludes
hot tap operations involving systems for transmitting and distributing
substances such as gas, steam, water, or petroleum products when they are
performed on pressurized pipelines, provided that ALL of the following are true:
4.3
Continuity of service is essential
4.4
Shutdown is impractical
4.5
Workers follow documented procedures and
use special equipment or systems proven to provide effective protection for
them.
4.6
Supervisors approve
Excludes
activities that involve solely the following commonly encountered energy
sources (not considered hazardous energy):
4.6.1
Potable water, fire suppression water
systems, or similar neutral pH waters at temperatures <130 degrees F and
pressures <90 psig where volumes that could be delivered (line size) do not
present an engulfment, impact, displacement, or other associated hazard to the
worker and where the isolating valve is in the immediate vicinity of the
workers.
4.6.2
Electrical energy below hazardous
thresholds defined in the Electrical Safety Manual. If voltage is above 50V, an
Electrical Work Permit (EEWP) will be required. Refer to ES&H
Manual Chapter 6230 Appendix D Energized Electrical Work Permit. This includes
DC high voltage over 5kV and over 5mA.
4.6.3
Compressed air pressures 30 psig and below
where the isolating valve is in the immediate vicinity of the workers.
4.6.4
Changing gas cylinders (inert, flammable,
or oxygen) serving equipment or manifolds where each pigtail has a valve to
isolate it from the manifold.
Excludes the method for system
operator control in OSHA 1910.269(d)(8)(v).
Excludes general access to
accelerator or beamline enclosures under controlled or supervised access
according to Accelerator Safety policies and procedures, provided that the
worker is not working on or in close proximity to exposed electrical
conductors.
Excludes radiation-generating
devices (RGD) covered by RADCON policy and procedures (see RADCON
field operations information) . Systems that include an RGD may
still be subject to the requirements of this manual.
Excludes situations where
the division director or department head can conclusively demonstrate that
de-energizing introduces further or increased hazards or is infeasible due to
equipment design or operational limitations. Operational limitations are generally
applied to life and death situations, deactivation of emergency alarm systems,
interrupting hazardous locations, ventilation, or removal of illumination for a
large populated area. However, other means to mitigate the hazards must be
determined using the Jefferson Lab Work Planning and Control Manual.
Note: No one may allow work on energized equipment or bypass the LOTO
requirements for any stored energy source just to limit disruptions to a
project, research milestone, or timeline. This excludes electrical
infrastructure owned and maintained by the local power company.
5.0 HEC
Program Requirements
Hazardous Energy Control (HEC) is part of the work planning
and control (WPC) process and involves establishing a safe work condition on
equipment before performing work. Requirements for the HEC program originate in
regulatory requirements.
There are two general categories of hazardous energy control with different
regulatory and process requirements: simple and complex.
For the criteria to determine if you may use the simple process, see ES&H
Manual Chapter 6110, Appendix T1: Lockout/Tagout (LOTO) Procedure (Simple
and Complex).
5.1 TJNAF Definitions of
Simple, Complex and Group LOTO
SIMPLE LOTO
TJNAF considers LOTO as simple when all of the following criteria are met:
·
the machine or equipment has no potential for
stored or residual energy or re-accumulation of stored energy after shutdown
which could endanger employees;
·
the machine or equipment has a single energy
source which can be readily identified and isolated;
·
the isolation and locking out of that energy
source will completely de-energize and deactivate the machine or equipment;
·
the machine or equipment is isolated from that
energy source and locked out during servicing or maintenance;
·
a single lockout device will achieve a
locked-out condition;
·
the lockout device is under the exclusive
control of the authorized employee performing service or maintenance (e.g.,
cord and plug);
·
the servicing or maintenance does not create hazards for other employees; and,
·
the employees, in utilizing simple LOTO, have had no accidents involving unexpected activation
or re-energization of the machine or equipment during service or maintenance.
IF the work
does not meet all the conditions for simple LOTO, then it is a complex lockout-tagout and requires
a written procedure. The procedure may be a standard maintenance procedure and
used repeatedly, or a specific task- or equipment-based procedure developed as
part of the WPC process and included in a work control package.
COMPLEX LOTO
TJNAF defines
a LOTO as complex when one or more of the following exist:
·
Multiple energy sources
· Multiple
crews & crafts
·
Multiple locations and employers
·
Multiple disconnecting means
·
Particular sequences
· Job
or task that continues for more than one work shift
If a complex hazardous energy
condition occurs during work and there is no equipment-specific LOTO
procedure or plan, then you may use form Template for a Complex LOTO
Procedure to develop a plan. The work may need to be paused to provide
for development, SME review, and approval of the field-developed procedure.
Email an electronic version of the completed form Template for a Complex
LOTO Procedure to the Industrial Safety Group Lead. |
Note: The
complex LOTO procedure shall vest primary responsibility in an authorized
employee for a set number of employees working under the protection of a group
LOTO device when he or she stops working on the machine or equipment being
serviced or maintained.
GROUP LOTO
TJNAF defines LOTO as group when more than one department, organization, or employer is
involved in executing a lockout tagout.
This requires assignment of overall job-associated lockout tagout
control responsibility be given to an authorized employee designated to
coordinate affected work forces and ensure continuity of protection. Primary responsibility is vested in an
authorized employee for a set number of employees working under the protection
of a group lockout-tagout device.
5.2 Program Requirements
This program establishes requirements to meet the OSHA regulations and to confirm that multiple energy types and a wide variety of applications are evaluated for hazards with the potential to expose staff to injury and cause damage to government and proprietary property. The following list provides an overview of requirements that originate in regulations and best practices.
5.2.1 All workers working on locked out equipment must join the LOTO and apply their LOTO locks to that equipment. Persons applying locks must be trained in accordance with section 7.0.
5.2.2 No one may ever remove another person’s personal LOTO lock, except under the restrictions of section 4.0.
5.2.3 No one may operate or attempt to operate any energy isolation device that has a lock or tag attached (other than during the initial challenge to establish the LOTO)
5.2.4 No one may remove installed locks, tags, and energy-isolation devices from equipment and attempt to reenergize as part of inspecting and assessing HEC program requirements, inspecting LOTO equipment, or inspecting and assessing LOTO procedures and processes.
5.2.5 If the work expands outside of the defined LOTO scope of work, then the work must be halted and the LOTO boundaries are changed to accommodate the new scope of work.
5.2.6 If a worker finds a discrepancy between configurations depicted in drawings to those found in the field, the worker must report the discrepancy to the line supervisor, who supports actions to correct the discrepancy.
5.2.7 Establish all isolations of hazardous energy following the requirements in this program. Do not use push buttons, selector switches, hardware and software interlocks, or control circuits to isolate hazardous energy—they are not energy isolation devices.
5.2.8
When procuring
new research and facility equipment and machinery, the technical representative
must specify lockout capabilities in the procurement. Upon major modifications
to existing research and facility equipment, the technical representative must
make provisions for lockout capability and the capacity to accept multiple-lock tongs. Abandoned legacy equipment and
systems in facilities where there is inadequate documentation, configuration
management, and transfer of knowledge related to the construction and operation
of old facility and experimental equipment, must undergo a detailed engineering
and technical review. When planning to remove such legacy systems and
equipment, research and facility
staff may need to collaborate to develop and implement hazardous energy control. Refer to OSHA 1910.7
for Nationally Recognized Testing Laboratory (NRTL) equipment and Jefferson Lab
Non-NRTL procedures for Non-NRTL equipment.
5.3
Program Administrative Requirements
ESH, through deployed safety service
staff, provide support to organizations for implementing the HEC program, and
for confirming compliance with OSHA
1910.147(a)(3)(i). Jefferson Lab divisions, through line managers,
supervisors, and flow down to authorized LOTO and affected employees, are the
primary local distributed administrators of the HEC program.
5.4
Developing Supplemental Procedures for a
Division
If
division staff have unique energy hazards or other regulatory requirements
specific to their work, they may develop and approve a supplemental procedure.
That procedure must be at least as stringent as the requirements in this
manual. The HEC program manager must review and concur with the procedure and
any later revisions.
Items to consider incorporating into a supplemental procedure unique to a
division’s activities are as follows:
5.4.1 Forms
5.4.2
Procedure template for complex LOTO
5.4.3
Complex LOTO procedure approval and
revision process
5.4.4
Requirements for Qualified Persons
maintaining LOTO equipment
5.4.5
Annual reviews for procedures specific to LOTO
equipment, machines, or systems
5.4.6
Configuration Control Drawings
5.4.7
Conduct of operations requirements
5.4.8
Directions to address hazards and systems
unique to the division
5.4.9
Division-specific training requirements
for HEC and LOTO
5.5
Conducting
Annual Reviews
The
Electrical Safety Program Manager (ESPM) is responsible for administering this
program. The ESPM shall identify work groups
requiring LOTO field audits, to include subcontractors when they are performing
work. The ESPM shall discuss with
supervisors the requirements of this program and the conduct of field
audits. The ESPM shall develop the audit
schedule with each work group’s supervisor, to ensure each procedure group is
evaluated annually and that the schedule is executed as planned.
Every
LOTO procedure shall be audited annually, subject to the following
requirements.
· Supervisors should group procedures together for
similar equipment. If procedures are
grouped, only one representative procedure shall be audited. Audits should be scheduled such that the same
procedure is not audited in consecutive years.
·
Field audits
should normally be performed on a LOTO in progress.
· The audit shall be performed by a supervisor and
documented on the audit checklist. (Insert link) A copy of the completed
checklist shall be submitted to the ESPM.
The ESPM and supervisor shall develop corrective actions for
deficiencies if required.
· The ESH electrical safety group should perform one
audit a month, and document on the audit checklist. The focus of this audit is to evaluate the
effectiveness of the HEC training program.
The ESPM shall prepare a quarterly report to summarize results. This report shall be approved by the ESH manager. The report shall consist of the following elements
·
Summary of audits
performed
·
Review of major
deficiencies
·
Review of
effectiveness of previous corrective actions
·
Analysis of
trends in performance from quarter to quarter.
The report shall be briefed at the
director’s safety council meeting.
Supervisors should use the report to provide feedback to workers.
6.0
Responsibilities
Note: Management
authority may be delegated to a task-qualified TJNAF employee at the discretion
of the responsible manager.
6.1
Employees at Jefferson Lab
6.1.1
Recognize and respect LOTO measures.
6.1.2
Do not operate or attempt to
operate any energy isolation device that has an LOTO lock or tag attached.
6.1.3
Do not remove any lock or tag
except those meeting the criteria outlined within ES&H Manual Chapter 6110 Appendix T2 Special Lockout/Tagout
(LOTO) Procedure.
6.2
Qualified Tagger
6.2.1 Maintain appropriate LOTO training (ESC001
for Electrical, but not necessary for Non-Electrical, ESC007 Lockout/Tagout and
ESC008 LOTO Practical) and take LOTO refresher training every 3 years to maintain Qualified Worker status.
6.2.2
If a qualified tagger finds a
discrepancy between configurations depicted in drawings to those found for the
equipment, the worker must report the discrepancy to their supervisor.
6.2.3 Must be trained to understand the
purpose and function of the LOTO program and energy control.
6.2.4
Recognize
applicable hazardous energy sources, types of energy, and ways to isolate and
control the energy sources.
6.2.5
Recognize how
lockouts can hinder facility operations, especially when operations are needed
when the remote controls are locked out.
6.2.6
Understand simple,
complex, and group LOTO procedures and the limitations.
6.2.7
Demonstrate
practical understanding and the ability to apply and remove LOTO tags. Requalify
for On-the-Job Training
(OJT) every year to maintain equipment specific qualifications.
6.2.8
Obtain specific LOTO training on equipment being serviced.
6.2.9
Perform LOTO process steps
(in accordance with ES&H Manual Chapter
6110 T1 Lockout/Tagout (LOTO) Procedure (Simple and
Complex) only after authorization from the supervisor of the equipment which
requires the securing of the hazardous energy source.
6.3
Supervisor
6.3.1
Only assign Qualified Taggers, and
provide equipment-specific LOTO training, for equipment under your authority.
6.3.2
Take action to rectify
configuration discrepancies between drawings and LOTO placement.
6.3.3
If the work expands beyond the LOTO
tag defined scope of work, ensure the work is stopped, a new tag is issued, and
the boundaries are changed to accommodate the new scope of work.
6.3.4
Maintain familiarity with Jefferson
Lab's LOTO programs and procedures, when supervising employee(s) who use LOTO procedures.
6.3.5 Establish procedures for all isolations of hazardous energy
and coordinate with other supervisors to ensure all energy sources are
identified. Understands that other employees will be
affected when shutting down equipment. Notify other employees before shutting
down equipment and coordinate isolating LOTO procedures to make sure all
hazardous energy sources are isolated.
6.3.6 Know how to identify hazardous energy sources specific to the
equipment and the work that is under their supervision.
6.3.7
Understand the difference between simple,
complex, and group LOTO procedures
6.3.8
Perform inspections for compliance
with LOTO procedures as part of regular supervisory oversight.
6.4
Technical Representative (TR)
6.4.1
Maintain LOTO
qualifications when supervising subcontractors who perform LOTO on site.
6.4.2 Review and approve subcontractor’s
procedures or provide
equipment-specific LOTO procedure(s) to subcontractors as needed. Must inform
subcontractors of any known hazards and must
document the agreement on this disclosure. If a subcontractor finds a discrepancy
on the job, they must notify the TR and the TR will alert the appropriate
Supervisor.
6.4.3 Jefferson
Lab will install the first
lockout device on a piece of equipment, machine, or system. Contractors must apply their lock before working on the equipment.
(ES&H Manual Chapter 6110 Appendix T1
Lockout/Tagout (LOTO) (Simple and Complex) Procedure) for further subcontractor procedures.
6.4.4 Implement group LOTO and act as Group
LOTO liaison, in accordance with ES&H Manual Chapter 6110 Appendix T3 Group Lockout/Tagout (LOTO) Procedure, if Jefferson Lab
employee(s)
and subcontractor(s) under your authority are concurrently working on the same
equipment/system. If the LOTO is a complex LOTO, the TR must confirm that a Qualified Worker coordinates with the
subcontractor to inform them of any specific considerations.
6.4.5 If the subcontractor elects to use the Jefferson Lab program,
ensure they perform the following:
6.4.5.1 Complete and maintain appropriate LOTO
training (ESC001 for Electrical, but not necessary for Non-Electrical, ESC007 Lockout/Tagout
and ESC008 LOTO Practical) and equipment specific training.
6.4.5.2 Participate, if requested, in OSHA
required annual JSA LOTO review.
6.4.5.3 Undertake corrective actions,
including retraining of staff and subsequent demonstration of proficiency, if
JSA or subcontractor observations indicate unsafe or non-compliant performance.
6.4.6 If subcontractors elect to use their own Lockout/Tagout
program, the Electrical Safety Engineer or Authority Having
Jurisdiction (AHJ) will review
their program and approve if:
6.4.6.1
The
subcontractors’ program meets or exceeds the requirements of OSHA 29 CFR 1926 Construction Industry Regulations and NFPA 70E (2015 Edition), Article 110.3, Host and
Contract Employers’ Responsibilities when performing construction type work activities
6.4.6.2
The subcontractors’
program meets or exceeds the requirements of OSHA 29 CFR 1910 General Industry Regulations and NFPA 70E (2015 Edition), Article 110.3, Host and
Contract Employers’ Responsibilities when doing service or maintenance on machines or equipment.
6.4.6.3 If a subcontractor’s LOTO program
is more stringent than Jefferson Lab’s, then Jefferson Lab will also follow
these procedures.
6.5
Group LOTO Coordinator (follows all of the rules under 5.3
for Supervisors)
6.5.1
Ensure all energy sources are under
LOTO.
6.5.2
Account for all persons working on
the job/task.
6.5.3
Ensure all steps of the Group LOTO procedures are
properly carried out.
6.6
Safety Warden
6.6.1 Assess
effectiveness of the functional locks and tags observed during routine safety
inspections.
6.7
Electrical Safety Engineer
6.7.1 Administer
annual review of the application of LOTO procedures as outlined in section 5.4.
6.7.2 Conduct inspections to ensure LOTO
procedures and requirements are being followed.
6.7.3
Provide
LOTO training.
7.0
Training
Requirements
The Hazardous Energy Control (HEC)
program involves all Jefferson Lab staff, who must be appropriately trained for
their role in the program. Line managers and supervisors must verify that their
staff receive training to confirm that all employees understand the purpose and
function of the HEC program. Since hazardous energy types and magnitudes vary
widely across Jefferson Lab and are specific to equipment, line managers and
supervisors must verify that each authorized employee receives training on the
recognition of hazardous energy sources, the type and magnitude of the energy
available in their workplaces, and the methods and means needed for energy
isolation and control.
For all other staff whose work
operations are or may be in an area using energy control procedures, managers
must verify such employees know about controlling hazardous energy, and about
the prohibition on restarting or reenergizing equipment that is locked or
tagged
The training requirements for
employees are below:
7.1
Complete
and maintain appropriate LOTO training (ESC001 for Electrical, but not necessary
for Non-Electrical, ESC007 Lockout/Tagout and ESC008 LOTO Practical). This is
documented in TJNAFs Learning Management System (LMS).
7.2
Supervisors
MUST verify that their
employees have received equipment specific procedure or other LOTO
procedure training and it is up-to-date.
Training expires every 3 years
and must be repeated for refresher training. This is documented in LMS.
7.3
Supervisors
MUST verify that each
employee can recognize hazardous energy sources, the type and magnitude of the
energy available in their work area(s), and the methods and means to isolate
and control the energy.
7.4
OJT
will be documented by supervisors. The training will be equipment specific and
there will be a procedure established that the employee can follow. If an
employee’s job assignment changes, the employee will need to be retrained. This
training is valid for 1 year.
This training MUST be documented. Most times, JLab requires training to be
documented by signing an Operational Safety Procedure (OSP). Information regarding
OSPs can be found in ES&H Manual Chapter 3210 and 3310.
7.5
Retraining
may be needed if periodic inspections or audits identify deficiencies or gaps
in knowledge and determine that retraining is needed to establish proficiency.
Retraining will be scheduled and documented as soon as possible (not to exceed
90 days) to correct deficiencies or gaps.
7.6
Retraining
also includes when a particular procedure is revised. Retraining will occur
immediately when there is a revision to a procedure.
8.0 LOTO Requirements
As the hardware needed for lockout
varies across Jefferson Lab, division staff maintain control over LOTO equipment.
Divisions provide specific devices for the equipment in their areas.
All lockout equipment must conform
to the requirements in this section. Use only the locks and danger tags shown
in (ES&H Manual Glossary). Jefferson Lab does not permit any
other locks or danger tags.
This section discusses the
following:
·
Establishing
LOTO requirements
·
Procuring
the hardware
·
Inspecting
LOTO equipment
8.1
Establishing
LOTO requirements
8.1.1
Supervisors
appoint a Qualified Person for LOTO equipment.
8.1.2
The
Qualified Person, with the support of the supervisor who appointed them, is
responsible for procuring lockout devices and maintaining the division’s LOTO
equipment (as explained in the following sections).
8.2
Division
directors through line managers and supervisors, must provide adequate
resources to the Qualified Person for providing the necessary LOTO equipment. Qualified
Persons must procure the lockout hardware needed to control all of the
hazardous energy sources inherent in and around their equipment. The following
sections describe the requirements for devices, locks, and tags.
8.2.1 Lockout devices and tags must be
able to withstand the environment to which they are exposed for the maximum
time that exposure is expected.
8.2.2 Lockout devices must be substantial
enough to prevent their removal (barring excessive force or unusual
techniques).
8.2.3 Qualified Persons must order locks
and lockout devices from Jefferson Lab’s standard procurement procedure. The
locks must be inspected upon receipt. Locks must be the type that can be opened
with a key. The key MUST remain in the control and possession of the person
applying the lock. For all other LOTO supplies, Qualified Persons may use Jefferson
Lab’s standard procurement procedure.
8.2.4 Do not use lockout devices for
purposes other than controlling hazardous energy when performing construction,
service work, maintenance, modifications, or demolition.
8.3
Tags
8.3.1
Tags
used to identify lockouts must be standard, heavy-duty, and labelled DANGER/LOCKED OUT/DO NOT OPERATE. (ES&H Manual Glossary) lists the two types of danger tags
the Jefferson Lab workers may use onsite for any LOTO. Jefferson Lab expects Qualified
Worker’s and other authorized workers to use this Danger tag when applying a
lock to an LOTO isolation device. For tagout only directions, see (ES&H Manual Chapter 6110 Appendix T1 Lockout/Tagout
(LOTO) Procedure
(Simple and Complex).
8.3.2
Qualified
Persons may reuse tags. Do not use tags for purposes other than lockout or
tagout. The person applying the lock MUST retain control over their key and
keep it in their possession.
8.3.3
Tags
and tag attachments must be substantial enough to prevent inadvertent or
accidental removal.
8.3.4
Workers
should install the danger tags directly on the lock. If this is not practical,
the LOTO station should be stocked with environmental-tolerant, self-locking,
non-reusable, attachment cable tie with minimum unlocking strength of 50lbs.
(for example, a nylon cable tie-wrap) to attach tag as closely as practical to
the lock. Wire is not acceptable.
Note:
Authorized
workers may remove a lock from a lockout box and carry it with them for ready
use during their shift. Authorized workers must note the removal and, if they
use the lock, record the lockout, as usual. If they do not use the lock before
the end of their shift, they must return it and record the return.
8.3.5 For Group LOTO, Qualified Workers are permitted to
remove a lock and tag from a single lock LOTO box and use it as their lock. A
PIC should be the first lock on and the last lock on using the Red Lockbox/PIC
lock. A hasp with a personal lock from the PIC followed by other locks on the
equipment/lockbox will be necessary along with the proper Group LOTO form. (see
10.3 and 10.6)
8.3.6 The lock must be noted in the permit sheet with lock
or tag number, building location where the lock is being used,
equipment-specific procedure number applicable for the group LOTO, and the
authorized worker’s name, phone number, and date.
8.3.7 Return a lock not in active use to the LOTO box before
the end of the workday.
8.3.8 For a simple LOTO, authorized workers working outside of a radiation area are permitted to remove a lock from an LOTO box and carry it with them during the shift for ready use. If the worker enters a radiation area, the lock would be permitted inside the radiation areas in accordance with Jefferson Lab’s As Low As Reasonably Achievable (ALARA) procedures.
8.3.9 After removing a lock, note its release on the permit
sheet with the lock and tag number, building location that the lock and tag
were being used at, the worker’s name and badge number, phone number, and date.
8.3.10 Divisions may institute more stringent requirements
for their simple LOTO processes in supplemental procedures.
8.4
Inspecting
an LOTO Equipment
8.4.1 The Qualified Person is responsible for the LOTO
equipment and will use a checklist (created by the division due to each
division having unique equipment) for an LOTO Equipment Inspection every 6 months to verify the
status of the locks, the quality of the tags, and other documents.
8.4.2 Divisions may inspect their lockout equipment more
often and document the process.
8.4.3 Upon request by the Qualified Worker, an LOTO
authorized worker may perform inspections. They will document the date of the inspection
on the checklist and keep the checklist as inspection records.
8.4.4 Inspections may include verifying that installed
locking devices are properly attached and that the equipment is secured
appropriately. Inspectors may manipulate in-use or active locks and tags to
inspect labels and inscriptions.
8.4.5 Installed locking devices or tags in active use that
are in areas posing an unacceptable safety risk (such as radiological areas,
hazardous chemicals zones, or high overhead areas) may be excluded form a periodic
inspection cycle. Inspectors may make reasonable attempts to view such locks
and tags, such as using remote cameras or binoculars.
8.4.6 The Qualified Worker must document any discrepancies
from the requirement in this manual. These can be entered into the Corrective
Action Tracking System (CATS) system so that it automatically routes corrective
actions (if identified) to notify the designated person(s). Also, an ES&H Safety
Coordinator is also automatically notified and considers possible reports to
the DOE Noncompliance Tracking System (NTS).
9.0
Accounting
for Potentially Hazardous Energies in Other Areas or in Combination
9.1
Control concurrent and
other area hazards through work planning and control. The work planner must
analyze not only the hazards to remove by the LOTO, but also those hazards that
workers may encounter while applying or working under the protection of the LOTO.
The work planner also must identify the controls needed to mitigate those
hazards. For more information on hazards analysis, refer to the Jefferson Lab ES&H Manual
Chapter 3210 Work Planning, Control, and Authorization Process.
9.1.1 In complex process systems (for example, chemical or
nuclear), procedural approaches can differ. Line breaking procedures, such as
for contaminated or hazardous piping networks, must supplement the LOTO procedure
if workers need to open, disconnect, or remove piping.
9.1.2
For lockouts and tagouts in areas that pose
an unacceptable safety risk (such as radiological areas, hazardous chemical
zones, or high overhead areas with strict access controls), the work planner
may document alternative means for positive LOTO on the device. Such instances
require concurrence from the HEC program manager and approval from the division
director or department head for the LOTO procedure.
9.2
The work
planner must consider controlling energy in combination with other situations
that may increase the hazards. The following is only a partial list of
dangerous combinations to consider:
9.2.1 Water and electricity: potential for shock or arc flash hazard when working on water lines over electrical components or when working on electrical systems in a wet location.
9.2.2 Compressed air and toxic materials: what are the results of inadvertent activation (will it generate toxic or radioactive dusts or aerosols that create contamination or personal exposure)?
9.2.3 Work on a ladder and unexpected energy or noise: consider the location of overhead water or air lines when placing the ladder; consider the effect of unexpected effect of air, water, or elevated noise level from release of compressed air (a startled worker may fall or drop tools).
9.2.4 Inert gas in a confined space: consider asphyxiation hazards in a work location with poor or no ventilation; include in the procedure to shut the gas source off and lock it out to avoid oxygen depletion.
9.2.5 Magnetic fields and metal: strong magnetic fields may propel ferrous tools.
9.2.6
Pneumatic and
thermal: consider thermal and pneumatic hazards near live steam or pressure
relief valves. Relieving highly compressed, nominal-temperature gases could
create a blockage which prevents the needed, natural boil off (venting) of a
cryogenic liquid. In this case, the pressure inside a dewar may rise until it
reaches a dangerously high level.
10.0 Appendices
10.1 Lockout/Tagout (LOTO) Procedure (Simple and Complex)
ES&H Manual Chapter
6110 Appendix T1 Lockout/Tagout (LOTO) Procedure (Simple
and Complex) contains the guidelines for locking and tagging out of hazardous
energy sources when maintenance or service work is to be performed. LOTO references in this appendix apply to maintenance, service, and
construction applications. Refer to ES&H Manual Chapter 6111 Administrative Control Using Locks and Tags for administrative configuration
control applications.
10.1.1
Configuration
management requirements for equipment
specific LOTO procedures include:
·
Document
numbers
·
Owner
identification
·
Revision
number, if applicable
·
Date
of efficacy
·
Expiration/review
date
·
Approval
record
·
Change
record
·
Archival
of previous versions
10.2
Special
Lock and Tag Procedures (includes Lockon and Tagon, LOTO in Hazardous
Areas, Non-electrical Isolation, and LOTO in Confined Spaces)
In accordance
with Jefferson Lab procedures (ES&H Manual Chapter 6110 Appendix T1 Lockout/Tagout
(LOTO) Procedure
(Simple and Complex) and ES&H Manual Chapter 6111 Administrative Control
Using Locks and Tags) a lock and/or tag is removed only by the Qualified
Tagger who placed it on the equipment, or an authorized person in the administrative control scenario. If
the Qualified Tagger is unavailable, or the information is missing or
illegible, ES&H Manual Chapter 6110 Appendix T2 Special Lockout/Tagout
(LOTO) Procedure
is utilized.
10.3
Group
Lockout/Tagout (LOTO) Procedures (includes a section for subcontractors)
ES&H Manual Chapter 6110 Appendix T3 Group Lockout/Tagout
(LOTO) Procedure
provides members of a group a way to secure hazardous energy sources with
protection equivalent to that provided by the individual procedure outlined in ES&H Manual Chapter 6110 Appendix T1 Lockout/Tagout
(LOTO) Procedure
(Simple and Complex).
10.4
LOTO Zero Energy and Zero
Voltage Verification Procedures
ES&H Manual Chapter 6110 Appendix T4 Lockout/Tagout
(LOTO) Zero Energy and Zero Voltage Verification provides instructions for isolating
and testing for voltage and other energy sources.
10.5 LOTO Forms and Templates
ES&H Manual Chapter 6110 Appendix T5 Lockout/Tagout
(LOTO) Forms and Templates provides forms needed for to
perform certain LOTOs and procedures. This appendix also provides temples
necessary for creating LOTO plans for Complex LOTOs.
10.6 Approved
Locks and Tags
ES&H Manual Chapter
6110 Appendix T6 Lockout/Tagout (LOTO)
Provides a list of approved lab
wide locks, tags and devices associated with LOTO processes.
11.0
Related Documents
This manual implement requirements established by the
following basis documents.
11.1 Code of Federal Regulations, 10 CFR 851, “Worker Safety and Health Program.”
11.2 Code of Federal Regulations, 29 CFR 1926.417, “Lockout and Tagging of Circuits.”
11.3 Code of Federal Regulations, 29 CFR 1910.146, “Permit-Required Confined Space”
11.4 Code of Federal Regulations, 29 CFR 1910.147, “Control of Hazardous Energy (LOTO).”
11.5 Code of Federal Regulations, 29 CFR 1910.269, “Electric Power Generation, Transmission, and Distribution.”
11.6 Code of Federal Regulations, 29 CFR 1910.333, “Selection and Use of Work Practices.”
11.7 “Conduct of Operations Requirements for DOE Facilities,” DOE Order 422.1, June 29, 2010.
11.8 “Standard for Electrical Safety in the Workplace,” NFPA 70E-2015
This procedure implements requirements established by the
following Jefferson Lab policies and procedures.
11.9 Safety and Health, ES&H Manual Chapter 1100 Environmental, Safety, and Health Policy
11.10 ES&H Manual Chapter 6200 Electrical Safety Program
The following documents provide background information
relevant to the subject of this procedure.
11.11 ANSI/ASSE Z244.1 – LOTO and Alternative Methods.
11.12 Accident Prevention Manual for Industrial Operations, National Safety Council.
11.13 OSHA INSTRUCTION, Directive CPL 02-00-147 2/11/08.
11.14 OSHA 3120 2002, Control of Hazardous Energy LOTO.
12.0
Revision
Summary
Revision
2.5 – 10/30/2023 Added
new 5.1 to Section 5.0 per the Director’s Safety Council Lockout Tagout
Pause Actions: Provided clarification on the definitions of Simple, Complex and
Group LOTO per feedback of affected workforce.
Revision 2.4 -
05/22/2023 Section
1.0: Added shall, should, and may
language; Section 5.4: Complete rewrite
to ensure field audits are performed and documented IAW OSHA
1910.147(C)(6); NFPA 70E (2015) 110.1(i)
and 120.2(c)(3); and NFPA 70E (2021)
110.5(m); Section 5.5: Deleted and
incorporated into section 5.4; Section 6.7:
Revised to indicate responsibility to administer program IAW section 5.4
TPOC change - 01/28/2023 per CBailey (Industrial Safety
Program Lead) change TPOC from TFitzgerald to PStanley; ES&H Manual Editor
fixed format only; no content review at this time
Revision 2.3 - 02/16/2022 Updated SAF104 to reflect only ESC007.
Added ESC001 to reflect that this is a requirement for Electrical Personnel
ONLY. Updated training requirement course per CATS#STR-2019-14-01-02. Added amplifying
information for the Group LOTO as per CATS# INSP-2018-002-01-02. Minor edits no
approval needed.
Revision 2.2 - 10/21/21 Updated section 10 to reflect T6
appendix. Updated hyperlinks to appendixes. Added details to section 5.4,
addressing findings from IA-2021-07. No approval is needed for minor edits per email
from T Fitzgerald to S. Hoey.
Revision 2.1 - 06/22/21 Updated section
10 to reflect T6 appendix. Updated hyperlinks to appendixes. No approval needed
for minor edits.
Revision 2.0 - 01/13/21 Updated all
areas of the document and reformatted, updated the header and footer, change
ESH&Q to ES&H. Approved
by Lab Director and ES&H Director.
Revision 1.7- 03/24/20 Updated training
requirement course in Table 1 per CATS#STR-2019-14-01-02
Revision 1.6- 11/12/19 Updated section
4.1 per CATS#NE-2019-05-02-01 to add required configuration management controls
for equipment specific LOTO procedures; updated TR responsibilities to clarify
subcontractor’s use of Jefferson Lab’s program or their own program for
Lockout/Tagout procedures; updated TPOC from T.Kujawa to T.Fitzgerald
Revision 1.5- 09/25/18 Updated
Supervisor and TR responsibilities to clarify LOTO training for subcontractors per
CATS# INSP-2018-002-01-02
Periodic Review- 03/09/18 No changes per TPOC
Periodic Review- 03/09/15 No
substantive changes
Revision 1.4- 05/20/14 Added Required Safety Training Table
Revision
1.3- 11/07/13 Removed Section 3.8 ESH&Q
Training Committee; disbanded per M.Logue.
Revision
1.2- 02/18/13 Clarification of process steps per
T.Kujawa
Revision
1.1- 12/01/11 Clarification of process steps and
updates made to format; qualifying periodic review, no substantive changes
required.
Revision
1.0- 11/02/09 Update to reflect current
laboratory operations
|
ISSUING
AUTHORITY |
TECHNICAL
POINT-OF-CONTACT |
APPROVAL
DATE |
NEXT REVIEW
DATE |
REVIEW
CYCLE |
rev |
|
|
ES&H Division |
01.13.2021 |
10.30.2026 |
3 years |
2.5 |
|