TITLE

ES&H Manual

 

DOCUMENT ID

6110 Hazardous Energy Control Program

 

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

Phillip Stanley

01.13.2021

10.30.2026

3 years

2.5

 

This document is controlled as an online file.  It may be printed but the print copy is not a controlled document. 

It is the user’s responsibility to ensure that the document is the same revision as the current online file.  This copy was printed on 11/3/2023.