TITLE

ES&H Manual

 

DOCUMENT ID

6110 Appendix T1:

Lockout/Tagout Procedure - Simple and Complex

 

1.0           Purpose

Tags provide warning information only and do not physically restrain energy-isolating devices. If it is not feasible to install a lock on an energy-isolating device, you must establish some other physical means of controlling the energy supply. Not feasible means that you cannot purchase a device or manufacture it in facility craft shops, or that space limitations prevent physical application. Other physical means may include removing a fuse, blocking a control switch, opening an extra disconnecting device, removing a valve handle, or any other method that reduces the likelihood of inadvertent energizing. 

 

29 CFR 1910.147 allows using tags alone as the sole means of placing equipment out of service. Before the tagout option is permitted, the Person In Charge (PIC), line supervisor, and Hazardous Energy Control (HEC), Subject Matter Expert (SME) or division Environmental, Safety, and Health (ES&H) coordinator must determine if all conditions below exist: 

 

·        A lockout device for that equipment is not commercially available. 

·        It is not possible to fabricate a device in-house. 

·        Another means of physical control is not available to control the hazardous energy (contact the HEC program manager for consultation on other options). 

 

For tagout only in a simple Lockout/Tagout (LOTO), the authorized worker/qualified worker must document the tagout requiring permission in the permit. For tagout only in a complex LOTO, the PIC must document the rational for tagout on the permit. Use of a logbook is permitted. 

 

When tagging out the equipment, workers must use the Danger tags required by Jefferson Lab. Authorized workers must attach this tag to the energy-isolating device with a cable tie or equivalent means so that environmental conditions do not deteriorate the attaching cable tie or make the tag itself unreadable during the tagout. 

 

Note: When tagout alone is deemed acceptable (at a minimum, if the job location is left unattended), verify the integrity of the tagout by confirming the Zero Energy Verification (ZEV) and/or Zero Voltage Verification (ZVV) upon return. This includes, at a minimum, going off-site (off Jefferson Lab property) or leaving the job for more than two hours. 

It is permissible to use lockon and tagon to keep critical and essential loads and services available.

 

This appendix contains the guidelines for locking and tagging out of hazardous energy sources when maintenance or service work is to be performed. Lockout/Tagout (LOTO) references in this appendix apply to maintenance, service, and construction type work activities when performed by lab employees. Refer to ES&H Manual Chapter 6111 Administrative Control Using Locks and Tags for administrative configuration control applications.

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

2.0           Responsibilities

Note: Management authority may be delegated to a task-qualified TJNAF employee at the discretion of the responsible manager.

                      2.1          Employees at Jefferson Lab

 

2.1.1       Recognize and respect LOTO measures.

2.1.2       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.

 

2.2            Qualified Tagger

 

2.2.1       Maintain appropriate LOTO training (ESC001- for electrical workers ONLY, ESC007, and ESC008 LOTO Practical).

2.2.2       Obtain specific LOTO training on equipment being serviced.

2.2.3       Perform LOTO procedure process steps listed below.

 

2.3            Supervisor

 

2.3.1       Only assign Qualified Taggers, and provide equipment-specific LOTO training, for equipment under your authority.

2.3.2       Maintain familiarity with Jefferson Lab's LOTO programs and procedures. (If you supervise employee(s) who use LOTO procedures.)

2.3.3       Perform inspections for compliance with lock and tag procedures as part of regular supervisory oversight.

 

2.4            Technical Representative (TR)

 

2.4.1       Maintain LOTO qualifications. (If they supervise subcontractors who perform LOTO on site.)

2.4.2       Provide equipment-specific LOTO procedures to subcontractors on an as needed basis.

2.4.3       Implement group LOTO and act as Group LOTO Coordinator in accordance with ES&H Manual Chapter 6110 Appendix T3 Group Lockout/Tagout (LOTO) Procedure if Jefferson Lab employee(s) and subcontractor(s) are concurrently working on the same equipment/system.

2.4.4       If the subcontractor elects to use the Jefferson Lab program, ensure they perform the following:

 

2.4.4.1  Complete and maintain appropriate LOTO training (ESC001- for electrical workers ONLY, ESC007, ESC008 Lockout/Tagout, and LOTO Practical) and equipment specific training;

2.4.4.2  Participate, if requested, in OSHA required annual Jefferson Lab LOTO review.

2.4.4.3  Undertake corrective actions, including retraining of staff and subsequent demonstration of proficiency, if Jefferson Lab or subcontractor observations indicate unsafe or non-compliant performance.

 

2.4.5       If the subcontractor elects to use their own Lockout/Tagout (LOTO) program, review their program and approve if: 

2.4.5.1  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.

2.4.5.2  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.

2.4.5.3  If a subcontractor’s LOTO program is more stringent than Jefferson Lab’s, then Jefferson Lab will also follow these procedures.

2.4.6.6  It is preferable, whenever feasible, that the construction and service contractors and subcontractors perform their own independent ZEV or ZVV along with the Jefferson Lab authorized worker. At a minimum, the contractor must witness the Jefferson Lab authorized worker perform the ZEV or ZVV. For electrically energized equipment, a Jefferson Lab Qualified Electrical Worker (QEW) must perform the ZVV and the rules for contractors are as follows: 

2.4.6.7  If the contractors are not performing electrical work, they do not need to follow NFPA 70E (2015 Edition) or QEW training requirements and cannot perform ZVV. They must witness the Jefferson Lab QEW perform a ZVV. 

2.4.6.8  If the contractors are QEWs and completed NFPA 70E (2015 Edition) training, they may perform ZVV at their discretion. At least one contractor representative must either witness the ZVV performed by the Jefferson Lab QEW or perform their own independent ZVV as confirmation. If representatives perform the ZVV, they must be a QEW and qualified to perform this task. They should have documentation. If there is any question about the qualifications of the subcontracted work, notify your supervisor.

2.4.6.9  If a ZVV cannot be performed with a VVU, planning and documentation should include the means of verifying that electrical energy is not present.

3.0            Controlling Hazardous Energy (Simple LOTO)

A simple hazardous energy control process involves an LOTO that does not need an equipment-specific written procedure. The process involves trained and qualified Jefferson Lab staff with knowledge of the construction and operation of the equipment and knowledge of the energy source and tasks associated with servicing and maintaining the equipment. If the LOTO does not meet the conditions that follow, then it is complex, and there must be a written procedure. 

 

You must meet all of the following conditions to use a simple LOTO: 

 

·                 The equipment has a single energy source, which you can easily identify and isolate.

·                 Isolating and locking out the single energy source completely de-energizes and deactivates the equipment. 

·                 The equipment has no potential for stored or residual energy nor any possibility after the shutdown to re-accumulate stored energy that could endanger workers. 

·                 A single lockout device establishes an energy-safe work condition. 

·                 The authorized workers exclusively control the lockout device. 

·                 The servicing or maintenance does not create hazards for other workers. 

·                 The LOTO is not beyond one work shift/crew.

 

3.1            Equipment Connected with Cord and Plugs 

 

Work on electrical equipment connected by cord and plug does not need LOTO if all of the following is true: 

 

3.1.1       Unplugging removes the sole energy source 

3.1.2       There is no stored energy in the equipment, machine, or system 

3.1.3       The plugs are under the exclusive control of the workers (if there is more than one worker, see ES&H Manual Chapter 6110 Appendix T3 Group Lockout/Tagout (LOTO) Procedure).

 

Workers must take further steps to investigate and verify that no other energy sources associated with the equipment, machine, or system are active, such as a capacitor, hydraulic, or mechanical devices independent of the electrical source. 

 

If workers lose control of the plug because they temporarily leave the area, then when they return they must reestablish control of the plug before resuming work. 

 

3.2            Controlling Hazardous Energy (Simple LOTO)

 

A simple hazardous energy control process involves an LOTO that does not need an equipment-specific written procedure. The process involves trained and qualified Jefferson Lab staff with knowledge of the construction and operation of the equipment and knowledge of the energy source and tasks associated with servicing and maintaining the equipment. If the LOTO does not meet the conditions that follow, then it is complex, and there must be a written procedure.

 

You must meet all of the conditions listed above in Section 3.0 to use a simple LOTO AND for electrical energies, you MUST be a QEW to perform any ZZV checks.

 

3.3            Implementing a Simple LOTO

 

When the conditions for using a simple LOTO are met, the process in this section establishes an energy- safe work condition before any service or maintenance work. If all of the conditions are not met for simple LOTO, you must implement a complex LOTO process. There may be other situations that may or may not be applicable to implementing a simple LOTO, such as: 

  

·                 Trapped-key interlock systems 

·                 Transferring keys 

·                 Temporarily removing LOTO for equipment testing 

·                 Removing LOTO when person who applied it is unavailable 

·                 Determining if tagout alone is acceptable 

·                 LOTO extending beyond one year 

·                 LOTO involving non-Jefferson Lab workers 

4.0           Process Steps for a Simple LOTO

4.1            Simple LOTO

 

4.1.1         

 

Do not attempt to operate an energy isolation device with any other LOTO lock already applied. Doing so might inadvertently energize the equipment, causing serious injury or death by exposure to hazardous energy. 

 

4.1.2         

 

Only authorized workers that are qualified electrical workers (as described in the Electrical Safety Manual) may perform LOTO on electrical equipment. 

 

 

4.1.3       The authorized workers implementing the simple LOTO must know the construction and operation of the equipment being serviced and must be trained and knowledgeable to perform the following steps in sequence. Equipment design may necessitate performing the verification in Step 6 before applying the lock and tag in Step 7 for the Simple LOTO procedure in section 4.2. 

 

4.1.4       Authorized LOTO workers perform all of the following steps in the next section.

 

4.2            Simple LOTO Procedure

 

Only Qualified Taggers may perform the following process steps. 

Identify the single hazardous energy source and related hazards and controls by following these steps. 

 

Step 1:                    Determine the Hazards

 

Perform or review the work’s Task Hazard Analysis.

 

a.                Identify the correct energy-isolation device before operation.

b.               Evaluate the type and magnitude of the potentially hazardous energy, and the means of controlling the energy.

c.                Review specific equipment, written procedures, blueprints, system diagrams, valve lineups, and operating manuals (these are usually in a division’s repository online, in manufacturers information such as a manual, and are included for OSPs). FML maintains most of the Single-Line drawings for the lab and are the preferred reference source for diagrams. If no diagrams can be located, it may be necessary for a SME to be on hand who is the expert on the equipment hazards and is able to locate all of the hazards.

d.               Confer with people who know the equipment. Make sure there are no mechanical or electrical interlocks

e.                Be alert to multiple energy sources.

f.                Take steps to confirm that the means used (a disconnect, a circuit breaker, a valve, and so on) for energy isolation correctly corresponds to the equipment being used.

g.               Check the isolation label and match it to the label on the equipment. Take special care with look-alike equipment. 

h.               Do not proceed until knowledge of the hazard(s) is known.

 

Note: Always remember! Do not use push buttons, selector switches, hardware and software interlocks, or control circuits—they are not energy isolation devices. 

 

Step 2:                    Choosing Locking Devices

 

a.                Obtain lockout devices and tags from the LOTO box or the Store Room. If it is not practical to install the danger tag directly on the lock, use an environment-tolerant, self-locking, non-reusable, attachment cable tie with a minimum unlocking strength of 50 lbs. (for example, a nylon cable tie-wrap). Wire is not acceptable. This cable tie wrap is available in the LOTO box. See ES&H Manual Chapter 6110 Appendix T6 Approved Locks and Tags List (LOTO).

 

Note: Authorized workers may remove a lock from a lockout box and carry it with them for ready use during their shift. They must note the removal. If they do not use the lock before the end of their shift, they must return it and record the return.

 

Step 3:                    Risk Assessment

 

Taking into account the risk assessment, consider ahead of time the appropriate safe work practices for performing the isolation and verifying a zero-energy state.

 

Step 4:                    Determine the Need for a Written Procedure

 

LOTO applications require a written procedure unless all of the following elements exist:

 

a.                The equipment has no potential for residual, stored, or the re-accumulation of stored, energy after shutdown.

b.               The equipment has a single energy source, which can be readily identified and isolated.

c.                The isolation and locking out of the energy source completely de-energizes and de-activates the equipment.

d.               The equipment is isolated from its energy source and locked out during servicing and maintenance.

e.                A single lock out device will achieve a lock out condition.

f.                The lock out device is under exclusive control of the authorized employee performing the servicing or maintenance.

g.               The servicing or maintenance procedure does not create hazards for other employees.

h.               There is no record of incidents involving the unexpected activation or re-energization of the equipment during servicing or maintenance within Jefferson Lab.

 

NOTE:  An optional LOTO form will satisfy the minimal information required to be included in a written LOTO procedure. Equipment that is similar in its operation can be grouped under one LOTO procedure.

 

Step 5:                    Coordinate Work/Notify Others

 

a.                Notify all affected individuals; inform them that the equipment will be placed out of service until work is completed. Coordinate work with system owners, building managers or safety wardens as deemed necessary.

b.               Notify affected employees. Considerations include: 

 

1.               Plan for advance notice when activities affect fire protection systems, and utility systems and equipment. 

2.               Notify all affected employees of the impending shutdown and lockout, including anticipated duration. 

3.               Notify all limited authorized workers and affected employees of their role in the process. 

 

Step 6:                    Shut down equipment. Considerations include: 

 

a.                If the scope of work involves shutting down and isolating any electrical, steam, water, or other utility or building distribution systems, a Facilities authorized worker must be the first to apply the locking device and then initiate the shutdown. This would make this type of LOTO a Complex LOTO (please see Complex LOTO in Section 5.0). 

b.               Usually, the person implementing the simple LOTO is qualified to operate the equipment. If not, the authorized worker must request assistance with the shutdown from a knowledgeable and qualified affected employee (due to multiple groups, this would change the LOTO to a Complex LOTO. Please see Section 5.0). 

c.                If there are multiple people on the LOTO, then this would make this type of LOTO a Complex LOTO (please see Complex LOTO in Section 5.0). 

 

NOTE: It may be more practical and safer to perform voltage verification before applying locks/tags to the isolation device. If this is the case, secure the equipment and proceed to Step 6. Once a de-energized state has been verified, come back to Step 4 and continue with the LOTO process.

 

Step 7:                    Isolate Energy Sources

 

Note: For an electrical hazard, only a QUALIFIED PERSON wearing proper PPE may operate the isolation and verify that there is zero voltage. Use information in Refer to the ESH 6200 Manual and NFPA 70E, Standard for Electrical Safety in the Workplace, 2015 Edition (Article 130) to set up proper barriers for shock and arc flash.

 

 

a.                Don appropriate personal protective equipment (PPE).

b.               Set appropriate arc flash and shock barriers with red and white electrical safety barrier tape. Refer to the ESH 6200 Manual and NFPA 70E, Standard for Electrical Safety in the Workplace, 2015 Edition (Article 130).

c.                Secure the equipment:

 

1.               Put all appropriate energy-isolating devices in a safe state (usually “off”) while following an orderly shutdown sequence.

2.               Isolate the energy source by operating the energy isolation (switch off, valve closed, and so on). 

 

d.               Secure the energy source using a Jefferson Lab approved LOTO lock. A multi-lock hasp is used if there is a possibility that other employees may also work on the equipment or system. 

 

NOTE: If the equipment is un-lockable see 4.2 Special Tag Out Situations Without Locks

 

e.                Apply the lockout device and tag by completing the following steps:

 

1.               Apply the lockout device and tag to the energy isolation device so that it physically prohibits operation. If multiple LOTO workers perform work, use an LOTO hasp and apply all applicable lockout devices and tags to the LOTO device. 

 

Note: If multiple workers need to apply their locks to a group lockout device, then there must be a designated PIC for the simple LOTO. 

 

2.               Write your name, phone number, the date applied, and any other relevant information on the LOTO tags (this applies to all staff working under the LOTO). 

3.               The tag must be:

 

§     Legible – Indicating the identity of the person who applied the device(s).

§     Attached by durable means to the shackle of the accompanied lock, or a non-reusable method capable of withstanding a 50-pound pull, minimally equivalent to a nylon cable tie.

 

 

NOTE: When using blocking devices (blind flanges, pancakes, blocking plates, …) to restrain stored or residual energy within piping systems during an LOTO; the mechanical devices used must comply with the requirements of Jefferson Lab’s Pressure System policy and procedure.

 

Step 8:                    Verify Lockout and Try (Attempt to Restart)

 

Verify proper isolation by completing the following steps:

 

a.                Don appropriate PPE.

b.               Assume the equipment is energized, or charged, until it has been determined to be de-energized.

c.                EVERY TIME: Challenge your LOTO lock to confirm that the lock is fully latched, and that it cannot be removed from the isolation device. 

d.               Whoever applies the first lock: Challenge the energy isolation to confirm it will not operate. 

e.                Witness the verification of a de-energized state.

1.             All Qualified Taggers having applied a personal lock and/or tag are required to perform or witness the verification of the de-energized state (refer to ES&H Manual Chapter 6110 Appendix T3 Group Lockout/Tagout (LOTO) Procedure for any exceptions to this step).  

f.                Verify the integrity of your lockout.

1.             Attempt to restart the equipment using the normal equipment controls. Verify the equipment does not power up or start. 

g.               Try to restart the equipment. 

1.               Have an authorized employee attempt to operate the equipment controls, or otherwise verify the equipment cannot be restarted. Attempt to restart the equipment using the normal equipment controls. Verify the equipment does not power up or start. Return operating controls to the safe (usually “off”) position.

h.               If there is evidence of hazardous energy or the potential to store hazardous energy, stop work. You need a complex LOTO procedure (proceed to section 5.0). 

i.                 If there is no evidence of hazardous energy, continue to next step. 

 

Step 9:            For electrical energies:

 

a.                If there is a risk of exposure to any form of hazardous energy when performing a Zero Energy Verification, obtain the appropriate PPE for the hazard.

1.               If there is a risk of any exposure to electrical hazards, obtain the needed personal protective equipment (PPE) according to the hazard class tables in the Electrical Safety Manual. Only a QEW can perform the ZVV on equipment with electrical hazards above the thresholds identified in the Electrical Safety Manual. 

2.               If a ZVV cannot be performed with a VVU, planning and documentation should include the means of verifying that electrical energy is not present.

b.               Test the metering equipment for proper operation immediately before verifying a de-energized state.

c.                Verify incoming power has been de-energized. 

d.               Test the metering equipment for proper operation immediately after verifying a de-energized state.

1.               Refer to the VUU equivalency dated October 19, 2018, on the Electrical Safety Committee website under EAHJ actions, for an exception to this step.

 

Step 10:          Perform the Work

Declare an energy-safe work condition and allow servicing or maintenance work to proceed. During work, follow these steps as needed. 

 

 

If at any time during service or maintenance the staff discovers further uncontrolled energy sources or energy accumulating to hazardous levels, the authorized workers must stop the work and replace the simple LOTO with a complex LOTO. Workers must report this to supervision.

 

a.                Keep the lockout in place for the duration of work. 

b.               Other LOTO authorized workers and limited authorized workers from the same crew, trade, or employer may join the LOTO by applying their lock and tag. 

c.                Workers must remain vigilant and limit the scope of work to that defined for the servicing and/or maintenance. 

d.               If the workers identify a task outside of the defined scope of work, then they must stop work and the Person In Charge or the Qualified Person must confirm that the simple LOTO controls the hazards associated with the new task. If not, delay the work until you can modify the LOTO. Document this decision. 

e.                Periodically re-check the integrity of the lock and/or tag, minimally:

 

1.               When there is a possibility of energy build up.

2.               When tasks last more than one shift.

 

NOTE: If the work being performed on the de-energized (LOTO) equipment exists in an area with other energized equipment that is similar in size, shape, and construction, then an alerting method (for example safety signs, barricades, attendants, …) shall be employed to prevent one from entering the energized look-alike equipment.

 

Step 11:                 Prepare to Re-Energize

 

a.                Ensure the equipment has been properly re-assembled:

 

1.               Electrical jumpers and grounds, tools, work aids, spare parts and other such devices have been collected and removed, and

2.               Personnel have moved to safe positions.

 

b.               Close all cabinets and panels completely.

c.                Notify all affected individuals when work is complete and ready for energizing.

d.               Clear blocking devices or grounded equipment to return the equipment to service.

e.                Ensure equipment/control switches are in a safe state (usually “off”) to guarantee:

 

1.               Unexpected startup.

2.               Inadvertent overload of circuit breakers and switches.

3.               Safe start-up sequencing.

 

Step 12:                 Remove Locks and Tags

 

a.                Each Qualified Tagger removes their lock(s) and/or tag(s). Refer to ES&H Manual Chapter 6110 Appendix T2 Special Lockout/Tagout (LOTO) Procedure, for any exceptions to this step.

b.               Remove all barriers.

 

NOTE: The removal of equipment, that has lock(s) and/or tag(s) attached to it, constitutes a removal of the lock(s) and/or tag(s); therefore, all lock(s) and/or tag(s) shall be removed by their owners before work is performed on the equipment.

 

Step 13:                 Energize

 

a.                Be prepared to shut down the equipment immediately if needed. Enlist the help of others as necessary.

b.               Test equipment to verify proper operation.

c.                If testing indicates the equipment must undergo LOTO again, go back to Step 6.

d.               Remove barriers if the LOTO can be cleared and the equipment is operating normally.

5.0           Controlling Hazardous Energy Complex LOTO

Use the complex hazardous energy control process if you cannot meet the conditions for a simple LOTO. The complex LOTO process requires a written LOTO procedure and a designated Person In Charge (PIC) who is accountable for all staff working on the equipment and for safely executing the complex LOTO. The most common circumstance needing a complex process involves equipment with multiple hazardous energy sources or multiple groups/people. If workers identify a complex hazardous energy condition during the course of work, and no equipment-specific LOTO procedure or plan already exists, one will need to be developed. This is through the OSP system.

 

The Complex LOTO procedure involves one or more of the following:

 

a.      Multiple energy sources

b.     Multiple crews

c.      Multiple crafts

d.     Multiple locations

e.      Multiple employers

f.      Multiple disconnecting means

g.     Particular sequence

h.     Job or tasks that continue for more than one work period (no more than one shift).

 

5.1            Choosing a Person in Charge (PIC)

 

5.1.1       For a complex LOTO, the line supervisor of the organization where the majority of work occurs appoints a Person In Charge for service and maintenance work. The PIC is typically the building maintenance foreman or a maintenance mechanic the foreman designates. The PIC can also be designated as a TR, for contractors, or the Group LOTO Coordinator for complex/group LOTO. For service and maintenance on scientific and specialty research equipment, the PIC must have in-depth knowledge of the construction and operation of the equipment and be able to identify all hazardous energy sources that need control for the planned scope of work. The PIC can be a shift or duty position if the work occurs during multiple shifts or if operations routinely rotates persons through the position as part of normal operations. 

 

5.1.2       Sometimes, the person most knowledgeable about specialized scientific equipment is the manufacturer or their representative. The PIC may need to consult the manufacturer’s staff to develop plans for hazardous energy control. The PIC coordinates the activities of all members of the group, regardless of craft, company, or organization, to confirm continuity of protection and to confirm that the workers use a group lockout mechanism, such as a multi-lock hasp or lockbox, if needed. See ES&H Manual Chapter 6110 Appendix T3 Group Lockout/Tagout (LOTO) Procedure.

 

5.2            Complex LOTO Procedure

 

Use the following step-by-step process for a complex HEC situation:

 

                                        Step 1:                    The Line Manager or Supervisor and the Person in Charge (PIC) will determine if there is an existing plan or procedure fir the complex LOTO, and proceed as follows:

 

a.                If YES, then go to the next step.

b.               If NO, then go to Step 5

 

                                        Step 2:                    The Line Manager or Supervisor and the PIC will review the plan or procedure. Confirm the LOTO steps are adequate for the intended scope of work. 

                                        Step 3:                    The Line Manager or Supervisor and the PIC will keep a record of the review which includes the date of review and the reviewer.

                                        Step 4:                    If the plan is sufficient for the intended scope of work, identify all other work planning and control documents to use, schedule the service or maintenance, and skip to step 6. If not, go to step 5.

                                        Step 5:                    The Work Planner will create a complex LOTO plan.

                                        Step 6:                    The PIC and Qualified Persons notify affected employees by completing the following steps. 

 

Note: Plan for advance notice (minimum of 48 hours) for activities that affect fire protection systems and utility systems and equipment. 

 

a.                Notify all affected employees of the impending shutdown and lockout, including the length of time anticipated. 

b.               Notify all limited authorized workers and affected employees of their role in the process. 

 

                                        Step 7:                    Qualified Persons shut down equipment. Considerations include:

 

a.                Usually, the person implementing the complex LOTO is qualified to operate the equipment. If not, the authorized worker must request assistance with the shutdown from knowledgeable affected employees. 

b.               If there are multiple workers on the LOTO, the PIC determines how many of them must witness the equipment shutdown (unless they also know the equipment and are an affected employee) and verify that the controls are in the OFF or safe position (see ES&H Manual Chapter 6110 Appendix T3 Group Lockout/Tagout (LOTO) Procedure). 

 

Step 8:                    Prepare to Isolate

 

a.                Don appropriate personal protective equipment (PPE).

b.               Set appropriate arc flash and shock barriers with red and white electrical safety barrier tape. Refer to the ESH 6200 Manual and NFPA 70E, Standard for Electrical Safety in the Workplace, 2015 Edition (Article 130).

 

Step 9:                    The Qualified Person will isolate the energy source by operating the energy isolation (switch off, valve closed, and so on). The Qualified Person will apply the lockout device and tag by completing the following steps:

 

a.                Depending on the equipment design, you may need to verify the isolation (see step 10) before applying the lock and tag. 

b.               Obtain lockout devices and tags from the LOTO box

c.                Apply the lockout device and tag to the energy isolation device so that it physically prohibits operation. If multiple LOTO workers perform work, use an LOTO hasp and apply all applicable lockout devices and tags to the LOTO device. 

d.               Write your name, phone number, the date applied, and any other relevant information on the LOTO tags.

 

Step 10:                 The Qualified Person will verify proper isolation by completing the following steps:

 

a.                EVERY TIME: Challenge your LOTO lock to confirm that the lock is fully latched, and that it cannot be removed from the isolation device. 

b.               The PIC or whoever applies the first lock: Challenge the energy isolation to confirm it will not operate. 

c.                The PIC or designated authorized worker attempts to restart the equipment using the normal equipment controls. Verify the equipment does not power up or start. 

 

Step 11:                 The Qualified Person will Conduct a ZEV and/or ZVV by following these  steps:

 

a.                If there is a risk of any exposure to electrical hazards, obtain the needed personal protective equipment (PPE) according to the hazard class tables in the Electrical Safety Manual. Only a Qualified Person can perform the Zero Voltage Verification on equipment with electrical hazards above the thresholds identified in the Electrical Safety Manual. 

b.               If a ZVV cannot be performed with a VVU, planning and documentation should include the means of verifying that electrical energy is not present. This MUST be documented in the OSP.

c.                Perform or witness ZVV or ZEV. 

d.               Test the energy source using appropriately rated instruments. 

 

Note: For electrical hazards, use only an NRTL-listed voltage tester or multimeter meeting the requirements in the Electrical Safety Manual.

 

e.                Check any instrument used to test for voltage, pressure, or temperature for proper operation both before and after use on a known live source. 

 

Step 12:                 Remove and release stored energy (there are a lot of power supplies around the lab that use grounding sticks for voltages lower than 600VAC):

 

a.                Use a grounding/shorting stick to dissipate any stored/residual energy. 

b.               Ground the electrical components/circuits as required for the duration of the job or task. 

c.                Verify that the stored/residual energy has been dissipated.

d.         Don appropriate PPE.

e.         Put all control mechanisms into a safe state and lock controls where possible.

f.          Bleed the system of energy.

g.         Block raised dies, gears, or equipment that could descend or move when the energy is removed.

h.         Lower suspended loads to the floor or secure them independently.

i.          Release any stored spring tension.

j.          Check the system for possible re-accumulation of stored energy. Continue this check until the possibility of re-accumulation no longer exists, or until the LOTO is cleared.

 

Step 13:                 If deemed practical for use, then protective grounds shall be applied when working on de-energized electrical systems which normally operate above 600 VAC (grounding devices must be rated for the available fault duty that is applied where it could be reasonably anticipated that the conductors or circuit parts being de-energized could contact other exposed energized conductors or circuit parts).

 

NOTE: In the event of a scenario where the energy source is not present during the lockout/tagout, additional safety measures are implemented to eliminate inadvertent energization. These additional steps are performed to ensure that the failure of any energy isolation device does not energize the equipment being worked on.

 

A written and approved Task Hazard Analysis is required under this no-energy lockout scenario, and the approval of the task includes a review from a second individual familiar with the equipment being lockout.

 

Step 14:                 Qualified Persons will perform the servicing or maintenance work under the complex LOTO. During work, follow these steps as needed:

 

a.                Keep the lockout in place for the duration of work. 

b.               Other LOTO authorized workers and limited authorized workers from the same crew, trade, or employer may join the LOTO by applying their lock and tag if they receive clearance from the Person in Charge. 

c.                Apply your personal LOTO locks and tags to each of the energy isolations listed in the LOTO procedure. 

d.               If you must temporarily remove one or more LOTO devices before work is complete, such as for testing or repositioning equipment, see ES&H Manual Chapter 6110 Appendix T2 Special Lockout/Tagout (LOTO) Procedure.

e.                Workers must remain vigilant and limit the scope of work to that defined for the servicing and/or maintenance. 

f.                If the workers identify a task outside of the defined scope of work, then they must stop work and the PIC must decide to either to submit a new LOTO procedure for approval or forego the work until the LOTO can be changed.

 

Step 15:                 The PIC and Qualified Persons will proceed to Section 7.0 for removing LOTOs.

6.0           Exceptions to the Use of a Lock and/or Tag

6.1            Cord & Plug - Electrical Equipment

 

LOTO requirements do not apply to electrical equipment that is equipped with cords and receptacle plugs if removing the plug completely de-energizes the equipment and the plug is under exclusive control, of the worker, at all times. Unload the equipment prior to unplugging the cord-and-plug. If these conditions cannot be guaranteed, then LOTO measures are required. 

 

Work on electrical equipment connected by cord and plug does not need LOTO if all of the following is true: 

 

6.1.1       Unplugging removes the sole energy source 

6.1.2       There is no stored energy in the equipment, machine, or system 

6.1.3       The plugs are under the exclusive control of the workers (if there is more than one worker, see ES&H Manual Chapter 6110 Appendix T3 Group Lockout/Tagout (LOTO) Procedure.

 

Workers must take further steps to investigate and verify that no other energy sources associated with the equipment, machine, or system are active, such as a capacitor, hydraulic, or mechanical devices independent of the electrical source. 

 

If workers lose control of the plug because they temporarily leave the area, then when they return they must reestablish control of the plug before resuming work. 

 

NOTE:  There are lockable “boots” available to secure electrical plugs.

 

6.2            Special Tag Out Situations Without Locks (see ES&H Manual Chapter 6110 Appendix T2 Special LOTO for more information)

 

Jefferson Lab, in accordance with OSHA, permits the use of tags alone in certain limited situations. To be a candidate for a tag-only control, an energy source must meet all of the following criteria:

 

6.2.1       Equipment design precludes the installation of a lock on an energy isolation device(s).

6.2.2       At least one additional safety measure is employed that provides a level of safety equivalent to that obtained by use of a lock.

6.2.3       The LOTO procedure to be used is documented.

7.0           Removing LOTOs

7.1            This section explains how to do the following: 

 

7.1.1       Release a simple or complex LOTOs 

7.1.2       Provide feedback and make improvements 

 

7.2            Releasing Simple or Complex LOTOs

 

7.2.1       Confirm that the work under the LOTO is complete. 

7.2.2       Return all controls to the OFF position. 

 

Step 1:                    The Qualified Person or PIC will confirm that it is safe to reenergize by completing the following systems:

 

a.                Confirm that the work under the LOTO is complete.

b.               Return all controls to the OFF position.

c.                Clear all tools and workers. Check the work area to confirm that all tools, debris, and workers are at a safe distance from the equipment.

d.               Replace safety guards. Check the equipment to confirm that any removed guards are reinstalled.

e.                Clear blocked mechanical equipment or grounded equipment to prepare it for return to service.

f.                Confirm all workers remain clear of the equipment’s point of operation or hazard zone.

 

Step 2:                    The PIC must direct the removal of all lockout devices and tags from isolation. Only the Qualified Person and authorized workers who applied each lockout device may remove it. Remove all barriers.

 

Exception: If the worker who placed the lock and tag is not available, follow the procedure in ES&H Manual Chapter 6110 Appendix T2 Special Lockout/Tagout (LOTO) Procedure.

 

Step 3:                    The PIC and Qualified Person will notify all affected employees that the LOTO is released and the equipment, machine, or system is to be reenergized and returned to service. 

 

a.                Notify a worker qualified to operate the equipment, machine, or system that it can return to service. 

b.               Reenergize and restore the equipment to the normal condition.

 

Note: CFR 1910.147 requires separate notifications to affected employees: one for removing an LOTO and another before reenergizing equipment. At times, notification when removing an LOTO and notification when energizing the equipment may occur at the same time. At other times, there are other simultaneous work activities that allow for removing the LOTO to complete specific maintenance, service, or changes and for which a notification is made to affected employees concerning the LOTO removal but not immediate reenergizing of equipment. The notice to affected employees that a system will be started up occurs later when all related work activities and associated LOTOs are removed. It is acceptable to apply instructions in work controls documents to address final notification to affected employees for equipment startup

 

Step 4:                    For complex LOTOs, the PIC will sign off on the LOTO procedure when cleared. Keep the completed, signed LOTO procedure according to your division’s record keeping practices. 

 

7.3            Providing Feedback and Making Improvements

 

When the HEC procedure is complete and the LOTO is released the PIC must solicit feedback from all employees involved in the HEC process. The PIC may document any feedback received. The PIC informs line management of any substantive changes needed to improve the process. 

8.0           Revision Summary

TPOC change - 01/28/23  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 – 02/16/22  TPOC reviewed appendix for requirements of CATS IA-2022-08-05-02; no further updates are necessary and CATS item was closed.  Updated PIC and Group lockout responsivities, added reference links, added barrier information, and updated training information as per CATS#NE-2019-05-02-01, CATS# INSP-2018-002-01-02, and CATS#STR-2019-14-01-02. Minor edits only, no approval needed.

Revision 2.2 - 10/22/21  Addressed issues identified during IA- 2021-07.  Minor edits no approval needed.

Revision 2.1 - 06/22/21  Updated section references and removed work planner reference. Deleted nuclear facility reference, Minor edits no approval needed.

Revision 2.0 - 01/13/21  Updated and restructured entire manual, updated header and footer, changed ESH&Q to ES&H. Approved by Laboratory Director and ES&H Director

Revision 1.10 – 11/12/19   Updated Purpose to add configuration management controls for equipment specific LOTO procedures per CATS#NE-2019-05-02-01; 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 1.9 – 10/24/18     Updated verbiage for Process Step 6, electrical energies re: the revised ZERO ENERGY VERIFICATION equivalency per TPOC

Revision 1.8 – 03/23/18     Updated Process Step 6 regarding the use of equipment specific ZERO ENERGY VERIFICATION per 10CFR851 requirement

Revision 1.7 – 04/24/17     Minor edits to reflect recommendations from the annual LOTO review

Revision 1.6 – 01/18/17     Updated to include noteworthy practice on protective grounding and guidance for using blocking devices re: CATS MOA-2016-32-01 and MOA-2016-32-03

Revision 1.5 – 05/16/16     Added note under Step 7 to clarify work performance in areas with both energized and de-energized equipment.

Revision 1.4 – 03/09/15 – Periodic Review; clarification of 2.0 Responsibilities; replaced ‘Work Control Document’ with ‘procedure’; deleted reference to ESH Manual Chapter 3310 OSP Program. 

Revision 1.3 – 08/02/13 – Added clarification to Process Step 9 for removal of equipment per T.Kujawa.

Revision 1.2 – 09/10/12 – Removed Special Lockout Situations without Tags in response to CATS item MOA-2012-19-01-01.

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 – 04/04/09 – Update to reflect current laboratory operations.

 

 

 

ISSUING AUTHORITY

TECHNICAL POINT-OF-CONTACT

APPROVAL DATE

REVIEW DATE

REVIEW CYCLE

rev

 

 

ES&H Division

Phillip Stanley

01.13.2021

01.28.2023

3 years

2.3

 

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 2/21/2023.