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6110 Appendix T1: Lockout/Tagout Procedure - Simple and Complex |
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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
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.
2.3.1 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
4.1.1
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 |
01.13.2021 |
01.28.2023 |
3 years |
2.3 |
|