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6110
Appendix T3 Group Lockout/Tagout
(LOTO) Procedure |
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1.0 Purpose
This 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. Group LOTO is a complex LOTO. A group LOTO can be applied even under the following conditions:
·
There
is only one source of hazardous energy
·
The
equipment meets all of the conditions for simple LOTO in ES&H Manual Chapter 6110
Appendix T1 Lockout/Tagout (LOTO) Procedure, except that there are several workers servicing the system
or equipment
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.
2.2.1
Maintain
appropriate LOTO training (ESC001- for electrical workers, ESC007, and ESC008 Lockout/Tagout
Practical).
2.2.2
Obtain specific LOTO training on equipment being
serviced.
2.2.3
Perform Group LOTO process steps (listed below in section 3.0)
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
Be a Qualified Tagger. (If you supervise
subcontractors who perform LOTO on
site.). More than likely the TR will be the Group LOTO Coordinator and the PIC.
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 this 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, ESC007,
and ESC008 Lockout/Tagout 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 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.
2.5.1
Be a Qualified Tagger.
2.5.2
Account for all persons assigned to the work.
2.5.3
Ensure all energy sources are under LOTO.
2.5.4
Ensure all process steps of the Group LOTO procedure,
outlined below are properly carried out.
Unless otherwise stated within this
procedure, the Group LOTO Coordinator performs the process steps listed below.
Step 1:
Determine the Hazards
Perform or review the work’s Task Hazard Analysis.
a.
Evaluate the type and
magnitude of the potentially hazardous energy, and the means of controlling the
energy.
b.
Review specific
equipment, written procedures, blueprints, system diagrams, valve lineups, and
operating manuals.
c.
Confer with people who
know the equipment.
d.
Be alert to multiple
energy sources.
e.
Do not proceed until knowledge of the hazard(s) are known
Step 2:
Develop the Written Procedure:
a.
Group LOTO
applications require a written procedure.
|
NOTE: Completion of a Group
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 3:
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.
Ensure all potential
sources of hazardous energy, including stored/residual energy, are known,
documented, and understood.
c.
Coordinate the LOTO with
other system owners who may be affected by the work.
d.
Review the job,
equipment, and planned processes with all affected groups.
e.
Post the Group LOTO Form
or the written Group LOTO procedure at the area of the group lockout device for
the duration of the work.
Step 4:
Isolate Energy Sources:
a.
Identify and locate all
energy sources associated with the job.
b.
Don appropriate personal protective equipment
(PPE) and set up electrical barriers for shock and arc flash. Refer to the ESH
6200 Manual and NFPA 70E, Standard for Electrical Safety in the Workplace, 2015
Edition (Article 130) for more information about barriers.
c.
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.)
d.
Attach a “Danger” tag. 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.
e.
Perform
the required tests to verify that all hazardous energy sources have been de-energized.
f.
Each
group should be present to witness the zero-energy verification, or utilize the
group LOTO form to verify the zero-energy state of the equipment.
g.
Identify,
locate, and remove any potential energy to ensure residual, stored or
accumulated energy creates no hazard.
h.
Perform
the required tests to verify that stored/residual energy has been drained from
the system and will not re-accumulate.
i.
Record
all energy-isolating and energy-draining devices on the Group LOTO Form or
within the written LOTO procedure.
Step 5:
Test LOTO Device Applications
Advise all responsible
Qualified Taggers that they have a right to personally verify that the
hazardous energy sources have been effectively de-energized.
|
NOTE: The responsible Qualified Tagger who opts to verify the
effectiveness of the isolation measures must do so before commencement of
work and in the presence of the Group LOTO Coordinator. |
Step 6:
Lockout Box (optional)
a.
Designate a specific
location for a lockout box. Ensure all
responsible Qualified Taggers know, and have access to the location. The
PIC/Group LOTO Coordinator is responsible for the box as well as placing a Red
PIC/Lockbox lock on the equipment and lockbox. The PIC/Group LOTO Coordinator
will ALWAYS be the first to put this lock and tag on along with a personal lock
and tag.
b.
Place all keys to the
locks, used to isolate the energy sources in Step 4, in the lockout box.
c.
Lock the lockout box
with the Group LOTO Coordinator(s)’ lock and tag.
d.
Place a copy of the Group
LOTO Form near the lockout box so
it is readily accessible to all responsible Qualified Taggers.
|
NOTE: A lockout box is one example of a mechanism
that can be used during a group lockout situation; other comparable group
lockout device mechanisms may also be utilized. |
Step 7:
Prior to Commencement of Work
The bulleted activities below are to be performed by responsible
Qualified Taggers
a.
Review the Group LOTO
Form and any other associated procedures.
b.
Apply individual locks
to the lockout box prior to work.
c.
Visually verify the
isolation of hazardous energy sources at each location listed on the Group LOTO
Form or within the written Group LOTO procedure to ensure that the integrity of
a proper LOTO has been achieved (i.e., it must be verified that each lock and
tag is physically in place as noted on the Group LOTO Form or within the
written Group LOTO procedure). This action can be accomplished by the Group’s LOTO
Coordinator(s) on behalf of the Qualified Taggers working on the group lockout.
The group lockout box remains locked at all
times until the Group LOTO Coordinator(s) determines it is safe to remove the
keys (i.e. the Group LOTO Coordinator(s)’ lock stays on the box until it is
deemed appropriate for removal).
a.
Communicate the job-status
to affected personnel at the beginning of each shift.
b.
Ensure all responsible
Qualified Taggers visually verifies the isolation of hazardous energy sources
at each location listed on the Group LOTO Form or within the written Group LOTO
procedure at each shift change. This is to ensure that the integrity of the LOTO
has been maintained (i.e., it must be verified that each lock and tag is
physically in place as noted on the Group LOTO Form or within the written Group
LOTO procedure). This action can be accomplished by the Group’s LOTO
Coordinator(s) on behalf of the Qualified Taggers working on the group lockout.
|
NOTE: It is the responsible Qualified Tagger’s lock
(the one attached to the lockout box) that gets switched at a shift, or
personnel change, not the locks on
the equipment. |
Step 9:
Job Completion (Group LOTO Coordinator)
a.
Review the job for
completeness to ensure that no one will be endangered by the removal of the
lock devices.
b.
Notify the system owners
that the work is complete and the equipment is ready for re-energizing.
c.
Remove the keys from the
lockout box and the LOTO devices from the equipment.
d.
Test equipment to verify
proper operation.
e.
Remove all barriers.
f.
Complete the Group LOTO
Form with system verification and depositing.
4.0
Group
LOTO Things to Consider
4.1 You may use a multi-lock hasp or lockbox as the hardware to implement a simple group LOTO.
4.2 A complex LOTO procedure involving a group LOTO must meet the requirements in ES&H Manual Chapter 6110 Appendix T5 Lockout/Tagout (LOTO) Forms and Templates. If a lockout involves only a few energy-isolating devices and a few qualified workers, you may use multi-lock hasps instead of a lockbox. However, if the hasp with multiple locks is too heavy for the device being isolated (that is, a small breaker or line valve) then you must use a lockbox.
4.3 If using hasps, then each energy-isolating device must have a hasp, and each worker must apply a personal LOTO lock on each hasp. For continuity of protection, the Person In Charge (PIC) must be the first to lock on each hasp, and the last to lock off each hasp after work is complete.
4.4 For a large group of authorized workers, the PIC determines how many of them must witness the equipment shutdown.
4.5 All approved LOTO equipment (i.e. locks and tags) can be found in ES&H Manual 6110 T6. These items can be found in the Stockroom.
5.0
Master
and Subordinate Lockbox Grouping
5.1 You may refer to one or more lockboxes under a master procedure for a complex LOTO or another group LOTO procedure. This is useful when managing lockouts with extensive scope and complexity.
5.2 Only one procedure per lockbox may be for a complex group LOTO. If you need to group multiple complex LOTO procedures under one master lockbox, then first build each procedure into its own separate group LOTO. When using master and subordinate lockboxes, each lockbox must have its own procedure number attached to the lockbox. The master lockbox procedure for a complex LOTO must refer to each subordinate lockbox using a separate line item on the isolation checklist.
6.0
Revision
Summary
Revision 2.2- 05/22/23 Section
3.a, step 4: Minor formatting corrections; added a step to ensure that each
group involved in LOTO coordinate to observe the zero-energy verification or
utilize group LOTO form to verify zero energy state. Updated to reflect CATS #IA-2022-08-02-01
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 2.1- 02/16/22 Updated
training requirements as per CATS#STR-2019-14-01-02. Updated lockbox and PIC/Group LOTO information as per CATS# INSP-2018-002-01-02. Minor edits only no approval needed.
Revision 2.0 – 01/13/21 Updated steps and format. Update header and footer. Approved by Director and ES&H
Director
Revision 1.4 – 10/23/19 Updated TPOC from T.Kujawa
to T.Fitzgerald; updated TR responsibilities to
clarify subcontractor’s use of Jefferson Lab’s program or their own program for
Lockout/Tagout procedures
Revision 1.3 – 11/02/17 Updated Process Steps for developing the written procedure
per TPOC
Revision 1.2 – 03/09/15 Periodic Review; added Group LOTO Procedure for determining
hazards; deleted Multiple or Single equipment distinction
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 Updated to reflect current laboratory operations.
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ISSUING
AUTHORITY |
TECHNICAL
POINT-OF-CONTACT |
APPROVAL
DATE |
NEXT REVIEW
DATE |
rev |
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ES&H Division |
01.13.2021 |
05.22.2026 |
2.2 |
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