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ES&H Manual
Chapter 6110 Hazardous Energy Control (HEC) Program
Purpose

The mission of Jefferson Laboratory as a scientific and engineering research center needs a large and diverse installed infrastructure, with facilities, equipment, and machines that have a wide variety of hazardous energy sources. The hazardous energy sources associated with scientific and research-related equipment may be completely different to those of facility infrastructure equipment. No matter what the source, mitigating hazards by isolating hazardous energy and using Lockout/Tagout (LOTO) is part of Integrated Safety Management at Jefferson Lab under Title 10 of the Code of Federal Regulations (CFR), Part 851, Worker Safety and Health Program, and several other CFR and regulatory safety standards.

This manual describes the Hazardous Energy Control (HEC) program and how to implement it. The goal of the HEC program is to prevent injury to staff or damage to government and proprietary property that may result from an unexpected startup of equipment and machinery, or inadvertent release of stored energy.

Refer to Environmental, Safety, and Health (ES&H) Manual Chapter 6111 Administrative Control Using Locks and Tags for administrative control applications.

This program satisfies the requirements of OSHA 29 CFR1910.147 The Control of Hazardous Energy (Lockout/Tagout); the standard used when servicing and maintaining equipment/systems and NFPA 70E (2015 Edition), Article 120, Establishing an Electrically Safe Work Condition.

Jefferson Lab's construction subcontractors follow OSHA 29 CFR1926 Safety and Health Regulations for Construction; which is the standard for construction work activities. Technical Representatives(TRs) are tasked with reviewing subcontractors' programs for compliance.



Scope

LOTO is required whenever there is the potential for someone to be injured by the unexpected start-up of equipment or by a release of stored energy during maintenance and service work. ALL employees are responsible for the LOTO program and are to work safely to control the hazardous energy potentials when performing maintenance, repair, or modifications, or builds to any equipment.

The definition of hazardous energy is: Any form of energy that can cause personal injury or equipment damage. Forms and sources of energy can include:

  • Electrical
  • Pressure
  • Vacuum
  • Mechanical
  • Hydraulic
  • Rotation
  • Pneumatic
  • Gravitation
  • Non-Ionizing Radiation
  • Lasers
  • Chemical
  • Thermal
  • Cryogenic

This manual explains the Hazardous Energy Control (HEC) program and the minimum requirements to control hazardous energy for equipment with one or more sources of energy. This manual also addresses alternative means to isolate equipment and systems when the isolation is not required for maintenance or servicing (see section 4.2 and 10.13).

Table 1: LOTO Training Requirements

Electrical Non-Electrical
ESC001- Basic Electrical Safety ESC007- LOTO
ESC007- LOTO ESC008- LOTO Practical
ESC008- LOTO Practical  


Technical Appendices:

T1 Lockout/Tagout (LOTO) Procedure (Simple and Complex)
ES&H Manual Chapter 6110 Appendix T1 Lock, Tag, Try (LTT) Procedure contains the guidelines for locking and tagging out of hazardous energy sources when maintenance or service work is to be performed. LTT references in this appendix apply to maintenance, service, and construction applications. Refer to ES&H Manual Chapter 6111 Administrative Control Using Locks and Tags for administrative configuration control applications.

Configuration management requirements for equipment specific LTT procedures include:
  • Document numbers
  • Owner identification
  • Revision number, if applicable
  • Date of efficacy
  • Expiration/review date
  • Approval record
  • Change record
  • Archival of previous versions

Lockout/Tagout Multiple Energy Form: Click for Word Document

T2 Special Lockout/Tagout (LOTO) Procedures
In accordance with Jefferson Lab procedures (ES&H Manual Chapter 6110 Appendix T1 Lock, Tag, Try (LTT) Procedure and ES&H Manual Chapter 6111 Administrative Control Using Locks and Tags) a lock and/or tag is removed only by the Qualified Tagger who placed it on the equipment, or an authorized person in the administrative control scenario. If the Qualified Tagger is unavailable, or the information is missing or illegible, ES&H Manual Chapter 6110 Appendix T2 Special Lockout/Tagout (LOTO) Procedures is utilized.

Special Lock and Tag Removal Form: Click for Word Document

T3 Group Lockout/Tagout (LOTO) Procedure
ES&H Manual Chapter 6110 Appendix T3 Group Lock, Tag, Try (LTT) 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 Lock, Tag, Try (LTT) Procedure.

Group Lockout/Tagout (LOTO) Form - Single Equipment: Click for Word Document


Group Lockout/Tagout (LOTO) Form - Multiple Equipment: Click for Word Document

T4 Lockout/Tagout (LOTO) Zero Energy and Zero Voltage Verification
ES&H Manual Chapter 6110 Appendix T4 Lockout/Tagout (LOTO) Zero Energy and Zero Voltage Verification provides 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.
T5 Lockout/Tagout (LOTO) Forms and Templates
ES&H Manual Chapter 6110 Appendix T5 GLockout/Tagout (LOTO) Forms.
T6 Lockout/Tagout (LOTO) Locks, Tags, and Devices List
ES&H Manual Chapter 6110 Appendix T6 Lockout/Tagout (LOTO) Approved Locks and Tags List provides descriptions of approved locks and tags.
Responsibilities:

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

Employees at Jefferson Lab
Qualified Tagger
  • Maintain Qualified Worker status.
  • If a qualified tagger finds a discrepancy between configurations depicted in drawings to those found for the equipment, the worker must report the discrepancy to their supervisor.
  • Must be trained to understand the purpose and function of the LOTO program and energy control.
  • Recognize applicable hazardous energy sources, types of energy, and ways to isolate and control the energy sources.
  • Recognize how lockouts can hinder facility operations, especially when operations are needed when the remote controls are locked out.
  • Understand simple, complex, and group LOTO procedures and the limitations.
  • Demonstrate practical understanding and the ability to apply and remove LOTO tags. Requalify for On-the-Job Training (OJT) every year to maintain equipment specific qualifications.
  • Obtain specific LOTO training on equipment being serviced.
  • Perform LOTO process steps (in accordance with ES&H Manual Chapter 6110 T1 Lockout/Tagout (LOTO) Procedure (Simple and Complex) only after authorization from the supervisor of the equipment which requires the securing of the hazardous energy source.
Supervisor
  • Only assign Qualified Taggers, and provide equipment-specific LOTO training, for equipment under your authority.
  • Take action to rectify configuration discrepancies between drawings and LOTO placement.
  • If the work expands beyond the LOTO tag defined scope of work, ensure the work is stopped, a new tag is issued, and the boundaries are changed to accommodate the new scope of work.
  • Maintain familiarity with Jefferson Lab's LOTO programs and procedures, when supervising employee(s) who use LOTO procedures.
  • Establish procedures for all isolations of hazardous energy and coordinate with other supervisors to ensure all energy sources are identified. Understands that other employees will be affected when shutting down equipment. Notify other employees before shutting down equipment and coordinate isolating LOTO procedures to make sure all hazardous energy sources are isolated.
  • Know how to identify hazardous energy sources specific to the equipment and the work that is under their supervision.
  • Understand the difference between simple, complex, and group LOTO procedures.
  • Perform inspections for compliance with LOTO procedures as part of regular supervisory oversight.
Technical Representative (TR)
  • Maintain LOTO qualifications when supervising subcontractors who perform LOTO on site.
  • Review and approve subcontractor's procedures or provide equipment-specific LOTO procedure(s) to subcontractors as needed. Must inform subcontractors of any known hazards and must document the agreement on this disclosure. If a subcontractor finds a discrepancy on the job, they must notify the TR and the TR will alert the appropriate Supervisor.
  • Jefferson Lab will install the first lockout device on a piece of equipment, machine, or system. Contractors must apply their lock before working on the equipment. (ES&H Manual Chapter 6110 Appendix T1 Lockout/Tagout (LOTO) (Simple and Complex) Procedure) for further subcontractor procedures.
  • Implement group LOTO and act as Group LOTO liaison, in accordance with ES&H Manual Chapter 6110 Appendix T3 Group Lockout/Tagout (LOTO) Procedure, if Jefferson Lab employee(s) and subcontractor(s) under your authority are concurrently working on the same equipment/system. If the LOTO is a complex LOTO, the TR must confirm that a Qualified Worker coordinates with the subcontractor to inform them of any specific considerations.
  • If the subcontractor elects to use the Jefferson Lab program, ensure they perform the following:
    • Complete and maintain appropriate LOTO training (SAF 104 Lockout/Tagout) and equipment specific training.
    • Participate, if requested, in OSHA required annual JSA LOTO review.
    • Undertake corrective actions, including retraining of staff and subsequent demonstration of proficiency, if JSA or subcontractor observations indicate unsafe or non-compliant performance.
  • If subcontractors elect to use their own Lockout/Tagout program, the Electrical Safety Engineer or Authority Having Jurisdiction (AHJ) will review their program and approve if:
    • 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
    • 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.
    • If a subcontractor's LOTO program is more stringent than Jefferson Lab's, then Jefferson Lab will also follow these procedures.
Group LOTO Coordinator (follows all of the rules under 5.3 for Supervisors)
  • Ensure all energy sources are under LOTO.
  • Account for all persons working on the job/task.
  • Ensure all steps of the Group LOTO procedure are properly carried out.
Safety Warden
  • Assess effectiveness of the functional locks and tags observed during routine safety inspections.
Electrical Safety Engineer
  • Conduct annual review of the application of LOTO procedures as outlined in OSHA 1910.147.
  • Conduct inspections to ensure LOTO procedures and requirements are being followed.
  • Provide LOTO training.

NOTE: Questions concerning outsiders' actions and knowledge of LOTO procedures should be made to the Electrical Safety Engineer. See also ES&H Manual Chapter 3410 ES&H Aspects of Procurements
Document Control:
  • ISSUING AUTHORITY:   ES&H Division
    TECHNICAL POINT-OF-CONTACT:  Tim Fitzgerald
    APPROVAL DATE:   01/13/2021
    REVIEW DATE:  10/21/2024
    REVISION HISTORY
    Revision 2.3 - 2/16/2022 - Updated SAF104 to reflect only ESC007. Added ESC001 to reflect that this is a requirement for Electrical Personnel ONLY. Updated training requirement course per CATS#STR-2019-14-01-02. Added amplifying information for the Group LOTO as per CATS# INSP-2018-002-01-02. Minor edits no approval needed.
    Revision 2.2 - 10/21/21 - Updated section 10 to reflect T6 appendix. Updated hyperlinks to appendixes. Added details to section 5.4, addressing findings from IA-2021-07. No approval is needed for minor edits per email from T Fitzgerald to S. Hoey.
    Revision 2.1 - 06/22/21 - Updated section 10 to reflect T6 appendix. Updated hyperlinks to appendixes. No approval needed for minor edits.
    Revision 2.0 - 01/13/21 - Updated all areas of the document and reformatted, updated the header and footer, change ESH&Q to ES&H. Approved by Lab Director and ES&H Director.
    Revision 1.8 - 03/24/20 - Updated training requirement course in Table 1 per CATS#STR-2019-14-01-02
    Revision 1.7 - 11/12/19 - Updated section 4.1 per CATS#NE-2019-05-02-01 to add required configuration management controls for equipment specific LTT procedures; updated SOTR 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 1.6 - 09/25/18 - Updated Supervisor and SOTR responsibilities to clarify LTT training for subcontractors per CATS# INSP-2018-002-01-02.
    Periodic Review - 03/09/18 - No changes per TPOC.
    Revision 1.5 - 03/09/15 - Periodic Review; no substantive changes.
    Revision 1.4 - 05/20/14 - Added Required Safety Training Table.
    Revision 1.3 - 11/07/13 - "3.8 ES&H Training Committee" (committee has been disbanded) per MLogue.
    Revision 1.2 - 02/18/13 - Clarification of process steps per TKujawa.
    Revision 1.1 - 12/01/11 - Clarification of process steps and updates made to format. Qualifying periodic review, no substantive changes required.
    Revision 1.0 - 11/02/09 - Update to reflect current laboratory operations.

This document is controlled as an on-line 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 on line file. .