Chapter
18LOCKOUT/TAGOUT AND VERIFICATION
Chapter
1818.5.1.1 Preparing and Posting Equipment-Specific Written Procedures18.5.2 General LOTO Procedure
18.5.1.2 Elements of an Equipment-Specific Written Procedure
18.5.1.3 Required Content
18.5.2.1 LOTO Application Steps
18.5.2.2 Release from LOTO Steps
18.6.4 Reauthorization and Retraining18.6.3.1 LOTO-Authorized Employee Training Requirements
18.6.3.2 Supervisor Authorization
18.7.3 Tags18.7.2.1 Key Control – Personal Locks
18.7.2.2 Key Control – Personal Locks Keyed Alike
18.12.1 Shift Change LOTO Procedure18.13 LBNL Subcontractors
18.12.2 When There Is a Gap Between Shifts18.12.2.1 Leaving Locks in Place18.12.3 Unforeseen Shift Change Problems
18.13.1 Construction Project Manager Responsibilities18.14 Students, Guests, and Visitors
18.13.2 Construction Subcontractor Responsibilities
18.13.3 Maintenance Subcontractors
18.13.4 LBNL Procurement Responsibilities
18.13.5 EH&S Responsibilities
18.19.1 Appendix 1: LOTO vs. Administrative Locking
18.19.2 Appendix 2: Equipment-Specific Lockout/Tagout Posted Procedure
18.19.3 Appendix 3: Sample LOTO Log
18.19.4 Appendix 4: LOTO Inspection Form
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It is Laboratory policy to prevent the unintended or unexpected startup or release of hazardous energy during servicing, maintenance, or modification activities. No employee shall install, service, remove, or perform maintenance on any equipment or machinery that may involve an energy hazard, until that equipment has been deenergized, locked, tagged and verified to be in a zero energy state in accordance with this document.
To establish minimum safety requirements for the lockout and tagout of hazardous energy sources and the verification of energy isolation through the use of isolating devices and techniques during service or maintenance on equipment.
This program applies to all workers who may be exposed to hazardous energy while performing any servicing, maintenance, or modification activity.
The lockout/tagout and verification procedures identified in this document must be strictly followed when it is necessary to work on any equipment that generates, holds, or may release, any form of hazardous energy while the equipment is shut down, including, but not limited to:
LOTO is required whenever service, maintenance, or modification is being performed on equipment or apparatus in which the unexpected energization or start-up of the equipment, or the release of stored energy, could cause injury to people or damage to equipment.
LOTO procedures do not apply under the following three conditions:
The use of a plug LOTO device is strongly recommended (see Figure 18-1).
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Figure 18-1. Lockout Box for Plugs
Special safety equipment may be required. See PUB-3000, Chapter 8 (Electrical Safety).
Each worker is responsible for his or her own safety. Never undertake
a task that you feel is unsafe.
All workers are responsible for recognizing when LOTO is being
used, the general reasons for LOTO, and the importance of not tampering with
or removing a lock and tag.
LOTO-Authorized Employees have responsibility for recognizing the conditions of work that require LOTO, assessing all of the hazardous energy sources, using correct procedures and materials to implement LOTO, and maintaining control over their key.
Each LOTO-Authorized Employee performing servicing, maintenance, or modification is responsible for applying his or her own lock and tag.
NEVER apply LOTO for anyone else. See Section 18.11 for Group LOTO Procedures.
Supervisors are responsible for:
The EH&S Division is responsible for:
The Facilities Division Director is responsible for ensuring that all outside contractors operating under the supervision of the Facilities Division are informed of, and adhere to, the LBNL LOTO policy (see Section 18.13 (LBNL Subcontractors)).
All LOTO operations shall utilize either an equipment–specific written procedure or the General LOTO procedure, as applicable. Regardless of the procedure used, it is important that the following LOTO principles are strictly adhered to:
An equipment-specific written energy control procedure must be developed and used whenever equipment or apparatus undergoing servicing, modification, or maintenance:
The procedure must be posted on or near the equipment, or provided in such a manner as to ensure that all LOTO-Authorized Employees are provided this information before starting the work.
A written energy-control procedure must be generated by the department, group, or LOTO-Authorized Employee most familiar with the equipment. This procedure must be used by any LOTO-Authorized Employee who will LOTO the equipment.
The procedure must be reviewed and updated as necessary any time there is a change in the equipment or associated hazards.
Supervisors must ensure that equipment requiring written procedures are so identified, and that the procedure is posted on the equipment or is readily available to the worker(s) authorized to LOTO the equipment.
If the written procedure is not posted on the equipment, the equipment must be clearly labeled to indicate the availability and location of the procedure. The supervisor or worker responsible for the equipment may determine the appropriate format and content of the label. For example:
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The written hazardous energy control procedure must be specific to each piece of equipment (by model number or serial number) or apparatus, and must be inclusive of all energy types it contains. More complex equipment may require a separate procedure for each type of hazardous energy to be controlled, or a separate procedure for each type of maintenance or servicing task expected to take place. Maintenance and service manuals must be consulted to ensure accuracy and sufficient level of detail.
Equipment-specific written procedures must incorporate all of the applicable elements of each step in Section 18.5.2 (General LOTO Procedure). It is essential that the specific application of each LOTO step be clearly explained in the context of the specific equipment or apparatus.
In addition, each written Hazardous Energy Control procedure must identify the specific equipment or apparatus to which the procedure applies, and must identify the following elements:
See Section 18.19.2 (Appendix 2: Equipment-Specific Lockout/Tagout Posted Procedure) for an example of an equipment-specific written procedure format.
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Figure 18-2. LOTO Hardware
Before starting any LOTO procedure, the LOTO-Authorized Employee(s) performing the work shall physically locate and identify all isolating devices to be sure which switches, valves, or other energy isolating devices apply to the equipment or apparatus to be locked out. Any questionable identification of electrical or other energy sources shall be resolved by the LOTO-Authorized Employee(s) with their supervisor before proceeding.
If safety would be compromised by following this prescribed sequence of procedures, the LOTO-Authorized Employee, with supervisor approval, may modify the sequence. However, all steps must be performed.
Push buttons, selector switches, interlock circuits, and other control-type devices are not energy-isolating devices.
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Figure 18-3. Lockout/Tagout Methods
Notify all affected employees. The LOTO-Authorized Employee must notify all Affected Employees of the impending shutdown. These persons must be informed that they are not to disturb the lockout device or attempt to re-start the equipment until they are informed that the lockout has been cleared and it is safe to resume normal operations.
Note: For verification of electrical energy isolation, a best practice procedure (if safe to do so) may include an “on-off-on” procedure, wherein: (1) the equipment is placed in an operating condition; (2) the disconnect is operated; (3) the equipment is confirmed to have switched off; (4) the disconnect is re-energized; (5) the equipment is confirmed to have switched on; (6) the disconnect is operated; (7) equipment is confirmed to have switched off.
This can only be accomplished by an electrically Qualified and LOTO-Authorized Person (see PUB-3000, Chapter 8 (Electrical Safety)).
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Figure 18-4. Placement of a Blocking Device
Only electrically Qualified and LOTO-Authorized Persons can test for verification of electrical deenergization (see PUB 3000, Chapter 8 (Electrical Safety)). The qualified tester, if other than the LOTO-Authorized Employee, must be identified in the Remarks section on the tag.
All energy is to be treated as present until positively proven otherwise.
The lock and tag shall remain in place until work on the equipment is 100 percent complete. In rare circumstances, it may be necessary to temporarily remove LOTO devices before work is 100 percent completed (such as for adjustment or repositioning equipment). See Section 18.8 (Temporary Removal of LOTO Devices).
General awareness training shall be done to ensure that every Lab employee knows and understands the purpose, contents, and application of this program to the level necessary for their job requirements. The awareness-level LOTO course described below for Affected and Other Employees fulfills this initial training requirement.
Reminder: LOTO may only be performed by LOTO-Authorized Employees who have completed formal classroom training per Section 18.6.3.1, have received task and equipment-specific on-the-job training, and have been authorized by their Supervisor per Section 18.6.3.2.
Affected and Other Employees are required to be trained in LOTO awareness, which describes the use of this energy control program, how to recognize LOTO, why LOTO is implemented, and about the prohibition of attempts to restart or re-energize equipment that has been locked and tagged out.
Tampering with or removing someone else’s LOTO devices can cause serious injury or fatalities, and is a serious safety violation!
LOTO awareness training is obtained through EHS 10, New Employee Health and Safety Orientation and Training.
A LOTO-Authorized Employee is a worker who is:
The classroom training requirement for LOTO-Authorized Employees is obtained through EHS 256, Lockout/Tagout.
As the outcome of LOTO training, LOTO-Authorized Employees must be able to recognize applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and procedures for their isolation and control.
LOTO-Authorized Employees may also need to be Qualified and Authorized Electrical Workers to perform verification of electrical deenergization. Refer to PUB-3000, Chapter 8 (Electrical Safety) for detailed training requirements for Qualified and Authorized Electrical Workers.
Specific authorization is to be provided by the Supervisor after the employee satisfies the classroom training requirement and has received equipment-specific training. The supervisor must ensure that the employee is thoroughly familiar with the equipment (within the context of his or her job function) and with the energy-control procedures. A practical exercise may be required by the Supervisor to demonstrate proficiency. The content of this exercise will depend on the types of hazardous energy control and the complexity of the procedure’s steps.
Once satisfied that both the training and authorization requirements have been met, the supervisor may authorize an employee to perform LOTO. This authorization stipulates the specific equipment or types of equipment on which the LOTO-Authorized Employee may perform LOTO.
Reauthorization is required when:
Retraining and/or reauthorization may be required when:
Documentation of equipment-specific training must be in writing. Training documentation must be retained for 3 years, and be readily available for inspection by LBNL EHS representatives or LOTO program evaluators upon request.
Only LBNL-approved locks may be used when performing LOTO (see Figure 18-5). The currently approved lock is a padlock, American brand, type #1107. This lock is color-coded to indicate the user group, as in the following table:
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COLOR |
USER |
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Brown |
Painters and carpenters |
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Blue |
Electricians |
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Black |
Refrigeration Shop |
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Green |
Maintenance personnel |
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Gold |
Riggers |
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Red |
General (LBNL-wide) |
Note that the red lock is used by all LBNL LOTO-Authorized Employees outside of the Facilities Division.
LBNL LOTO locks may not be used for any purpose other than LOTO.
The following are additional requirements pertaining to LOTO Locks:
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Figure 18-5. LBNL-Approved LOTO Lock and Key
Each LBNL-approved LOTO padlock has two keys: primary and emergency. The primary key must be in the control of the LOTO-Authorized Employee who applied the lock. The emergency key must be kept in a secured area (e.g., a lock box) with access restricted to the LOTO-Authorized Employee's immediate Supervisor and one level of management above the LOTO-Authorized Employee's Supervisor.
A group of locks with a common key may be used for equipment with multiple energy-isolation devices, if desired. If a group of locks is keyed alike for this purpose, one key only may be issued for use by the LOTO-Authorized Employee and a second key may be kept for emergency use, as described above.
The following are requirements for LOTO tags:
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Figure 18-6. LBNL LOTO Tag
A Division may develop LOTO procedures or requirements specific to their operational needs. Such Division-specific procedures or requirements must:
See Pub-3000, Chapter 8 (Electrical Safety) for ESO and ESC contact information.
When LOTO devices must be temporarily removed from the energy-isolating device so that the equipment or component can be reenergized for adjustment or positioning, the following sequence of eight actions must be taken:
WARNING: This is considered to be an emergency procedure, only to be undertaken in extreme circumstances and with Divisional approval.
When the LOTO-Authorized Employee who applied a LOTO device is not available to remove it, that device may be removed by his or her Supervisor if it is safe to do so, and only after the following emergency removal procedure has been implemented:
Extreme care must be taken, and the following four steps must be performed:
- These efforts must be documented (email, registered letter, voicemail, telephone verbal assurance to the Supervisor and one other person, etc.).
- If the employee is contacted, the Supervisor must inform the employee that his or her LOTO devices are being removed.
- The Supervisor must verify that it is safe to remove the LOTO devices.
- The Supervisor may then use the emergency key to remove the LOTO devices, or the lock may be cut off if the key is not available. (See Section 18.7.2 (Keys).)
- Before the worker returns to any work duty, the Supervisor must ensure that the LOTO-Authorized Employee is presented with the removed lock upon returning to work and is informed of the reasons for the emergency removal.
- The emergency procedure must be duly recorded in the department's lockout/tagout records and signed by both the Supervisor and LOTO-Authorized Employee.
Note: If the LOTO-Authorized Employee's immediate supervisor is not available, the emergency removal may be performed by one level of management above the LOTO-Authorized Employee's Supervisor, or by a delegated individual with documented authorization by the supervisor to perform this function, using the above steps. Contact the LBNL Electrical Safety Officer at extension 3414 if no authorized person is available to implement the emergency removal procedure.
In the rare cases that a device is not capable of being locked out, a "tag-out only" procedure may be used, subject to the following conditions. The following criteria must be met before using a “tag-out only” procedure:
Any energy-isolating device capable of being locked must be locked WITHOUT EXCEPTION.
To conduct a tag-out only procedure, the LOTO-Authorized Employee must follow all of the steps outlined in Section 18.5.2 (General LOTO Procedure), with the following two changes:
Extra caution must be exercised when using a Tag-Out Only Procedure. Tags may evoke a false sense of security by the at-risk employee. Tags are warning devices and do not provide the physical restraint provided by a lock.
When multiple LOTO-Authorized Employees perform servicing, maintenance, or modification on the same piece of equipment or apparatus, the Supervisor may determine that the use of a group LOTO procedure is appropriate.
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Figure 18-7. Gang Lock Boxes
If equipment will remain de-energized after the end of a shift, and work will continue by the oncoming shift, an orderly transfer of LOTO devices between LOTO-Authorized Employees from the offgoing and oncoming shifts must be performed, subject to the following conditions:
The following criteria must be met before using a shift change procedure:
If the meeting between off-going and oncoming shift workers does not occur, the off-going shift employee’s LOTO devices shall remain in place. The oncoming employee who will be working on that equipment shall add his/her LOTO lock and tag to a multiple lock adaptor and proceed with the work, following the requirements of this document. This worker shall remove his/her LOTO when finished working on the equipment.
If the orderly transfer of LOTO devices is not possible because of a gap in shifts, contact the EH&S Electrical Safety Officer at X4694 for further direction.
All outside subcontractors involved in construction or maintenance for LBNL who engage in activities covered by the LBNL LOTO Program shall be required to include in their safety plans LOTO procedures that conform to the requirements of this document. All subcontractor employees are responsible for personally locking out and tagging out the equipment that they work on.
The LBNL Project Manager is responsible for ensuring that all construction subcontractors for that project are informed of the LBNL LOTO policy, procedures, and devices as described in this Chapter.
The Project Manager is responsible for communicating information about the Subcontractor’s LOTO procedures to LBNL workers who are affected by the Subcontractor’s LOTO activities.
When work will include an activity requiring LOTO, construction subcontractors are required, in accordance with this Chapter, to include their company’s LOTO procedures in their construction safety plans. A subcontractor operating under an approved safety plan will provide their own LOTO equipment.
All construction subcontractor employees have the responsibility to implement LOTO procedures for equipment that they are working on. All construction subcontractor employees have potential exposure to LOTO activities and must be trained in the recognition of the procedure and the importance of respecting locks and tags.
When the Facilities Division requires local oversight of a utility or other system that is associated with subcontract work, it may forbid the subcontractor from operating that system. This does not relieve the subcontractor from their LOTO responsibilities. In such instances, the controlling LBNL shop will implement the following procedure:
All subcontractors who perform servicing, maintenance, or modifications on equipment or facilities that fall under the scope of Section 18.3 of this chapter are required to provide a safety plan that includes LOTO. The service subcontractor has all of the responsibilities described for construction subcontractors, as described in Section 18.13.2, above. The Laboratory point of contact for the subcontractor has all of the responsibilities described for Construction Project Managers, as described in Section 18.13.1, above.
LBNL Procurement is responsible for obtaining the contractor safety plan and forwarding it to EH&S for review.
EH&S shall review the contractor safety plan and ensure that it provides a level of LOTO safety equivalent to this Chapter and 29 CFR 1910.147(c)–(f).
All visiting scientists, engineers, participating guests and students who work in areas in which LOTO is utilized are considered Affected or Other Employees and must receive LOTO awareness training in accordance with Section 18.6.2.
However, visiting scientists or students who perform service, maintenance, or equipment modification are required to be trained as a LOTO-Authorized Employee in accordance with Section 18.6.3. As such, they must be specifically LOTO-Authorized in accordance with Section 18.6.3.2, and must adhere to LOTO procedures as described in Section 18.5.2 (General LOTO Procedure).
The LBNL Supervisor responsible for a visitor has all of the responsibilities of a Supervisor, as described in this chapter.
Each division is responsible for conducting an inspection and certification of its energy-control procedures annually. Division Safety Coordinators will work with the EH&S Electrical Safety Engineer. EH&S will coordinate the audit sitewide.
The periodic inspection must be performed and documented by a LOTO-Authorized Employee other than the one utilizing the procedures being inspected. Specifically, the inspector must be able to determine whether:
The periodic inspection must be designed to correct any deviations or inadequacies observed. The inspection should provide for a demonstration of the procedures. Following the inspection, there must be a review of each employee's responsibilities under the energy control procedure that was inspected.
The certification must state that the periodic inspection has been performed. The certification must identify the machine(s) or equipment on which the energy-control procedure was utilized, the date of the inspection, the employees included in the inspection, and the employee performing the inspection. See Section 18.19.4 (Appendix 4: LOTO Inspection Form).
All inspection records shall be forwarded to the EH&S Electrical Safety Engineer.
Sump pumps, emergency lights, refrigerators, or equipment that must be shut down in a controlled manner fall into a class of equipment that should not be accidentally deenergized.
When a circuit breaker, disconnect switch, or energy-securing device is readily accessible to any employee, the circuit breaker or disconnect switch may be tagged to indicate that it is not to be turned off (see Figure 18-8).
The energy-securing device must not be locked by any means that would prevent the device from being used as an emergency disconnect.
The tag must include the name of the responsible person and an alternate, date, and phone number.
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Figure 18-8. Tag-On
Administrative Lock: Any lock that is used for a purpose other than LOTO. The lock may serve a safety function other than LOTO, a configuration control function, or other purpose. An administrative lock, unlike a LOTO lock, may be controlled by one or more individuals. An administrative lock shall not be labeled with a danger tag or sticker. An administrative lock is not a substitute for a LOTO lock. A LOTO lock cannot be used as an administrative lock.
Affected Employee: A person whose job requires him/her to be near or around the hazard zone (but not within the hazard zone) when equipment or apparatus is being maintained or serviced under a locked-out or tagged-out condition. See also the definitions for LOTO-Authorized Employee and Other Employee.
Associated Equipment: Equipment or apparatus that interacts with the primary equipment or apparatus to be serviced or maintained. This interaction may be hazardous to employees servicing the primary equipment or apparatus.
Blocked: A condition where a mechanical device is inserted into the energy path to physically prevent movement. Most commonly used with mechanical machinery or fluid filled lines.
Capable of being locked out: An energy-isolating device is capable of being locked out if it has a hasp or other means of attachment to which, or through which, a lock can be affixed with the device in the “off” or de-energized position, or it has a locking mechanism built into it. Other energy isolating devices are capable of being locked out if lockout can be achieved without the need to dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy control capability.
Continuous positive control: The cord and plug are in the physical possession, or in the control of, the LOTO-Authorized Employee performing service or maintenance (such as the cord is in their hand, or the plug is in their pocket).
Isolation Point: A location such as a valve, breaker, switch, blank off, or block-out, or other lockable point located such that when in the ‘OFF’ position prevents the flow or release of hazardous energy. Computer control circuitry, software, or other interlocks do not constitute control points.
Cord and Plug Powered Equipment: Portable electric equipment, such as power tools, computers, printers, appliances, etc., for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the energy source and by the plug being under the continuous control of the employee performing the servicing or maintenance.
Dissipated: A condition where all stored energy has been reduced to a non-hazardous level. Most commonly used with energy storing devices such as capacitors, pressure receivers, accumulators, reservoirs, or springs.
EH&S: Environment, Health, and Safety.
Emergency Removal of LOTO Devices: A procedure for the removal of a lock and tag, including any energy isolating device to be removed by someone other than the employee who applied them. Only the Supervision can remove an LOTO-Authorized Employee’s lock and tag.
Energized: Connected to an energy source or containing residual or stored energy.
Energy isolating device: A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following:
Energy-isolating devices must be capable of allowing a lock to be installed. Push buttons, selector switches, software interlocks or control circuit type devices are not energy isolating devices and cannot be used to isolate hazardous energy.
Energy source: Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy, including ionizing and non-ionizing radiation.
Equipment or Apparatus: Commercially purchased and non-purchased LBL or other custom built devices that utilize energy to operate.
Evaluator: An LOTO-Authorized Employee, not involved in the LOTO procedures being inspected, trained in evaluating the effectiveness of the procedures and applicable LOTO-Authorized Employees performance.
Exposure: Being subjected to a source of risk presented by hazardous energy sources.
Gang Lock Box: A box used to contain the LOTO lock key(s) of designated LOTO-Authorized Employee(s) during a group LOTO procedure. Individual LOTO locks are placed on the gang box by each LOTO-Authorized Employee covered under the designated LOTO-Authorized Employee. The gang lock box shall be constructed in such a way as to permit multiple individual LOTO locks to be attached to the outside of the enclosure, preventing it from being opened except by removal of every individual LOTO lock.
Group Lockout/Tagout: A procedure to coordinate the servicing or maintenance work assignment of several groups, multiple energy sources, or multiple LOTO procedures extending over more than one shift (days or weeks).
Hazard Zone: The space near a source of hazardous energy where a person could be harmed if the hazardous energy was suddenly or unexpectedly released, such as the unexpected release of stored pressure, the unexpected movement of a machine, or the spray from a hazardous chemical that was unexpectedly released.
Hazardous Energy: Energy, that if not controlled is of such a magnitude that it is capable of causing harm to a person or loss of resources (See also Pub 3000 and other Work Smart Standards).
Hazardous Energy Control: The process of systematically implementing mechanical means to prevent hazardous energy from flowing to a person.
Hazardous Energy Control Procedure: A written document that contains equipment-specific information and procedural steps that an LOTO-Authorized Employee must follow in order to safely control hazardous energy during servicing or maintenance of equipment or apparatus. Procedures must be reviewed annually.
Hazardous Energy Source: A piece of equipment or apparatus, process line, etc., which is a source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy, including stored energy such as springs, capacitors, gravity, etc., and which by release of that energy source poses a threat or danger to personnel or equipment.
Individual Lock (See also LOTO Lock): A lock issued to an LOTO-Authorized Employee for which no other employee has the key or means of opening without using destructive force. Locks used for control of hazardous energies shall be unique in design and color, shall not be used for any other purpose, and shall be easily distinguishable from other standard locks (Administrative Lock, multi-key, combination, and other non-LOTO locks).
Isolated: A condition where all sources of hazardous energy have been controlled by physically stopping the energy path so that the energy cannot flow to workers. The term “isolated” is commonly used with electrical circuits and fluid lines.
LOTO-Authorized Employee: A person who has completed the required hazardous energy control training (general and procedure-specific), and is LOTO-Authorized by the Supervisor to lockout and tagout energy control points for a specific equipment or apparatus to perform service or maintenance. A person must be an LOTO-Authorized Employee to apply a lock or tag to control hazardous energy. See also the definitions for Affected Employee and Other Employee.
LOTO Lock (See also Individual Lock): A lock issued to an LOTO-Authorized Employee for which no other employee has the key or means of opening without using destructive force. Locks used for control of hazardous energies shall be unique in design and color, shall not be used for any other purpose, and shall be easily distinguishable from other standard locks (Administrative Lock, multi-key, combination, and other non-LOTO locks).
Lockout/Tagout: The method of applying a mechanical lockout device and a tag on an energy isolating device by an LOTO-Authorized Employee in accordance with established written procedures, in order to control hazardous energies and prevent the equipment from being operated until the lockout device is removed.
Lockout Device: A device that utilizes a positive means, such as a single key LOTO lock, to hold an energy isolating device in the safe position and prevent the energizing of equipment or apparatus. Included are lockout hasps, blank flanges and bolted slip blinds.
Lockout Tag: A distinctive, durable tag attached to the LOTO lock shackle, that identifies it as a lockout device and identifies the individual who placed the lock, the individual’s phone number, and the time and date it was placed. The tag shall be of a standard shape and size for use throughout LBNL. A lockout tag is not a substitute for a lockout device.
LOTO: Lockout/Tagout and verification.
Nationally Recognized Testing Laboratory (NRTL): A private sector organization,
recognized by OSHA, that determines that specific equipment and materials (products)
meet consensus-based standards of safety to provide the assurance that these
products are safe for use in the U. S. workplace.
Normal Production Operations: The utilization of a piece of equipment or apparatus
to perform its intended functions.
Other Employee: A person whose work duties require them to be in proximity to an area where energy control procedures have been implemented on equipment or apparatus, or in areas where energy isolation devices have been locked out. See also the definitions for Affected Employee and LOTO-Authorized Employee.
Qualified Person: An electrical worker, designated by LBNL supervision, who by reason of experience and instruction has demonstrated familiarity with the construction, installation, maintenance and operation of the electrical equipment and installations and the electrical hazards involved. This employee also is required to be current with all required qualification training. See PUB-3000, Chapter 8.
Routine Operations: Safe service, maintenance, adjustments and inspections
taking place during normal production operations.
Stored Energy Source: Any device that is capable of holding energy after equipment
shutdown. This includes, but is not limited to, capacitors, tanks, pipes, springs,
and flywheels.
Tagout: The placement of a tagout device on an energy-isolating device, in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed. Using tag out alone as a form of hazardous energy control is not a positive means of controlling hazardous energy and shall not be used without an approved locking device.
Tagout Device: A prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with an established procedure, to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed. The tag shall include the reason for placing the tag, name of employee placing the tag, how that employee may be contacted, and date the tag was placed. Tags must be durable and able to withstand the environment to which they are exposed for the maximum time exposure is expected. These tags shall not be used for other purpose.
Zero Energy State: A condition that is reached when all energy sources to
or within equipment are isolated, blocked, or otherwise relieved, with no possibility
of reaccumulation. Equipment is not safe to work on until it is in a zero energy
state.
A careful distinction must be made between LOTO and various other locking practices, collectively referred to as “Administrative Locking" (see Figure 18-9). While LOTO locks are placed by individual workers to protect themselves against inadvertent energization of equipment, Administrative Locks are used when there is the need to provide “operational control” (control of a system, utility, or facility).
Administrative Locking does not provide individual personal protection for at-risk workers as that achieved by LOTO.
Examples of Administrative Locking may include:
In these types of situations, the purpose of Administrative Locking is vastly different from the control of hazardous energies for the protection of the worker in the hazard zone. An employee applying Administrative Locking is not near the hazard zone, and therefore does not need to use the specific personalized locks and tags required by traditional LOTO requirements.
If the employee applying the Administrative Lock in any way becomes exposed to the controlled hazardous energies, he or she must first apply his or her LOTO lock and tag.
Administrative Locks can be common locks with more than one key, so that anyone with access to the keys can open the control point as needed. The lock is not specific to an individual, but to a specialized working group or trade. Administrative Tags, likewise, are also common to multiple people and do not need to have an individual’s name shown.
If the person removing the Administrative Lock is not the same person who placed it, a documented understanding must exist between the two persons of the intent behind the placement of the lock and the conditions necessary for its safe removal.
Other examples of administrative locking are:
In many applications, it is appropriate to use a combination of Administrative Locking and LOTO controls. For example, if one group or shop must retain oversight of a utility while others are performing work associated with that system, an Administrative Lock may be placed by the oversight group in parallel with the individual LOTO locks and tags placed by each LOTO-Authorized Employee.
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Figure 18-9. Example of Administrative Locking
Equipment-Specific Lockout/Tagout Posted Procedure
Name of Equipment or Apparatus: ___________________________________________
1. Purpose: An equipment-specific written energy control procedure must be developed and used whenever equipment or apparatus: a) Has more than one energy source; b) Requires the operation of more than one device to isolate the hazardous energy; or c) Has the potential for stored, residual, or accumulated hazardous energy. The attached LOTO posted procedure provides specific information on
how to properly lock out the equipment or apparatus identified above.
This information includes specific methods and devices for locking out
hazards and describes how to establish a verified de-energized state. |
| 2. Authorization: Only trained LOTO-Authorized Employees may apply LOTO devices to energy control points on this equipment or apparatus. This designation must be in writing after classroom LOTO training and hands-on training for this particular energy control procedure (conducted by an LOTO-Authorized instructor) |
| 3. LOTO Devices: Only LBNL lockout/tagout devices are to be used. Advise all Affected Employees that LOTO procedures will be performed and lockout/tagout will occur. |
| 4. Procedural Steps: Refer to LBNL PUB-3000, Chapter 18 “Lockout/Tagout” for lockout/tagout requirements and General Procedures. Specific energy control locations are provided in the attached posted procedure. |
5. Procedure Approval and Training Record: Procedure Written By (Print): ____________________________________ Signature: _______________________________________ Date: ___________ Procedure Approved By (Print): __________________________________ Signature: _______________________________________ Date: ___________ The undersigned LOTO-Authorized Employee has demonstrated LOTO proficiency for each form of hazardous energy on this equipment or apparatus, and has successfully completed equipment-specific LOTO training per the attached posted procedure. Trainers Name (Print): ____________________________________ Trainers Signature: _______________________________________ Date: ___________ LOTO-Authorized Employee’s Name (Print): ________________________ LOTO-Authorized Employee’s Signature: ___________________________ Date: ___________ LOTO-Authorized Employee’s Name (Print): ________________________ LOTO-Authorized Employee’s Signature: ___________________________ Date: ___________ Use Additional Sheets As Necessary |
Equipment-Specific Lockout/Tagout Posted Procedure
Name of Equipment or Apparatus: _______________________________________________
A. |
B. |
C. |
D. |
E. |
F. |
PROCEDURE REQUIRING LOTO |
ENERGY SOURCE(S) |
ENERGY TYPES BEING CONTROLLED |
WHERE TO LOTO |
WHAT LOTO DEVICE TO USE |
HOW TO TEST FOR VERIFICATION OF HAZARDOUS ENERGY CONTROL |
Restoring equipment to service (to be performed by the LOTO-Authorized Employee):
This form shall be completed by the designated LOTO-authorized worker who inspected the LOTO-authorized worker's use of LOTO procedures. The work supervisor confirms performance of the inspection by signing this form.
Date
1. List the equipment/machines on which the LOTO procedure is being used.
2. Provide the names of the LOTO-authorized workers who performed the LOTO procedure that was inspected.
3. Identify any discrepancies uncovered by completing the LOTO Inspection Checklist. List any corrective actions.
Signature of inspector Date
Signature of Division Safety Coordinator Date
_____________________
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