Att 10 - Control of Hazardous Energy_070924.pdf

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 1 of 26

Control of Hazardous Energy 1

(Lockout/Tagout) 2

NIST S 7101.56 4

Approval Date: 07/09/2024 5 Effective Date:1 04/01/2015 6

1. PURPOSE 9

The purpose of this suborder is to define the requirements and associated roles and 10 responsibilities to protect NIST employees and covered associates2 from exposure to 11 hazardous energy during the servicing or maintenance of machines or equipment (hereafter 12 referred to as “equipment”). 13

2. BACKGROUND 16

a. NIST must meet or exceed the requirements established by Occupational Safety and Health 17

Administration in 29 Code of Federal Regulations (CFR) 1910.147, The Control of 18 Hazardous Energy. Implementation of this suborder fulfills those requirements. 19

b. This suborder supersedes NIST Health and Safety Instruction (HSI) 21, Control of 21

Hazardous Energy (Lockout/Tagout), June 1994. 22

3. APPLICABILITY 25

a. The provisions of this suborder apply to equipment servicing and maintenance activities, 26 conducted by NIST employees, covered associates, and non-Research-and-Development 27 (non-R&D) contractors that could harm an individual if the equipment being serviced or 28 maintained were to unexpectedly energize, start up, or release stored energy. 29

1 For revision history, see Appendix A.

2 As per NIST O 7101.00: Occupational Safety and Health Management System, a NIST associate permitted to perform work at a NIST workplace and subject to NIST policies and procedures to the extent allowed by law and the terms of the associate’s agreement. Covered associates include Foreign and Domestic Guest Researchers (including contractors who perform NIST R&D/technical work); Research Associates; Intergovernmental Agency Personnel Act assignees; Facility Users; Volunteer Students; and other federal employees who perform work at NIST workplaces.

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b. When servicing or maintenance activities are conducted exclusively by non-R&D 31 contractors, Organizational Units (OUs) need only follow Section 6.g and meet the Affected-32 Employee training requirements in Section 6.j. 33

c. Applicability to Normal Production Operations. 35

(1) The provisions of this suborder apply to servicing and maintenance that takes place 37 during normal production operations only when: 38

(a) A NIST employee or covered associate is required to remove or bypass a guard or 40 other safety device; or 41

(b) A NIST employee or covered associate is required to place any part of his/her body 43 into an area on a machine or piece of equipment where work is actually performed 44 upon the material being processed (point of operation) or where an associated danger 45 zone exists during an equipment operating cycle. 46

(2) The provisions of this suborder do not apply to minor tool changes and adjustments and 48 other minor servicing activities that take place during normal production operations if 49 these activities are routine, repetitive, and integral to the use of the equipment for 50 production, provided that the work is performed using alternative measures, such as 51 machine guarding, that provide effective protection. 52

d. Control of hazardous energy operations, also known as Lockout/Tagout or "LOTO", with 54 potential exposure3 to electrical hazards (e.g., shock, arc flash) from work on, near, or with 55 conductors or equipment in electric-utilization installations are covered by this suborder. 56 Please see Section 6 of NIST S 7101.64 for additional electrical safety requirements. 57

e. Exclusions. The provisions of this suborder do NOT apply to: 59

(1) The act of taking equipment out of service in accordance with NIST S 7101.73. 61

(2) Work on cord- and plug-connected electrical equipment that meets ALL of the following 63 conditions: 64

(a) The equipment has a single energy source; 66

3 Exposed (as applied to energized electrical conductors or circuit parts) – Capable of being inadvertently touched or approached nearer than a safe distance by a person. It is applied to electrical conductors or circuit parts that are not suitably guarded, isolated, or insulated.

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(b) All hazardous energy to which employees could be exposed can be controlled by 68 unplugging the equipment; and 69

(c) The plug is under exclusive control of the employee servicing or maintaining the 71 equipment. 72

(3) Hot-tap operations involving transmission and distribution systems for substances such as 74 gas, steam, water, or petroleum products are performed on pressurized pipelines, 75 provided that it can be demonstrated that: 76

(a) Continuity of service is essential; 78

(b) Shutdown of the system is impractical; 80

(c) Special equipment (e.g., bolted blinds and blank flanges) is used which will provide 82 proven effective protection for NIST employees and covered associates; and 83

(d) Documented procedures are followed. 85

4. REFERENCES 88

a. 29 CFR 1910.147, The Control of Hazardous Energy (lockout/tagout). 89

b. 29 CFR 1910.333, Selection and Use of Work Practices. 91

c. ANSI Z535.5, Safety Tags and Barricade Tapes (for Temporary Hazards) (most recent 93 version). 94

5. APPLICABLE NIST OCCUPATIONAL SAFETY AND HEALTH DIRECTIVES 97

a. NIST O 7101.00: Occupational Safety and Health Management System 98

b. NIST S 7101.20: Work and Worker Authorization Based on Hazard Reviews 100

c. NIST S 7101.23: Safety Education and Training 102

d. NIST N 7101.64: Electrical Safety 104

e. NIST S 7101.73: Out of Service 106 https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_id=9804&p_table=STANDARDS https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9910 https://nistsafety.nist.gov/safetyweb/safetyweb/ViewTopicHome/1581 https://www.nist.gov/oshe/safety-programs/work-and-worker-authorization-based-hazard-reviews-hazard-review https://www.nist.gov/oshe/safety-programs/safety-education-and-training-set-program https://www.nist.gov/oshe/safety-programs/electrical-safety-program https://www.nist.gov/oshe/safety-programs/out-service-oos

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6. REQUIREMENTS 108

a. General Requirements 109

(1) OUs shall establish energy-control procedures, employee training, and annual inspections 111 prior to conducting servicing or maintenance on equipment where the unexpected 112 energizing, startup, or release of stored energy could occur and cause injury. 113

(2) Locks and tags used for LOTO shall not be used for any other purpose (e.g., removing 115 equipment from service per NIST S 7101.73). 116

NOTE: Please see NIST S 7101.73 for requirements for taking equipment out of 118 service. 119

(3) Tagout without Lockout 121

(a) If an energy-isolating device is not capable of being locked out by any means, a 123 tagout system shall be used. 124

(b) If an energy-isolating device is capable of being locked out, lockout shall be used 126 unless it can be demonstrated that the utilization of a tagout system will provide 127 employees and covered associates with full protection, which requires that ALL of 128 the following be met: 129

i. The tagout device shall be attached at the same location that the lockout 131 device would have been attached; 132

ii. Full compliance with all tagout-related provisions of this suborder shall be 134 demonstrated; and 135

iii. Such additional elements as are necessary to provide the equivalent safety 137 available from the use of a lockout device shall be demonstrated. Additional 138 means to be considered shall include the implementation of additional safety 139 measures such as removal of an isolating circuit element, blocking of a 140 controlling switch, opening of an extra disconnecting device, or removal of a 141 valve handle to reduce the likelihood of inadvertent energization. 142

(c) At least one additional safety measure shall be utilized for tagout activities involving 144 potential exposure to electrical hazards (e.g., shock, arc flash). Examples of 145 additional safety measures include the removal of an isolating circuit element, 146 blocking of a controlling switch, or opening of an extra disconnecting device. 147

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(d) Whenever replacement or major repair, renovation, or modification of equipment is 148 performed, and whenever new equipment is installed, energy-isolating devices for 149 such equipment shall be designed to accept a lockout device whenever the unexpected 150 energization or startup of the equipment, or release of stored energy, could cause 151 injury to employees. 152

b. Requirements for Written LOTO Procedures 154

(1) Written LOTO procedures are required unless ALL of the following circumstances 156 pertain: 157

(a) The equipment has no potential for stored or residual energy or re-accumulation of 159 stored energy after shutting down which could endanger employees; 160

(b) The equipment has a single energy source which can be readily identified and 162 isolated; 163

(c) The isolation and locking out of that energy source will completely de-energize and 165 deactivate the equipment; 166

(d) The equipment is isolated from that energy source and locked out during servicing or 168 maintenance; 169

(e) A single lockout device will achieve a locked-out condition; 171

(f) The lockout device is under the exclusive control of the Authorized Employee 173 performing the servicing or maintenance; 174

(g) The servicing or maintenance does not create hazards for Other Employees; and 176

(h) The OU, in utilizing this exception, has had no accidents involving the unexpected 178 activation or re-energization of the equipment during servicing or maintenance. 179

(2) If a written procedure is required, the Authorized Employee shall: 181

(a) Ensure that the procedure clearly and specifically outlines the scope, purpose, 183 authorization, rules, and techniques to be utilized for the control of hazardous energy, 184 and the means to enforce compliance, including, but not limited to, the following: 185

i. A specific statement of the intended use of the procedure; 187

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ii. Specific procedural steps for shutting down, isolating, blocking, and securing 188 the equipment to control hazardous energy; 189

iii. Specific procedural steps for the placement, removal, and transfer of LOTO 191 devices and the responsibility for them; and 192

iv. Specific requirements for testing the equipment to determine and verify the 194 effectiveness of LOTO devices and other energy-control measures. 195

c. Conduct of LOTO 197

(1) LOTO shall be performed only by trained Authorized Employees in the following 199 sequence. 200

(a) Notifications shall be initiated prior to LOTO to ensure area supervisors and affected 202 personnel are aware of the energy source being locked out or controlled. This 203 notification should also include the anticipated duration of the shutdown. Authorized 204 Employees will also advise on any support equipment that may be impacted, 205 additional safety precautions being taken, and the type of control device(s) being 206 used. 207

(b) Preparations for the shutdown shall begin after all notifications have been made. 209

Authorized Employees must be fully aware of the type and magnitude of the energy, 210 associated hazards, and control methods of the energy involved. Authorized 211 Employees shall refer to owner/service manuals of the equipment they are working on 212 to ensure they are fully aware of any and all associated hazards. 213

(c) In performing the shutdown, Authorized Employee shall first advise Affected 215

Employees that shutdown is taking place. They shall then locate the energy source(s) 216 (always looking for hidden energy sources) and follow the procedures established to 217 shut down the equipment as prescribed. An orderly shutdown must be utilized to 218 avoid any additional or increased hazard(s) to employees as a result of the equipment 219 stoppage. 220

(d) All energy-isolating devices that are needed to control the energy to the equipment 222 shall be physically located and operated by an Authorized Employee in such a 223 manner as to isolate the equipment from the energy source(s). 224

i. Authorized Employees isolating electrical disconnects and breakers must 226 comply with the requirements in Section 6 of NIST S 7101.64. 227

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(e) LOTO devices shall be affixed to energy-isolating devices by Authorized Employees. 228

i. Lockout devices, where used in accordance with this suborder, shall be 230 affixed in a manner that will hold the energy-isolating devices in a "safe" or 231 "off" position. 232

ii. A lock and a tag shall be placed on each disconnecting means used to de-234 energize equipment on which work is to be performed. The lock shall be 235 attached so as to prevent persons from operating the disconnecting means 236 unless they resort to undue force or the use of tools. 237

iii. Tagout devices, where used in accordance with this suborder, shall be affixed 239 in such a manner as will clearly indicate that the operation or movement of 240 energy-isolating devices from the "safe" or "off" position is prohibited. Where 241 tagout devices are used with energy-isolating devices designed with the 242 capability of being locked, the tag attachment shall be fastened at the same 243 point at which the lock would have been attached. Where a tag cannot be 244 affixed directly to the energy-isolating device, the tag shall be located as close 245 as safely possible to the device, in a position that will be immediately obvious 246 to anyone attempting to operate the device. 247

(f) After LOTO devices have been applied to energy-isolating devices, all potentially 249 hazardous stored or residual energy shall be relieved, disconnected, restrained, or 250 otherwise rendered safe. If there is a possibility of re-accumulation of stored energy 251 to a hazardous level, verification of isolation shall be continued until the servicing or 252 maintenance is completed, or until the possibility of such accumulation no longer 253 exists. 254

(g) Prior to starting work on equipment that has been locked or tagged out, the 256

Authorized Employee shall verify that isolation and de-energization of the equipment 257 have been accomplished. 258

i. Verification of de-energization for electrical conductors and circuits where 260 potential exposure to electrical hazards (e.g., shock, arc flash) could occur 261 must be conducted in accordance with the requirements of Section 6.d of 262

NIST S 7101.64. 263

(h) Before LOTO devices are removed and energy is restored to the equipment, actions 265 shall be taken by the Authorized Employee(s) to ensure that: 266

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i. The work area is inspected to ensure that any nonessential items have been 268 removed and that the equipment components (e.g., guards) are operationally 269 intact; 270

ii. The work area is checked to ensure that all employees have been safely 272 positioned or removed; 273

iii. After LOTO devices have been removed by the Authorized Employee(s) who 275 applied them but before energy is restored to the equipment, Affected 276 Employees are notified of the removal of the LOTO devices; and 277

iv. When the Authorized Employee who applied a LOTO device is unavailable 279 to remove it, that device may be removed under the procedures outlined in 280 Section 6h. 281

d. Temporary Removal of LOTO Devices 283

In situations in which LOTO devices must be temporarily removed from the energy-isolating 284 device and the equipment energized to test or position it or a component thereof, the 285 following steps shall be taken in sequence: 286

(1) Clear the equipment of tools and materials; 288

(2) Remove employees from the equipment area; 290

(3) Remove the LOTO devices; 292

(4) Energize and proceed with testing or positioning; and 294

(5) De-energize all systems and reapply energy-control measures in accordance with Section 296

6c of this suborder to continue the servicing and/or maintenance. 297

e. Group LOTO Procedure 299 When multiple Authorized Employees (including servicing contractors) perform service or 300 maintenance on the same piece of equipment, a supervisor or Primary Authorized Employee 301 may determine that a group LOTO procedure is appropriate. 302

(1) General Requirements 304

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(a) When more than one employee would be required to apply a LOTO device to the 306 same isolation point, a group LOTO device shall be utilized to allow each 307 employee’s LOTO lock to be affixed at the disconnecting device. 308

(b) When it is not practical to have all authorized employee LOTO locks to be attached 310 at the energy isolation device, a group lockbox shall be utilized. 311

(c) When LOTO is required to be performed and doing so requires securing multiple 313 energy sources with multiple authorized employees, a lockbox shall be utilized. 314

(2) When servicing or maintenance is performed by a crew, craft, department, or other 316 group, that entity shall utilize a procedure that affords the employees a level of 317 protection equivalent to the implementation of a personal LOTO device. 318

(3) When a group lockbox is required, all of the following requirements apply: 320

(a) A group LOTO lock shall be applied to each disconnecting device; 322

(b) The group LOTO lock keys shall be placed in the lockbox; 324

(c) All employees, including the Principal Authorized Employee, shall affix their 326

LOTO locks to the lockbox; and 327

(d) The Principal Authorized Employee shall then affix a Job LOTO lock and tag to 329 lockbox. 330

(4) The Principal Authorized Employee shall convene a meeting of all group members 332 covered under the LOTO procedure. 333

(5) The Primary Authorized Employee may delegate a Principal Authorized Employee the 335 primary responsibility for a specified group working under the protection of the group 336 LOTO procedure. Supervisory responsibility is then vested in the Principal Authorized 337 Employee for the specific employees working under the protection of the group LOTO 338 devices. 339

(6) Each member of the specified group shall be trained and Authorized as described in this 341 suborder’s training requirements. 342

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(7) The Principal Authorized Employee shall ensure that each step of the written LOTO 344 procedure has been completed and shall ascertain the exposure status of individual group 345 members with regard to the lockout or tagout of the equipment. 346

(8) Each Authorized Employee performing work on the equipment shall ensure every step 348 of the written procedure has been completed prior to placing their personal LOTO 349 device on the group LOTO device, group lockbox, or comparable mechanism when 350 he/she begins work. 351

(9) When the work has been completed, and after each employee has removed his/her 353 respective lock or tag from the group LOTO device, the Principal Authorized Employee 354 shall remove his/her LOTO lock or tag from the group LOTO device and return the 355 equipment to service as described in the procedure. 356

f. LOTO Procedures for Shift Changes 358

The following procedures shall be utilized during shift or personnel changes to ensure the 359 continuity of LOTO protection, including provision for the orderly transfer of LOTO device 360 protection between departing and oncoming employees, to minimize exposure to hazards 361 from the unexpected energization or start-up of the equipment, or the release of stored 362 energy. 363

(1) The requirements for group LOTO apply. 365

(2) The group LOTO lock shall remain attached to each energy control device. 367

(3) The job lock shall remain affixed to the lockbox or other approved group LOTO device. 369

(4) All off-going shift employees shall remove their individual LOTO locks and tags from 371 the lockbox or other approved group LOTO device. 372

(5) The off-going principal authorized employee shall brief the oncoming person in charge of 374 the status of the project and inform all oncoming employees of any potential hazards. 375

(6) The person in charge of the off-going shift shall transfer custody of the key for the job 377

LOTO lock attached to the lockbox or approved group LOTO device to the oncoming 378 person in charge. 379

(7) All oncoming Authorized Employees shall place their locks and/or tags onto the group 381

LOTO device. 382

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(8) Before work begins, the oncoming Authorized Employees shall verify isolation and de-384 energization of the equipment that has been locked or tagged out prior to restarting work. 385

g. LOTO Conducted by Non-R&D Contractors 387

(1) Contracting Officers (COs) or Contracting Officer Representatives (CORs) overseeing 389 non-R&D contractor shall ensure non-R&D contractors are not permitted to commence 390 work on NIST equipment when LOTO is required until: 391

(a) They have been provided with a copy of this suborder by the controlling NIST 393 organization and understand the requirements for LOTO devices; 394

(b) They have exchanged LOTO programs with the controlling NIST organization; 396

(c) The exchange of LOTO programs has been documented using the exchange-of-398 LOTO-programs form provided by the Office of Safety, Health, and Environment 399 (OSHE); and 400

(d) Information concerning non-R&D contractor LOTO procedures has been 402 communicated to NIST Affected Employees. 403

(2) When LOTO is performed by non-R&D contractors, the CO or COR shall ensure the 405 following: 406

(a) Prior to the non-R&D contractor performing their LOTO steps, the NIST organization 408 responsible for the system and/or equipment being turned over to the contractor shall: 409

i. Document and obtain the non-R&D contractor’s agreement via the COR on 411 the condition/status of the system and/or equipment being turned over; and 412

ii. Affix their LOTO device(s) on all sources of energy and verify zero energy. 414

(b) The non-R&D contractor has applied their LOTO devices in accordance with their 416 contractor safety plan accepted by NIST. 417

(c) Prior to any testing of any system or equipment that requires re-introducing the 419 system or equipment into the NIST infrastructure, the NIST organization responsible 420 for the system and/or equipment shall ensure by applicable means that doing so 421 would have no impact to the NIST infrastructure. 422

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(d) Prior to acceptance and the introduction or re-introduction of any system into the 424 NIST infrastructure by a non-R&D contractor, the NIST organization responsible for 425 the system or equipment shall ensure by applicable means that doing so would have 426 no impact to the NIST infrastructure. 427

(e) The LOTO lock and tag from the responsible NIST organization for the system 429 and/or equipment shall be the last to be removed. 430

h. LOTO Device Emergency Removal 432

WARNING: This is considered to be an emergency procedure only to be undertaken in 434 extreme circumstances with a supervisor’s approval and using extreme care. 435

(1) When an Authorized Employee who has applied a LOTO device is not available to 437 remove it, someone in his/her immediate supervisory chain may authorize its removal in 438 accordance with this emergency removal procedure. If the Authorized Employee's 439 immediate supervisor is not available, the emergency removal may be performed by one 440 level of management above the Authorized Employee's immediate supervisor or by a 441 delegated individual with documented authorization from the immediate supervisor. 442

(2) The following steps must be performed and documented using the Emergency LOTO 444

Lock Removal form provided by OSHE. 445

(a) The supervisor must verify the Authorized Employee is not at the NIST facility. The 447 supervisor must make every reasonable effort to contact the Authorized Employee. 448 This may include a telephone call to the employee's home or other location. These 449 efforts must be documented (e.g., email, registered letter, voicemail, or telephone 450 verbal assurance, etc.) by the supervisor. 451

(b) If the Authorized Employee is contacted, the supervisor must inform the employee 453 that his/her LOTO device is being removed. 454

(c) The supervisor must verify that it is safe to remove the LOTO device. 456

(d) The supervisor may then authorize another Authorized Employee to remove the 458 LOTO device. 459

(e) The supervisor must ensure that before the LOTO device owner returns to work, 461 he/she is presented with the removed device and is informed of the reasons for the 462 emergency removal. 463

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(f) The emergency procedure form must be signed by the supervisor and the Authorized 464 Employee who removed the lock and be retained in the OU’s LOTO records. 465

i. Locks, Tags, and Devices 467

Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other 468 hardware shall be provided by the OU for isolating, securing, or blocking of equipment from 469 hazardous-energy sources. 470

(1) General lockout device and tag requirements include: 472

(a) Locks and tags must be singularly identifiable; 474

(b) LOTO locks and tags must be the only devices used for controlling hazardous energy 476 during LOTO activities and not be used for any other purpose (e.g., for restricting 477 access, removing from service); 478

(c) LOTO locks and tags must be durable enough to withstand wet, damp, and corrosive 480 environments while they are in use on equipment, including ensuring the print on the 481 tag does not become illegible; 482

(d) LOTO locks must be substantial enough to prevent removal without the use of 484 excessive force or unusual techniques such as using bolt cutters or other metal cutting 485 tools; 486

(e) LOTO tags must be substantial enough to prevent inadvertent or accidental removal, 488 which means that they must have an attachment means of a non-reusable type, be 489 attachable by hand, be self-locking, and be non-releasable with a minimum unlocking 490 strength of no less than 225 N (50 lbf)), i.e., they must have characteristics similar to 491 those of a one-piece all-environment-tolerant nylon cable tie; and 492

(f) LOTO locks and tags shall be standardized in at least one of the following criteria: 494 color, shape, or size; additionally, in the case of tagout devices, print and format shall 495 be standardized. 496

(2) NIST’s LOTO device requirements are as follows: 498

(a) Personal locks shall have red bodies and singular keys. 500

i. Authorized Employees with multiple personal locks may have them keyed 502 alike. 503

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ii. Personal locks must contain the identity of the Authorized Employee who 504 applies them. 505

iii. Supervisors of Authorized Employees may maintain copies of the keys to the 507 Authorized Employees’ personal locks to be used for emergency device 508 removal only. 509

(b) Group locks shall have red bodies and be keyed alike for each work group. 511

i. Group locks must contain the identity of the responsible organization that 513 applies them. 514

ii. Supervisors shall maintain copies of the keys to the group locks to be used for 516 emergency device removal only. 517

(c) Job locks shall have red bodies and may be keyed alike. 519

i. Job locks must contain the identity of the responsible organization that applies 521 them. 522

ii. Supervisors may maintain copies of the keys to the job locks to be used for 524 emergency device removal only. 525

(d) Lockout tags must meet the following ANSI Z535.5 criteria: 527

i. Danger tags shall have the word “Danger” in safety white letters on a 529 rectangular safety red background; 530

ii. Danger tags will be on a safety white stock; 532

iii. Danger tags must contain the action statement, “Do Not Operate,” and, at a 534 minimum, the Authorized Employee’s name and phone number; pictures and 535 other information may also be applied to the tags; 536

iv. Tag message lettering should be typed; if printed messages are applied, they 538 must be legibly printed; and 539

v. Backs of tags may be used to give additional operating instructions, 541 emergency procedures, emergency telephone numbers, or to reinforce the 542

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 15 of 26 critical role that the LOTO tag holds; the back side of the tag should refer to 543 the front side of the tag and vice versa. 544

vi. Locks and tags used in conducting group LOTO shall: 546

(i) Have a distinguishing identifier to identify it as a group LOTO lock 548 and tag; 549

(ii) Locks shall be keyed alike to a single master for each work group; 551 and 552

(iii) Each lock shall be individually numbered. 554

vii. Locks and tags used as job locks and tags shall: 556

(i) Have a distinguishing identifier to identify them as a job LOTO lock 558 and/or tag; 559

(ii) Locks shall not be keyed alike; and 561

(iii) Each lock shall have an identifier indicating the organization to which 563 it belongs. 564

j. Training 566

(1) Training shall be provided, documented, and recorded in accordance with the 568 requirements of NIST S 7101.23. 569

(2) Training of Authorized, Affected, and Other Employees and their Official First-Level 571 Supervisors 572

(a) Authorized Employees shall complete: 574

i. The training provided by OSHE on the Control of Hazardous Energy (LOTO) 576 program; 577

ii. The activity-specific training required by hazard reviews applicable to the 579 work to be conducted, including: 580

(i) The recognition of applicable hazardous-energy sources; 582

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(ii) The types and magnitudes of those hazardous-energy sources; and 583

(iii) The methods and means necessary for energy isolation and control, 585 and where tagout only is used, review of the following key points: 586

[i] Tags are essentially warning devices and do not provide 588 physical restraint like a lock. 589

[ii] When a tag is attached to an energy-isolating device, it is not to 591 be removed without authorization from the Authorized 592 Employee identified on the tag, and it is never to be bypassed, 593 ignored, or otherwise defeated. 594

[iii] Tags shall be legible and understandable by all employees. 596

[iv] Tags and their means of attachment shall be made of materials 598 that will withstand environmental conditions encountered while 599 on equipment. 600

[v] Tags may evoke a false sense of security and their meaning 602 needs to be understood as part of the overall energy-control 603 program. 604

[vi] Tags shall be securely attached to energy-isolating devices so 606 they cannot be inadvertently or accidentally detached during 607 use. 608

(b) Affected Employees shall complete activity-specific training on the purpose and use 610 of the energy-control procedures applicable to their assigned duties and work 611 locations and of the prohibition of attempts to re-start or re-energize equipment that is 612 locked or tagged out. 613

(c) When non-R&D contractors perform LOTO, Affected Employees shall be provided 615 with information concerning the non-R&D contractor’s energy control procedures. 616

(d) The activity-specific training for Authorized and Affected Employees shall be 618 provided by Authorized Employees who have successfully completed training on the 619 Control of Hazardous Energy (LOTO) program and who are familiar with the 620 applicable energy sources and the methods and means of energy isolation and control. 621

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(e) Official First-Level Supervisors of Authorized Employees shall complete the training 622 provided by OSHE on the Control of Hazardous Energy (LOTO) program. 623

(f) Other employees shall complete training provided by OSHE on the general purpose 625 and use of energy-control procedures and of the prohibition of attempts to re-start or 626 re-energize equipment that is locked or tagged out.4 627

(3) Retraining of Authorized and Affected Employees 629

(a) Authorized and Affected Employees shall complete activity-specific retraining 631 whenever:5 632

i. A change in their job assignment requires Authorized and Affected 634 Employees to service and maintain or operate additional equipment or 635 introduces them to new energy sources; 636

ii. A change in equipment or its operation presents a new hazard; 638

iii. A change in LOTO procedures is introduced; 640

iv. A LOTO annual inspection points to a systemic deficiency warranting 642 retraining; or 643

v. A LOTO annual inspection, observation, or other condition reveals deviations 645 from LOTO procedures or a employee is found to lack knowledge of those 646 procedures. 647

k. LOTO Annual Inspections 649

(1) Annual Inspection of LOTO Procedures. 651

(a) Each energy-control procedure shall be separately inspected annually to ensure that 653 the energy-control procedure is adequate and is being properly implemented by 654 Authorized Employees. 655

4 This training is part of training assigned automatically by the NIST electronic safety-training application to all employees and covered associates entering on duty.

5 The requirements in Sections 6j(2)(a)i-iii coincide with requirements in the Hazard Review suborder (a) to conduct hazard reviews when changes to existing activities introduce new or increase existing hazards, and (b) for the authorization of employees.

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(b) At a minimum, these inspections shall include a demonstration of the procedures by 657 Authorized Employees while servicing and/or maintaining equipment. 658

(c) The inspector, who must be an Authorized Employee other than the one(s) utilizing 660 the energy-control procedure being inspected, shall observe the implementation of the 661 energy-control procedure for the servicing and/or maintenance being evaluated and 662 talk with employees and covered associates implementing the procedure to determine 663 that all the requirements of this suborder are understood and being followed. 664

(d) The Authorized Employee performing the inspection may be someone who 666 previously has or currently implements the energy-control procedure being inspected, 667 as long as he/she is not implementing any part of the energy-control procedure while 668 it is being inspected. 669

(e) The inspector must be able to determine whether: 671

i. The steps in the energy-control procedure are being followed; 673

ii. The employees involved know their responsibilities under the procedure; and 675

iii. The procedure is adequate to provide the necessary protection, and, if 677 inadequate, what modifications are needed. 678

(f) Procedures may be reviewed together during one inspection as long as they involve 680 the same or similar types of energy-control methods. 681

i. If procedures are grouped together for annual inspection, it is recommended 683 that one or more of the individual procedures (from the same group or from 684 similar procedures from the previous year) be reviewed on its own so that 685 over time each procedure is reviewed individually. 686

(g) Annual inspections shall be recorded using the LOTO inspection form provided by 688

OSHE and maintained by the OU until the completion of the next annual inspection. 689 If inspections reveal inadequate or improper LOTO procedures, the hazard or 690 discrepancy must be mitigated immediately and Authorized and Affected Employees 691 must be retrained as indicated in Section 6j. 692

l. Records Required by this Suborder 694

Records required by this suborder are to be kept for one year. 695

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 19 of 26

7. DEFINITIONS 697

a. Affected Employee – Any employee who uses equipment subject to being serviced or 698 maintained under LOTO, or whose job requires him or her to work in an area in which such 699 servicing or maintenance is being performed. 700

b. Authorized Employee – A person who has completed the required hazardous-energy-control 702 training (general and procedure-specific) and is authorized by their Division Chief or 703 designee to lock and tag out the energy-control points in specific equipment or apparatus in 704 order to perform service or maintenance. A person must be an Authorized Employee to apply 705 a lock or tag to control hazardous energy. 706

c. Capable of Being Locked Out – An energy-isolating device is considered capable of being 708 locked out if it has a hasp or other means to attach a lock, has a locking mechanism built into 709 it, or can be locked without dismantling, rebuilding, or replacing the energy-isolating device 710 or permanently altering its energy-control capability. 711

d. Energized – Connected to an energy source or containing stored energy. 713

e. Energy-Isolating Device – A mechanical device that physically prevents the transmission or 715 release of energy, including but not limited to the following: a manually operated electrical-716 circuit breaker; a disconnect switch; a manually-operated switch by which the conductors of 717 a circuit can be disconnected from all ungrounded supply conductors and, in addition, no 718 pole can be operated independently; a line valve; a block; and any similar device used to 719 block or isolate energy. Push buttons, selector switches, and other control-circuit-type 720 devices are not energy-isolating devices. 721

f. Energy-Isolation Point – A location at which the flow or release of hazardous energy can be 723 prevented when a mechanism such as a valve, breaker, switch, blank off, or block-out is 724 placed in the “OFF” position. Control circuits such as computer-control circuitry and 725 software are not energy-isolation points. 726

g. Exclusive Control – A condition in which a employee has taken actions or is continuously in 728 a position to prevent (exclude) other individuals from re-energizing or starting equipment 729 while it is being serviced or maintained. 730

h. Group Lock Box – A key box containing the key(s) used to lock out equipment being 732 serviced by multiple Authorized Employees. Each Authorized Employee involved in the 733 servicing places his/her personal locks on the group lock box. The keys to the equipment 734 cannot be accessed until all Authorized Employees remove their locks. 735

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 20 of 26

i. Group LOTO – A procedure to coordinate service or maintenance work by several 737 Authorized Employees on locked/tagged out equipment. More than one Authorized 738 Employee may need access to the locked/tagged out equipment because it has multiple 739 energy sources, requires multiple LOTO procedures, or the work to be performed extends 740 across shifts. 741

j. Group Lockout Devices – Locks and tags used for group LOTO. 743

k. Hazardous Energy – Energy capable of causing personal harm or property damage if it is not 745 controlled. Types of hazardous energy include, but are not limited to, electrical, mechanical, 746 rotational, gravitational, chemical, radioactive, hydraulic, pneumatic, and thermal. 747

l. Hazardous-Energy Control – The process of systematically implementing engineering and 749 administrative means to prevent hazardous energy from flowing to a person. 750

m. Hazardous-Energy-Control Procedure – An equipment-specific procedure Authorized 752 Employees must follow to safely control hazardous energy during servicing or maintaining of 753 the equipment. 754

n. Hazardous-Energy Source – Equipment, machine, apparatus, process piping, and so on, 756 which is a source of hazardous energy. 757

o. Hot Tap – A procedure used in servicing and/or maintenance that involves welding on a 759 piece of equipment (pipelines, vessels, or tanks) under pressure, in order to install 760 connections or appurtenances. Hot taps are commonly used to replace or add sections of 761 pipeline without the interruption of service for air, gas, water, steam, and petrochemical 762 distribution systems. 763

p. Job Lock – A lock used in the performance of LOTO to allow for maintaining continuity of a 765 lockout/tagout condition between shift or workgroup changes. 766

q. Lockout – The placement of a lockout device on an energy-isolating device, in accordance 768 with an established procedure, to ensure the energy-isolating device and the equipment being 769 controlled cannot be operated until the lockout device is removed. 770

r. Lockout Device – Any device that uses a positive means such as a lock, blank flanges, and 772 bolted slip blinds to hold an energy-isolating device in a safe position to prevent equipment 773 from unexpectedly energizing. 774

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 21 of 26

s. Non-R&D Contractor – A NIST associate who performs non-R&D work at a NIST 776 workplace in accordance with the safety requirements of a contract or other legal 777 arrangement, such as a Memorandum of Understanding, with NIST Non-R&D contractors 778 include, but are not limited to, construction contractors; facilities contractors; equipment 779 installation, service, and maintenance contractors; Health Unit contractors; contract cafeteria 780 employees; and janitorial contractors. 781

t. Normal Operations – The utilization of equipment to perform intended functions. 783

u. Other Employee – An employee with duties that are or may be in an area where energy-785 control procedures may be utilized. 786

v. Personal Lock (or Locks) – A singularly keyed lock, or singularly keyed locks, issued to an 788 Authorized Employee used exclusively for the control of hazardous energy. 789

w. Personal Lockout Devices – Locks and tags used for personal LOTO. 791

x. Personal LOTO – LOTO performed by a single Authorized Employee on equipment with 793 one of more sources of hazardous energy. 794

y. Primary Authorized Employee – A primary authorized employee would coordinate 796 authorized employee changes and affected workforces (multiple work crews) with equipment 797 operators before and after completion of servicing and maintenance operations that require 798 LOTO. He/she also has the responsibility to ensure continuity of protection with respect to 799 multi-shift energy isolation (e.g., through the use of a "Job Lock". 800

z. Principal Authorized Employee – Principal authorized employee(s) would be designated for 802 each workforce or crew. When more than one crew, craft, department, etc., is involved, one 803 principal authorized employee would account for a single group of servicing/maintenance 804 personnel. Each principal employee is responsible (to the primary authorized employee) for 805 maintaining accountability and for the individual exposure status of each employee in that 806 specific group in conformance with the company procedure. 807

aa. Servicing and/or Maintenance – Workplace activities such as constructing, installing, setting 809 up, adjusting, inspecting, and modifying equipment that could expose employees to the 810 unexpected release of hazardous energy. Maintenance activities may also include lubrication, 811 cleaning, or unjamming equipment, and making adjustments or tool changes. 812

bb. Setting up – Any work performed to prepare equipment to perform its normal operation. 814

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 22 of 26

cc. Stored Energy – Energy located within any device after equipment is shut down. This 816 includes, but is not limited to, capacitors, tanks, pipes, springs, and flywheels. 817

dd. Tagout – The placement of a tagout device on an energy-isolating device, in accordance with 819 an established procedure, to indicate that the energy-isolating device and the equipment 820 being controlled shall not be operated until the tagout device is removed. 821

ee. Tagout Device – A prominent warning device, such as a tag and a means of attachment that 823 can be securely fastened to an energy-isolating device in accordance with an established 824 procedure, to indicate that the energy-isolating device and the equipment being controlled 825 may not be operated until the tagout device is removed. 826

8. ACRONYMS 829

a. CO – Contracting Officer 830

b. COR – Contracting Officer Representative 832

c. LOTO – Lockout/Tagout 834

d. OSHE – Office of Safety, Health, and Environment 836

e. OU – Organizational Unit 838

f. R&D – Research and Development 840

9. ROLES AND RESPONSIBILITIES 843

Roles and responsibilities common to all NIST OSH suborders can be found in Section 8 of 844 NIST O 7101.00. The roles and responsibilities specific to this suborder are as follows: 845

a. OU Directors are responsible for: 847

(1) Establishing policies and procedures, as needed, for the requirements of this program to 849 be met as it applies to their employees and covered associates and to LOTO procedures 850 performed during their OU operations and ensuring that those policies and procedures are 851 implemented; and 852

(2) Ensuring subordinate managers have the authority, resources, and training needed to 854 implement OU-established policies and procedures. 855

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 23 of 26

b. The Chief Safety Officer is responsible for ensuring the training specified in Section 6.j for 856 Other Employees is included in the NIST General Safety Training. 857

c. Division Chiefs (or Equivalents)6 are responsible for: 859

(1) Implementing this program as it applies to activities involving their personnel in 861 accordance with any applicable OU-established policies and procedures; 862

(2) Allocating budgetary and other resources capable of ensuring the health and safety of 864 employees, covered associates, and visitors in divisional work areas; 865

(3) Providing support to group leaders, safety personnel, employees, and covered associates 867 in carrying out their responsibilities with respect to implementing the requirements of this 868 suborder and managing LOTO procedures within the division; and 869

(4) Acting on all incidents involving LOTO and related safety concerns reported by 871 personnel quickly and completely to protect employees and covered associates from the 872 health and physical hazards. 873

d. Line Management is responsible for: 875

(1) Ensuring LOTO procedures are developed for work that requires these procedures; 877

(2) Ensuring required training has been completed by affected employees and covered 879 associates; 880

(3) Ensuring LOTO inspections are conducted at the proper frequency by the appropriate 882 personnel; and 883

(4) Providing oversight as necessary aimed at ensuring that employees and covered 885 associates who perform LOTO do so in accordance with this suborder. 886

e. Employees and Covered Associates are responsible for: 888

(1) Completing the training required by this program and their OUs/divisions; 890

(2) Requesting additional training as needed or as conditions change; and 892

6 Some NIST OUs do not have Division Chiefs; these OUs shall designate other individuals to carry out these responsibilities.

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 24 of 26

(3) Performing LOTO in accordance with their training and the requirements of this 894 suborder. 895

10. AUTHORITIES 898

There are no authorities specific to this suborder alone. 899

11. DIRECTIVE OWNER 902

Chief Safety Officer 903

12. APPENDICES 906

A. Revision History 907

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 25 of 26

Appendix A. Revision History 909

Version No.

Approval Date

Deployment Start Date

Effective Date Brief Description of Change; Rationale

1 03/20/14 06/25/14 04/01/15 None – Initial document

2 11/05/15 11/05/15 11/05/15

• Made suborder applicable to “associates”.

• Added new Section 3c(1) to clarify the relationship between this suborder and NIST N 7101.64, Electrical Safety; added “to which employees could be exposed” to Section 3c(2)(b).

3 03/14/18 07/30/19 04/01/20

• Changed “Associates” and “Contractors” to “Covered Associates” and “Non-R&D Contractors” to align the suborder with NIST O 7101.00.

• Indicated that LOTO locks and tags are not to be used for equipment taken out of service when that equipment presents no hazards to personnel.

• Added requirements for tracking of locks and tags.

• Added additional requirements for group

LOTO.

• Revised the LOTO procedure for shift changes.

• Added additional requirements for LOTO conducted by non-R&D contractors.

4 06/17/19 07/30/19 04/01/20

• The term "employee" replaces “worker” to represent federal employees and covered NIST associates to be consistent with terminology used in 29 CFR 1910.147.

• The terms “Primary Authorized Employee” and “Principal Authorized Employee” have been added and defined.

• The term “job lock” replaces “supervisor lock”.

5 01/07/21 NA 04/01/20 • Updated suborder links.

NIST S 7101.56 Ver. 6 (Uncontrolled Copy in Print) Page 26 of 26

Appendix A. Revision History (continued) 913

Version No.

Approval Date

Effective Date Brief Description of Change; Rationale

6 07/09/24 10/01/24

• Section 1 – Updated to be consistent with other suborders.

• Section 2.b – Content moved to Section 3.d.

• Section 5 – NIST S 7101.23 and S 7101.73 added.

• Section 6.a(2) – Added note regarding NIST S 7101.73.

• Section 6.a(3)(c) – Added.

• Section 6.b(2) – Removed reference to NIST IT application for developing LOTO procedures.

• Section 6.c(1) – Content removed as OSHA does not require a procedure for tracking LOTO locks and tags.

• Section 6.c(1)(d)i – Content added regarding the use of electrical disconnects and breakers.

• Section 6.c(1)(g)i – Content added for verification of de-energization.

• Section 6.e(1)(b) – Modified from “electrical power disconnect” to “electrical isolation device”.

• Section 6.j(1) – Content added regarding compliance with

NIST S 7101.23.

• Section 6.l – Added requirements for records retention.

• Section 9 – Responsibilities…