Attachment 9_APR8715.1 Chapter 31 Lockout_Tagout.pdf

APR 8715.1 This document is uncontrolled when downloaded or printed.

Verify current version before use at:

https://cdms.nasa.gov/directive/library/ARC

Ames Procedural Requirements

APR 8715.1

Effective Date: ___Feb. 27, 2025______

Expiration Date: ___Feb. 27, 2028______

COMPLIANCE IS MANDATORY

Subject: Chapter 31 – Lockout/Tagout

Responsible Office: Code QH / Occupational Safety, Health, and Medical Service Division

CHANGE LOG

Status [Baseline /Revision

/Cancelled]

Document Revision

Date of Change

Description

Revision 1 8/2/2019 Reformatted entire chapter and sections to meet AMS requirements.

Added: Written Lockout Procedures; Selecting Personnel to Perform Work under Lockout; Personnel Selection for Conventional and Complex Lockout Work – Non-Electrical Hazards; Personnel Selection for Electrical Lockout; Energized Electrical Work;

Inspection of Lockout Procedures for Adequacy and Employee Knowledge, Skill, and Proficiency; Lockout Performed for Support of Confined Space Work.

Added to references to Appendix C and added Appendices E through L. Deleted sections on Discipline; Contractors; sections

31.38.3 through 31.38.6; and all reference to Cal/OSHA.

Revision 2 11/20/2024 Heavy revisions throughout chapter and reduction of appendices.

Attachment 9

TABLE OF CONTENTS

PREFACE

P.1 Purpose P.2 Applicability P.3 Authority P.4 Applicable Documents and Forms P.5 Measurement/Verification P.6 Cancellation

CHAPTER 31 LOCKOUT/TAGOUT (LOTO)

31.1 Responsibilities

31.2 Administrative Locking

31.3 Configuration Control Locking

31.4 Tagged To Remain Energized

31.5 LOTO Work Categories

31.6 Hazardous Energies

31.7 General Programmatic Requirements

31.8 Additional Provisions for Electrical Lockout/Tagout

31.9 Hazards Analysis

31.10 Written Lockout Procedures

31.11 Absence of Voltage Verification (Electrical LOTO and Switching)

31.12 Qualification and Authorization

31.13 Training

31.14 Selecting Personnel to Perform Lockout/Tagout and Work Under Lockout/Tagout

31.15 Authorization

31.16 Reauthorization and Retraining LOTO

31.17 Energized Electrical Work

31.18 Communication of the Program Requirements

31.19 Employee Awareness of LOTO

31.20 Tagout Only

31.21 Lockout/Tagout Equipment and Hardware

31.22 Inspection of Lockout Procedures for Adequacy and Employee Knowledge, Skill, and Proficiency

31.23 Periodic Inspections and Recordkeeping

31.24 Controls, Control Circuitry, and Software Controls

31.25 Partial Re-Energizing Equipment During a Lockout Process

31.26 Group Lockout

31.27 Shift Changes

31.28 Emergency Removal of LOTO Devices – Abandoned Lock

31.29 Lockout Performed for Support of Confined Space Work

31.30 Support for Construction Contractors for Electrical and Electrical Components of Complex Lockout Tagout

APPENDIX A. DEFINITIONS

APPENDIX B. ACRONYMS

APPENDIX C. HAZARDOUS ENERGIES DEFINED AND DESCRIBED

APPENDIX D. LOCKOUT/TAGOUT PROCEDURE AUDIT FORM (EXAMPLE)

PREFACE

P.1 PURPOSE

This Chapter provides requirements for activities that require control of all hazardous energies to protect workers.

This Chapter specifies the control of hazardous energies via lockout/tagout requirements and work practices that are to be used in conjunction with APR 8715.1 Chapter 11, Electrical Safety.

P.2 APPLICABILITY

This directive is applicable to ARC and associated facilities (e.g., NASA Research Park).

This directive applies to contractors, grant recipients, or parties to agreements only to the extent specified or referenced in the appropriate contracts, grants, or agreements.

In this directive, all mandatory actions (i.e., requirements) are denoted by statements containing the term "shall." The terms "may" or "can" denote discretionary privilege or permission, "should" denotes a good practice and is recommended, but not required, "will" denotes an expected outcome, and "are/is" denotes descriptive material.

In this directive, all document citations are assumed to be the latest version unless otherwise noted.

P.3 AUTHORITY

NPR 8715.1, NASA Safety and Health Programs NPR 8715.3, NASA General Safety Program Requirements

P.4 APPLICABLE DOCUMENTS AND FORMS

29 CFR 1910, OSHA General Industry Regulations & Standards 29 CFR 1926, OSHA Construction Industry Regulations & Standards APR 8715.1 Chapter 11, Electrical Safety APR 8715.1 Chapter 26, Confined Space Entry APR 8715.1 Chapter 27 Construction Management NFPA 70 – National Electrical Code, 2023 or most recent edition NFPA 70E – Standard for Electrical Safety in the Workplace, 2024 or most recent edition

P.5 MEASUREMENT/VERIFICATION

Verification of conformance to requirements in this directive are measured through Center and

Responsible Organizational management reviews, self-assessments, and subsequent analysis and reports of conformance to requirements, as well as periodic internal audits.

Additional verification will be tracked through Agency triennial audits and Ames Annual Voluntary Protection Program (VPP) self-inspections.

P.6 CANCELLATION

CHAPTER 31 LOCKOUT/TAGOUT (LOTO)

31.1 Overview

31.1.1 This chapter provides requirements to address lockout/tagout (LOTO) hazards encountered by all who may work on and/or use lockout/tagout at Ames Research Center (ARC).

31.1.2 In addition to the requirements set forth in this chapter, full compliance with the latest editions of NFPA 70E Standard for Electrical Safety in the Workplace, 29 CFR 1910 General Industry, 29 CFR 1926 Construction Industry Regulations & Standards, and all equipment manufacturer’s recommendations shall be required under this chapter.

31.1.3 See APR 8715.1 Chapter 11 Electrical Safety for electrical safety requirements during lockout/tagout, which are complementary to the lockout/tagout requirements of this chapter.

31.1.4 See APR 8715.1 Chapter 27 Construction Safety Management for lockout/tagout requirements for construction projects, which are complementary to the lockout/tagout requirements of this chapter.

31.2 Responsibilities

31.2.1 All employees shall:

a. Understand the general reasons for LOTO.

b. Recognize when LOTO is being used.

c. Understand the importance of not tampering with or removing a lock and/or tag.

d. Follow the minimum requirements of this chapter.

31.2.2 Authorized employees shall:

a. Complete the NASA ARC Lockout Tagout SATERN Course within the last three years.

b. Recognize the conditions of work that require LOTO.

c. Use the materials and procedures specified in this chapter to implement the LOTO program.

31.2.3 Affected employees shall:

a. Complete the NASA ARC Lockout Tagout SATERN Course within the last three years.

b. Recognize the conditions of work that require LOTO.

31.2.4 Supervisors for all employees shall:

a. Ensure employees understand the general reasons for LOTO.

b. Ensure employees recognize when LOTO is being used.

c. Ensure employees understand the importance of not tampering with or removing a lock and/or tag.

d. Obtain energy-isolating devices capable of accepting a lock on all new machines and equipment or whenever major repair, renovation, or modification is performed, per 29 CFR 1910.147(c)(2)(ii).

e. Ensure employees shall follow the minimum requirements of this chapter.

31.2.1 Supervisors of affected and authorized employees shall:

a. Complete the NASA ARC Lockout Tagout SATERN Course within the last three years.

b. Provide authorization for employees and maintain records of authorized employees.

c. Ensure that authorized employees have attended the NASA ARC Lockout Tagout SATERN Course within the last three years. Provide additional on-the-job training if the employee is not thoroughly familiar with the equipment and/or written procedure.

d. Provide required LOTO equipment to employees and ensure that they use it.

e. Ensure the equipment-specific written procedures for complex lockout tagout exist and are validated.

f. Ensure that records of LOTO events are maintained in a logbook or other record storage device.

g. Maintain complex lockout tagout written procedures for 5 years after completion of the LOTO.

h. Ensure annual review and update of the Organization's LOTO procedures and employee authorizations are reviewed and updated as needed.

31.2.2 Supervisors of affected employees shall:

a. Complete the NASA ARC Lockout Tagout SATERN Course within the last three years.

b. Understands when an employee becomes an affected employee.

c. Ensure affected employees completed the NASA ARC Lockout Tagout SATERN Course within the last three years.

d. Ensure affected employees are able to recognize the conditions of work that requires LOTO.

31.2.3 The Occupational Safety, Health, and Medical Service Division (Code QH) shall:

a. Administer, maintain, and revise the LOTO policy as needed.

b. Develop and present the NASA ARC Lockout/Tagout Training course as needed.

c. Perform a periodic audit of each Directorate's LOTO program implementation.

31.2.4 Contracting Officer’s Representatives (CORs) shall:

a. Enforce requirements set forth in this chapter for contractors under COR’s contract.

b. Ensure that contractors comply with the provisions of the approved LOTO program.

31.2.5 Contractors shall meet the requirements set forth in this chapter.

31.3 Administrative Locking

31.3.1 A careful distinction must be made between LOTO and various other locking practices, collectively referred to as Administrative Locking. The LOTO procedure is specifically reserved for those instances in which a zero-energy state must be ensured to allow personnel to service, maintain, or modify, or disconnection of equipment and facilities.

31.3.2 Administrative locking is not permitted as a means of protection during a servicing, maintenance, or modification procedure, and is not a substitute for LOTO.

31.3.3 Administrative locking is distinguished from LOTO in both practice and purpose. A group rather than an individual may control an administrative lock.

31.3.4 An administrative application shall not use ARC-designated LOTO locks or LOTO tags.

31.3.5 A "Caution, Special Condition” tag is an administrative locking tag that shall not be used as a LOTO tag.

31.3.6 Tags shall be applied to administrative locking when no personnel are actively maintaining, servicing, demolishing, installing, modifying, or adjusting equipment that has hazardous energy to be controlled.

31.3.7 Administrative locking may be performed for many reasons, including equipment security, programmatic purposes, or general safety.

31.3.8 The color for administrative locks used for downed equipment or systems without personnel working downstream shall be any color besides red and directorate specific lockout/tagout program shall set up color choice.

31.3.9 The use of configuration control locking shall be dictated based on paragraph 31.4.

31.3.10 The color for administrative locks not used for downed equipment or systems shall be any color that is not red, yellow, or gold.

31.3.11 Examples of administrative locking where tags are not required are:

a. Locked fences around high-voltage transformers.

b. A locked door to a laboratory that contains hazardous equipment.

31.3.12 Examples of administrative locking where tags are required are:

a. Locks on overhead-crane disconnect switches for non-maintenance reasons.

b. A water valve locked in the open position.

31.4 Configuration Control Locking

31.4.1 Configuration control locking is a sub-set of administrative locking. Civil servants and resident contractors are the users of configuration control locking. Configuration control locking shall be applied when a LOTO is applied when work being done by non-resident contractors. Configuration control locking shall be applied during a group LOTO to maintain configuration for the duration of the LOTO containing multiple shifts.

31.4.2 Configuration control locking is not a substitute for personnel protection for LOTO.

31.4.3 A group rather than an individual may control a configuration control lock.

31.4.4 A “caution” tag shall be used with a configuration control lock. An allowance to use a ‘danger’ tag is allowable when a civil servant or resident contractor is operating a group lockout tagout with the non-resident contractor is part of the group lockout tagout.

31.4.5 Configuration control locks shall be yellow or gold.

31.4.6 Examples of configuration control locking are:

a. Locking of equipment during an active LOTO between shifts or during non-working days.

b. Resident contractor or civil servant providing configuration control locks to an active LOTO to work being done by non-resident contractor that the non-resident contractor is providing LOTO locking for personnel protection.

31.5 Tagged To Remain Energized

31.5.1 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 de-energized.

31.5.2 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.

31.5.3 The energy-securing device shall not be locked by any means that would prevent the device from being used as an emergency disconnect.

31.6 LOTO Work Categories

31.6.1 Work practices shall be followed in compliance with applicable OSHA regulations and industry safety standards, which are detailed in the documents listed in section P.4.

31.6.2 The control of hazardous energy requires strict adherence to documented (written) procedures to achieve a state of safety where the hazardous energy is positively isolated from the worker.

31.6.3 Based on the applicable OSHA regulations and NFPA standards covering LOTO along with adopted industry standards that cover this activity, there are two separate LOTO categories described in this procedure, as identified in the following “Table of LOTO Categories".

31.7 Hazardous Energies

31.7.1 An energy is considered hazardous if it is capable of causing harm; some energies are not considered harmful when present at or below a certain level. Appendix C Hazardous Energies Defined and Described lists examples of identified energy types and the levels at which they are considered harmful for the purposes of this chapter.

31.7.2 For some energies there is no definable limit between harmful or not, for example, mechanical energy as in the moving parts of a machine. It is difficult to quantify hazardous mechanical energies because of the many ways a person can interact with a mechanical device. Additionally, many of the listed energy types require an instrument or device to measure the level of energy in order to determine if a hazard is present or not and/or to what degree (e.g., electricity).

31.8 General Programmatic Requirements

31.8.1 The general programmatic requirements for control of hazardous energies during construction, demolition, servicing, and maintenance work are detailed in the table below.

31.8.2 Minor tool change exclusion for LOTO: For minor tool changes and adjustments and other minor servicing activities that take place during normal production operations if they are routine, repetitive, and integral to the use of the equipment for production. Provided that the work is performed using alternative measures that provide effective protection and are documented in an approved Job Hazard Analysis or Standard Operating Procedure and there are no electrical hazards that must be controlled to prevent electric shock, burns or flash exposure.

31.9 Additional Provisions for Electrical Lockout/Tagout

31.9.1 The items listed below are in addition to provisions listed in this section and exceed the minimum requirements of NFPA 70E Standard for Electrical Safety in the Workplace.

31.9.1.1 All persons working on de-energized equipment downstream of a lockout/tagout shall be required to personally conduct or witness the absence of voltage testing for the equipment before working on the equipment.

31.9.1.2 When there is use of a status board for circuit breakers or switches, a signed field copy of switching procedures or lockout tagout plan shall be provided by the persons performing the work after a lockout has been performed before the status board can be updated. Records shall be retained for five years. Either electronic or paper copies will be acceptable.

31.10 Hazards Analysis

31.10.1 Perform a hazards analysis on the machinery or equipment that is to be serviced, maintained, or disposed of is a fundamental practice to identify all:

a. Hazardous energies inherent in the work.

b. Determine the severity and likelihood of incidents that could occur as a result of the hazardous energies.

c. Identify the energy isolation points.

d. Identify and document effective means of LOTO for isolation points.

31.10.2 Appendix C, “Hazardous Energies Defined and Described” if the energy is considered hazardous at the level worked; this is with consideration that some energies are considered hazardous at any level (e.g., mechanical energy – moving parts, etc.)

31.11 Written Lockout Procedures

31.11.1 All lockout or tagout procedures shall be documented. This is a requirement of the applicable regulations and standards listed in section P.4.

31.11.2 A written lockout procedure, in addition to being required by the applicable regulations/standards, is necessary as:

a. It serves as the material to which a person is trained for a specific work situation.

b. The basis for the required annual procedure audit.

31.11.3 Any confined space operation where any worker would be exposed hazardous energies must be isolated for safe entry. Refer to Appendix C for a comprehensive list of Hazardous Energies. Not all items listed within Appendix C are applicable when working in a confined space.

31.11.4 In addition to each documented procedural step that must be detailed to isolate hazardous energy, each written lockout procedure shall contain the following information per 29 CFR 1910.147, Control of Hazardous Energy. Paragraphs referenced below are pertaining to 29 CFR 1920.147, Control of Hazardous Energy requirements:

a. The Scope, Purpose, Authorization, and Rules of the procedure - paragraph (c)(4)(ii).

b. A specific statement of the intended use of the procedure - paragraph (c)(4)(ii)(A).

c. A statement of the means to enforce compliance - paragraph (c)(4)(ii).

d. A list of the hazardous energies that are to be controlled in the procedure - paragraph (d)(1).

e. A statement of a requirement to notify Affected and Other persons of the intended lockout - paragraph

(c)(9).

f. Specific statement to notify these groups after the lockout has been cleared - paragraph (e)(2)(ii).

g. Specific, documented instructions on what must happen for shift changes, if appliable - paragraph

(f)(4).

h. Specific, documented instructions on what must happen if the equipment must be re-energized during the course of the servicing or maintenance work, if applicable - paragraph (f).

31.11.5 Electrical sections of all complex lockout procedures shall include the items above and the following:

a. Name of person in charge of the LOTO plan

b. Step-by-step procedures for LOTO with locations for implementer and verifier to initial during LOTO including locations where absence of voltage will be conducted and verification of dissipation for all stored energy

c. Locations of grounds and locks included on one-line diagram

d. Results of an arc flash and shock risk assessment including mitigations and Personal Protective

Equipment (PPE) to be worn during the LOTO

e. Picture of the arc flash label of the highest incident energy equipment being de-energized (if any equipment has over 40 cal/cm2 ratings, provide pictures of each location and mitigations planned.)

f. Signature blocks for the following people:

(1) Creator of the LOTO plan

(2) Reviewer of the LOTO plan

(3) Participants of the LOTO plan

(4) Safety representative of organization or delegated competent person in electrical safety handling the LOTO process review

Signatures shall validate the following:

(1) Creator of the LOTO plan: Creator states there are no known errors with the plan

(2) Reviewer of the LOTO plan: Reviewer has reviewed the LOTO plan and has validated there are no known errors in the plan

(3) Participants of the LOTO plan: Participants have reviewed, understands, and are able to safely perform the LOTO.

Note – If any of participants who have signed the plan are not implementing the LOTO (e.g., scheduling conflict), the new participants of the plan shall sign the document once they have reviewed, understand, and are able to safely perform the LOTO prior to implementing the LOTO.

(4) Safety representative of organization or delegated competent person in electrical safety has confirmed the plan has identified all electrical hazards and corresponding mitigation methods are in place. Safety representative of organization or delegated competent person will enforce the plan as written and stop work if there is a differing site condition related to the lockout/tagout to re-evaluate the plan for adjustment.

31.8.5.1 Absence of Voltage Verification (Electrical LOTO and Switching)

31.11.6 Absence of Voltage Verification shall occur in accordance with NFPA 70E with the additional requirement that all workers within the restricted approach boundary shall perform absence of voltage verification before starting the job task.

31.12 Qualification and Authorization

31.12.1 Only employees who are trained, certified (see NPR 8715.1) and authorized can perform LOTO.

Refer to sections 31.14 Selection of Personnel to Perform Lockout/Tagout and Work Under Lockout/Tagout.

31.12.2 Persons who are designated to perform an electrical simple lockout or the electrical part of a complex lockout must be designated as Qualified Electrical Workers by their management. Refer to APR

8715.1 Chapter 11 Electrical Safety for Qualified Electrical Worker requirements for electrical simple LOTO and electrical sections of complex LOTO.

31.12.3 Persons who may be considered an Affected or Other Person(s) must be informed that they are not to participate in a lockout process and are not to interfere with any work.

31.13 Training

31.13.1 Affected and Authorized Civil service and resident contractor workers who are affected or perform LOTO and their direct supervisors shall complete the NASA ARC Lockout/Tagout training course.

31.13.2 Recertification and refresher training is required every 3 years.

31.13.3 The NASA contracting officer will enforce the specification section of contract for noncompliance if records of training cannot be produced.

31.13.4 Training records shall be kept on file and archived for a duration 5 years or NRRS 1441.1 NASA Record Retention Schedules requirements, whichever is longer.

31.14 Selecting Personnel to Perform Lockout/Tagout and Work Under Lockout/Tagout

31.14.1 The person(s) performing LOTO and working under LOTO shall be qualified to perform lockout/tagout and the servicing or maintenance tasks and authorized to perform the LOTO on the equipment. Being qualified to do a task does not mean that someone is authorized to do a task.

31.14.1.1 Qualifying Personnel

As listed in the applicable regulations and standards (section P.4), the supervisor is tasked with the responsibilities of managing this program including qualifying workers who are competent to perform lockout.

A worker qualified to perform lockout shall be competent, experienced, and designated by management to perform servicing and maintenance on the machine or equipment that is being locked out. A worker may be qualified to work on some equipment and systems but considered unqualified to work on other equipment and systems. As a prerequisite to being authorized to participate in lockout, the person must be designated as qualified to perform this servicing and maintenance. Refer to APR 8715.1 Chapter 11 Electrical Safety for Qualified Electrical Worker requirements.

Not all persons designated as a supervisor or manager possess the necessary experience, technical expertise, and comprehensive knowledge of all aspects of the work to be performed. A competent person can be designated by the supervisor to qualify the authorized worker doing the task as being competent.

31.14.1.2 Authorizing Personnel

The supervisor is responsible to authorize qualified workers to perform servicing and maintenance on the machine or equipment that is being locked out. A worker may be authorized to work on some equipment and systems but considered unauthorized to work on other equipment and systems. Refer to section 31.15 Authorization.

31.15 Authorization

31.15.1 Each supervisor shall provide specific authorization for LOTO employees after qualification by training, certification, and performance evaluation.

31.15.1.1 Each supervisor shall provide a form for each employee who is qualified and authorized to perform LOTO to the LOTO program manager (Code QH). This form will need to be submitted each time reauthorization occurs.

31.15.2 The supervisor shall ensure that the employee is familiar with the equipment within the context of job task and with the energy-control procedures.

31.15.3 The supervisor or designated competent person shall provide additional on-the-job training until the employee is familiar with the equipment and energy-control procedures. When satisfied that both the training and proficiency are adequate, the supervisor may authorize an employee to perform LOTO.

31.15.4 The authorization shall stipulate the types of equipment and systems on which the authorized employee may perform LOTO.

31.15.5 Each supervisor shall maintain records of authorized employees and the type of on-the-job training that was given. See section 31.13.4 for record retention.

31.16 Reauthorization and Retraining LOTO

31.16.1 Any Employee reauthorization to perform LOTO is required when:

a. An authorized employee's job changes or is reassigned.

b. Change in machine, equipment, or process.

c. New energy-control procedures are implemented.

d. Three years since previous authorization or reauthorization occurred.

31.16.2 LOTO retraining is required when:

e. The supervisor of the qualified worker has reason to believe that an employee has inadequate knowledge of LOTO procedures or policy.

f. A periodic inspection shows a deficiency in the authorized employee's ability to implement LOTO policy correctly.

g. Three years since previous authorization or reauthorization occurred.

31.17 Energized Electrical Work

31.17.1 Electrical hot work or energized electrical work shall be avoided unless extenuating circumstances require live work to be conducted. Refer to APR 8715.1 Chapter 11 for electrical safety requirements for energized electrical work. When lockout of electrical hazards must be accomplished a Qualified Electrical Worker shall use a meter or instrument to verify that an electrically safe condition is achieved (zero energy state).

31.18 Communication of the Program Requirements

31.18.1 Communication of the requirements of this program is accomplished by education and training:

a. Education may be classroom-type sessions or computer-based training. Workers shall be educated on the aspects of this program that pertain to their work assignment. This includes any person who is considered an Affected Employee or Other Person as defined in Appendix A.

b. The education portion shall cover the hazardous energy control program; the identified hazardous energies; the ability to write procedures; the requirement to work per written procedures; methods and techniques for energy isolation; the requirements for use of a personal lock and identifying tag; and emergency lock removal.

c. Training is that part of the overall communication with the student that includes a demonstration of a task to be performed by an instructor followed by the student performing the task. The instructor evaluates the student for competency and proficiency.

d. The combination of the educational and training components shall, at a minimum include, the purpose and function of the energy control program, establish personnel with the ability to recognize hazardous energy sources including the energy types that personnel may be presented with in their workplace, recognition of the boundaries needed to maintain a safe distance from hazardous energy sources, and the methods and means for isolating the hazardous energies.

31.19 Employee Awareness of LOTO

31.19.1 Affected Employee training is required for any ARC employee who may be near to or affected by equipment on which LOTO is performed.

31.19.2 All employees shall:

a. Know how to recognize LOTO, why LOTO is implemented, and the importance of leaving LOTO devices in place.

b. Not tamper with LOTO devices or attempt to restart equipment to which LOTO is applied.

c. Complete the current Ames SATERN on-line Lockout/Tagout course material if their job requires them to be in the vicinity of LOTO protective devices.

31.20 Tagout Only

31.20.1 Any energy-isolating device capable of being locked out shall use an appropriate locking device and lock.

31.20.2 If equipment is incapable of being locked out, a "tagout only" procedure shall be employed.

31.20.3 An equipment-specific written energy control procedure is required to be approved by the responsible program authorized individual and safety manager prior to implementation whenever a “tagout only” procedure is employed.

31.20.4 If tagout must be used in lieu of lockout, a tag:

a. Is considered only a means of warning other persons.

b. Does not provide the physical security that a locked isolation device does.

c. Shall not be removed except by the person who placed the tag.

31.20.5 For a tagout only procedure, the authorized employee must follow all the steps outlined in the written procedure with a tag affixed to the same point where the lock would be installed.

31.20.6 Authorized Employee(s) must utilize a secondary means of isolating the hazardous energy such as:

a. Removal of an isolating circuit element, or

b. Opening of an extra energy isolating equipment in series with the original isolating equipment

31.20.7 The primary and secondary means of isolation shall be identified on the tags that are affixed to the energy isolating equipment.

31.21 Lockout/Tagout Equipment and Hardware

The supervisor whose employees perform LOTO is responsible for providing LOTO equipment/devices to those employees and shall ensure such equipment/devices are being used.

31.21.1 Padlocks and Padlock Labels

31.21.1.1 Padlocks shall be identified as being used for LOTO.

31.21.1.2 Padlocks used for LOTO at NASA Ames shall have a red body.

31.21.1.3 Red body padlocks shall be used for no other purpose at Ames other than LOTO.

31.21.1.4 Padlocks used for configuration control at NASA Ames shall have a yellow or gold body.

31.21.1.5 Yellow or gold body padlocks shall be used for no other purpose at Ames other than configuration control or administrative locking used for downed equipment without personnel working downstream.

31.21.1.6 Each padlock shall be identified with the authorized employee's name and contact information.

31.21.1.7 Durable padlock labels may be used for writing in the authorized employee's name and contact information.

31.21.1.8 Other means of permanent identification (e.g., engraving) are also permissible.

31.21.1.9 A manager may elect to utilize a checkout system that permits authorized employees to be issued locks from a common local supply. In such cases, the lock must be relabeled with the authorized employee’s name and contact information.

31.21.2 LOTO Keys

31.21.2.1 Each LOTO padlock shall have one (1) key only.

31.21.2.2 This one key shall only be used by the person issued the lock and not be loaned out.

31.21.2.3 A group of locks with a common key may be used for equipment with multiple energy isolation devices, if desired.

31.21.2.4 If a group of locks is keyed alike for this purpose, only one key shall be issued for use by the authorized employee performing LOTO.

31.21.2.5 When performing group LOTO and an employee leaves the worksite, the employee must first remove their lock.

31.21.2.6 If there is a period of time when no employees are on site working on the equipment, a configuration control lock shall be placed on the hasp or lock box until the LOTO is completed.

31.21.3 Personal Identifying Tags

31.21.3.1 A tag shall always be used in conjunction with a lock. If the energy-isolating device is not physically capable of being locked, attach tag only.

31.21.3.2 The tag shall be attached with a nylon locking cable tie able to withstand 50 pounds of pull force.

31.21.3.3 Tags used for outdoor applications shall be protected from the environment.

31.21.3.4 The authorized employee who performs LOTO shall complete all applicable sections of the tag.

31.21.4 Other Hardware

31.21.4.1 The manager shall provide other hardware as required, such as multiple lock hasps and circuit breaker and valve lockout devices.

31.21.4.2 Energy-isolating devices at NASA ARC shall accept a lockout device when new machines or equipment are installed, or whenever machines or equipment undergo major repair, renovation, or modification.

31.21.4.3 Generic plastic devices used to lock-over circuit breaker handles are not acceptable and do not meet the OSHA §1910.147 requirements for ‘substantial’ hardware.

31.22 Inspection of Lockout Procedures for Adequacy and Employee Knowledge, Skill, and Proficiency

31.22.1 The applicable regulations (listed in section P.4) require that periodic auditing of lockout procedures be performed at least annually.

31.22.2 Supervisors shall catalog all written LOTO procedures accomplished under their authority and provide documented records that procedures have been audited at least annually.

31.22.3 Written lockout procedure are required to be inspected periodically. The inspection is to:

a. Evaluate the worker’s knowledge, understanding, skill and proficiency.

b. Determine if the written procedure is adequate, sufficient, complete, and meets the requirements of the

NASA Ames Lockout/tagout program (this procedural document).

31.22.4 If the worker is found to be deficient in any of the requisite knowledge, understanding, skill, or proficiency regarding not meeting the minimum requirements of the audit inspection, the worker shall be re-educated and re-trained to establish skill and proficiency. See template lockout/tagout procedure audit form in Appendix D.

31.22.5 If the procedure is found to be deficient in some way, it shall be revised to correct any deficiencies and all workers who may use this procedure be retrained to the revised corrected procedure.

31.23 Periodic Inspections and Recordkeeping

31.23.1 At least annually, the manager/supervisor of an organization implementing LOTO shall perform an inspection of the LOTO program in accordance with 29 CFR §§1910.147(c)(6).

31.23.2 The inspection shall be conducted by an Authorized employee to identify and correct any deviations or deficiencies.

31.23.3 Inspection records shall be signed, dated and retained for program reviews for 5 years.

31.23.4 A sample checklist that can be used to document this inspection is provided in Appendix D.

31.23.5 See below for conducting an audit of a LOTO program.

Table 3. General Programmatic LOTO Audit

31.23.6 Recordkeeping Requirements

31.23.6.1 Each LOTO event shall be documented in the department log, project log, or a dedicated LOTO logbook.

31.23.6.2 The following information shall be captured and documented:

a. Name of authorized employee who performed LOTO.

b. Date and time LOTO were applied.

c. Equipment and circuit identification.

d. Reason for LOTO.

e. LOTO procedures and hazard analysis for LOTO.

f. Date and time of LOTO removal, if applicable.

g. Name of authorized employee who removed LOTO if different from authorized employee who initiated LOTO, if applicable.

31.23.6.3 At the discretion of the supervisor, recordkeeping requirements may be satisfied by an orderly system of archiving completed tags.

31.23.6.4 Records shall be maintained for five years. Either electronic or paper copies will be acceptable.

31.24 Controls, Control Circuitry, and Software Controls

31.24.1 Machine controls, control circuitry, and software controls are not energy isolating devices and shall not be used to control hazardous energy in any work category.

31.25 Partial Re-Energizing Equipment During a Lockout Process

31.25.1 If a servicing or maintenance task requires that the equipment be restarted to verify work, assess something (e.g., proper alignment), or any other necessary work, the written lockout procedure shall clearly list the required steps to:

a. Re-energize the machine or equipment.

b. Perform the necessary work.

c. Restore the equipment to the locked-out state.

31.26 Group Lockout

31.26.1 Group lockout is any lockout (or tagout) operation that involves more than one person.

31.26.2 Multiple lockout hasps can be used to allow more than one lock to be applied to a single energy isolating device if the device is substantial enough to hold all the lockout hardware.

31.26.3 Each participant applies his/her personal lock to the hasp along with the personal tag.

31.26.4 For other group lockout situations, a lock box can be used. In this process, one lock is used to lock out a single isolation device; the key from that lock is placed in the lock box. Then all participants place their personal lock and tag on the box. The personal safety of each participant is preserved as the box cannot be opened until all participants remove their personal lock.

31.26.5 For more extensive operations, a large group lockout process may be necessary. This type of process shall be managed by a designated person. This person:

a. Oversees the preparation for the work,

b. Oversees the actual lockout process, and

c. Coordinates the work as necessary to assure that it is done in a manner consistent with maintaining worker safety all times during the process.

31.27 Shift Changes

31.27.1 If a shift change will or may occur during the course of a lockout process, the written procedure shall detail how the transfer of lockout is to take place to ensure all energy sources remain isolated at all times.

31.27.2 If the work is not finished in one shift, a configuration control lock and tag shall be installed where the authorized/qualified worker locks are located. Authorized/qualified workers shall remove their LOTO locks and tags prior to the end of their shift.

31.27.3 A representative from outgoing shift shall be present to inform the oncoming shift representative of any potential hazard.

31.27.4 An oncoming shift shall verify a zero-energy state still exists and place its lock and tags on the group LOTO device, immediately.

31.28 Emergency Removal of LOTO Devices – Abandoned Lock

31.28.1 When the authorized employee who applied a LOTO device is not available to remove it, the supervisor may remove the device after contacting the Authorized Employee. This is considered to be an emergency procedure, to be undertaken only in extreme circumstances.

31.28.2 Extreme care must be taken, and the following steps shall be performed:

a. The manager verifies that the Authorized employee is not at the facility.

b. The manager makes every reasonable effort to contact the authorized employee, including a telephone call to the employee's home and mobile telephone number(s).

c. If the employee is contacted, the manager informs the employee that his/her LOTO devices are being removed.

d. The manager verifies that it is safe to remove the LOTO devices.

e. The manager or designated representative then cuts off the lock (s).

f. The manager ensures that the Authorized employee is presented with the removed lock immediately upon returning to work and is informed of the reasons for the emergency removal.

g. The emergency procedure is recorded in the department's lockout/tagout records and signed by both the manager and the Authorized employee.

h. The manager notifies the Lockout/Tagout Program Manager (Code QH) of each destructive lock removal by email or written notice.

31.29 Lockout Performed for Support of Confined Space Work

31.29.1 Persons who will enter a permit-required confined space entry that has potential exposure to hazardous energy in the confined space shall be ‘Authorized’ and ‘Qualified’ to perform lockout on energies that must be isolated before entry.

31.29.2 Such work shall conform to the requirements in APR 8715.1 Chapter 26, Confined Space Entry.

31.30 Support for Construction Contractors for Electrical and Electrical Components of Complex Lockout Tagout

31.30.1 When providing switching support for construction contractors, the following items shall be required.

31.30.1.1 Authorized and qualified persons providing switching support shall verify de-energization equipment being worked on by construction contractors via testing for absence of voltage at all potential feeds or backfeeds to the equipment at the completion of switching.

31.30.1.2 Authorized and qualified persons providing switching support shall provide configuration control locking and danger tags on the equipment switched.

31.31.1.2.1 It is acceptable to use a group lockout box with the configuration control lock as part of the group lockout box as long as persons providing switching support are in control of the group lockout box and the construction contractor places their locks and tags on the group lockout box.

31.30.1.3 When an authorized and qualified person is providing access to equipment to a construction contractor, that person shall verify the equipment is properly switched and the construction contractor is using correct lock and tag for the lockout/tagout.

31.30.1.4 When there is use of a status board for circuit breakers or switches, a signed field copy of the switching procedures or lockout tagout plan shall be provided by the persons performing the work after switching has been performed before the status board can be updated.

31.30.1.5 Refer to paragraph 31.10.5. Switching procedures shall meet the same requirements as a lockout/tagout submittal.

31.30.1.6 Construction contractor shall hold an outage meeting before the power is isolated. Persons providing the switching and creators of the switching plan shall attend meeting to validate construction contractor’s lockout/tagout plan and switching plan match lock placement and grounding placement.

APPENDIX A. DEFINITIONS

Note: Many of the terms used in this Chapter are defined in 29 CFR §1910.147.

Affected Employee An employee whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed.

Authorized Employee A person who locks out or tags out machines or equipment in order to perform servicing or maintenance on that machine or equipment. An affected employee becomes an authorized employee when that employee's duties include performing servicing or maintenance covered under this section.

Authorizing Person A person who selects the persons who are to become an Authorized Person under the 29 CFR §1910.147 definition and scope, conducts the required hazards analyses, provides equipment-specific training to potential authorized persons, manages the annual Control of Hazardous Energy procedure inspection, determines the pass/fail of persons performing such procedures, re-trains persons who do not pass the inspections or do not demonstrate sufficient knowledge, revises the Control of Hazardous Energy procedures as necessary, reports result to the responsible supervisor.

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: A manually operated electrical circuit breaker; a disconnect switch; a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors, and, in addition, no pole can be operated independently; a line valve; a block; and any similar device used to block or isolate energy. Push buttons, selector switches and other control circuit type devices are not energy isolating devices.

Lockout The placement of lockout device on an energy-isolating device, in accordance with an established procedure, ensuring that the energy-isolating device and the equipment being controlled cannot be operated until the lockout device is removed.

MACC Contractor Multiple Award Construction Contractor. IDIQ (Indefinite Delivery Indefinite Quantity) Contract for renovation and construction of facilities.

Maintenance See Servicing.

Non-Resident Contractor Contractor that is not a resident contractor at Ames Research Center.

Contractor that is contracted for a short duration for a specific task such as a MACC (Multiple Award Construction Contract) contractor or a sub-contractor to a MACC or a resident contractor.

Other Persons Any person who needs to know about the requirements of lockout procedure, such as what does a lock and tag look like, how to recognize a work situation under lockout, and this person must not approach or attempt to become in the work situation. This is a group of people who may be incidentally in the area where work under a lockout is being performed but not considered an Affected Person.

Qualified Employee A worker qualified to perform lockout shall be competent, experienced, and designated by management to perform servicing and maintenance on the machine or equipment that is be locked out. A worker may be qualified to work on some equipment and systems but considered unqualified to work on other equipment and systems. As a prerequisite to being authorized to participate in lockout, the person must be designated as qualified to perform this servicing and maintenance.

Resident Contractor Contractor that has a long-term service or operational contract with Ames Research Center.

Servicing (or Maintenance) Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include lubrication, cleaning or unjamming of machines or equipment, and making adjustments or tool changes, where the employee may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy.

Substantial Lockout devices including lockout accessories, lock-over devices, or generic devices used to attach a lock to an isolating device must be substantial enough to prevent removal without the use of excessive force or unusual techniques such as by the use of bolt cutters or other metal cutting tools.

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.

Tagout Device A prominent warning device, such as a tag and a means of attachment that 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.

Zero Energy or 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 re-accumulation. Equipment is not safe to work on until it is proven that it is in a zero-energy state.

APPENDIX B. ACRONYMS

APD Ames Policy Directive APR Ames Procedural Requirement ARC Ames Research Center CEC California Electric Code CFR Code of Federal Regulations COR Contracting Officer’s Representative HVAC Heating, Ventilation, and Air Conditioning IDIQ Indefinite Delivery Indefinite Quantity LOTO Lockout Tagout MACC Multiple Award Construction Contractor NASA National Aeronautics and Space Administration NEC National Electrical Code (NFPA 70) NFPA National Fire Protection Association NPD NASA Policy Directive NPR NASA Procedural Requirement OSHA Occupational Safety and Health Administration

APPENDIX C. HAZARDOUS ENERGIES DEFINED AND DESCRIBED

C.1 Some energies are difficult to quantify in regard to when the level of energy becomes hazardous, for example mechanical energy. This type of energy has many forms in the workplace situation – revolving, crushing, snagging, shearing, linear motion with high inertia (impact potential), to highlight a few; there is no reliable way to quantify hazardous mechanical energy. Therefore, assume that if it can move that energy must be isolated and controlled to prevent movement during servicing or maintenance tasks.

C.2 Some energies are considered hazardous by definition, such as chemical energies, corrosives, flammables, or oxidizers, for example.

C.3 Some energies require an instrument, meter, or other measuring device to assess the level of energy present or to determine if there is zero energy present, e.g., electrical energy, radiation, noise.

C.4 The following are examples of Hazardous Energies and the Levels Considered to be Hazardous.

Electrical:

a. Shock: Low Voltage, Potentials are > 30V RMS or DC, but 600V

b. Shock: High Voltage, Potentials are > 600V

c. Arc Flash/Blast: 1.2 cal/cm2 at working distance

d. Static Electricity

e. Stored Electrical Energy: See Item #9 – Potential Energy Chemical:

a. Corrosive

b. Reactive

c. Oxidizer

d. Toxic

e. Flammable

f. Pyrophoric

g. Irritant Pressure:

a. Pneumatic, hydraulic

b. Vacuum < 1 atmosphere Mechanical:

a. Energy capable of crushing, pinching, cutting, snagging, striking, trapping Thermal:

(1) >60°C or 140°F surface temperature

(2) Contact with cold surface at or below 0°C or 32°F.

(3) Hot liquids

(4) Cold liquids

(5) Steam Ionizing Radiation:

a. Greater than 2mRem/hr Non-Ionizing Radiation:

a. Ultraviolet: > ACGIH - Effective Irradiance TLV – UVA, actinic region

b. Infrared: > ACGIH Spectral Radiance TLV

c. Rf/Microwave: frequency dependent, < than 10 mW/cm2

d. Laser: Class II, Class III, Class IV

e. Magnetic Fields: frequency dependent, B(mT) = 60/frequency Potential Energy:

a. Flywheels

b. Springs

c. Differences in elevation

d. Elevated parts that could drop

e. Capacitors

f. Batteries

g. Permanent magnets

h. Static Magnetic Fields > 2 Teslas