Attachment F - Control of Hazardous Energy_LOTO.pdf

Control of Hazardous Energy (Lockout/Tagout)

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 1 of 24

Control of Hazardous Energy 3

(Lockout/Tagout)4

NIST S 7101.56 6

Approval Date: 01/7/2021 7 Effective Date:1 04/01/2020 8

1. PURPOSE11

This suborder establishes the safety requirements necessary to protect NIST employees and 12 covered associates (hereafter referred to as “employee2”) from exposure to hazardous energy 13 during the servicing or maintenance of machines or equipment (hereafter referred to as 14 “equipment”), and the organizational roles and responsibilities for ensuring that those 15 requirements are met. 16

2. BACKGROUND19

a. NIST must meet or exceed the requirements established by Occupational Safety and Health20

Administration in 29 Code of Federal Regulations (CFR) 1910.147, The Control of 21 Hazardous Energy. Implementation of this suborder fulfills those requirements. 22

b. Work involving exposure3 to electrical hazards (e.g. shock, arc flash) from work on, near, or24 with conductors or equipment in electric-utilization installations, NIST must meet or exceed 25 the requirements established by OSHA in 29 CFR 1910.333, Selection and Use of Work 26 Practices. Implementation of this suborder and NIST Suborder (S) 7101.64, Electrical Safety 27 fulfills those requirements. 28

c. This suborder supersedes NIST Health and Safety Instruction (HSI) 21, Control of30

Hazardous Energy (Lockout/Tagout), June 1994. 31

1 For revision history, see Appendix A.

2 The term "employee" shall represent federal employees and covered NIST associates to be consistent with terminology used in 29 CFR 1910.147.

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.

Attachment F https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_id=9804&p_table=STANDARDS https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.333 https://nistsafety.nist.gov/Programs/Programs/View/13

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 2 of 24

3. APPLICABILITY 33

a. The provisions of this suborder apply to equipment servicing and maintenance activities, 34 conducted by NIST employees, covered associates, and non-Research-and-Development 35 (non-R&D) contractors that could harm an individual if the equipment being serviced or 36 maintained were to unexpectedly energize, start up, or release stored energy. 37

b. When servicing or maintenance activities are conducted exclusively by non-R&D 39 contractors, Organizational Units (OUs) need only follow Section 6g and meet the Affected-40 Employee training requirements in Section 6j. 41

c. Applicability to Normal Production Operations. 43

(1) The provisions of this suborder apply to servicing and maintenance that takes place 45 during normal production operations only when: 46

(a) A NIST employee or covered associate is required to remove or bypass a guard or 48 other safety device; or 49

(b) A NIST employee or covered associate is required to place any part of his/her body 51 into an area on a machine or piece of equipment where work is actually performed 52 upon the material being processed (point of operation) or where an associated danger 53 zone exists during an equipment operating cycle. 54

(2) The provisions of this suborder do not apply to minor tool changes and adjustments and 56 other minor servicing activities that take place during normal production operations if 57 these activities are routine, repetitive, and integral to the use of the equipment for 58 production, provided that the work is performed using alternative measures, such as 59 machine guarding, that provide effective protection. 60

d. For work involving exposure to electrical hazards (e.g. shock, arc flash) from work on, near, 62 or with conductors or equipment in electric-utilization installations, the electrical LOTO 63 requirements of NIST N 7101.64, Electrical Safety, not the LOTO requirements of this 64 suborder, apply. 65

e. Where the work to be performed only involves the operation of circuit breakers or service 67 disconnects to perform LOTO and the tasks involved do not result in exposing any electrical 68 or electro-mechanical circuits, components, or parts, the LOTO requirements of this 69 suborder, not the electrical LOTO requirements of NIST N 7101.64, Electrical Safety, apply, 70 but those performing the task of operating circuit breakers or service disconnects shall be 71

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 3 of 24 trained and qualified to perform those tasks in accordance with the requirements of NIST N 72 7101.64, Electrical Safety. 73

f. Exclusions. The provisions of this suborder do NOT apply to: 75

(1) The act of taking equipment out of service provided no hazards to personnel exist. 77

(2) Work on cord- and plug-connected electrical equipment that meets ALL of the following 79 conditions: 80

(a) The equipment has a single energy source; 82

(b) All hazardous energy to which employees could be exposed can be controlled by 84 unplugging the equipment; and 85

(c) The plug is under exclusive control of the employee servicing or maintaining the 87 equipment. 88

(3) Hot-tap operations involving transmission and distribution systems for substances such as 90 gas, steam, water, or petroleum products are performed on pressurized pipelines, 91 provided that it can be demonstrated that: 92

(a) Continuity of service is essential; 94

(b) Shutdown of the system is impractical; 96

(c) Special equipment (e.g., bolted blinds and blank flanges) is used which will provide 98 proven effective protection for NIST employees and covered associates; and 99

(d) Documented procedures are followed. 101

4. REFERENCES 104

a. 29 CFR 1910.147, The Control of Hazardous Energy (lockout/tagout). 105

b. 29 CFR 1910.333, Selection and Use of Work Practices. 107

c. ANSI Z535.5, Safety Tags and Barricade Tapes (for Temporary Hazards) (most recent 109 version). 110 https://nistsafety.nist.gov/Programs/Programs/View/13 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

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d. NIST O 7101.00, Occupational Safety and Health Management System 112

5. APPLICABLE NIST OCCUPATIONAL SAFETY AND HEALTH SUBORDERS 115

a. NIST S 7101.20: Work and Worker Authorization Based on Hazard Reviews 116

b. NIST N 7101.64: Electrical Safety 118

6. REQUIREMENTS 121

a. General Requirements 122

(1) OUs shall establish energy-control procedures, employee training, and annual inspections 124 prior to conducting servicing or maintenance on equipment where the unexpected 125 energizing, startup, or release of stored energy could occur and cause injury. 126

(2) LOTO locks and tags are not to be used for equipment removed from service when that 128 equipment presents no hazards to personnel. 129

(3) Tagout without Lockout 131

(a) If an energy-isolating device is not capable of being locked out by any means, a 133 tagout system shall be used. 134

(b) If an energy-isolating device is capable of being locked out, lockout shall be used 136 unless it can be demonstrated that the utilization of a tagout system will provide 137 employees and covered associates with full protection, which requires that ALL of 138 the following be met: 139

i. The tagout device shall be attached at the same location that the lockout device 141 would have been attached. 142

ii. Full compliance with all tagout-related provisions of this suborder shall be 144 demonstrated. 145

iii. Such additional elements as are necessary to provide the equivalent safety 147 available from the use of a lockout device shall be demonstrated. Additional 148 means to be considered shall include the implementation of additional safety 149 measures such as removal of an isolating circuit element, blocking of a 150 https://nistsafety.nist.gov/safetyweb/safetyweb/ViewTopicHome/1581 https://nistsafety.nist.gov/Programs/Programs/View/37

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 5 of 24 controlling switch, opening of an extra disconnecting device, or removal of a 151 valve handle to reduce the likelihood of inadvertent energization. 152

(c) Whenever replacement or major repair, renovation, or modification of equipment is 154 performed, and whenever new equipment is installed, energy-isolating devices for 155 such equipment shall be designed to accept a lockout device whenever the unexpected 156 energization or startup of the equipment, or release of stored energy, could cause 157 injury to employees. 158

b. Requirements for Written LOTO Procedures 160

(1) Written LOTO procedures are required unless ALL of the following circumstances 162 pertain: 163

(a) The equipment has no potential for stored or residual energy or re-accumulation of 165 stored energy after shut down which could endanger employees; 166

(b) The equipment has a single energy source which can be readily identified and 168 isolated; 169

(c) The isolation and locking out of that energy source will completely de-energize and 171 deactivate the equipment; 172

(d) The equipment is isolated from that energy source and locked out during servicing or 174 maintenance; 175

(e) A single lockout device will achieve a locked-out condition; 177

(f) The lockout device is under the exclusive control of the Authorized Employee 179 performing the servicing or maintenance; 180

(g) The servicing or maintenance does not create hazards for Other Employees; and 182

(h) The OU, in utilizing this exception, has had no accidents involving the unexpected 184 activation or re-energization of the equipment during servicing or maintenance. 185

(2) If a written procedure is required, the Authorized Employee shall: 187

(a) Use NIST’s online energy-control procedure application to develop an equipment-189 specific LOTO procedure; or 190

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(b) If not using NIST’s online energy-control procedure application, ensure that the 191 procedure clearly and specifically outlines the scope, purpose, authorization, rules, 192 and techniques to be utilized for the control of hazardous energy, and the means to 193 enforce compliance, including, but not limited to, the following: 194

i. A specific statement of the intended use of the procedure; 196

ii. Specific procedural steps for shutting down, isolating, blocking, and securing the 198 equipment to control hazardous energy; 199

iii. Specific procedural steps for the placement, removal, and transfer of LOTO 201 devices and the responsibility for them; and 202

iv. Specific requirements for testing the equipment to determine and verify the 204 effectiveness of LOTO devices and other energy-control measures. 205

c. Conduct of LOTO 207

(1) Each OU shall establish a procedure for tracking the application of LOTO locks and tags 208 when equipment is required to be taken out of service for 24 hours or more and LOTO 209 devices are applied. The information shall be readily available for auditing purposes and 210 contain at a minimum the following information: 211

(a) Tag number (if applicable); 213

(b) Name of employee applying the LOTO device and tag; 215

(c) Date and time LOTO devices and tags are applied; 217

(d) Location and equipment being locked and tagged, including where the LOTO devices 219 are applied; and 220

(e) Date LOTO devices are removed. 222

(2) LOTO shall be performed only by trained Authorized Employees in the following 224 sequence. 225

(a) Notifications shall be initiated prior to LOTO to ensure area supervisors and affected 227 personnel are aware of the energy source being locked out or controlled. This 228 notification should also include the anticipated duration of the shutdown. Authorized 229 Employees will also advise on any support equipment that may be impacted, 230

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 7 of 24 additional safety precautions being taken, and the type of control device(s) being 231 used. 232

(b) Preparations for the shutdown shall begin after all notifications have been made. 234

Authorized Employees must be fully aware of the type and magnitude of the energy, 235 associated hazards, and control methods of the energy involved. Authorized 236 Employees shall refer to owner/service manuals of the equipment they are working on 237 to ensure they are fully aware of any and all associated hazards. 238

(c) In performing the shutdown, Authorized Employee shall first advise Affected 240

Employees that shutdown is taking place. They shall then locate the energy source(s) 241 (always looking for hidden energy sources) and follow the procedures established to 242 shut down the equipment as prescribed. An orderly shutdown must be utilized to 243 avoid any additional or increased hazard(s) to employees as a result of the equipment 244 stoppage. 245

(d) All energy-isolating devices that are needed to control the energy to the equipment 247 shall be physically located and operated by an Authorized Employee in such a 248 manner as to isolate the equipment from the energy source(s). 249

(e) LOTO devices shall be affixed to energy-isolating devices by Authorized Employees. 251

(i) Lockout devices, where used in accordance with this suborder, shall be affixed in 253 a manner that will hold the energy-isolating devices in a "safe" or "off" position. 254

(ii) A lock and a tag shall be placed on each disconnecting means used to de-256 energize equipment on which work is to be performed. The lock shall be attached 257 so as to prevent persons from operating the disconnecting means unless they 258 resort to undue force or the use of tools. 259

(iii) Tagout devices, where used in accordance with this suborder, shall be affixed in 261 such a manner as will clearly indicate that the operation or movement of energy-262 isolating devices from the "safe" or "off" position is prohibited. Where tagout 263 devices are used with energy-isolating devices designed with the capability of 264 being locked, the tag attachment shall be fastened at the same point at which the 265 lock would have been attached. Where a tag cannot be affixed directly to the 266 energy-isolating device, the tag shall be located as close as safely possible to the 267 device, in a position that will be immediately obvious to anyone attempting to 268 operate the device. 269

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(f) After LOTO devices have been applied to energy-isolating devices, all potentially 271 hazardous stored or residual energy shall be relieved, disconnected, restrained, or 272 otherwise rendered safe. If there is a possibility of re-accumulation of stored energy 273 to a hazardous level, verification of isolation shall be continued until the servicing or 274 maintenance is completed, or until the possibility of such accumulation no longer 275 exists. 276

(g) Prior to starting work on equipment that has been locked or tagged out, the 278

Authorized Employee shall verify that isolation and de-energization of the equipment 279 have been accomplished. 280

(h) Before LOTO devices are removed and energy is restored to the equipment, actions 282 shall be taken by the Authorized Employee(s) to ensure that: 283

(i) The work area is inspected to ensure that any nonessential items have been 285 removed and that the equipment components (e.g., guards) are operationally 286 intact; 287

(ii) The work area is checked to ensure that all employees have been safely 289 positioned or removed; 290

(iii) After LOTO devices have been removed by the Authorized Employee(s) who 292 applied them but before energy is restored to the equipment, Affected Employees 293 are notified of the removal of the LOTO devices; and 294

(iv) When the Authorized Employee who applied a LOTO device is unavailable to 296 remove it, that device may be removed under the procedures outlined in Section 297 6h. 298

d. Temporary Removal of LOTO Devices 300

In situations in which LOTO devices must be temporarily removed from the energy-isolating 301 device and the equipment energized to test or position it or a component thereof, the 302 following steps shall be taken in sequence: 303

(1) Clear the equipment of tools and materials; 305

(2) Remove employees from the equipment area; 307

(3) Remove the LOTO devices; 309

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(4) Energize and proceed with testing or positioning; and 311

(5) De-energize all systems and reapply energy-control measures in accordance with Section 313

6c of this suborder to continue the servicing and/or maintenance. 314

e. Group LOTO Procedure 316 When multiple Authorized Employees (including servicing contractors) perform service or 317 maintenance on the same piece of equipment, a supervisor or Primary Authorized Employee 318 may determine that a group LOTO procedure is appropriate. 319

(1) General Requirements 321

(a) When more than one employee would be required to apply a LOTO device to the 323 same isolation point, a group LOTO device shall be utilized to allow each 324 employee’s LOTO lock to be affixed at the disconnecting device. 325

(b) When it is not practical to have all authorized employee LOTO locks to be attached 327 at the electrical power disconnecting device, a group lockbox shall be utilized. 328

(c) When LOTO is required to be performed and doing so requires securing multiple 330 energy sources with multiple authorized employees, a lockbox shall be utilized. 331

(2) When servicing or maintenance is performed by a crew, craft, department, or other 333 group, that entity shall utilize a procedure that affords the employees a level of 334 protection equivalent to the implementation of a personal LOTO device. 335

(3) When a group lockbox is required, all of the following requirements apply: 337

(a) A group LOTO lock shall be applied to each disconnecting device; 339

(b) The group LOTO lock keys shall be placed in the lockbox; 341

(c) All employees, including the Principal Authorized Employee, shall affix their 343

LOTO locks to the lockbox; and 344

(d) The Principal Authorized Employee shall then affix a Job LOTO lock and tag to 346 lockbox. 347

(4) The Principal Authorized Employee shall convene a meeting of all group members 349 covered under the LOTO procedure. 350

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(5) The Primary Authorized Employee may delegate a Principal Authorized Employee the 351 primary responsibility for a specified group working under the protection of the group 352 LOTO procedure. Supervisory responsibility is then vested in the Principal Authorized 353 Employee for the specific employees working under the protection of the group LOTO 354 devices. 355

(6) Each member of the specified group shall be trained and Authorized as described in this 357 suborder’s training requirements. 358

(7) The Principal Authorized Employee shall ensure that each step of the written LOTO 360 procedure has been completed and shall ascertain the exposure status of individual group 361 members with regard to the lockout or tagout of the equipment. 362

(8) Each Authorized Employee performing work on the equipment shall ensure every step 364 of the written procedure has been completed prior to placing their personal LOTO 365 device on the group LOTO device, group lockbox, or comparable mechanism when 366 he/she begins work. 367

(9) When the work has been completed, and after each employee has removed his/her 369 respective lock or tag from the group LOTO device, the Principal Authorized Employee 370 shall remove his/her LOTO lock or tag from the group LOTO device and return the 371 equipment to service as described in the procedure. 372

f. LOTO Procedures for Shift Changes 374

The following procedures shall be utilized during shift or personnel changes to ensure the 375 continuity of LOTO protection, including provision for the orderly transfer of LOTO device 376 protection between departing and oncoming employees, to minimize exposure to hazards 377 from the unexpected energization or start-up of the equipment, or the release of stored 378 energy. 379

(1) The requirements for group LOTO apply. 381

(2) The group LOTO lock shall remain attached to each energy control device. 383

(3) The job lock shall remain affixed to the lockbox or other approved group LOTO device. 385

(4) All off-going shift employees shall remove their individual LOTO locks and tags from 387 the lockbox or other approved group LOTO device. 388

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(5) The off-going principal authorized employee shall brief the oncoming person in charge of 390 the status of the project and inform all oncoming employees of any potential hazards. 391

(6) The person in charge of the off-going shift shall transfer custody of the key for the job 393

LOTO lock attached to the lockbox or approved group LOTO device to the oncoming 394 person in charge. 395

(7) All oncoming Authorized Employees shall place their locks and/or tags onto the group 397

LOTO device. 398

(8) Before work begins, the oncoming Authorized Employees shall verify isolation and de-400 energization of the equipment that has been locked or tagged out prior to restarting work. 401

g. LOTO Conducted by Non-R&D Contractors 403

(1) Contracting Officers (COs) or Contracting Officer Representatives (CORs) overseeing 405 non-R&D contractor shall ensure non-R&D contractors are not permitted to commence 406 work on NIST equipment when LOTO is required until: 407

(a) They have been provided with a copy of this suborder by the controlling NIST 409 organization and understand the requirements for LOTO devices; 410

(b) They have exchanged LOTO programs with the controlling NIST organization; 412

(c) The exchange of LOTO programs has been documented using the exchange-of-414 LOTO-programs form provided by the Office of Safety, Health, and Environment 415 (OSHE); and 416

(d) Information concerning non-R&D contractor LOTO procedures has been 418 communicated to NIST Affected Employees. 419

(2) When LOTO is performed by non-R&D contractors, the CO or COR shall ensure the 421 following: 422

(a) Prior to the non-R&D contractor performing their LOTO steps, the NIST organization 424 responsible for the system and/or equipment being turned over to the contractor shall: 425

i. Document and obtain the non-R&D contractor’s agreement via the COR on the 427 condition/status of the system and/or equipment being turned over; and 428

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ii. Affix their LOTO device(s) on all sources of energy and verify zero energy. 430

(b) The non-R&D contractor has applied their LOTO devices in accordance with their 432 contractor safety plan accepted by NIST. 433

(c) Prior to any testing of any system or equipment that requires re-introducing the 435 system or equipment into the NIST infrastructure, the NIST organization responsible 436 for the system and/or equipment shall ensure by applicable means that doing so 437 would have no impact to the NIST infrastructure. 438

(d) Prior to acceptance and the introduction or re-introduction of any system into the 440 NIST infrastructure by a non-R&D contractor, the NIST organization responsible for 441 the system or equipment shall ensure by applicable means that doing so would have 442 no impact to the NIST infrastructure. 443

(e) The LOTO lock and tag from the responsible NIST organization for the system 445 and/or equipment shall be the last to be removed. 446

h. LOTO Device Emergency Removal 448 WARNING: This is considered to be an emergency procedure only to be undertaken in 449 extreme circumstances with a supervisor’s approval and using extreme care. 450

(1) When an Authorized Employee who has applied a LOTO device is not available to 452 remove it, someone in his/her immediate supervisory chain may authorize its removal in 453 accordance with this emergency removal procedure. If the Authorized Employee's 454 immediate supervisor is not available, the emergency removal may be performed by one 455 level of management above the Authorized Employee's immediate supervisor or by a 456 delegated individual with documented authorization from the immediate supervisor. 457

(2) The following steps must be performed and documented using the Emergency LOTO 459

Lock Removal form provided by OSHE. 460

(a) The supervisor must verify the Authorized Employee is not at the NIST facility. The 462 supervisor must make every reasonable effort to contact the Authorized Employee. 463 This may include a telephone call to the employee's home or other location. These 464 efforts must be documented (e.g., email, registered letter, voicemail, or telephone 465 verbal assurance, etc.) by the supervisor. 466

(b) If the Authorized Employee is contacted, the supervisor must inform the employee 468 that his/her LOTO device is being removed. 469

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(c) The supervisor must verify that it is safe to remove the LOTO device. 470

(d) The supervisor may then authorize another Authorized Employee to remove the 472 LOTO device. 473

(e) The supervisor must ensure that before the LOTO device owner returns to work, 475 he/she is presented with the removed device and is informed of the reasons for the 476 emergency removal. 477

(f) The emergency procedure form must be signed by the supervisor and the Authorized 479 Employee who removed the lock and be retained in the OU’s LOTO records. 480

i. Locks, Tags, and Devices 482

Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other 483 hardware shall be provided by the OU for isolating, securing, or blocking of equipment from 484 hazardous-energy sources. 485

(1) General lockout device and tag requirements include: 487

(a) Locks and tags must be singularly identifiable; 489

(b) LOTO locks and tags must be the only devices used for controlling hazardous energy 491 during LOTO activities and not be used for any other purpose (e.g., for restricting 492 access, removing from service); 493

(c) LOTO locks and tags must be durable enough to withstand wet, damp, and corrosive 495 environments while they are in use on equipment, including ensuring the print on the 496 tag does not become illegible; 497

(d) LOTO locks must be substantial enough to prevent removal without the use of 499 excessive force or unusual techniques such as using bolt cutters or other metal cutting 500 tools. 501

(e) LOTO tags must be substantial enough to prevent inadvertent or accidental removal, 503 which means that they must have an attachment means of a non-reusable type, be 504 attachable by hand, be self-locking, and be non-releasable with a minimum unlocking 505 strength of no less than 225 N (50 lbf)), i.e., they must have characteristics similar to 506 those of a one-piece all-environment-tolerant nylon cable tie; and 507

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(f) LOTO locks and tags shall be standardized in at least one of the following criteria: 509 color, shape, or size; additionally, in the case of tagout devices, print and format shall 510 be standardized. 511

(2) NIST’s LOTO device requirements are as follows: 513

(a) Personal locks shall have red bodies and singular keys. 515

i. Authorized Employees with multiple personal locks may have them keyed alike. 517

ii. Personal locks must contain the identity of the Authorized Employee who applies 519 them. 520

iii. Supervisors of Authorized Employees may maintain copies of the keys to the 522 Authorized Employees’ personal locks to be used for emergency device removal 523 only. 524

(b) Group locks shall have red bodies and be keyed alike for each work group. 526

i. Group locks must contain the identity of the responsible organization that applies 528 them. 529

ii. Supervisors shall maintain copies of the keys to the group locks to be used for 531 emergency device removal only. 532

(c) Job locks shall have red bodies and may be keyed alike. 534

i. Job locks must contain the identity of the responsible organization that applies 536 them. 537

ii. Supervisors may maintain copies of the keys to the job locks to be used for 539 emergency device removal only. 540

(d) Lockout tags must meet the following ANSI Z535.5 criteria: 542

i. Danger tags shall have the word “Danger” in safety white letters on a rectangular 544 safety red background; 545

ii. Danger tags will be on a safety white stock; 547

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iii. Danger tags must contain the action statement, “Do Not Operate,” and, at a 549 minimum, the Authorized Employee’s name and phone number; pictures and 550 other information may also be applied to the tags; 551

iv. Tag message lettering should be typed; if printed messages are applied, they must 553 be legibly printed; and 554

v. Backs of tags may be used to give additional operating instructions, emergency 556 procedures, emergency telephone numbers, or to reinforce the critical role that the 557 LOTO tag holds; the back side of the tag should refer to the front side of the tag 558 and vice versa. 559

vi. Locks and tags used in conducting group LOTO shall: 561

(i) Have a distinguishing identifier to identify it as a group LOTO lock and tag; 563

(ii) Locks shall be keyed alike to a single master for each work group; and 565

(iii) Each lock shall be individually numbered. 567

vii. Locks and tags used as job locks and tags shall: 569

(i) Have a distinguishing identifier to identify them as a job LOTO lock and/or 571 tag; 572

(ii) Locks shall not be keyed alike; and 574

(iii) Each lock shall have an identifier indicating the organization to which it 576 belongs. 577

j. Training 579

(1) Training of Authorized, Affected, and Other Employees and their Official First-Level 581

Supervisors 582

(a) Authorized Employees shall complete: 584

i. The training provided by OSHE on the Control of Hazardous Energy (LOTO) 586 program; 587

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ii. The activity-specific training required by hazard reviews applicable to the work to 589 be conducted, including 590

(i) The recognition of applicable hazardous-energy sources; 592

(ii) The types and magnitudes of those hazardous-energy sources; and 594

(iii) The methods and means necessary for energy isolation and control, and 596 where tagout only is used, review of the following key points: 597

[i] Tags are essentially warning devices and do not provide physical 599 restraint like a lock. 600

[ii] When a tag is attached to an energy-isolating device, it is not to be 602 removed without authorization from the Authorized Employee identified 603 on the tag, and it is never to be bypassed, ignored, or otherwise defeated. 604

[iii] Tags shall be legible and understandable by all employees. 606 [iv] Tags and their means of attachment shall be made of materials that will 608 withstand environmental conditions encountered while on equipment. 609 [v] Tags may evoke a false sense of security and their meaning needs to be 611 understood as part of the overall energy-control program. 612 [vi] Tags shall be securely attached to energy-isolating devices so they 614 cannot be inadvertently or accidentally detached during use. 615

(b) Affected Employees shall complete activity-specific training on the purpose and use 617 of the energy-control procedures applicable to their assigned duties and work 618 locations and of the prohibition of attempts to re-start or re-energize equipment that is 619 locked or tagged out. 620

(c) When non-R&D contractors perform LOTO, Affected Employees shall be provided 622 with information concerning the non-R&D contractor’s energy control procedures. 623

(d) The activity-specific training for Authorized and Affected Employees shall be 625 provided by Authorized Employees who have successfully completed training on the 626 Control of Hazardous Energy (LOTO) program and who are familiar with the 627 applicable energy sources and the methods and means of energy isolation and control. 628

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(e) Official First-Level Supervisors of Authorized Employees shall complete the training 629 provided by OSHE on the Control of Hazardous Energy (LOTO) program. 630

(f) Other employees shall complete training provided by OSHE on the general purpose 632 and use of energy-control procedures and of the prohibition of attempts to re-start or 633 re-energize equipment that is locked or tagged out.4 634

(2) Retraining of Authorized and Affected Employees 636

(a) Authorized and Affected Employees shall complete activity-specific retraining 638 whenever:5 639

i. A change in their job assignment requires Authorized and Affected Employees to 641 service and maintain or operate additional equipment or introduces them to new 642 energy sources; 643

ii. A change in equipment or its operation presents a new hazard; 645

iii. A change in LOTO procedures is introduced; 647

iv. A LOTO annual inspection points to a systemic deficiency warranting retraining; 649 or 650

v. A LOTO annual inspection, observation, or other condition reveals deviations 652 from LOTO procedures or a employee is found to lack knowledge of those 653 procedures. 654

(3) Training shall be documented and recorded in accordance with the requirements, roles, 656 and responsibilities in the Safety Education and Training suborder. 657

k. LOTO Annual Inspections 659

(1) Annual Inspection of LOTO Procedures. 661

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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(a) Each energy-control procedure shall be separately inspected annually to ensure that 663 the energy-control procedure is adequate and is being properly implemented by 664 Authorized Employees. 665

(b) At a minimum, these inspections shall include a demonstration of the procedures by 667 Authorized Employees while servicing and/or maintaining equipment. 668

(c) The inspector, who must be an Authorized Employee other than the one(s) utilizing 670 the energy-control procedure being inspected, shall observe the implementation of the 671 energy-control procedure for the servicing and/or maintenance being evaluated and 672 talk with employees and covered associates implementing the procedure to determine 673 that all the requirements of this suborder are understood and being followed. 674

(d) The Authorized Employee performing the inspection may be someone who 676 previously has or currently implements the energy-control procedure being inspected, 677 as long as he/she is not implementing any part of the energy-control procedure while 678 it is being inspected. 679

(e) The inspector must be able to determine whether: 681

i. The steps in the energy-control procedure are being followed; 683

ii. The employees involved know their responsibilities under the procedure; and 685

iii. The procedure is adequate to provide the necessary protection, and, if inadequate, 687 what modifications are needed. 688

(f) Procedures may be reviewed together during one inspection as long as they involve 690 the same or similar types of energy-control methods. 691

(g) If procedures are grouped together for annual inspection, it is recommended that one 693 or more of the individual procedures (from the same group or from similar procedures 694 from the previous year) be reviewed on its own so that over time each procedure is 695 reviewed individually. 696

(2) Annual inspections shall be recorded using the LOTO inspection form provided by 698

OSHE and maintained by the OU until the completion of the next annual inspection. If 699 inspections reveal inadequate or improper LOTO procedures, the hazard or discrepancy 700 must be mitigated immediately and Authorized and Affected Employees must be 701 retrained as indicated in Section 6j. 702

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 19 of 24

7. DEFINITIONS 703

a. Affected Employee – Any employee who uses equipment subject to being serviced or 704 maintained under LOTO, or whose job requires him or her to work in an area in which such 705 servicing or maintenance is being performed. 706

b. Authorized Employee – A person who has completed the required hazardous-energy-control 708 training (general and procedure-specific) and is authorized by their Division Chief or 709 designee to lock and tag out the energy-control points in specific equipment or apparatus in 710 order to perform service or maintenance. A person must be an Authorized Employee to apply 711 a lock or tag to control hazardous energy. 712

c. Capable of Being Locked Out – An energy-isolating device is considered capable of being 714 locked out if it has a hasp or other means to attach a lock, has a locking mechanism built into 715 it, or can be locked without dismantling, rebuilding, or replacing the energy-isolating device 716 or permanently altering its energy-control capability. 717

d. Energized – Connected to an energy source or containing stored energy. 719

e. Energy-Isolating Device – A mechanical device that physically prevents the transmission or 721 release of energy, including but not limited to the following: a manually operated electrical-722 circuit breaker; a disconnect switch; a manually-operated switch by which the conductors of 723 a circuit can be disconnected from all ungrounded supply conductors and, in addition, no 724 pole can be operated independently; a line valve; a block; and any similar device used to 725 block or isolate energy. Push buttons, selector switches, and other control-circuit-type 726 devices are not energy-isolating devices. 727

f. Energy-Isolation Point – A location at which the flow or release of hazardous energy can be 729 prevented when a mechanism such as a valve, breaker, switch, blank off, or block-out is 730 placed in the “OFF” position. Control circuits such as computer-control circuitry and 731 software are not energy-isolation points. 732

g. Exclusive Control – A condition in which a employee has taken actions or is continuously in 734 a position to prevent (exclude) other individuals from re-energizing or starting equipment 735 while it is being serviced or maintained. 736

h. Group Lock Box – A key box containing the key(s) used to lock out equipment being 738 serviced by multiple Authorized Employees. Each Authorized Employee involved in the 739 servicing places his/her personal locks on the group lock box. The keys to the equipment 740 cannot be accessed until all Authorized Employees remove their locks. 741

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 20 of 24

i. Group LOTO – A procedure to coordinate service or maintenance work by several 743 Authorized Employees on locked/tagged out equipment. More than one Authorized 744 Employee may need access to the locked/tagged out equipment because it has multiple 745 energy sources, requires multiple LOTO procedures, or the work to be performed extends 746 across shifts. 747

j. Group Lockout Devices – Locks and tags used for group LOTO. 749

k. Hazardous Energy – Energy capable of causing personal harm or property damage if it is not 751 controlled. Types of hazardous energy include, but are not limited to, electrical, mechanical, 752 rotational, gravitational, chemical, radioactive, hydraulic, pneumatic, and thermal. 753

l. Hazardous-Energy Control – The process of systematically implementing engineering and 755 administrative means to prevent hazardous energy from flowing to a person. 756

m. Hazardous-Energy-Control Procedure – An equipment-specific procedure Authorized 758 Employees must follow to safely control hazardous energy during servicing or maintaining of 759 the equipment. 760

n. Hazardous-Energy Source – Equipment, machine, apparatus, process piping, and so on, 762 which is a source of hazardous energy. 763

o. Hot Tap – A procedure used in servicing and/or maintenance that involves welding on a 765 piece of equipment (pipelines, vessels, or tanks) under pressure, in order to install 766 connections or appurtenances. Hot taps are commonly used to replace or add sections of 767 pipeline without the interruption of service for air, gas, water, steam, and petrochemical 768 distribution systems. 769

p. Job Lock - A lock used in the performance of LOTO to allow for maintaining continuity of a 771 lockout/tagout condition between shift or workgroup changes. 772

q. Lockout – The placement of a lockout device on an energy-isolating device, in accordance 774 with an established procedure, to ensure the energy-isolating device and the equipment being 775 controlled cannot be operated until the lockout device is removed. 776

r. Lockout Device – Any device that uses a positive means such as a lock, blank flanges, and 778 bolted slip blinds to hold an energy-isolating device in a safe position to prevent equipment 779 from unexpectedly energizing. 780

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 21 of 24

s. Non-R&D Contractor – A NIST associate who performs non-R&D work at a NIST 782 workplace in accordance with the safety requirements of a contract or other legal 783 arrangement, such as a Memorandum of Understanding, with NIST Non-R&D contractors 784 include, but are not limited to, construction contractors; facilities contractors; equipment 785 installation, service, and maintenance contractors; Health Unit contractors; contract cafeteria 786 employees; and janitorial contractors. 787

t. Normal Operations – The utilization of equipment to perform intended functions. 789

u. Other Employee – An employee with duties that are or may be in an area where energy-791 control procedures may be utilized. 792

v. Personal Lock (or Locks) – A singularly keyed lock, or singularly keyed locks, issued to an 794 Authorized Employee used exclusively for the control of hazardous energy. 795

w. Personal Lockout Devices – Locks and tags used for personal LOTO. 797

x. Personal LOTO – LOTO performed by a single Authorized Employee on equipment with 799 one of more sources of hazardous energy. 800

y. Primary Authorized Employee - A primary authorized employee would coordinate 802 authorized employee changes and affected workforces (multiple work crews) with equipment 803 operators before and after completion of servicing and maintenance operations that require 804 LOTO. He/she also has the responsibility to ensure continuity of protection with respect to 805 multi-shift energy isolation (e.g., through the use of a "Job Lock". 806

z. Principal Authorized Employee - Principal authorized employee(s) would be designated for 808 each workforce or crew. When more than one crew, craft, department, etc., is involved, one 809 principal authorized employee would account for a single group of servicing/maintenance 810 personnel. Each principal employee is responsible (to the primary authorized employee) for 811 maintaining accountability and for the individual exposure status of each employee in that 812 specific group in conformance with the company procedure. 813

aa. Servicing and/or Maintenance – Workplace activities such as constructing, installing, setting 815 up, adjusting, inspecting, and modifying equipment that could expose employees to the 816 unexpected release of hazardous energy. Maintenance activities may also include lubrication, 817 cleaning, or unjamming equipment, and making adjustments or tool changes. 818

bb. Setting up – Any work performed to prepare equipment to perform its normal operation. 820

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 22 of 24

cc. Stored Energy – Energy located within any device after equipment is shut down. This 822 includes, but is not limited to, capacitors, tanks, pipes, springs, and flywheels. 823

dd. Tagout – The placement of a tagout device on an energy-isolating device, in accordance with 825 an established procedure, to indicate that the energy-isolating device and the equipment 826 being controlled shall not be operated until the tagout device is removed. 827

ee. Tagout Device – A prominent warning device, such as a tag and a means of attachment that 829 can be securely fastened to an energy-isolating device in accordance with an established 830 procedure, to indicate that the energy-isolating device and the equipment being controlled 831 may not be operated until the tagout device is removed. 832

8. ACRONYMS 835

a. CO – Contracting Officer 836

b. COR – Contracting Officer Representative 838

c. LOTO – Lockout/Tagout 840

d. OSHE – Office of Safety, Health, and Environment 842

e. OU – Organizational Unit 844

f. R&D – Research and Development 846

9. ROLES AND RESPONSIBILITIES 849

a. OUs: Ensuring that the requirements in Section 6 are met. 850

b. Chief Safety Officer: Ensuring that the training specified in Sections 6j for Other Employees 852 is included in training assigned automatically by the NIST electronic safety-training 853 application to employees and covered associates entering on duty. 854

10. AUTHORITIES 857

There are no authorities specific to this suborder alone. 858

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 23 of 24

11. DIRECTIVE OWNER 862

Chief Safety Officer 863

12. APPENDICES 866

A. Revision History 867

NIST S 7101.56 Ver. 5 (Uncontrolled Copy in Print) Page 24 of 24

Appendix A. Revision History 869

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, Occupational Safety and Health Management System.

• 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.

https://oshe.nist.gov/apps/docs/programs/Documents/NIST%20O%207101-00%20-%20Occupational%20Safety%20and%20Health%20Order_020216.docx https://oshe.nist.gov/apps/docs/programs/Documents/NIST%20O%207101-00%20-%20Occupational%20Safety%20and%20Health%20Order_020216.docx https://oshe.nist.gov/apps/docs/programs/Documents/NIST%20O%207101-00%20-%20Occupational%20Safety%20and%20Health%20Order_020216.docx