GPR 1700.5.pdf

DIRECTIVE NO. GPR 1700.5D APPROVED BY Signature: Original Signed By

EFFECTIVE DATE: July 27, 2020 NAME: Eric K. Isaac

EXPIRATION DATE: July 27, 2025 TITLE: Director, Safety and Mission Assurance

CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.govTO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

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Goddard Procedural Requirements (GPR)

COMPLIANCE IS MANDATORY

Responsible Office: Code 360 / Safety Division

Title: Control of Hazardous Energy (Lockout/Tagout)

PREFACE

P.1 PURPOSE

This directive identifies practice and procedure requirements designed to protect employees through

Lockout/Tagout (LOTO) procedures. Specific definitions, practices, and procedures are outlined in

Occupational Safety and Health Administration (OSHA) Standards under 29 CFR. 1910.147, “The

Control of Hazardous Energy.”

P.2 APPLICABILITY

a. This directive applies to all civil servants and, to the extent provided in their contracts, contractors who perform hazardous-energy control operations at the Goddard Space Flight Center (GSFC), including Greenbelt, Wallops Flight Facility, and remote locations under GSFC control. This directive applies to all hazardous-energy control operations (both industrial and construction) such as, but not limited to, electrical, mechanical, hydraulic, pneumatic, chemical, and thermal sources. This directive applies to the control of energy during servicing and/or maintenance of machines and equipment. This directive also applies when an employee is required to remove or bypass a guard or safety device or when an employee is required to place any part of their body into an area on a machine or piece of equipment where an associated danger exists during a machine operating cycle.

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

c. 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 expected outcome; and “are/is” denotes descriptive material.

P.3 AUTHORITIES

a. 29 CFR Part 1910.147, The Control of Hazardous Energy (Lockout/Tagout), OSHA

b. 29 CFR Part 1926.417, Locking and Tagging of Circuits

DIRECTIVE NO.

GPR 1700.5D

EFFECTIVE DATE: July 27, 2020

EXPIRATION DATE: July 27, 2025

P.4 APPLICABLE DOCUMENTS AND FORMS

a. NPR 8715.3, NASA General Safety Program Requirements

b. GPR 1700.7, Electrical Safety

c. National Fire Protection Association (NFPA) 70E, Standard for Electrical Safety in the Workplace

d. GSFC Form 23-99, Control of Hazardous Energy Lockout/Tagout (LOTO) Periodic Inspection Form

P.5 CANCELLATION

GPR 1700.5C, Control of Hazardous Energy (Lockout/Tagout)

P.6 SAFETY

Safety requirements as noted through this document.

P.7 TRAINING

Authorized and affected employees shall be trained in accordance with Section 7. Training records are maintained as described in P.8.

P.8 RECORDS

Record Title Record Custodian Retention

LOTO Authorized Training and Associated OJT

Office of Human

Resources and Supervisors

NRRS 3/33C Destroy 5 years after employee discontinues or completes training.

Emergency Removal of LOTO

Device

LOTO Authorized

Manager/Supervisor

NRRS 1/117.5. Destroy 3 years after end of the calendar year.

Periodic Audit of the Control of Hazardous Energy Program.

LOTO Authorized

Manager/Supervisor and

Safety Office

NRRS 1/125A. Destroy when 10 years old or when superseded or obsolete, whichever comes first.

LOTO Event Log. LOTO Authorized

Manager/Supervisor

NRRS 1/117.5. Destroy 3 years after end of the calendar year.

Periodic Inspection Records Supervisor NRRS 1/117.5. Destroy 3 years after end of the calendar year.

*NRRS – NASA Records Retention Schedules (NRRS 1441.1) http://nodis3.gsfc.nasa.gov/library/lib_docs.cfm?range=1___

P.9 MEASUREMENT/VERIFICATION

a. Periodic Hazardous Energy Control Programmatic Audit Findings, noncompliance with OSHA or this GPR will be tracked to closure in the safety findings database.

PROCEDURES

1. ROLES AND RESPONSIBILITIES

1.1 Safety Division Control of Hazardous Energy Program Manager shall:

a. Evaluate/approve specific written procedures for (1) equipment that cannot be locked out; or (2) situations when a secondary means of isolation is not possible or deemed appropriate;

b. Provide information and consultation as necessary to management and employees involved in LOTO operations;

c. Review LOTO procedures for specific projects at the request of project managers or supervisors;

d. Review periodically this directive and the effectiveness of the LOTO program as outlined herein;

e. Assist LOTO-Authorized Managers and Supervisors as requested in providing LOTO training for civil service staff;

f. Provide contract and specification review as requested by project management and/or supervisors;

g. Function as the regulatory liaison with outside agencies as needed for LOTO issues; and

h. Verify compliance with standards set forth in the program by performing periodic audits of LOTO operations and the GSFC Control of Hazardous Energy Program.

1.2 LOTO-Authorized Managers and Supervisors shall:

a. Complete LOTO Authorized Employee training;

b. Ensure that identified LOTO-authorized employees complete LOTO Training Course and initial OJT for all applicable LOTO procedures;

c. Maintain records, including LOTO classroom and OJT training;

d. Upon the completion of training requirements, certify employees have been trained per this GPR;

e. Provide additional OJT as needed to ensure that employees are thoroughly familiar with new or changed equipment and/or procedures;

f. Maintain control of emergency keys for LOTO locks/devices;

g. Remove LOTO locks/devices in the event of an emergency or assign to designee and document;

h. Develop, make available and maintain written equipment-specific procedures;

i. Perform periodic inspections and certify their completion in accordance with 29 CFR 1910.147;

j. Maintain records of LOTO events;

k. Ensure an Energy Control Program and associated LOTO procedures are written and adhered to in accordance with the requirements defined in 29 CFR 1910.147;

l. Ensure affected employees in areas where authorized employees are performing service or maintenance have been identified and trained; and

m. Submit tagout procedures (only permitted when lockout/tagout is not feasible) to Code 360 Safety

Division for review and approval.

1.3 LOTO-Authorized Employees shall:

a. Complete the Organizational LOTO Training and initial OJT for all applicable LOTO procedures in order to be able to recognize the conditions of work requiring the utilization of LOTO procedures, determine and verify that isolation and de-energization methods are adequate, and determine whether residual or stored energy is present;

b. Use the materials and procedures specified in their organizations’ Energy Control Program and this directive to implement the LOTO program compliance requirements;

c. Apply LOTO devices (e.g., isolation devices, locks, and tags) in accordance with this GPR, control of hazardous energy procedures, and applicable equipment specific LOTO procedures;

d. When tagging out the energy source, use a standard LOTO tag which can be acquired via store stock. The organization performing the LOTO will be responsible for procuring and using the correct tag and lock;

e. Participate in the development of written equipment-specific procedures; and

f. Participate in periodic inspections and evaluate LOTO procedures for equipment they do not specifically service at least annually in accordance with 29 CFR1910.147(c)(6).

1.4 All Affected Employees shall:

Be familiar with their organizations’ LOTO Program (if civil servant) or their companies’ LOTO program (if contract employees, and to the extent required/provided in their contracts), and:

a. Be familiar with the purpose and use of LOTO procedures;

b. Understand how to recognize LOTO procedures when in use;

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

LOTO procedure; and

d. Complete LOTO Affected Employee training.

1.5 Contracting Officers shall:

To extent required/included in contracts, enforce the contract safety clauses and specifications for noncompliance if records of equivalent training cannot be produced or if LOTO procedures are found to be deficient with respect to this document.

1.6 Contracting Officer’s Representatives (CORs) shall:

a. Contact Safety Division office or Directorate Safety Representative for support in reviewing written

LOTO programs; and

b. To the extent required/included in contracts, ensure onsite contractors, and construction contractors in their Divisions are informed of and adhere to this GPR.

1.7 Onsite and Construction Contractors to the extent provided in contracts, shall:

a. Submit to the COR as part of the contract-required Safety Plan a LOTO program that meets the provisions of this directive; and

b. Make available to the COR upon request training, certification, or other records that meet the requirements in this document.

1.8 All organizations (civil servant and contractors) responsible for procurement or design of hazardous energy producing equipment shall require the design and procurement of hazardous energy-producing equipment to allow for the acceptance of a primary lockout device when new machinery or equipment is installed, repaired, renovated, or modified.

1.9 All organizations (civil servant and contractors) responsible for equipment with hazardous energy shall render hazardous energy producing equipment safe and communicate any potential hazards of equipment prior to transfer or disposal of equipment.

2. LOTO PROCEDURAL REQUIREMENTS

LOTO-identified activities shall have written equipment-specific LOTO procedures for each LOTO activity unless exclusions apply (see sections 2.1 and 2.5). Typical activities requiring LOTO procedures include, but are not limited to:

a. Service or maintenance of equipment with multiple energy sources;

b. Working on or near equipment with movable parts;

c. Clearing blocked or jammed mechanisms; and

d. Working on lines carrying hazardous materials/substances, materials/substances under pressure, or materials/substances involving dangerous temperatures.

Appendix A of 29 CFR 1910.147 provides a sample of a typical “minimum” LOTO procedure.

LOTO equipment-specific procedures shall include the requirements outlined in 29 CFR 1910.147(c)(4).

2.1 Exclusions

LOTO procedures do not apply, to minor tool changes, adjustments or other minor servicing activities that take place during normal production operations if they are routine, repetitive, and integral (as defined by OSHA) to the use of the equipment for production, provided that the work is performed using alternative measures that provide effective protection.

Refer to the decision-making flowchart in Appendix C. Use the flowchart as a tool to guide actions taken during the assessment of a variety of potential LOTO situations.

2.2 Emergency Removal

The LOTO authorized Manager or Supervisor may remove the energy-controlling device when the authorized employee who applied a LOTO device is not available to remove it. This emergency procedure will be performed only under extreme circumstances and in accordance with 29 CFR1910.147

(e) (3) the specific procedure shall include the following elements at a minimum:

a. Verification by the employer that the authorized employee who applied the device is not at the facility;

b. Making all reasonable efforts to contact the authorized employee to inform him/her that his/her lockout or tagout device has been removed; and

c. Ensuring that the authorized employee has this knowledge before he/she resumes work at that facility.

Documentation shall be maintained by the authorized Manager/Supervisor summarizing the circumstances of the emergency removal of a LOTO device or tagout device and rationale in such an event.

2.3 Tagout Only Procedures

Any energy-isolating device capable of being locked out shall be locked out using the LOTO program, without exception.

The use of a “tagout only” procedure shall:

a. Be permitted only if an energy-controlling source is incapable of being locked out and equipment was in place prior to 1990. All new or redesigned equipment with hazardous energy requiring service or maintenance must be designed with means of isolation in accordance with OSHA regulations and this GPR;

b. Provide an equivalent level of safety as if a lockout device was in place. Where possible, include a secondary means of isolating the hazardous energy. Examples include removal of an isolating circuit element, blocking of a controlling switch, opening of an extra disconnect device, or removal of a valve handle. Secondary means of isolation will be identified on the tag, and tags be affixed to both the primary energy-isolating device at the same location that the lockout device would be attached, and to the mechanism at the secondary point of isolation;

c. Use an equipment-specific LOTO written procedure approved by the Code 360 Safety Division if it is determined that an energy-supplying source is incapable of being locked out and a second means of isolation is not possible; and

d. Comply with all tagout procedure and device requirements outlined in 29 CFR 1910.147.

2.4 Equipment De-Energization (Outage)

All affected employees shall be notified prior to the de-energizing of equipment to be locked and/or tagged out. The person responsible for the outage will contact the Facility Operations Manager (FOM)

08/16 or personnel with authority over the area and the affected employees’ Supervisor, who will then notify the affected persons as to when and where the LOTO procedure will take place, and on what equipment.

LOTO authorized employees must verify that affected personnel communication has taken place prior to performing LOTO.

2.5 Equipment-Specific Written Procedures

The organization performing the service or maintenance shall develop, document and utilize for the control of potentially hazardous energy when employees are engaged in the activities covered by this document. The LOTO manager or supervisor will ensure a procedure is written to address all LOTO operations that do not meet the exception as stated below.

The following events requiring LOTO are exempt from developing equipment-specific written procedures for a particular machine or equipment:

a. When all the following are true:

1. The machine or equipment has no potential for stored or residual energy or re-accumulation of stored energy after shut down which could endanger employees;

2. The machine or equipment has a single energy source which can be readily identified and isolated;

3. The isolation and locking out of that energy source will completely de-energize and deactivate the machine or equipment;

4. The machine or equipment is isolated from that energy source and locked out during servicing or maintenance;

5. A single lockout device will achieve a locked-out condition;

6. The lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance;

7. The servicing or maintenance does not create hazards for other employees; and

8. The employer, in utilizing this exception, has had no accidents involving the unexpected activation or re-energization of the machine or equipment during servicing or maintenance.

b. When the work is an electric power generation, transmission, or distribution and compliance with

29 CFR 1910.333 and GPR 1700.7 is maintained.

2.6 Requirements for Shift and Personnel Changes

The LOTO authorized employees designated as the lead for the maintenance activity for both shifts shall ensure the continuity of LOTO protection during shift or personnel changes if work is to be continued by an oncoming shift and orderly transfer of LOTO devices and procedures between authorized employees or supervisors.

2.6.1 The outgoing shift shall:

a. Be present during LOTO transition with the oncoming shift;

b. Remove locks and tags after oncoming shift has applied their locks and tags, and give an update of any work changes; and

c. Inform the oncoming authorized employees of any potential hazards.

2.6.2 The oncoming shift shall:

a. Be present during the LOTO transition with the outgoing shift;

b. Verify all energy sources are isolated and a zero energy state still exists; and

c. Place its lock and tag on the group LOTO device, immediately.

2.7 Group Lockout Tagout

When servicing and or maintenance is performed by a crew, department, or other group, Lockout or

Tagout procedures used shall:

a. Give the employees a level of protection equivalent to that provided in a personal Lockout or Tagout procedure;

b. Incorporate these additional requirements over personal Lockout procedures. The first or lead lock on a group lockout tree or box will be red to adhere to the standardization protocols set forth in this document. It is the first lock on and the last lock off. Other locks on the tree or box can vary in shape, size or color depending on the organization’s protocol for LOTO devices;

c. Assure that an authorized employee is assigned primary responsibility for a set number of employees working under the protection of a group Lockout or Tagout device; and

d. Assure that the authorized employee be able to determine the exposures of individual group members with regard to the Lockout or Tagout of the machine or equipment.

3. LOTO DEVICES

3.1 Lockout Locks

Lockout locks shall be red in color and not be used for any other purpose. Red shrink wrap material can be used to meet this requirement. See Figure 1 for examples of red locks and acceptable red shrink wrap material.

3.2 Lockout Locks

LOTO devices shall be:

a. Durable to the environment to which they are exposed.

b. Indicate the identity of the employee applying the device(s). This can be accomplished with a legible tag or legibly written on the lock itself.

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c. Be provided by the authorized user’s organization. This includes locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware for the purpose of isolating, securing or blocking of machines or equipment from hazardous energy sources.

3.3 LOTO Keys

The primary key used for a LOTO pad lock shall remain in the possession of the authorized employee who applied the lock.

Organization may maintain a backup key. If an emergency key is available, the key shall be:

a. Kept in a secured area (e.g., a lock box) with access limited to the authorized employee’s immediate supervisor; and

b. Used only in accordance with Section 2.2 of this procedure.

Figure 1

3.4 LOTO Tags

Tags shall not be used in lieu of a lock unless the energy-isolating device is not physically capable of being locked. In the event a lock cannot be used, tagout procedures will comply with 29 CFR

1910.147(c)(3) and Section 2.3 of this document.

Tagout Tags shall:

a. Contain a statement prohibiting the operation of the energy isolating device or removal of the tag and clearly identify use for lockout/tagout;

b. Conform to the durability and securing requirements specified in 29 CFR 1910.147(c)(5); and

c. Indicate the identity of the authorized employee applying the LOTO device. All other applicable sections of the tag should be completed.

4. Record of LOTO Events

Documentation for each LOTO event shall be recorded in an organizational/department or project log, or the equivalent. The following information should be recorded:

a. Name of authorized employee who performed the LOTO process;

b. Date and time LOTO was applied;

c. Equipment and/or circuit identification;

d. Reason for LOTO application;

e. Schematic drawing or print numbers of equipment/machine being serviced, when available;

f. Date and time of proposed LOTO removal; and

g. Name of authorized employee who removed LOTO if different from authorized employee who initiated the LOTO process.

5. Release from Lockout and/or Tagout

Before the device(s) is/are removed and energy restored, the authorized employee shall:

a. Inspect the machine/equipment for foreign objects and remove them to bring an operational safety state; and

b. Ensure other employee(s) are in a safe area away from the machine / equipment when being re-energized after the completion of maintenance or repair, notify affected employee(s) about the

LOTO devices been lifted.

6. Periodic Inspections and Audits

6.1 Periodic Inspections

Organizations (civil servant and contractors) performing lockout/tagout, shall perform annual periodic inspections in accordance with OSHA regulations (29 CFR 1910.147(c)(6). Periodic inspections must include the following:

a. Performed by an authorized employee other than the personnel utilizing the energy control procedure being inspected;

b. Evaluate if equipment-specific LOTO procedure is adequate and provides necessary protection from potential hazard energy;

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c. Review employee’s understanding of their responsibilities and whether the steps are being followed of the equipment-specific LOTO procedure being audited;

d. Include a representative sample of employees responsible for implementing the equipment-specific procedures and review any findings with all authorized employees which are responsible for implementing the equipment-specific LOTO procedure;

e. Audit both affected and authorized personnel when tagout procedures are used when LOTO is not feasible (Section 2.3); and

f. Certification from the employer that periodic inspections have been completed and shall include the following:

1. Machine or equipment requiring equipment-specific LOTO procedure;

2. Date of inspection;

3. Name of authorized employee(s) being reviewed;

4. Name of authorized employee(s) performing inspection.

GSFC Form 23-99 provides an example template for completing periodic inspections.

6.2 Control of Hazardous Energy Program Audit

GSFC Safety Office shall perform periodic audits of the GSFC Control of Hazardous Energy Program and this GPR. Audits will include sampling reviews of civil servant and contractor organization’s control of hazardous energy programs and compliance with OSHA regulations and this GPR.

7. Control of hazardous energy training

Authorized and affected Employee training shall:

a. Include the course content requirements as defined by 29 CFR 1910.147(c)(7);

b. Include a method to verify proficiency (e.g., written examination, observation) to determine adequacy and retention of training for Authorized Employees;

c. Include on-the-job training on lockout/tagout program and equipment specific procedures for authorized employees;

d. Be conducted periodically but not less than every 3 years or whenever there is a change in their job assignments, a change in machines, equipment or processes that present a new hazard, or when there is a change in the energy control procedures;

e. Be conducted whenever a periodic inspection reveals, or whenever the manager or supervisor has reason to believe, that there are deviations from or inadequacies in the authorized or affected employee’s knowledge or use of these LOTO procedures. The retraining activity must re-establish authorized or affected employee proficiency and introduce new or revised control methods and procedures as necessary; and

f. Be maintained in GSFC learning records database for civil servant personnel. Contractors may their organizations method for tracking and documenting training completion.

Appendix A – Definitions

A.1 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.

A.2 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.

A.3 Capable of being locked out – An energy-isolating device is capable of being locked out if it has a hasp or other means of attachment to which or through which a lock can be affixed, or it has a locking mechanism built into it. Other energy-isolating devices are capable of being locked out if lockout can be achieved without the need to dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy control capability.

A.4 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.

A.5 Energy source – Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy.

A.6 Lockout – The placement of a 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.

A.7 Lockout/Tagout (LOTO)-Authorized Managers and Supervisors – The person who is responsible for managing and supervising the lockout/tagout operations and authorized employees performing LOTO operations.

A.8 Lockout device – A device that utilizes a positive means such as a lock, either key or combination-type, to hold an energy isolating device in a safe position and prevent the energizing of a machine or equipment. Included are blank flanges and bolted slip blinds.

A.9 Normal production operations – The utilization of a machine or equipment to perform its intended production function.

A.10 Servicing and/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 energizing or startup of the equipment or release of hazardous energy.

A.11 Setting up – Any work performed to prepare a machine or equipment to perform its normal production operation.

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A.12 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.

A.13 Tagout device – A prominent warning device, such as a tag and a means of attachment, which can be fastened securely 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.

Appendix B – Acronyms

CFR Code of Federal Regulations

COR Contracting Officer’s Representatives

CPR Cardiopulmonary Resuscitation

FAR Federal Acquisition Regulation

FOM Facility Operations Manager

GPR Goddard Procedural Requirement

GSFC Goddard Space Flight Center

LOTO Lockout/Tagout

NASA National Aeronautics and Space Administration

NPR NASA Procedural Requirement

NRRS NASA Records Retention Schedules

OJT On-the-Job Training

OSHA Occupational Safety and Health Administration

Appendix C - LOTO Process

CHANGE HISTORY LOG

Revision Effective Date Description of Changes

Baseline 06/02/05 Initial Release

A 04/02/10 Administratively Revised to update the Responsible Office

Code, Organization Title and organization name within the document.

Administratively extended for 1 year from original expiration date.

B 01/13/12 Document has been updated to comply with standardization requirements for LOTO devices across the center.

C 10/26/15 Update to remove administrative locking requirements. Group lockout tagout added. Updated Responsible Office Code and

Organization name within the document.

D 07/27/20 Document was revised to reflect current GSFC practices, additional of lockout/tagout requirements in NFPA 70E, and highlight procedures to comply with OSHA standards. Major changes include:

- Added section to clarify requirements for periodic inspections and added a form to provide a template for complying with OSHA periodic inspections.

- Refresher training was updated from every 4 years to 3 years to match new requirements in NFPA 70E.

- Added GSFC practice of performing periodic audits to ensure GSFC organizations including contractors are complying with OSHA and GPR requirements.