This information applies to Authorized Employees/Workers who perform Lockout/Tagout for protection of personnel from unexpected energization or startup of machinery and equipment, or the release of hazardous energy during operations, service, or maintenance activities.
Required Procedure
The Department Chair/Division Manager is responsible for directly implementing this procedure. This procedure also applies to lockout/tagout for conduct of operations on a graded approach for protection of equipment/programs and to provide operational information.
Lockout/tagout applies to fixed, permanently installed equipment, to temporarily installed equipment, and to portable equipment.
If an energy isolating device is capable of being locked, the Authorized Employee/Worker performing service or maintenance must use a lock.
Step 1 | Supervisors must ensure that all personnel are trained
to the hazard level they will be exposed:
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Step 2 | Authorized Employees/Workers must develop plans and controls for the servicing and maintenance, including lockout/tagout, of machines and equipment as per the requirements in the Work Planning and Control for Experiments and Operations Subject Area. |
Step 3 | Authorized Employees/Workers must visually inspect the
equipment prior to LOTO. If the equipment that will be deenergized exists
in a work area with other energized equipment that is similar in size,
shape, and construction that might be look-alike equipment and could be
mistaken for the equipment that is to be serviced or maintained. One of
the following methods must be used to prevent access to the wrong equipment:
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Step 4 | The equipment operator or the Authorized Employee/Worker must shutdown machine or equipment using the normal shutdown procedures. |
Step 5 | Authorized Employees/Workers, while performing the lockout/tagout process, must verify that all sources of hazardous energy are controlled to minimize exposure to all persons whether or not they are involved in servicing/maintenance. |
Step 6 | The Department/Division ensures that a specific written
lockout/tagout (LOTO) plan, when required (go to the various lockout/tagout
procedures in the Introduction
section), is developed, documented, and used (see the exhibit Samples
of Lockout/Tagout Plans). The plan must clearly and specifically outline
the scope, purpose, authorization, rules, and techniques to be used for
the control of hazardous energy including:
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Step 7 | The Department/Division ensures that all equipment that
may require servicing or maintenance and is capable of causing injury
is capable of being locked out. Note: Equipment installed before January 2, 1990, was not required to have means for locking out. Ensure equipment that is designed to accept a lockout device is installed whenever major replacement, repair, renovation, or modification of the equipment is performed. |
Step 8 | Whenever outside service personnel are required to perform lockout/tagout, as per the requirements of this procedure, the hosting Department/Division must ensure that they comply with the requirements of this procedure or that they have an approved equivalent procedure. |
Step 9 | Each Department/Division must conduct periodic inspections (audits) at least annually, of at least one LOTO in progress and LOTO plans in detail (see the exhibit Criteria for LOTO Inspections [Audits]. The Inspector (an Authorized Employee/Worker other than the one using the energy-control procedure being inspected) must keep a record of the LOTO procedure being audited to include the date, employees performing the procedure, and the person performing the audit. The Inspection must correct any deficiencies in the procedure, or in understanding the requirements of the procedure. Where tagout only is used for energy control, the inspection must include a review of the limitations of tagout only (i.e., tags are essentially warning devices that may evoke a false sense of security); tags must be legible and understandable by all Authorized Employees/Workers and Affected Employees/Workers; and the tags and their attachment means must withstand the environment they will encounter. A copy of the record of audit must be available for review for the past full year. |
Step 10 | If an energy isolating device is not capable of being locked, tagout devices must be affixed to clearly indicate that the operation of the energy isolating device is prohibited and additional means must be used for full employee protection, including the implementation of additional safety measures such as the removal of an isolating circuit element, blocking of a controlling switch, opening of an extra disconnecting device, or the removal of a valve handle to reduce the likelihood of inadvertent energization. |
Step 11 | The equipment required for LOTO for servicing or maintenance
includes a distinctive red tag (BNL Stock #S-81045) and a distinct Master
Lock with a red band (BNL Stock #I-65064) to be identifiable to the Authorized
Employee/Worker and only used for personal LOTO. LOTO locks with multiple
keys are allowable. An organizational-level procedure is required to document
how multiple keys are controlled (either destruction of additional keys
or controlled through administrative procedure). Contractors may use a Danger Tag that meets ANSI Z535.5, Safety Tags and Barricade Tapes and must use red banded locks with similar look to the BNL required lock. Tags must be capable of withstanding the environment to which they are exposed (laminating, sleeves, etc.). The equipment required for LOTO for conduct of operations must be compliant with ANSI Z535.5 –Safety Tags and Barricade Tapes, and any operations or system lock may be used when required (existing tags may be used until exhausted). Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware must be supplied by the Department/Division for BNL employees and by the employer for non-BNL employees. |
Step 12 | Tags are required in addition to locks with the following
exceptions:
Contractor tags must clearly indicate the company and employee applying the lock, if this information is not contained on the lock. |
Step 13 | Authorized Employees/Workers ensure that Hold tags are logged in LOTO log books when utilized |
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