LOTO manual for beginners

8/14/2019 LOTO manual for beginners

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NFPA 70E

LOCKOUT/ TAGOUTGUIDE


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FORWAR

FORWARD

This Guide was developed by NECA to assist the industry in understanding and applying Lockout/Tagout (LOTO).

The content is based on the NFPA 70E requirements in Article 120 Establishing an Electrically Safe Work Condi-

tion. However, reference to the Occupational Safety and Health Administration (OSHA) regulations associatedwith LOTO will be made.

This reference is not designed as a replacement for the NFPA standard nor the OSHA regulations. Its purpose is

to serve as a quick reference for contractors working in the eld. We encourage all members to obtain a copy of

NFPA 70E and to consult the applicable OSHA regulations.

We would like to thank all individuals and organizations whose contributions facilitated the development of this

Guide. It is our sincere desire that the use of this Guide will assist our industry in creating a safer and more pro-

ductive workplace.


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TABLE OF CONTEN

TABLE OF CONTENTS

Forward 2

Overview 4-8

LOTO Preparation 9Hazard Control Procedure Determination 10-11

Individual LOTO 12

Simple LOTO Procedure 13-21

Simple LOTO Removal 22

Complex LOTO Procedure 23-33

Complex LOTO Removal 34

Appendices

- Glossary 35-36

- Lock and Tag Suitable for Use Checklist 37Acknowledgements 38


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OVERVIE

OVERVIEW

A universal safety concept is to control hazardous energy. This applies to all forms of energy including, mechanical,pneumatic, hydraulic and electric. This document will focus on controlling electrical hazardous energy. When workin

with electricity this means all live parts must be deenergized, the energy source locked out and/or tagged out (LOTOand conditions veried before work can be performed.1Consensus standards and government regulations direct themethods by which energy control or LOTO are performed.

NFPA (National Fire Protection Association) 70EThe NFPA 70E Standard for Electrical Safety in the Workplace is the consensus standardmost commonly referred to for electrical safety-related work practices. It has been inexistence since 1979 and it applies to all installations covered by the National Electrical Code(NEC). The Committee which developed this standard consists of competent individualsrepresenting all interests.

The NFPA 70E requirements for controlling hazardous energy can be found in Article 120Establishing an Electrically Safe Work Condition. It is divided into three sections:

> Section 120.1 Process of Achieving an Electrically Safe Work Condition.All possible sources of electrical supply must be determined using up-to-date informationsuch as drawings, diagrams and identication tags. The load must be interrupted,disconnecting devices opened, and visually veried. LOTO is then implemented. Voltagemust be tested. If there is the potential for induced or stored voltage, grounds must be

applied.

1OSHA 1910.333 (a)(1) prohibits work on live parts ... unless the employer can demonstrate that deenergizingintroduces additional or increased hazards or is infeasible due to equipment design or operational limitations.

Also see 1926.416(a)(1). Consult the NECA PPE Selector Guide for required precautions when working energized.


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OVERVIE

> Section 120.2 Working On or Near Deenergized Electrical Conductors or

Circuit Parts That Have Lockout/Tagout Devices Applied

All electrical circuits, conductors and parts must be considered energized until the LOTOprocedure is completed. Any employees directly or indirectly exposed to the electricalenergy must be involved in the process. Training must be provided in accordance with theextent to which the employee is involved. A plan and procedures must be in place forexecution of all elements of LOTO. This includes the training required, unique identicationof the LOTO devices, the forms of control used, elements of control, coordination withLOTO procedures for other energy sources, and annual audit procedures.

LOTO devices must be unique and clearly identiable as a LOTO device. It may not beused for another purpose. Locks must be associated with and operable by only theindividual who installed it. Tags shall be suitable for the purpose and contain a statementprohibiting operation of the disconnecting device and removal of the tag.

The forms of control are related to the complexity of the energy control. An individualLOTO is used by a qualied person when the disconnecting means remains visible tothat person during the work and the work does not extend beyond one shift. A SimpleLOTO procedure can be used when qualied person(s) are working on one set of conductorsor circuit parts. Each person must have control over his or her lockout. A ComplexLOTO must be used when there are multiple elements involved such as multiple crews,energy sources, or locations. In the Complex LOTO procedure, a qualied person isappointed responsibility for the procedure. This person must account for all energysources and all persons working on the job. A written plan is needed for execution of theLOTO procedure.

The elements of control follow the steps from deenergization, verication, and applicationand removal of the LOTO devices for testing or positioning of equipment and/or returningto service. It addresses what happens during shift changes and coordination with other jobs or tasks.


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OVERVIE

Each of these standards has basic requirements in common. In fact, OSHA nds an electrical

LOTO program using the procedures in 1910.147 compliant with 1910.333 so long as the

procedures include:

1) a qualied person ensuring tests are performed to verify the circuit is deenergized andcannot be inadvertently energized or energized by induced voltage or backfeed, and

2) if a tag alone is used, an additional safety measure is used that includes the removal

of an isolating circuit element, blocking of a controlling switch, or opening of an extra

disconnecting device.

Although the regulations have similarities, compliance often mandates that one navigate

these standards to address requirements applicable to the unique steps for tasks in given

operation. For example, in power transmission and distribution, OSHA authorizes the systemoperator to place and remove LOTO devices that are in a central location and inaccessible to

the authorized employees. However, the employers hazardous energy control procedures

must still provide employees the same level of personal control they would have in personal

LOTO.


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OVERVIE

Electrically Safe Work Condition

In the example cited above, the employer must decide how to meet the level of protection

required. This is common in OSHA standards. They are written in performance-based

language leaving the employer to determine procedures.When a compliance inspection isconducted, OSHA may defer to consensus standards to compare the effectiveness of the

employers procedures with industry accepted practice.

This leads back to the purpose of this Guide. In the case of electrical LOTO for NEC

installations,NFPA 70E is used. It calls for live parts to be placed in an electrically safe work

condition before employees can work on or near them. An electrically safe work condition is

dened as A state in which an energized conductor or circuit part has been disconnected

from the energized parts, locked/tagged in accordance with established standards, tested to

ensure the absence of voltage and grounded if determined necessary. This Guide will providesimplied instructions for achieving an electrically safe work condition. It offers the basics

of compliance. All electrical contractors should become familiar with NFPA 70E and the

applicable OSHA regulations to ensure the safety of their employees.


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LOTO PREPARATIO

LOTO PREPARATION

1.Review the Company Written LOTO Plan.

2.Identify all energy sources including stored energy.3.Locate all disconnecting means and identify procedures to release stored energy.

4.Determine the means for verifying disconnection.

5.Identify all workers who may be affected or exposed by the LOTO.

6. Ensure that all employees are trained to the degree necessary to execute theirresponsibilities as related to the LOTO procedure.

7.Identify the appropriate voltage tester that will be used.

8.Develop procedures* for verifying operability of tester and determine appropriate procedure.

9.Determine the need for grounding.

10.Develop the procedures for controlling energy.

11.Coordinate electrical LOTO procedures with other means of hazardous energy control.

* NOTE: Field and test lab procedures.


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HAZARDOUS ELECTRICAL ENERGY CONTROL PROCEDURES DETERMINATIO

HAZARDOUS ELECTRICAL ENERGY CONTROL PROCEDURES DETERMINATION

Continue

Determina

Go to next

Is the employee performing work qualied?

Is the work minor maintenance, servicing, adjusting,

cleaning, inspection, operating conditions, or similar?

Is the equipment with exposed conductors or circuit parts

adjacent to the disconnecting means and visible to the

individual while work is performed?

Will the work extend beyond one shift?

An Individual qualied employee control is allowed.

Work can be performed without the placement of

lockout/tagout devices on the disconnecting means.

(See NFPA120.2(D)(1)).Go to Individual Qualied Employee Control

on page 12.

Yes

Yes

Yes

No

No

No

No

Yes


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HAZARDOUS ELECTRICAL ENERGY CONTROL PROCEDURES DETERMINATIO

Is the purpose of the lockout limited to work byqualied persons performed on or near electrical

equipment or conductors?

HAZARDOUS ELECTRICAL ENERGY CONTROL PROCEDURES DETERMINATION

A Complex L

can be perfor

Go to page

Will the work involve only one qualied person

deenergizing one set of conductors or circuit parts?

Does the work involve different disconnecting means?

Will the job/task extend into more than one work period?

A Simple LOTO can be performed.

Go to page 13.

Yes

Yes

No

No

No

No

Yes

Yes


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INDIVIDUAL QUALIFIED EMPLOYEE CONTR

INDIVIDUAL QUALIFIED EMPLOYEE CONTROL

When work such as minor maintenance,

servicing, inspection and cleaning are performed

lockout/tagout may not be needed. The disconnectingmeans must be adjacent to the conductor,

circuit parts, and equipment and clearly visible

to the qualied employee involved in the work.

Work cannot extend beyond one shift.


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SIMPLE LOTO PROCEDUR

SIMPLE LOTO PROCEDURE

Step 1. Notify Personnel

All employees need to be made aware that a lockout/tagout is going to take place.

Affected employees

Informed power will be off, the reason

for it and not to operate equipment

Responsible (qualied) Employee

Informed of all energy sources and

location including stored energy


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Step 2. Disconnect and Deenergize

The responsible qualied person shall ensure the load is interrupted and disconnected from all energy sources todeenergize the circuit or equipment.

Interrupt load-

Switches should beactivated to turn off the

circuit or equipment

Deenergize -

Operate disconnecting

means and verify

disconnection


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Step 3. Release Stored Energy

After disconnecting and deenergizing, residual energy may remain stored in the equipment or circuits. Electrical enefrom capacitors must be discharged and high capacitance elements short circuited according to established proced

Procedures must also be coordinated with other LOTO efforts and stored energy such as hydraulic, pneumatic, and

mechanical must be released.

Discharge electrical energy

Release all other stored energy


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Lock Use

The exposed employee shall

apply a lock or be accounted

for by other means.

Tag Use

Each employee shall apply a tag,

sign tag or be accounted for by

other means.

Additional safety measure with

(Removal of an isolating circuit

element, blocking of a controlling

switch, opening of an extra disco

necting device, or the removal of

valve handle to reduce the likelih

of inadvertent energization.)


Step 4. Apply Locks and/or Tags

Apply locks (or tags) to all disconnecting means used to deenergize the circuit. A tag without the use of a lock may be applied in situations where the equipment does not allow a lock. If a tag is used, another safety measure must be

used to protect employees. The responsible person must account for all exposed employees.


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Step 5. Verication - Attempt to Operate

Ensure the equipment is or circuit is deenergized and cannot be reenergized with the lock or tag in place by attempt

to operate the equipment, switches and/or other disconnecting means.


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Step 6. Verication - Test for the Absence of Voltage*

Testing for the absence of voltage is a critical step. The tester itself must be tested before and after the equipment o

cuit to compete the verication process.

a) Select an appropriate voltage tester b) Inspect the tester

* NOTE: See NFPA 70E 110.9 and 130.4 for requirements when using test instruments and equipment.


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Step 6. Verication - Test for the Absence of Voltage



c) Verify proper operation of the tester* d) Test for voltage e) Verify proper operation of test

* Sample Procedure - Verication of Tester

1. Test for voltage on circuit2. Deenergize the circuit3. Retest deenergized circuit for voltage using same voltage tester


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Step 7. Apply Grounds

Where there is potential for induced voltage, release of stored electrical energy or other potential contact with

energized parts, apply grounds rated for the maximum available fault current for the time necessary to clear the fau


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Step 8. Perform Work

Once the LOTO procedure has been completed according the

established procedures, work can be performed using

approved work practices.

The LOTO will remain in place until work is complete. If testing

or positioning requires the equipment to be reenergized,

contact your supervisor for applicable procedures. For additional

information see OSHA 1910.147 (f)(1). If work must extend for

more than one work period, one energy source, one work location,

or if another individual or crew is involved, the Complex LOTO

procedure must be used.


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REMOVAL OF SIMPLE LOTO 2

1.Perform quality tests/checks

2.Remove locks and/or tags

3.Notify owner and return disconnect to operating condition

4. Verify task complete

5. Remove tools and equipment

6. Remove grounds

7. Notify personnel

2In a Simple LOTO, if the individual who installed the LOTO is not presentto remove the lock and/or tag, an attempt must be made to contact them.See OSHA 1910.147(e)(3) Exemption to paragraph (e)(3).


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COMPLEX LOTO PROCEDUR

COMPLEX LOTO PROCEDURE

Step 1. Identify a Person-in-Charge

A person-in-charge must be assigned at the location to install or direct

the installation of lockout and/or tagout devices and prepare a written

plan for the LOTO that:

a) addresses how the energy will be controlled,

b) ensures all exposed employees understand the hazards,

c) establishes a method for accounting for all exposed persons

involved in the LOTO,

d) denes the transfer of LOTO to successive shifts and

e) denes how effective communication with all employees is

to be accomplished.


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Step 2. Prepare a written plan for this LOTO

The person-in-charge must prepare a written plan outlining the procedures for the LOTO. Be sure to review the proc

dures for how employees are accounted for during the course of the LOTO and for changes in shifts should they oc

Person-in-charge shall lock his/her key in a lock box. Sign in/out log for all personnel entering the area.


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Step 3. Notify Personnel

All personnel need to be made aware that a lockout/tagout is going to take place.

Affected Employees

Informed power will be off, the reason for it and not

to operate equipment

Authorized Employees

Informed of equipment/circuit to be locked

or tagged out and procedures


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Step 4. Disconnect and Deenergize

The responsible qualied person shall ensure the load is interrupted and disconnected from all energy sources to

deenergize the circuit or equipment.

Interrupt load - Switches should be activated

to turn off the circuit or equipment.

Deenergize- Operate disconnecting

means and verify disconnection.

(Visually verify blades open or use othermeans such as indicator lights.)


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Step 5. Release Stored Energy

After disconnecting and deenergizing, residual energy may remain stored in the equipment or circuits. Electrical ene

from capacitors must be discharged and high capacitance elements short circuited according to established procedProcedures must also be coordinated with other LOTO efforts and stored energy such as hydraulic, pneumatic, and

mechanical must be released.

Discharge electrical energy

Release all other stored energy


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Step 6. Apply Locks and/or Tags

Apply locks (or tags) to all disconnecting means used to deenergize the circuit. A tag without the use of a lock may

be applied in situations where the equipment does not allow a lock. If a tag is used, another safety measure must beused to protect employees. The responsible person must account for all exposed employees.

Lock Use

Each exposed employee shall apply a

lock or be accounted for by other means.

Person in charge shall lock keys in box.

Tag Use

Each employee shall apply a tag, sign tag

or be accounted for by other means.

Additional safety

measure with Tag

(Removal of isolatin

circuit element, blo

of controlling switch

opening of extra dis

necting device, or r

of valve handle to r

likelihood of inadve

energization.)


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Step 7. Verication - Attempt to Operate

Ensure the equipment or circuit is

deenergized and cannot be reenergizedwith the lock or tag in place by attempting

to operate the equipment, switches and/or

other disconnecting means.


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Step 8 Verication - Test for the Absence of Voltage*



a) Select an appropriate voltage tester b) Inspect the tester


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Step 8 Verication - Test for the Absence of Voltage*

Testing for the absence of voltage is a critical step.

The tester itself must be tested before and after theequipment or circuit to compete the verication process.

c) Verify proper operation of the tester*

d) Test for voltage

e) Verify proper operation of the tester

* Sample Procedure - Verication of Tester1. Test for voltage on circuit2. Deenergize the circuit3. Retest deenergized circuit for voltage

using same voltage tester


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Step 9. Apply Grounds

Where there is potential for induced voltage, release of stored electrical energy or other potential contact with

energized parts, apply grounds rated for the maximum available fault current for the time necessary to clear the fau


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Step 10. Perform Work

Once the LOTO procedure has been completed according

the established procedures, work can be performed usingapproved work practices.

The LOTO will remain in place until work is complete.

If testing or positioning requires the equipment to be

reenergized, contact the person-charge for applicable

procedures. For additional information see OSHA

1910.147 (f)(1). In the event of a shift/personnel change,

the person-in-charge shall place or supervise the place-

ment of a special supervisory lock that will remain in placeuntil the new authorized person(s) begin work and are

accounted for in accordance with the procedure in the

plan or apply their own personal locks.


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REMOVAL OF COMPLEX LOTO3

1.Notify personnel

2. Perform quality tests/checks

3.Remove of locks and/or tags

4. Notify owner and return disconnect to operating condition

5. Verify task complete

6. Remove tools and equipment

7.Remove grounds

3If the individual(s) who installed the LOTO is/are not present to remove a lock atag an attempt must be made to contact them. See OSHA 1910.147(e)(3) Exemto paragraph (e)(3). In a Complex LOTO, the person-in-charge will be responsib

accounting for all persons involved.


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GLOSSAR

GLOSSARY

This glossary includes denitions found in NFPA 70E and/or OSHA Regulations. It also includes terms used in this ma

as referenced in those documents for which a denition is offered here to clarify procedures described in this manual.

Affected Employee (OSHA) - an employee whose job requires him/her to operate or use a machine or equipmon which servicing or maintenance is being performed under lockout and/or tagout, or whose job requires him/h

to work in an area in which such servicing or maintenance is being performed.

Authorized Employee (OSHA) - an employee who locks out or tags out machines or equipment in order to

performservice or maintenance on that machine or equipment. (An Affected Employee becomes and Authoriz

Employee when that employees duties include performing servicing or maintenance under this section.)

Complex Lockout/Tagout - a procedure described in NFPA 70E where multiple energy sources, crews, locatio

or employers exist, or there are different disconnecting means or the job or task continues for more than one wo

period which requires a person in charge to be located at the job and to develop a written plan for the given LOTComplex Lockout/Tagout Written Plan - a written plan addressing the specic procedures for a given Complex LO

Deenergized (NFPA 70E) - free from any electrical connection to a source of potential difference and from elec

charge; not having a potential different from that of the earth.

Disconnecting Means (NFPA 70E) - a device, or group of devices, or other means by which the conductors of

circuit can be disconnected from their source of supply.

Electrically SafeWork Condition (NFPA 70E) - a state in which the conductor or circuit part has been disconn

from energized parts, locked/tagged in accordance with established standards, tested to ensure the absence o

voltage, and grounded if determined necessary.


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GLOSSAR

Energy isolating device (OSHA) - 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 ungrounde

supply conductors, and, in addition, no pole can be operated independently; a line valve; a block; and any simila

device used to block or isolate energy. Push buttons, selector switches and other control circuit type devices are

not energy isolating devices.

Individual Qualied Employee Control - a procedure described in NFPA 70E where the disconnecting means

remains visible and under the control of a qualied employee during a single shift while work is performed for

which the placement of LOTO devices is not required.

Involved Employee (NFPA 70E) - each person who could be exposed directly or indirectly to a source of elec-

trical energy. (Examples: Direct exposure - a qualied electrician working on the motor starter control, power

circuits, or motor. Indirect exposure - a person working on the coupling between the motor and compressor.)

Lockout (NFPA 70E) - installing a lockout device on all sources of hazardous energy such that operation of the

disconnecting means is prohibited and forcible removal of the lock is required to operate the disconnect means.Person-in-Charge (NFPA 70E) - the individual in a complex LOTO at that location who is responsible for prepa

ing the written plan and methods to account for all employees involved in the LOTO

Primary Authorized Employee - term created in OSHA interpretation letter similar to the responsible employee

as referenced by NFPA 70E.

Responsible Employee - a named assigned per this manual to the employee referenced in NFPA 70E who wil

take on responsibilities in a Simple LOTO where more than one individual is directly involved and authorized to

apply a lock or tag (See also Primary Authorized Employee)

Tagout -installing a tagout device on all sources of hazardous energy, such that operation of the disconnectmeans is prohibited. The tagout device shall be installed in the same position available for the lockout device.


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LOCKOUT/TAGOUT DEVICE CHECKLI

LOCKOUT/TAGOUT DEVICE CHECKLIST

Lockout Device:

__ readily identiable as lockout devices.__ used only for control of exposure to electrical energy hazards shall be unique.

__ identies the individual who installed it.

__ will prevent operation of disconnecting means unless undue force or the use of tools is employed to remove it.

__ is suitable for the environment and for the duration of the lockout.

__ the key or combination remains in the possession of the individual installing the lock or the person in charge.

Tagout Device:

__ includes a tag with an attachment means.

__ readily identiable as a tagout device.

__ suitable for the environment and duration of the tagout.

__ capable of withstanding 224.4 N (50 lb) of force exerted at a right angle to disconnecting means surface.

__ nonreusable, attachable by hand, self-locking, and nonreleasable, equal to an all-environmental tolerant nylon cabl

__ contains a statement prohibiting unauthorized operation of the disconnecting means or removal of the tag.

__ contains a statement prohibiting unauthorized removal of the device.


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ACKNOWLEDGEMEN

ACKNOWLEDGEMENTS

Program Developed by:

Joe OConnor

INTEC, Inc.

PO Box 163Waverly, PA 18471

www.intecweb.com

800.745.4818

Fax: 800.949.1930

Program Edited by:

James B. Lancour, PhD

jbl consulting and training

[email protected]

678.457.6108

Photographs Contributed by:

Todd Cratty

M45 Marketing Services

815.282.1606

Ryan Hand

Michael Mafoli

Wilson Electric Co.

Brad Munda

Kyle Borneman

Morse Group

Jeff Costello

Larry McCrae, Inc.

Dave Ganther

Bill Inforzato

J.P. Rainey Company, Inc.

George Novelli

Tom McCusker

Carr and Duff, Inc.

Todd Kindred

Northern Illinois Electrial JAT

610 South Rock Drive

Rockford, IL 61102815.969.8484


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Copyright 2008, National Electrical Contractors Association and INTEC, Inc.

National Electrical Contractors Association

3 Bethesda Metro Center, Suite 1100

Bethesda, MD 20814(301) 215-3110

Necessary measures have been taken to ensure the accuracy and reliability of the information herein;however, the National Electrical Contractors Association (NECA) and Intec make no representation, warranty

or guarantee either expressed or implied, in connection therewith. NECA and Intec disclaim any liability

or responsibility for any direct or indirect loss or consequential damages resulting from the use of any ofthe information herein, or for the violation of any federal, state or municipal regulation with which any ofthe information may con ict. This publication is sold with the understanding that NECA and Intec are not

engaged in rendering legal advice or safety and insurance consultation. If legal advice or expert assistanceis required, the services of a competent person should be sought. Disputes will be governed by the laws

of the State of Maryland.

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