section 8: energy safety and energy isolation lockout

UC System - Shop Safety Reference Manual Section 8 – Energy Safety and EI-LOTO December 2013

Section 8: Energy Safety and Energy Isolation – Lockout Tagout (EI-LOTO)

“Energy Safety” and Energy Isolation - Lockout/Tag-out (EI-LOTO) is required by CalOSHA and Federal OSHA and must be conducted on every campus and research field station by UC personnel and contractors. Because of the potential for injury from energy sources that operate equipment and utility systems, knowledge of energy safety and how to apply it to EI-LOTO guides safe design, selection, installation, set-up, adjustment and maintenance work on equipment by isolating energy sources from the equipment prior to commencing work. It is required by law to implement safe procedures when working on equipment or utility systems with one or more energy sources.

TYPES OF EQUIPMENT ENERGY

There are many different kinds of energy used to power equipment and different kinds of utility systems used to deliver specific types of energy. Types of energy that immediately come to mind include electricity, compressed air, steam, and water or hydraulic fluids under pressure. However, other types of energy can be stored or used to power equipment. Liquid or gas fuels, counter-weights, mechanical springs, elevated components that can fall, extreme heat, cryogenic (cold) liquids or gases, compressed gases, charged capacitors, kinetic energy such as fly-wheels or potential vehicle movement, even convective air or wind, may be hazardous types of energy that could cause equipment or utility systems to become hazardous to people if the energy is not safely isolated, or possible equipment movement prevented prior to working on the equipment.


ELECTRICAL SAFETY

Electricity can be deadly. Electrocution is the fourth leading cause of workplace fatalities. Only traffic accidents, violence, and construction-work rank higher. Almost 8,000 electrical-contact injuries occur every year in the United States, with about half resulting in permanent disabilities or death. Most of these accidents involve “low voltage” (which is considered 600 volts or less).

Electricity – How’s it work? In general metals, water, some gases, and many kinds of chemicals allow electricity to easily “flow” through them. They are known as “conductors”. (e.g. steel, iron, copper, aluminum, neon, mercury gas, etc…) Electricity flows from an equipment part with a “high electrical potential” to an equipment part with a “low electrical potential” which in most cases is commonly known as “ground”. Ground can literally be the ground you’re standing on when outdoors, but could be the floor of your shop / lab, or another part of equipment with a lower electrical potential like the metal box the electrical equipment is housed in. The amount and rate of electrical flow is based upon the “resistance” of the material the electricity is flowing through. A higher-resistance usually means a less-amount of electrical flow and more heat generated when electricity flows through a material. A material that has very high resistance is known as an “insulator”. Some plastics, rubber, wood, ceramics, glass, etc… are common materials that have very high resistance and are common insulators. “Dry Air” is also a good insulator. Air with high-moisture content (i.e. high humidity) can become a conductor when high-voltages are present (e.g. lightning, or a static discharge onto a part of your body). Nearly all equipment is designed to isolate conductors from you contacting them when in normal operation and energized, and safely allow the electricity to flow through the equipment and back to “ground” through the building’s electrical system while doing the “work” the equipment was designed to do. Vehicles and equipment that are isolated from “ground” but still use electricity will have an “on-board” ground system. The basic rules of electrical flow apply, but the equipment is “isolated” from the ground of the building or the surface the equipment / vehicle is rolling or set upon.

Keeping yourself safe around Electricity To keep safe when working with electricity, your body must never become part of the “pathway to ground” for the electricity to flow through. Electricity will flow in ALL PATHWAYS from the “high potential” source to the “lower potential” ground. So, when an electric shock occurs, instead of the electricity flowing safely back through the


building’s / equipment’s electrical system to “ground”, your body becomes part of the circuit allowing the electricity to flow to “ground” through you. In such a situation, your body may only have a small-amount of electricity flowing through it, while the majority of what may be available will take another pathway to ground that has less resistance than your body. But, it takes less than 0.15 milli-amps to pass-through your heart to stop it from beating, with death following shortly thereafter without immediate emergency medical treatment. To put this into perspective, the typical 15-amp wall-outlet that you plug your reading lamp into has 100 times more electric potential available to it than it takes to kill you! To prevent electric shock, always take measures to keep yourself insulated and isolated from contact with high electrical potential equipment components and “ground”.

Arc Blast / Arc Flash Rapid and uncontrolled electrical flow from high potential to low potential can cause a big explosion known as an “arc blast” or “arc flash”. Arc blasts / flashes occur when higher-voltage electrical components “arc” to ground rapidly. They are instantaneous explosions and are extremely dangerous with temperatures greater than 35,000 degrees F. They can result in fires, severe burns, concussion, impact by flying shrapnel, deafening noise, serious injury and/or death. To protect yourself from “arc flash” / “arc blast” when working with high voltages and/or large amperages, special tools are used, work methods followed and personal protective equipment must be worn. If you must work “live” on electrical parts, consult with safety engineering in your EH&S department for guidance on tool selection and development of safe work practices to prevent “arc blast / arc flash”.

WHAT TYPES OF ELECTRICAL EQUIPMENT

ARE SAFE TO USE?

You put yourself at risk when you use unsafe electrical equipment. Equipment that is improperly sized, or with faulty insulation, or of unsafe design, that has improper grounding, or defective parts, and/or loose connections is dangerous for fire and personal shock injury.

Grounding, Bonding and Ground Straps Grounding ensures a safe electrical pathway through the equipment in the event of malfunction, and bonding prevents the buildup of static electricity which can lead to sparks and possibly start a fire and/or hurt you. To ensure your safety, all 110 - 240 volt electrical equipment including hand-held power tools, extension cords, power strips, office equipment, etc… must have a three-pronged plug, or must be “double insulated” with a two-prong plug and a


“Nationally Recognized Testing Laboratory” (NRTL) listing. To ensure your safety, look at the manufacturer’s label affixed to the equipment and confirm that it is approved by an NRTL. Dispose / recycle equipment that does not have an NRTL listing. Depending upon the use of the equipment, it may need to be isolated in order for it to operate safely (e.g. any vehicle operating on rubber tires filled with air). Or, the isolated equipment may need to have a “Grounding Strap” installed on it connecting the equipment to ground to prevent the equipment from developing an electrical charge different from ground (e.g. rotating fan blades can build a static charge when running and arc-to-ground if not bonded). Bonding and Grounding straps are important so that when you touch equipment, there’s no possibility of an electrical static charge having built-up in the equipment that could “discharge to ground” through you. Only use equipment that has been properly grounded and/or bonded. Ask your supervisor if you have questions about whether the equipment you’re using is grounded / bonded.

NRTL “Approved Equipment” All “purchased” electrical equipment used by UC personnel / students must be approved by a “Nationally Recognized Testing Laboratory” (NRTL) (e.g. Underwriters Laboratory (UL), Factory Mutual (FM), Canadian Standards Association (CSA), etc…) and be properly grounded and bonded. There are several NRTLs in the business of “approving” electrically safe equipment. They are listed on the US Government OSHA website at the following link: https://www.osha.gov/dts/otpca/nrtl/ Testing laboratories investigate the design of equipment and predict how it could fail and potentially hurt you. They will not “approve” and put their NRTL label on the equipment unless it’s design and components used to build it meet very high standards in safety for the intended life of the equipment and beyond. Only purchase and use NRTL-approved electrical equipment. Every piece of equipment that is “approved” by an NRTL will have the approval noted on a name-tag attached to the frame or some other part of the equipment. Quality electrical-equipment manufacturers pay a lot of money to get their equipment “approved” by an NRTL to demonstrate its high quality to the consumer. Look for the approval label as part of your assurance the equipment is electrically safe to use for your intended application.

Extension cords and Power Strips Extension cords can be used on a temporary basis of 15-days or less, and must be “sized” for the intended electrical load they will be supplying power to. To properly “size” your extension cord, read the “name plate” data on your electrical equipment and understand how many “amps” the equipment will draw when running. Make sure your extension cord is sized / rated for higher amperage than your equipment will draw. Every extension cord has a tag attached to the cord stating its safe-amperage load rating. As a rule-of thumb, never use an extension cord rated less than 15-amps for any

https://www.osha.gov/dts/otpca/nrtl/


120 volt outlet. For any equipment that uses electricity to “heat” some part of the equipment, use a 20-amp extension cord. Select a UL approved #14 gauge heavy-duty extension cords for 15-amp circuits and UL approved #12 gauge heavy-duty extension cords for 20-amp circuits. Power strips may be used “permanently” in shop / office environments and adjacent to shop equipment for powering a series of computer and peripheral equipment used in a work-area, as long as the sum-total of all the amps drawn by the equipment plugged into the power-strip does not exceed 15-amps. Keep power strips protected from water or chemical spills and splashes by mounting them above ground / floor level. A good place to gain easy access and control your power strip’s on/off switch is on the “back” of your desktop peripherals, or adjacent to your shop equipment’s control panel. If cords are to be used in wet areas, outdoors, or areas where you may contact electrical parts and ground at the same time, use Ground Fault Circuit Interrupter (GFCI) equipped extension cords (see the paragraph below for more information about GFCIs.).

Safely Connecting Equipment to the Building Do not “daisy chain” extension cords and/or power strips. Electricity flowing in conductors create heat due to resistance. Longer wiring has greater resistance resulting in more heat produced internal to the cord. Purchase and install extension cords or power strips that have a cord long enough to extend from the wall-outlet to the location where you’re working. Extension Cords and Power Strips are available up to 100 feet in length and the wiring inside the cord is sized so resistance is low enough as to not generate unsafe amounts of heat inside the cord at the maximum amperage allowed by the NRTL approval.

Note the “white” power-strips in the photo at right. They are incorrectly

and unsafely “daisy-chained” together. Never daisy-chain power strips or extension cords in your work area. If needed, get longer

cords designed to deliver power to

your needed location.


Do not overload or use single to multiple outlet adapters. Overloading circuits produces excess heat. If additional electrical outlets are needed to power the equipment in your shop, contact Facilities Management to install them.

Cord Placement Extension cords or long equipment cords can be mounted overhead or secured on the floor with a non-conducting “cord-protector”. They must not run across walkways without cord-protection with a high-contrast color for high visibility, or through walls, or above ceilings.

Links to photos at left: (expand to see all) http://www.discountramps.com/floor-cable-cover.htm http://www.cableorganizer.com/cable-protector-ada/

http://www.discountramps.com/floor-cable-cover.htm

http://www.discountramps.com/floor-cable-cover.htm

http://www.cableorganizer.com/cable-protector-ada/

http://www.cableorganizer.com/cable-protector-ada/


Flammable Hazards Do not use extension cords or power strips in any location where flammable gases or flammable liquids / fuels are present. Plugging / unplugging equipment or turning on/off equipment in such areas can cause a spark that could ignite fuel vapors. If electricity must be used in such locations, explosion-proof wiring and cord-protection must be installed by qualified electricians to ensure safety.

Working On or Installing Electrical Equipment Any live parts on electrically powered equipment must be guarded. Bare conductors, exposed terminals, and energized metal parts may be at “line voltage” and shock you if you touch them with any part of your body or work tools. Never remove or ‘open up’ access panels on electrical equipment while it is energized. Never remove a guard or other equipment component designed to protect you from contacting energized conductors, unless the equipment is isolated from energy source and/or “locked out and tagged out” (see paragraphs below). When installing electrically powered equipment, clearly identify the “power shut-off” or “knife switch” with a label or other circuit identification. It’s recommended the shut-off / isolation switch be adjacent, and as close as practical, to the work-location so you can quickly turn off the equipment from the remote location if there is an emergency. All power sources and distribution panels must be secured, easily accessible, and free from obstruction for 36” in front of the switch.

ELECTRICAL

SAFETY WORK

TOOLS

Insulated Floor Mats If you’re working on live-parts, or have the potential to contact electrical conductors, consider laying down an electrical safety floor mat to stand on while doing your work. Such mats will prevent electricity from flowing through your body to ground. Make sure that the floor mat selected is rated for insulating you at the voltages you’re planning to work at. At right is a photo of an insulating floor mat adjacent to a work bench where electrical work is done. Note the electrically non-conductive wood bench tops and the electrically non-conductive floor mats personnel stand upon.


Insulated Tools Tools that are insulated are rated for use to do work up to a specific voltage level. These are generally rated 1000, 10,000 and >10,000 volts. Tools rated greater than 1000 volts must be tested annually or more frequently by a certificating agency to ensure the tools still have the electrical safety features built into the tool and have not been compromised. Any tool found to be electrically compromised at its rated voltage must either be repaired or replaced. To ensure electrical safety, only purchase and use tools that have an electrical rating higher than the voltages you plan to do work on.

REQUIRED PPE and TRAINING Employees who work directly with high voltage electricity (>600 volts) should use the personal protective equipment (PPE) required for the jobs they perform as outlined in your campus’ Electrical Safety Program, the National Electrical Code and/or as a best practice following “NFPA70E” PPE requirements. PPE equipment may include rubber insulating gloves, calorie-rated hoods, arc-blast suites, calorie-rated sleeves, insulated floor matting and protection blankets, line insulator hose, and flash-protective helmets and clothing designed to reduce electric shock / arc blast hazards. Inquire with your supervisor / PI in how your campus is managing high voltage electrical safety work rules, and get the training and equipment needed to work safe. Contact EH&S for further guidance and support to implement electrically safe work practices and PPE requirements for your high-voltage work.

Minimum PPE Requirements Personnel who routinely work on or near equipment with exposed conductors and potentially live electrical components from 50 – 600 volts, should wear at minimum insulated Electrically Rated (ER) Shoes, Safety Glasses and Fire Retardant (FR) rated 100% cotton clothing. Consult your EH&S department for help with selection of insulated tools, mats and PPE appropriate to your electrical safety based upon your equipment / process specific hazards.

Training Requirements Anyone who operates, services, or maintains electrical equipment must be appropriately trained. All employees should be trained to be thoroughly familiar with the safety procedures for their particular jobs and the equipment they use. At a minimum, training must include instruction in power tool safety, lock out/tag out procedures, and personal protective equipment use. Training records must be kept by the Shop Manager for a


minimum of 5-years. Consult with your EH&S department for specific guidance on training available, and record retention requirements, for your campus.

WORKING SAFELY AROUND ELECTRICITY

Since electrical accidents can be deadly, you must know how to work around electricity and consciously follow safety procedures. The best way to avoid shock is to eliminate the electrical current itself. Know the location of electrical panels in your shop / lab. This knowledge is important if an emergency power shut off is required.

Label the circuit breakers with the corresponding outlets and/or the equipment the breaker feeds power to on the interior of the panel door. Never use tape to secure any breaker in either an “on” or “off” position. The circuit breaker lever must be able to “trip” freely should a circuit be overloaded.

Make sure that electrical panels are visible and labeled as to which building circuit it is being fed by. Do not mount posters or any kind of postings on them. The only exception to this is the use of labels to distinguish circuits feeding them when multiple panels are in a single location.

Keep at least 3 feet of clearance in front of every electrical panel. The boxes stacked in front of the electrical panel in the photo at right demonstrate a commonly-cited offense by CalOSHA with fines up to $5000 to your department for repeat offense. Keep cover plates on all electrical outlets, junction boxes, and switches. Replace frayed or damaged cords and never use


electrical wires as supports for equipment, or hang things on them. Remove electrical equipment from service until frayed / damaged cords can be replaced. There should be no exposed wiring anywhere in your shop / lab. If there is, report it to your supervisor for repair or replacement. Turn off all electrical equipment when not in use. Never leave electrically powered equipment operating unsupervised unless its hazards are isolated from nearby personnel, and it’s designed for this purpose. Turn it off if you have to take a break or leave the area, even for a minute. Always switch off the power before unplugging a piece of equipment. Be sure to report any electrical failure or excessive heating of equipment to your supervisor as soon as it occurs. Before conducting maintenance or repair of any electrical equipment, ensure that all energy is released, power sources are disconnected, and lock out/tag out procedures are followed.

Ground Fault Circuit Interrupters (GFCIs) Certain environmental conditions can increase your exposure to potential hazards when working with electricity. You must take special precautions when working around wet or damp areas. Water and electricity are a deadly combination. Ground fault circuit interrupters (GFCI) must be used if working around areas that have a potential for water pooling, or if you can physically contact an electrical outlet and a part of the building’s plumbing at the same time. If you are doing temporary work in a wet area and must use electrical equipment, use a GFCI-equipped extension cord. These are readily available through industrial supply catalogues online. Special care is also needed when working in potentially hazardous environments. An accidental static discharge can cause a fire or explosion when flammable chemicals and combustible dusts are present.

Always install and use GFCI (Ground Fault Circuit

Interrupters) when using electricity in potentially wet or

outdoor locations. [http://www.helcohi.com/sse/waters/grounded.html]

http://www.helcohi.com/sse/waters/grounded.html

http://www.helcohi.com/sse/waters/grounded.html


WHO CAN COMPLETE ELECTRICAL WORK?

Facilities electricians must approve and/or conduct all maintenance, repair, and modification of existing electrical systems within campus buildings or structures. Installation, maintenance, and repairs of existing machinery or buildings may only be conducted by qualified personnel (e.g., mechanics, electricians, or specially trained individuals). All electrical work must adhere to the standards of the California Electrical Code and the National Electrical Code, with effort to guide best work practices by following the requirements of NFPA70E.

ALTERNATIVE ELECTRICAL SOURCES

Some equipment has alternative electrical energy sources used to power and/or store electricity in the equipment such as batteries, capacitors, emergency generation equipment, fuel cells, photovoltaic “solar” panels, etc... In such equipment, there may be electricity supplied to the equipment even when the equipment may be disconnected from a building’s power grid. Make sure you understand all the electrical energy sources that may power a piece of equipment prior to attempting to shut-down and work on the equipment. Ask your supervisor to explain all energy sources on any piece of equipment you are not familiar with. Concerning energy isolation of alternative electrical sources, please see the EI-LOTO recommendations below on how to safely shut-off and isolate these energy sources prior to working on equipment that uses them.

GENERATING ELECTRICITY AND BACK-

FEEDING “THE GRID”

Some equipment is designed to generate electricity and feed it back into the building’s electrical system commonly known as “the grid”. Systems such as photovoltaic solar panels, hydro dams, waste-heat conversion generators, fuel cells, flywheel electric storage, even dynamic-braking on electric motor drives, etc… are all considered equipment that back-feeds the grid. Such equipment must be safely shut-down and isolated from your facility’s grid prior to working on the wiring of the facilities or the power-lines coming into a facility. Every piece of equipment that generates electricity and back-feeds it into the grid, regardless of the amount of electricity it produces, is regulated by the State of California’s Public Utilities Commission (CA-PUC). The PUC must issue every unique generation location with a license to generate power and feed that power back into the grid. This is known as “Electric Rule No. 21” and is documented on the Cal. PUC Sheet # 23678 – E. Your local utility at your campus is the enforcing-body for this PUC rule and will work with you in approving any equipment design / installation intended to back-feed the grid, either in new research or new construction that includes power-generation on your campus.


Ensure that you comply with all requirements of “Electric Rule No. 21” as fines for non-compliance are $25,000 per day even if one watt of power is back-fed into the grid without being licensed by the PUC to do so.

COMPRESSED AIR AND OTHER GASSES

Compressed air distributed from your building’s air compressors are a common source of energy used in shop equipment and operate at 60 – 120psi depending upon your location. In addition, compressed gasses from gas cylinders are commonly used in many shops / labs to provide needed gasses for work and may operate up to 2000 psi and beyond. There are many hazards associated with compressed air and high-pressure gas cylinders. Both of these energy sources have their own chapters in this reference manual devoted to understanding and protecting yourself and others from the hazards of these energy sources. Concerning energy storage and isolation of compressed air and other gasses, ensure you understand if the equipment you’re working on has any pressure vessels that could store compressed air inside the equipment. If so, they must have a “pressure relief” valve installed on the pressure-vessel that will open and vent the vessel to a safe location and away from personnel in the event of an over-pressure situation. Periodic testing of pressure relief valves by actuation of their pop-off control lever should be conducted as part of routine maintenance to ensure safety when using pressure vessels. Use and install only relief valves that have been “approved” by an NRTL (see paragraph above that discusses NRTLs). Enroll any pressure vessel that stores or otherwise is pressurized by a compressed air system in the campus’ boiler / pressure vessel safety inspection program. These are required by law to be inspected periodically by professional engineers skilled in identifying problems with the vessel before they become catastrophic. This service is free for your department and offered on most campuses through your Risk Services Department and/or EH&S. Please see the EI-LOTO recommendations below on how to safely shut-off, vent to atmosphere and/or isolated these energy sources prior to working on equipment that uses them.

STEAM AND CONDENSATE

Steam and condensate are often part of a campus’ infrastructure and are used to transfer heat from a central heating plant to remote locations around campus. In addition, steam-heated heat-exchangers provide building heat, domestic hot water, may operate research sterilizers, heat recreational swimming pools, etc… Condensate is the liquid water that’s left in the steam system after the steam has given up its heat at the point of use, and is piped back to the steam-plant to be boiled into steam again. Central Plant Steam Systems on most campuses operate between 80 – 120 psi, with steam delivery at 300 – 375 degrees F. Condensate is in liquid form and 140 – 180


degrees F. Hazards associated with working with steam and condensate include serious burn potential due to flash-contact with steam or hot condensate if leaks occur, surface burns in contact with any hot piping carrying steam or condensate, hearing loss due to loud sound when steam leaks, flesh-cutting hot jets if directly contacting a steam-leak jet, and potentially hazardous chemical exposure if condensate containing special steam-system-conditioning chemicals contact your skin. If you have equipment that uses steam and/or generates condensate that is piped back to the steam plant, know the hazardous locations where the steam / condensate is piped and ensure these areas are insulated and/or guarded to prevent your accidental contact with them. Label steam / condensate piping as needed to quickly identify it separate from other kinds of nearby plumbing. If you notice exposed parts of equipment that transports or uses steam / condensate that are not guarded / protected, bring these locations to the attention of management so they can be insulated / guarded from contact. If you are purchasing or developing research equipment that uses steam / condensate, ensure that the equipment is designed to current boiler codes for safety. All pressure vessels must have a pressure relief valve installed on the pressure vessel that will safely vent the pressure vessel to atmosphere and away from equipment operators in the event of an over-pressure condition. Periodic testing of pressure relief valves by actuation of their pop-off control lever should be conducted as part of routine maintenance to ensure safety when using pressure vessels. Use / install only relief valves that have been “approved” by an NRTL (see paragraph above that discusses NRTLs). Enroll any pressure vessel that stores or otherwise is pressurized by the steam / condensate system in the campus’ boiler / pressure vessel safety inspection program. These are required by law to be inspected periodically by professional engineers skilled in identifying problems with the vessel before they become catastrophic. Follow EI-LOTO recommendations on isolating steam / condensate (see below) for all equipment prior to working on the equipment.

WATER AND HYDRAULICS

Cooling water, domestic water, high-pressure cutting slurries, hydraulic fluids, etc… are all examples of energy sources used in various kinds of shop / lab equipment. While normal domestic water systems operate from 30 – 80 psi, hydraulic systems can operate up to 3000 psi, and cutting slurries can operate as high as 50,000psi. Domestic and cooling water leaks can cause slip / fall hazards in your shop / lab. Domestic hot water is “hotter” than scalding temperature. Hazards for high-pressure liquids include heat, pinhole leaks and stored fluid energy that can cause unexpected machine movement. Extremely high pressures can create extremely high temperatures, so hydraulic and cutting fluids can cause skin burns due to contact with hot liquids. Leaks in high-pressure plumbing can cause extremely fine spray with flesh-cutting force to spray out of system leaks. Since accumulator / water-hammer tanks


and other pressure vessels can store high-pressure fluids, they must be vented to atmospheric pressure before work can safely be done on the equipment. To ensure safety, make sure that all components in any pressurized fluid piping system are rated at or well above the “normal / intended” working pressures in the system. Install and regularly test pressure relief valves in pressurized systems to ensure that if an over-pressure condition occurs, the relief valve will “pop off” and safely vent the system without an explosive pressure condition being generated. Follow EI-LOTO recommendations on isolating water, hydraulic and other fluids under pressure (see below) for all equipment prior to working on the equipment.

HOT / COLD SURFACES

Some equipment could generate heat, or could use steam or other hot liquid utilities, or uses cold (cryogenic) fluids in order for the equipment to function correctly. Such hot or cold surfaces and the source of the heat / cold must be guarded / isolated from contact prior to working on or with the equipment. Follow EI-LOTO recommendations on isolating hot / cold surfaces (see below) for all equipment prior to working on the equipment.

VACUUM ACCUMULATORS

Lab liquid-transfer vacuum systems, utility vacuum systems built into a building, and portable vacuum systems, are all examples of energy sources used in various kinds of shop / lab equipment that could have vacuum tanks and piping. Vacuum accumulator tanks can store high-volumes of vacuum and must be brought back to atmospheric pressure before work can safely be done on the equipment. If you’re body is exposed to a pipe under vacuum it can grab-onto and hold you tight through suction causing entrapment, serious bruising or other injury. To ensure safety, make sure that all components in any vacuum piping system are rated at or well above the “normal / intended” working pressures in the system. Install and regularly test vacuum relief valves to ensure that if an over-vacuum condition occurs, the relief valve will safely vent the system without an implosive pressure condition being generated. Follow EI-LOTO recommendations on isolating vacuum system components (see below) for all equipment prior to working on the equipment.

FUELS SAFETY

Hazards associated with working with fuels include serious burn potential due to flash-fires if leaks occur, surface “burns” from leaking super-chilled propane gas, etc… If you have equipment that uses fuels and stores fuels as part of the equipment operation, know the hazardous locations where the fuel tank(s) are located and piped on the equipment. Ensure these areas are insulated and/or guarded from heat sources


on the equipment, and no equipment operation could create sparks in or near any part of the fuel storage / piping system. Clean up any spilled fuels immediately using an absorbent material, and safely dispose of fuel-soaked absorbent with your EH&S Hazardous Waste Facility. Follow EI-LOTO recommendations on isolating fuel systems (see below) for all equipment prior to working on the equipment.

MECHANICAL EQUIPMENT HAZARDS AND

GUARDS

Your body is soft and fragile compared to the hard surfaces and high energy mechanical forces that operate most shop equipment, so never put any part of your body into equipment that can potentially move without notice, or when a guard is removed. Use push-sticks, extension tools, pry bars, or other means to safely work on equipment outside of any danger-area of the equipment. The following are types of mechanical energy to be aware of when assessing equipment-hazards.

Rotating Wheels / Fans / Drive Components Any equipment component that rotates as part of normal operation, and that can be potentially contacted by personnel must have machine guards installed to protect from contact with the rotating equipment with the exception of the specific location where the equipment is doing the intended work (e.g. the location where a drill chuck and bit is drilling a hole). Drive couplings, v-belts, etc. between electric motors and driven equipment must be completely protected from any accidental contact or the possibility of winding-up hair into the machine. A gap of ¼” or less is allowed between the machine guard and the rotating component. Larger gaps should be repaired and closed to the allowed ¼”.

Suspended Counter Weights / Elevated Components Counter weights or elevated components on equipment that could unexpectedly move if power were lost, or some part of the machine if it was to shift or actuate, must be prevented from movement prior to removing any guard that isolates contact from the component under normal-work conditions. Equipment components that suddenly move without expectation can cause you to be entrapped, crushed and seriously injured by the equipment.

Springs, Gas Struts and Other Mechanical Hazards Any equipment component that stores mechanical energy such as springs, gas struts, torsion bars, etc… as part of normal operation, and that can be potentially contacted by personnel or move a part of the machine when it’s de-energized must have machine guards installed to protect them from contact with the component that stores the mechanical energy. A gap of ¼” or less is allowed between the machine guard and the mechanical energy storage equipment.


If a machine guard protecting you from any of the above noted mechanical hazards must be removed to service or otherwise work on the equipment, EI-LOTO must be practiced as described below.

SUPERCONDUCTING MAGNETS AND LASERS

Hazards associated with working with superconducting magnets and lasers include exposure to high-levels of non-ionizing radiation. This can cause serious problems for people who have certain kinds of medical implants, can cause serious eye damage or blindness, skin burns, etc… If you have equipment that uses magnets and lasers as part of the equipment operation, know the hazardous locations on the equipment. Ensure you know where the gauss-line is located for your super-conducting magnet and do not enter inside that line with any iron-containing materials on your body, or in your pockets. Ensure hazardous areas are protected with guards and there is limited access to only personnel who have been fully trained on the equipment hazards, and are provided with necessary PPE, are allowed to be in the area of the equipment. Consult with your EH&S department about implementing hazard controls and EI-LOTO recommendations on isolating superconducting magnets and lasers. The energy isolation of superconducting magnets and lasers is beyond the scope of this reference manual.

WHAT IS ENERGY ISOLATION –

LOCKOUT/TAGOUT (EI-LOTO)?

Every piece of powered equipment or utility system uses or transports one or more types of energy. In commercially-purchased equipment, the design of the equipment safely controls the energy flowing to, through, or stored in the equipment when properly maintained and operating normally. However, when equipment is being installed, when maintenance work is being performed on it, or when it is being modified to perform specific functions, the energy sources must be isolated from the equipment to assure a safe working environment for the people working on the equipment. This is a specific and documented process called “Energy Isolation – Lockout/Tagout”, or shortened to “EI-LOTO”. It is required by Cal/OSHA and Federal OSHA law to be followed whenever equipment that has potentially hazardous energy associated with it is being worked on.

Does EI-LOTO apply to my work? If you or your department purchases, designs, builds, creates, maintains, modifies, teaches with, researches on or with, or in any way uses equipment that operates on and/or stores any type of potentially hazardous energy, then EI-LOTO must be applied to that equipment and your work-processes.

Does EI-LOTO apply to research equipment that is ‘one of a kind’, or does it only apply to building / utility systems? It applies to all types of equipment that utilize one or more potentially hazardous sources of energy to operate, regardless of whether the equipment is ‘one-of-a-kind’


research equipment, purchased “commercially available” equipment, or ‘one-of-a-kind’ building / utility systems unique to a particular location or operation.

Are there situations where EI-LOTO is not, or should not, be conducted? Yes, but very few. EI-LOTO does not need to be conducted for minor tool changes, adjustments, and other small service activities that take place during normal operations if they are routine, repetitive, and integral to the use of the equipment. (For example: Changing a drill bit on a drill press.) EI-LOTO does not need to be practiced if you are using equipment that has a single-source of energy, and you can disconnect the equipment from its energy source, and then you have exclusive control over the disconnect / plug. EI-LOTO may not be practiced if it can be demonstrated by management that:

1. Continuity of service is essential, and

2. Shutdown of the system is impractical,

and

3. Special equipment is provided or

special protective procedures are

documented and followed by personnel

that will provide effective / equivalent

safe-work protection for personnel.

In addition, EI-LOTO does not need to be practiced if management can demonstrate that by doing so would increase the work-hazards to people while doing the work. And, EI-LOTO does not need to be practiced when to do so would be life-threatening to persons relying on equipment to operate continuously. These very specific criterion are written into the law as outlined above, and must be met through a documented planning process to allow work to commence “live” or “hot” without EI-LOTO being practiced. Unless management can demonstrate that the intended work meets the requirements of the above criterion, EI-LOTO must be implemented prior to commencing work on equipment. If management can demonstrate the need to “work hot” or “work live”, then detailed work plans, special equipment, and safe work-processes must be created for the work prior to starting the work. The work-processes must create the safest work environment

EI-LOTO does not need to be practiced for single-energy-source equipment that you

can “unplug” as long as you have exclusive control over

the plug while it’s unplugged.


possible under the circumstances, equivalent in safety to practicing EI-LOTO as closely as possible. All personnel conducting the work must have documented training on the planned “hot work” processes specific to the equipment prior to starting the work. Contact your EH&S Department to get help in planning “Hot Work” / “Live Work” if needed, and to ensure your full compliance with legal / regulatory requirements for EI-LOTO.

What kinds of energy does EI-LOTO apply to? EI-LOTO is applied to ALL forms of potentially hazardous energy, and is applied to every individual piece of equipment that has potentially hazardous energy. The types of energy needing to be isolated include:

Potential / stored energy (E.g. mechanical springs in tension or compression,

pressurized compressed gas cylinders, suspended counter weights, flywheels,

hydraulic or gaseous reservoirs / tanks containing stored materials, liquid or

gaseous fuels, vehicles parked on a slope, etc.),

Kinetic energy (E.g. rotating flywheel, moving parts, rolling components, water

or other liquids / gases flowing through pipes, rotating fan blades, moving

vehicles, etc.) and,

Utility energy (electricity, compressed air, steam, domestic water, etc.) that may

be part of a particular machine or utility system.

What kinds of equipment might EI-LOTO be applied to? EI-LOTO may be applied to building mechanical systems such as electrical distribution equipment, pumps, HVAC and air handlers, some larger experimental equipment that is hard-wired and/or hard-plumbed to building utility systems such as a Scanning Electron Microscope, an air compressor, a printing press, some shop equipment such as a programmable milling machine, CNC equipment, wood-working equipment, powered cranes and other lift equipment, etc. It may be applied to a piece of equipment’s, or a building’s, plumbing or wiring systems and controls. It may be applied to “parked” vehicles. It may even apply to equipment that can be ‘unplugged’ but may have energy potentially stored in the ‘unplugged’ equipment.

What are the EI-LOTO Procedural Requirements? Cal/OSHA requires that every piece of fixed equipment that uses energy to operate must have a written energy isolation (EI-LOTO) procedure as part of the safe work practices on that equipment. This written procedure may act as an SOP for custom research equipment, or a job-planning tool for safe Facilities work, and becomes the basis of training for applying EI-LOTO to the specific piece of equipment to be worked on. Therefore, equipment owners, supervisors, maintenance personnel, researchers, students, contractors, etc. must be familiar with ALL the energy sources used by the equipment, and how the equipment functions. And, they must take measures to isolate or eliminate all energy sources prior to working on the equipment. An energy isolation procedure is a step by step instruction that details the location of all energy sources on


the equipment and what steps must be taken to isolate / block those energy sources prior to work.

EI-LOTO FOR ELECTRICITY

There are many different ways to lock out a piece of electrical equipment. In modern electrical equipment, the main electrical disconnect switch has one opening where a single lock can be placed. If more than one employee works on the equipment, a multiple-lock hasp suitable for the installation of several locks must be used, enabling all workers to lock out the machine with their individual locks. If the switches are in a metal box, the box itself must be locked out in the closed position. If a fuse was removed in order to de-energize the equipment, the empty-fuse-box must be locked. If the controls are in a metal-covered box, a common hasp can be welded or riveted to the door. Then the switch can be “opened” and the door closed and padlocked. Fuse boxes can also be locked in this way. In some equipment, an electric “control circuit” will actuate a main “power circuit”. In such situations, both the “primary power” and “control power” circuits must be ‘locked and tagged’ out before safe-work can proceed. Equipment that can be unplugged can have a “plug-lock” installed on the plug to prevent it from being “plugged in”. Capacitors must be safely discharged to ground with ground straps installed prior to working around, storing or transporting them. Once you think you have electrical equipment safely isolated with EI-LOTO, always verify that electricity is indeed “off” using a voltage meter prior to commencing to conduct work under EI-LOTO. Many people have lost their lives thinking that electrical conductors were “off” without verifying the electricity was off using their volt-meter. DON’T MAKE THIS FATAL MISTAKE. ALWAYS VERIFY THE ELECTRICITY IS DEAD OFF WITH PROPER EI-LOTO CONTROLS IN PLACE USING YOUR VOLTAGE METER PRIOR TO STARTING YOUR WORK!! Consult with your EH&S department if you have questions about applying EI-LOTO to your equipment. You may also refer to the UC Berkeley Electrical Safety Program’s Appendix on the UC Berkeley EH&S website (www.ehs.berkeley.edu) for safe procedures to discharge and ground capacitors as well as apply “Hot Work” / “Live Work” best practices and/or EI-LOTO to research and other types of equipment.

Locks and Tags on Single and Multiple Electrical Breakers Electrical Plug Lock Box


EI-LOTO FOR COMPRESSED AIR / GASSES /

HYDRAULIC FLUIDS

Machines activated by compressed air, gasses or hydraulics will have valves that control movement and flow of gas / fluid in pipes. In addition, compressors and pumps may need to have electrical power shut-off and locked / tagged out so they cannot run and generate pressure inside the equipment’s piping system. Pressure vessels must be vented to atmosphere with vent-valves locked / tagged open to prevent any build-up of pressure in the system while it’s being worked on. System-control valves will need not only to be locked out, but also bleed valves locked and tagged open to release any residual pressure to atmosphere in the system’s piping. Physically disconnect the equipment from the supply plumbing if possible, and install blinding-flanges or pipe caps and then install lock-out / tag out gear as shown in the photos below.

EI-LOTO FOR STEAM / PRESSURIZED WATER

Machines that use domestic water, steam and / or condensate will have valves that control movement and flow of the steam and liquids in pipes. In addition, pressure vessels that accumulate / store steam or provide pressure diaphragms to regulate water-hammer and surge may be need to be vented to atmosphere with vent-valves locked / tagged open to prevent any build-up of pressure in the system while it’s being worked on. System-control valves will need not only to be locked out, but also bleed

Locked Comp. Air Line Locked Gas Cylinder

Locked Propane Gas Cylinder Locked Globe Valve


valves locked and tagged open to release any residual pressure to atmosphere in the system’s piping. EI-LOTO equipment used to lock / tag out valves and piping are the same LOTO equipment shown above for piping systems.

EI-LOTO FOR HOT / COLD SURFACES

Hot or cold surfaces present contact-hazards for heat-flow. To adequately protect surfaces from contact when conducting EI-LOTO, install insulation blankets and leave all installed insulation intact as much as possible. Below are some ideas on conducting EI-LOTO on hot / cold surfaces:

Hot surfaces 1. Allow time to cool

2. Install Insulation Blankets – Lock in

place using a cable-lock.

3. Install a physical contact guard / barrier

– Lock in place with cable-lock or

custom-designed block that accepts

personnel’s lock.

Cold surfaces / cryogenic fluids 1. Install insulation blankets – Lock in

place using a cable-lock.

2. Transfer / remove cryogenic fluids to a

safe area away from the work area.

3. Vent away from work area and lock

“open” bleed valves

EI-LOTO FOR FUELS

Equipment that stores “on-board” fuel should have the fuel removed from the equipment as best as practically possible. Remove propane gas cylinders to safe storage racks until needed. Drain liquid fuel tanks and safely store liquid fuels away from the work area. Purge fuel piping with compressed air and ventilate empty fuel tanks to ensure no explosive atmosphere inside the tank prior to starting work on the equipment. Use a 4-gas meter if possible to confirm a safe-atmosphere for work to commence. Stage fuel absorbant pads near the work area in case liquid fuels spill during work activities. If fuels must remain “on-board”, conduct EI-LOTO on fuel shut-off valves, physically disconnect fuel pipes from the shut-off valve and flush fuel systems downstream of closed valves with compressed air to ensure no fuels can leak into the equipment while under EI-LOTO. Physically isolate and protect fuel storage from heat, spark or other ignition sources.

Use Heat Blankets to protect yourself from contact with hot / cold surfaces. Wrap the surface

with the blanket and lock it in place using a cable-lock.


EI-LOTO FOR MECHANICAL ENERGY

Mechanical components of equipment must be blocked, blinded and bled prior to working on the equipment through a documented EI-LOTO process. Blocks and Wedges are placed under raised dies, elevated lifts, counterweights, installing support rods for counterweights or elevated components, a bar through spokes of a wheel, flywheel or fan blades, a wedge-shape wheel-chalk for rolling components, wrapping and locking chains around a movable equipment component and locking it to an immovable object, or any machine component that might inadvertently move by sliding, falling or rolling. Mechanical components must be set in place on secure blocks (e.g. automotive jack stands) so that the weight of the components are solidly resting on the block and the block cannot be moved prior to starting work. Blinds are placed in piping at a flange junction to prevent fluid / gas flow in the piping. Blinds are a mechanical “block” that ensures that in no way can hazardous fluids or gas flow through the pipe and cause machine movement or personnel exposure to harm.

A “Blinding Flange” inserted into a piping system is used to ensure no possible flow of

liquid / gas in the system during EI-LOTO.


Bleeds are valves that must be locked “open” on any pressure vessel or piping system that could store pressure when the system is being worked on. Specific EI-LOTO procedures must be developed that include when and how to install bleeds to ensure equipment safety.

HOW IS LOCK OUT/TAG OUT (LOTO) APPLIED?

Lock out is a physical process used to stop / isolate the energy of a piece of equipment at its source. A typical scenario is that an electrical power switch, circuit breaker, or valve is turned off, and a locking device is attached to prevent the energy from being turned back on until the lock is removed by the person who placed it. Tag out is a written warning on a tag usually attached to the lock. The tag displays the name of the service person (or work lead), the reason for the LOTO, what date / time the tag was placed, and a contact phone number for the person who placed the lock and tag. When a lock cannot be placed on a machine, a tag may be used without the lock to convey the same safety-information. Locks and tags must be easy to read and durable enough to withstand a pull of 50 lbs. without failure, as well as the environmental conditions of the work area. Cal/OSHA compliance requires employers to create a written EI-LOTO procedure for each piece of single / multi-energy source equipment hard wired / plumbed or that has the potential of stored or kinetic energy at a state of rest. This procedure must be shared with all persons who work on the equipment as part of tailboard training/equipment orientation prior to start of work. Every person working on a piece of equipment must have their own set of keyed padlocks and other lock-out attachments for each specific energy source that powers the equipment. Each person must place their keyed padlock on a hasp that accepts multiple padlocks at each energy-isolation location. The hasps are installed on energy isolation devices such as electrical disconnect switches, piping valves, bleed valves (open position), blocking bars or rolling stops (kinetic energy), etc. so that once installed, energy cannot flow to the equipment, and moving parts cannot move. Every person must have their own locks installed on each energy source. Every energy source must be isolated from the equipment prior to work commencing. In addition to locking out energy sources, a written tag must be

A “Bleed Valve” on a piping system is locked “open” when the system

is under EI-LOTO.


installed on each “lock out” device by the “work lead” that details the reason for energy isolation, the date/time the tag was placed, who placed the tag and how they can be contacted, and who (i.e. what department / shop) is doing the work.

WHO MUST IMPLEMENT EI-LOTO?

EI-LOTO implementation responsibility may vary from department to department on your campus. Generally, for academic departments such as Physics, Chemistry, all Engineering practices, College of Environmental Design, Astronomy, Performing Arts, etc…, department management is responsible to assure that all aspects of EI-LOTO implementation are integrated into PI research, Lab/Shop operations, Teaching / Lecture activities, and professional “shops”. PIs may delegate the implementation of EI-LOTO processes to associate researchers under their supervision who have all the same implementation responsibilities as “Front-line Supervisors” noted in the paragraph below. For service / facilities maintenance departments, department management is responsible to assure that all aspects of EI-LOTO implementation are integrated into the department’s operations and activities, and are responsible to ensure staff are trained on, and provided tools to, conduct EI-LOTO.

WHO’S RESPONSIBLE FOR PROVIDING EI-LOTO

EQUIPMENT AND TRAINING?

Every “Front-line Supervisor” (i.e. a person who supervises, instructs or oversees personnel who are required to conduct EI-LOTO) is responsible for identifying all energy isolation locations and the specific types of equipment needed to safely isolate and install a hasp and lock on the isolation location. They are also responsible to provide keyed padlocks, tags and hasps to all “Qualified Personnel” who will be conducting EI-LOTO activities. Front-line Supervisors are specifically responsible for the following activities:

Assure that their direct-report personnel / research associates / students are

trained on EI-LOTO processes, and

Provide all said personnel with the proper EI-LOTO equipment, and

Identify all equipment under their supervision that requires EI-LOTO procedures,

and

Develop and provide procedures to conduct EI-LOTO safely and effectively on

equipment under their areas of responsibility, and

Develop written EI-LOTO procedures specific to that equipment, and

“Qualify” personnel in a documented process to conduct EI-LOTO activities, and

Assure that personnel are properly trained to conduct EI-LOTO prior to letting

them work on that equipment.


WHO CAN PERFORM LOTO PROCEDURES?

Only personnel who have attended training and have received permission from their Supervisor can conduct LOTO procedures. Training must include how to identify energy sources on equipment and safely conduct LOTO on those energy sources specific to that equipment.

Faculty and Staff Training All Faculty and Staff are made aware through the EH&S website and safety orientation training that “No person ever touches or tries to actuate an energy source that has been ‘locked’ and/or ‘tagged’ in the ‘off’ position by someone else. And further, never disturb a mechanical block that has been placed to prevent equipment movement by someone else.” In other words,…..

“If you didn’t put that lock or block there…. DON’T TOUCH IT!!”

“Qualified Person” Personnel who work on equipment that requires EI-LOTO must be “qualified” to do so by their Supervisor and follow EI-LOTO procedures developed for the equipment they are working on. They must be trained on, and remain current to, EI-LOTO requirements and application through documented training by their Supervisor and/or EH&S. A “Qualified Person” may develop written equipment-specific EI-LOTO procedures by completing an SOP that outlines a procedure specific to a piece of lab equipment, or completing the “University of California EI-LOTO Procedure” template outlined below and available as a download from the “Shop Manager’s Safety Management Tool Kit”.

QUALIFYING PERSONNEL

Only persons who are “Qualified” by their Supervisor may conduct EI-LOTO processes. A person must be “Qualified” by their Supervisor when their duties include performing cleaning, repairing, servicing, setting-up and adjusting operations on equipment requiring Energy Isolation for safe work activities. The Supervisor determines their qualification based upon the Supervisor’s knowledge of the qualified person’s skills, and the energy sources on the equipment. Qualified Person(s) may conduct EI-LOTO to the degree of their documented qualification, develop energy isolation procedures and conduct annual audits on existing procedures as detailed below. A “Qualified Person” is an individual formally recognized and documented as:

1. Having completed required classroom, trades or other training on EI-LOTO, and

2. Having sufficient understanding of EI-LOTO safe-work practices and equipment

to be able to recognize and positively control any hazards that may be present on

specific equipment they are trained on, and

3. Possessing the work experience and formal training necessary to execute work

according to recognized and accepted EI-LOTO safe-work practices, and

4. Having completed orientation to a specific equipment’s EI-LOTO procedure, or

5. Having developed and reviewed an EI-LOTO procedure for specific equipment

that is subsequently reviewed and approved by another “Qualified Person” or

their Supervisor.


A person may be considered “Qualified” with respect to certain equipment, certain types of energy sources, and certain safe-work methods on specific equipment, but not ‘Qualified’ for other equipment/locations within the same Department or Research Project. It is the responsibility of the “Qualified Person’s” Supervisor to determine limitations of “Qualification” for each and every person working under their direction, and document this on the “Qualified Person’s” record by completing and maintaining a copy in the “Qualified Person’s” permanent file. A “Qualified Person” template is available in the “Shop Manager’s Safety Management Tool Kit”.

HOW IS EI-LOTO APPLIED TO CONTRACTOR’S

WORK ON UC CAMPUSES?

If contractors are working on University equipment, then the Project Supervisor representing the department who owns the equipment is responsible for assuring the Contractor has an EI-LOTO program equivalent to the University’s program and follows it. The Project Supervisor is not responsible to evaluate the Contractor’s program, only to verify that the Contractor has one and intends on following it. The contractor must provide their own locks and hasps. The project supervisor must inform the contractor of any known energy sources on the equipment, any energy isolation procedure previously developed for the equipment should be provided to the contractor, and any other known hazards associated with the equipment made known. As work progresses, the contractor must inform the project supervisor of any newly discovered energy sources or hazards associated with the equipment. If University personnel and contractor personnel are working on the same piece of equipment, then the University must provide the hasps that the University personnel install their locks on, and contractor must provide the hasps that their personnel installs their locks on. Each work team installs their own hasp and personnel locks on each energy source. The project supervisor must hold joint tailboard meetings with all personnel who will be working on the equipment to promote understanding of safe work practices, energy isolation procedures specific to the equipment, and any hazard controls needed to complete work in a safe manner.

ARE THERE TIMES WHEN LOCKS MUST BE

APPLIED BUT TAGS ARE NOT NEEDED?

Yes, but only when ALL of the following criterion are met:

1. When the work to be done is completed within a single 8-hour shift, and

2. When the work to be done is done by only one person, and

3. When all energy isolation points are within eye-site of that person, and

4. When that person is present for the entire time the work is being done.


If any of the above criterion cannot be met during the work (for example, the person must leave to eat lunch or use the rest-room), then written tags must be installed at each energy isolation point prior to continuing the work. The only exception to bullet #4 above is when the person can ‘lock up’ the equipment and all its energy-isolation points in a room to which no one else has access, not even a janitor or a research associate. In such a situation, tags are not needed to be installed on lock-out points for the equipment.

CAN A ‘GENERIC’ PROCEDURE BE USED TO

GUIDE EI-LOTO ON A SPECIFIC PIECE OF

EQUIPMENT?

No. Every piece of equipment that has source(s) of energy that make the equipment operate must have an equipment-specific written procedure developed for that equipment. An exception to this rule is allowed when multiple identical pieces of equipment are located adjacent to each other, and the EI-LOTO procedure is the same for each one. In this situation, the same procedure can be used as long as the specific EI-LOTO energy-disconnect locations for each are individually identified in the procedure. The equipment-specific EI-LOTO procedure must be shared with anyone who may work on or with that equipment. Equipment operators and maintenance personnel must have documented training on the EI-LOTO procedure, its application within and to a department’s equipment, as well as how to understand and utilize the information provided on the equipment-specific procedure. Such procedures may be documented on the UC EI-LOTO template available in the Shop Manager’s Tool Kit, or in another written format that contains all the information needed to convey a procedure to safely conduct EI-LOTO for that specific equipment.

HOW ARE “EQUIPMENT SPECIFIC EI-LOTO

PROCEDURES” CREATED?

The UC EI-LOTO Procedure Template is available in the “Shop Manager’s Safety Management Tool Kit” to shop managers, equipment owners, project supervisors, etc. A copy of it also appears as the last two-pages of this section of the Shop Safety Manual. It may be downloaded and have information inserted into blue-fields, printed-out, and /or complete a checklist of energy sources and their isolation locations. The completed procedure becomes the written energy isolation procedure for that equipment. Original procedures developed are kept by responsible persons in each shop / department, with photo-copies displayed near the equipment, and provided to all personnel working on the equipment as part of tailboard trainings prior to work commencing. Copies may be sent to your EH&S department for inclusion in an Energy Isolation Procedure Library. Please contact your EH&S department for further


assistance on how record keeping for EI-LOTO procedures are handled on your campus.

WHO MUST CREATE “EQUIPMENT SPECIFIC EI-

LOTO PROCEDURES”?

Shop / Lab Supervisors must assure that all equipment under their responsibility have written EI-LOTO procedures developed for them. The supervisor may create the procedure, or may delegate this task to “Qualified Personnel” who will do this task.

DETERMINING THE EI-LOTO SEQUENCE

As part of EI-LOTO procedure development, the sequence that all energy sources are isolated must be determined and documented in the procedure. For example, some types of equipment may need to have the “main electrical power” shut off before the “control electrical power” and then the compressed air shut off last in order for the equipment to be safely locked and tagged out. The “Qualified Person” who develops the EI-LOTO procedure must determine the safest sequence to shut everything down and include this on the procedure as a step-by-step process. Usually, re-energizing the equipment for normal operation is done by simply reversing the EI-LOTO shut-down sequence. However, this may not be the case for some equipment, and if this is the case must be noted on the EI-LOTO procedure developed for that specific piece of equipment.

ARE THERE “RULES” AND/OR “SAFE WORK

PRACTICES” FOR EI-LOTO PRACTITIONERS TO

FOLLOW?

Yes. Every person doing EI-LOTO on a piece of equipment must have a uniquely-keyed padlock. Padlocks may not be ‘shared’ by more than one person unless a LOTO Log Book is used to track who used what lock on what piece of equipment at which energy-isolation lock-out point. If log books are used, they are to be kept and managed by the Shop / Lab Supervisor. Each person must have their own padlock installed on each LOTO point. Step-by-step LOTO work rules and procedures are detailed below, and are included on the ‘back-side’ of every UC EI-LOTO Template document. The “Work Rule Procedures” include instructions on “Standard EI-LOTO Procedures”, “Testing and Adjusting Equipment Procedures”, “Restoring Equipment to Use Procedures” and “Joint Projects Procedures”. Joint Projects procedures refer to situations where UC personnel from different departments work on the same equipment at the same time, or when UC personnel may work on the same equipment as contractors at the same time.


Personnel must follow equipment-specific EI-LOTO procedures and must not take short cuts. CalOSHA requires an annual in-house EI-LOTO audit to maintain or correct any EI-LOTO procedure so that it is current to the status of the equipment the procedure describes. Shop Managers must keep records of updated procedures, and conduct retraining of personnel on revised EI-LOTO procedures for equipment that has significantly changed from when personnel were previously trained on it.

Call EH&S for help in developing your equipment-specific EI-LOTO procedures, completing audits, and training personnel. Additional resources are available in the “UC Shop Manager’s Safety Management Tool Kit” and from EH&S.

PROVIDING LOCKS AND TAGS

Locks and Hasps Each person doing EI-LOTO has their own lock set, or is provided access to a shared lock set with a check-out lock-log book, and the only key to the locks used by the person. Locks and tags are provided to personnel by their Shop Manager, Supervisor and/or Department. While not required, it’s suggested all locks be ‘RED’ in color to quickly identify locked / tagged energy sources. The locks must be substantial and durable, and have the name of the person placing the lock or some other uniquely identifiable marking on them that can be traced through a log-book to the person who placed the lock. In addition, locks may have a color-coded stripe to indicate different shifts, types of crafts or lock owners. When more than one person is servicing a piece of equipment that must be locked out, a lockout adaptor hasp is used which allows all the persons working on the equipment to place their locks on the disconnecting means. Each worker puts one of their locks on every isolation device prior to starting work on a machine. After the work is completed, each worker removes their lock(s) and the machine is then returned to service.

Typical Locks and Hasps for use in Locking Out Equipment


Electrical Panels shown “Locked Out”

Piping shown “Locked Out”

HOW ARE EQUIPMENT-SPECIFIC EI-LOTO

PROCEDURES USED?

Once an equipment-specific EI-LOTO procedure is created, it must be provided to any and all personnel who may be using that equipment as part of their work / research / teaching / training on that equipment. The original procedure must be kept by the Shop / Lab Supervisor and copies should be posted on or nearby the equipment for quick / easy reference by users. For “facilities” equipment, the procedure can be saved in a PDF file and linked to the equipment’s asset tag number so that the EI-LOTO procedure generates along with a work-order for equipment

Equipment-Specific Energy Isolation Procedure shown in file on front of Equipment Control Panel.


maintenance. This allows a maintenance technician to plan their EI-LOTO activities back at their shop as they plan the rest of the job, prior to leaving for campus to conduct the work. For proprietary research equipment developed specifically for lab / research purposes, the written EI-LOTO procedure acts as your lab’s SOP for how to safely control and isolate energy sources associated with your lab equipment, and meets the requirements for your Lab SOPs / safety manual. Shop / Lab Supervisors must train personnel on the contents and application of the EI-LOTO procedures developed under their oversight, and inform where personnel can gain access to them as needed in their work area.

WHAT ARE THE BASIC RULES FOR

PRACTICING EI-LOTO?

Several basic safety rules are applied during every EI-LOTO situation. These are: 1. Only “Qualified Persons” may work on, or “practice”, EI-LOTO on equipment.

2. All equipment must be blocked and locked out to protect against accidental or

inadvertent operation when such operation could cause injury to personnel.

3. Never attempt to operate any switch, valve, or other energy isolating device

bearing a lock placed by someone else.

4. Never remove a blocking device until all personnel, tools and obstructions have

been cleared from the area, and all equipment guards have been properly

reinstalled.

5. Once EI-LOTO is in place, ALWAYS VERIFY electricity and other energy

sources are dead-off in conductors using a volt meter, or piping using pressure

gages, or verify bleed valves are open, prior to commencing work.

6. If the equipment or system must remain energized during work, contact EH&S

Safety Engineering to assist in developing adequate alternative hazard control

measures, such as the use of suitable temporary barriers, special tools and

personal protective equipment, prior to commencing work.

7. Develop and/or verify an EI-LOTO procedure and confirm it applies to the

equipment you’re working on prior to start.

8. Follow the EI-LOTO procedure as it is written, unless you discover needed

updates to the procedure as you implement it.

STANDARD EI-LOTO PROCEDURE

1. All maintenance personnel are issued a suitable lock (or locks for multiple energy

sources). Each lock has the individual worker’s name or other identification on it.

Each worker has the only key to the lock / lock set.

2. The Qualified Person checks to be sure that no one is operating the machinery

BEFORE turning off energy sources. All persons in the area, and especially the

machine operator and project supervisor, are informed before the energy sources


are being turned off because unexpected sudden loss of power could cause an

accident.

3. Steam, air, and hydraulic piping or tanks must be bled, drained, and/or brought to

atmospheric pressure and locked “open” to assure no pressure or vacuum in

piping or in reservoir tanks.

4. Gas cylinders must be locked ‘closed’ and if possible disconnected from

distribution piping.

5. Any mechanical component that could roll, shift or otherwise move, such as

springs, counterweights, wheels, fan blades, etc. must be chained, barred or

blocked.

6. Each person who will be working on the machinery must put a lock on each of

the machine’s lockout device(s). Each lock must remain on the machine until the

work is completed. Only the worker who placed the lock may remove their lock.

7. The Supervisor, Work Lead or “Qualified Person” places a tag on each lock-out

location.

8. All energy sources which could activate the machine must be locked or blocked

out following an equipment-specific EI-LOTO Procedure developed for that

equipment.

9. All disconnects must be tested to ensure that all energy sources to the machine

are off.

10. Electrical circuits must be checked by qualified persons with proper and

calibrated electrical testing equipment. Stored energy in electrical capacitors

must be safely discharged with grounding straps installed.

11. CAUTION: Return disconnects and operating controls to the “off” position after

each test.

12. Attach accident prevention tags which give the reason for placing the lock/tag,

the name of the person placing the lock/tag, how they may be contacted, and the

date and time the lock/tag was placed.

TESTING / ADJUSTING EQUIPMENT DURING

EI-LOTO

In many maintenance and repair operations, machinery must be tested and therefore energized before additional maintenance work can be performed. For such situations, this procedure must be followed:

1. Clear all personnel to safety.

2. Clear away tools and materials from equipment.

3. Remove blocks and lockout devices and re-energize systems, following the

established safe procedure.

4. Proceed with tryout or test.


5. Shut off all energy sources reinstalling lockouts on energy sources, reinstall

blocks, bleed all pressure systems and verify all energy sources de-energized

prior to continuing work.

Equipment design and performance limitations may dictate that effective alternative worker protection be provided when the established lockout procedure is not feasible. If machinery must be capable of movement in order to perform a maintenance task, workers must use extension tools, personal protective equipment and other means to protect themselves from moving parts and potential injury.

RESTORING EQUIPMENT TO SERVICE

After the work is completed and the equipment is ready to be returned to normal operation, this procedure must be followed:

1. Remove all non-essential items.

2. See that all equipment components are operationally intact, including reinstalling

guards and safety devices.

3. Repair or replace defective guards before removing locks.

4. Remove each lockout device using the correct removal sequence.

5. Make a visual check before restoring energy to ensure that everyone is

physically clear of the equipment.

Each lock is removed by the qualified person that applied it, or under his/her direct supervision. If the qualified person is absent from the work place then the lock or tag can be removed by a qualified person designated to perform this task provided that the immediate supervisor:

1. Verifies that the qualified person is not present and therefore unable to remove

the lock;

2. Makes all reasonable efforts to inform the qualified person that the lockout/tagout

device has been removed; and

3. Ensures that the qualified person knows their lockout/tagout device has been

removed before their work resumes.

Finally, notify any “Affected Person(s)” that equipment has been restored to its operational state.

APPLYING EI-LOTO TO JOINT PROJECTS

If University personnel and contractor personnel are working on the same piece of equipment, each work team installs their own hasp and locks on each energy source. The University provides the hasps that University personnel install their locks on, and the Contractor provides their hasps and locks that their personnel install / use.


[THIS PAGE LEFT INTENTIONALLY BLANK FOR PRINTING / DUPLEX PURPOSES.]

University of California - EI-LOTO “Equipment Specific” Procedure – TEMPLATE – Page 1

Equip. Name: ____________________ Building: _____________________________ Location / Room Number: ___________

PROCEDURE PREPARED BY:

__________________________ __________________________ (PRINT NAME)

SIGNATURE / DATE

ANNUAL REVIEW COMPLETED BY:

_____________________________________________________ (PRINT NAME)

SIGNATURE / DATE

1: ENERGY SOURCE 2: MAGNITUDE / TYPE 3: ISOLATION DEVICE / LOCATION / METHOD

ELECTRICITY– Main power Amps: Volts: # Phase:

ELECTRICITY– Control circuit(s) Amps: Volts: # Phase:

BATTERY / SOLAR / ALT POWER AC/DC/PH:

Amps: Volts:

COMPRESSED AIR / GASES PSI: Gas Type:

STEAM / CONDENSATE PSI: Source:

FLUID UNDER PRESSURE PSI: Source:

HEAT / COLD + / - C° or + / - F° Temp: Source:

VACUUM CHAMBER / PIPING Hg”: Source:

FUEL(S) - SOLID / LIQUID / GAS Volume: Fuel:

ROTATING WHEEL / FAN / DRIVE Details:

SUSPENDED WEIGHT Details:

MECHANICAL OTHER: Details:

Step 5 – Check off [X] and circle all PPE and safety equipment to be used for Energy Isolation.

PPE to be worn during work Safety Equipment to be used during work

GOGGLES / FACE SHIELD / WELD GEAR FIRE EXTINGUISHER / FIRE WATCHER

BOOTS – STEEL TOE / RUBBER / OTHER LINES BLINDED & TAGGED

GLOVES – LEATHER / RUBBER / INSULATED VALVES / SWITCHES - LOCKED & TAGGED

SAFETY HARNESS / LANYARD & LINE REMOVE FLAMMABLES / COMBUSTIBLES

RESPIRATOR – DUST / CHEMICAL BLEEDERS LOCKED OPEN & TAGGED

THERMAL – HEAT / COLD PROTECTION SHIELDS – ARC CURTAIN / HEAT BLANKET

APRON / WET GEAR / OTHER BLOCKS / BARS / BARRICADES / CHAINS

OTHER: _______________________________ TOOLS - LONG HANDLE / INSULATED

Instructions: Follow the steps to create a written sequence for de-energizing, lockout, testing, and start-up of equipment requiring energy isolation. Use completed procedure for safety meetings / training for the equipment-specific lockout process. Discuss with workers how equipment energy isolation – LOTO is applied to this specific equipment during these planned job / tasks. Also, discuss communication methods on the job site.

Describe scope of work here:

Instructions continued: Isolate energy sources in sequence. Assure each worker installs their own lock on each disconnect location. Supervisor/Authorized Person installs warning tags. Verify Energy Isolation prior to starting work. When testing / jogging equipment, follow program procedures on the back of this form. When restoring equipment to operation, reverse isolation sequence unless otherwise discussed / approved by the Project Supervisor. Use Personal Protective Equipment and safety equipment as noted below during work activities. Contact EH&S for technical support and special concerns.

Step 1 - Survey and Check

off [X] all Energy Sources

Step 4 – List sequence of Energy Isolation Number 1 up to 12

Step 2 – Note Magnitude and type of each energy source

Step 3 – Note Device and Location of each energy disconnecting / isolation source / method.

University of California - EI-LOTO “Equipment Specific” Procedure – TEMPLATE - Page 2

Standard Energy Isolation LOTO Procedure

1. All maintenance personnel are issued a suitable lock (or locks for multiple energy sources). Each lock has the individual

worker’s name or other identification on it. Each worker has the only key to the lock / lock set.

2. The Authorized Person checks to be sure that no one is operating the machinery BEFORE turning off energy sources. All

persons in the area, and especially the machine operator and project supervisor, are informed before the energy sources are

being turned off because unexpected sudden loss of power could cause an accident.

3. Steam, air, and hydraulic piping or tanks must be bled, drained, and/or brought to atmospheric pressure and locked “open” to

assure no pressure or vacuum in piping or in reservoir tanks.

4. Gas cylinders must be locked ‘closed’ and if possible disconnected from distribution piping.

5. Any mechanical component that could roll, shift or otherwise move, such as springs, counterweights, wheels, fan blades, etc.

must be barred or blocked.

6. Each person who will be working on the machinery must put a lock on each of the machine’s lockout device(s). Each lock must

remain on the machine until the work is completed. Only the worker who placed the lock may remove their lock.

7. The Supervisor or “Authorized Person” places a tag on each lock-out location.

8. All energy sources which could activate the machine must be locked or blocked out following an equipment-specific Energy

Isolation Procedure developed for that equipment. (Other side)

9. All disconnects must be tested to be sure that all energy sources to the machine are off.

10. Electrical circuits must be checked by qualified persons with proper and calibrated electrical testing equipment. Stored energy

in electrical capacitors must be safely discharged.

11. CAUTION: Return disconnects and operating controls to the “off” position after each test.

12. Attach accident prevention tags which give the reason for placing the lock/tag, the name of the person placing the lock/tag, how

they may be contacted, and the date and time the lock/tag was placed.

Testing / Adjusting Equipment during Lockout

In many maintenance and repair operations, machinery must be tested and therefore energized before additional maintenance work can be performed. For such situations, this procedure must be followed:

1. Clear all personnel to safety.

2. Clear away tools and materials from equipment.

3. Remove blocks and lockout devices and re-energize systems, following the established safe procedure.

4. Proceed with tryout or test.

5. Shut off all energy sources reinstalling lockouts on energy sources, reinstall blocks, bleed all pressure systems and verify all

energy sources de-energized prior to continuing work.

Equipment design and performance limitations may dictate that effective alternative worker protection be provided when the established lockout procedure is not feasible. If machinery must be capable of movement in order to perform a maintenance task, workers must use extension tools, personal protective equipment and other means to protect themselves from moving parts and potential injury. Restoring Equipment to Service

After the work is completed and the equipment is ready to be returned to normal operation, this procedure must be followed: 1. Remove all non-essential items.

2. See that all equipment components are operationally intact, including reinstalling guards and safety devices.

3. Repair or replace defective guards before removing locks.

4. Remove each lockout device using the correct removal sequence.

5. Make a visual check before restoring energy to ensure that everyone is physically clear of the equipment.

Each lock is removed by the authorized person that applied it, or under his/her direct supervision. If the authorized person is absent from the work place then the lock or tag can be removed by a qualified person designated to perform this task provided that the immediate supervisor:

1. Verifies that the qualified person is not present and therefore unable to remove the lock;

2. Makes all reasonable efforts to inform the qualified person that the lockout/tagout device has been removed; and

3. Ensures that the qualified person knows their lockout/tagout device has been removed before their work resumes.

Finally, notify any “Affected Person(s)” that the equipment has been restored to its operational state. Joint Projects

If University personnel and contractor personnel are working on the same piece of equipment, each work team installs their own hasp

and locks on each energy source. The University provides the hasps that University personnel install their locks on, and the Contractor

provides their hasps and locks that their personnel install / use.

UC System - Shop Safety Reference Manual Section 8 – Energy and Lockout Tagout Safety 37 June 2013

QUIZ – ENERGY SAFETY AND EI-LOTO

1. Which of the following are hazards of electricity?

a. Shock and Electrocution

b. Fire and burns

c. Explosion and arc blast

d. All of the above

2. True or False?

Energy sources, particularly electrical panels and pressurized plumbing control valves, should be properly secured easily accessible for 36” clearance.

3. True or False?

A compressed air powered nail-gun is likely made safe simply by unplugging it from the compressed air system.

4. True or False?

If I’m working on a large and heavy piece of equipment that I have jacked-up in

the air with a rugged scissors or hydraulic jack, as long as the jack’s in good

shape I don’t have to block the equipment before I crawl under it.

5. Once EI-LOTO is in place, who is allowed to remove the locks and tags to enable

machinery to restart?

a. The qualified person who locked it out only

b. Anybody who has the key to the lock

c. The shop supervisor (under emergency situations following strict

procedures for notifying the qualified person)

d. A and B

e. A and C

6. True or False?

Written procedures for Lock out/ tag out are needed for each and every piece of equipment that is connected to, or produces more than, one kind of utility-energy used for its operation.

7. True or False?

The EH&S Department on your campus has safety engineers available at no cost

to help you develop EI-LOTO procedures specific to your equipment. And, these

procedures can be used as SOPs for research lab equipment, and as job-

planning tools for facility maintenance.

8. True or False?

Lock out/ tag out is not required when replacing saw blades on a hand-held circular saw.


* Quiz Answers:

1. D

2. True

3. False – Compressed air equipment often has an accumulator tank inside the equipment that must

be bled to atmosphere before the equipment is safe to work on. Look at equipment manuals to

understand how your compressed air equipment operates, and locate safety bleed valves and

open them before working on the equipment.

4. False – Never put any part of your body underneath a heavy object that’s being held-up by jack or

hoist piece of equipment without blocking. Always raise the equipment and set it down securely

onto blocks that can support its weight before you put any part of your body underneath it.

5. E

6. True

7. True

8. True – As long as the circular saw is unplugged, and you have exclusive control over the plug.

section 8: energy safety and energy isolation lockout

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