According to NFPA 70E Sections 120.5(A)(4) and (5), two forms of hazardous electrical energy control are permitted:

• The simple lockout/tagout procedure, OR
• The complex lockout/tagout procedure

For the simple lockout/tagout procedure, a written lockout/tagout plan is not required and there is never more than one source of electrical energy. The qualified person performing the work is in charge and is responsible for their own lockout/tagout.

A complex lockout/tagout procedure usually involves more than one source of energy and often involves more than one single disconnecting means. For the complex lockout/tagout procedure, the person in charge shall have responsibility of the overall project and a written plan prepared before each lockout/tagout application.

Complex Lockout/Tagout Procedure

The "complex lockout/tagout procedure" is designed for situations where multiple energy sources and possibly multiple workers are involved. This complexity increases the risk and necessitates stringent control measures to ensure safety. Below is an expanded explanation of the key components:

Multiple Sources of Energy

In a complex lockout/tagout scenario, multiple energy sources need to be controlled. These could include electrical, mechanical, hydraulic, pneumatic, chemical, or thermal energy sources. Each of these energy sources might have separate isolation points and might require different methods or devices to effectively isolate them.

Multiple Disconnecting Means

Often, complex lockout/tagout procedures involve more than one disconnecting means. This could be due to the equipment's design, where different parts of a machine or different pieces of equipment are powered separately. Managing multiple disconnects requires careful coordination to ensure that all energy sources are adequately isolated before work begins.

Written Lockout/Tagout Plan

For complex procedures, a written lockout/tagout plan is mandatory. This plan should be specific to the task at hand and must be prepared before initiating the lockout/tagout. The plan should include:

• Identification of all energy sources and their respective isolation points.
• Specific methods and devices for isolating and securing each energy source.
• Step-by-step instructions for applying and removing lockout/tagout devices.
• Designation of the individual responsibilities of all involved personnel.
• Procedures for verifying that the system is de-energized and safe for work.

Person in Charge

The complexity of these scenarios requires that a designated person be in charge of the lockout/tagout procedures. This person, often referred to as the "lockout/tagout coordinator" or "project manager," is responsible for:

• Overseeing the implementation of the lockout/tagout plan.
• Ensuring that all personnel involved are properly trained and understand their roles and the hazards associated with the task.
• Confirming that all steps of the lockout/tagout plan are followed.
• Managing communication and coordination among all team members to prevent any procedural lapses that could lead to safety incidents.

Coordination Among Team Members

Complex lockout/tagout procedures typically involve multiple workers, and coordination becomes essential to safety. The person in charge must ensure that everyone involved is aware of their specific tasks and the timing of these tasks, especially in situations where workers depend on one another to apply or remove lockouts in sequence.

Verification of De-energization

Just as in simple lockout/tagout procedures, verifying that all energy sources are truly isolated and that the equipment is de-energized before work begins is crucial. This verification is often performed using testing equipment appropriate for each type of energy.

Documentation and Audits

Documentation of each step, as executed, is crucial in complex lockout/tagout procedures to maintain a record of compliance and safety. Regular audits of these procedures help identify potential areas for improvement and reinforce safety protocols.

Complex lockout/tagout procedures require meticulous planning and rigorous execution due to the increased risks from multiple energy sources and greater personnel involvement. By adhering to a well-defined plan and ensuring thorough communication and coordination, workplaces can safeguard against accidents and ensure that maintenance and repair activities are conducted safely.

Below is a sample of NFPA 70E. For the complete section, see the actual NFPA 70E text at NFPA.ORG. Once there, click on the free access link to NFPA 70E.

120.5(A)(5) Complex Lockout/Tagout Procedure.

(a) A complex lockout/tagout procedure shall be permitted where one or more of the following exists:

(1) Multiple energy source

(2) Multiple crews

(3) Multiple crafts

(4) Multiple locations

(5) Multiple employers

(6) Multiple disconnecting means

(7) Particular sequences

(8) Job or task that continues for more than one work period

(b) All complex lockout/tagout procedures shall require a written plan of execution that identifies the person in charge.

(c) The complex lockout/tagout procedure shall vest primary responsibility in an authorized employee for employees working under the protection of a group lockout or tagout device, such as an operation lock or lockbox. The person in charge shall be held accountable for safe execution of the complex lockout/tagout.

(d) Each authorized employee shall affix a personal lockout or tagout device to the group lockout device, group lockbox, or comparable mechanism when he or she begins work and shall remove those devices when he or she stops working on the machine or equipment being serviced or maintained.

(e) All complex lockout/tagout plans shall identify the method to account for all persons who might be exposed to electrical hazards in the course of the lockout/tagout.