Author: MASCT Vestas Standard Date: 23 September 2011

Approver: JAL Control of Hazardous Energy Page 1 of 18

Document: 0017-5309_V01

History of this Document

Version Date Description of changes
no.
V00 23-MAR-11 Initial Issue of Document
V01 23-SEP-11 Revision 01 – Essential edits and corrections necessary for implementation
 3.1.2: Added definition for Escorted Visitor
 4.4: Added requirement for ECC training
 5.2.1.d: Aligned to match Vestas Standard for Electrical Safety
 6.7.4.k: Added requirement to return lockout instruction to ECC for
record-keeping
 6.7.5.b: Specified that Person in Charge should lock the lockbox with
a control lock (instead of a personal lock)
 6.9.2: Simplified Person in Charge turnover process per 6.7.5.b
 6.10: Added allowance for temporary release for testing or
repositioning
 Other miscellaneous typo corrections

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trade secret, and other proprietary rights to it. The information in this document may not be used, reproduced, or disclosed except if and to the extent rights are expressly granted by Vestas in writing and subject to applicable
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Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 2 of 18
Document: 0017-5309_V01

Table of Contents
1 Purpose ......................................................................................................................................... 2
2 Scope ............................................................................................................................................. 2
2.1 Applicability of the standard ................................................................................................... 3
2.2 Requirement for a Written Program ....................................................................................... 3
3 Program Administration ............................................................................................................... 3
3.1 Roles and Responsibilities ..................................................................................................... 3
4 Training.......................................................................................................................................... 4
4.1 Lockout Level 1 – Basic Lockout User ................................................................................... 4
4.2 Lockout Level 2 – Person in Charge ...................................................................................... 5
4.3 Lockout Level 3 – Lockout Specialist ..................................................................................... 5
4.4 Energy Control Coordinator ................................................................................................... 6
5 Energised Work............................................................................................................................. 6
5.1 Normal Energised Work ......................................................................................................... 6
5.2 Energised Work That Normally Requires Lockout .................................................................. 6
5.3 Partial Energy Reduction ....................................................................................................... 7
5.4 Interlock Bypass .................................................................................................................... 7
6 Lockout Program .......................................................................................................................... 8
6.1 Compliance ............................................................................................................................ 8
6.2 Basic Lockout Rules .............................................................................................................. 8
6.3 Energy Isolation ..................................................................................................................... 8
6.4 Verification of Deenergisation ................................................................................................ 9
6.5 Requirement for Qualified Persons ...................................................................................... 10
6.6 Locks ................................................................................................................................... 10
6.7 Lockout Methods ................................................................................................................. 11
6.8 Tagout ................................................................................................................................. 13
6.9 Extended Shutdown ............................................................................................................. 14
6.10 Temporary Release for Testing or Repositioning ................................................................. 14
6.11 System Diagrams and Equipment Labelling ......................................................................... 14
6.12 Absent Person Lock Removal .............................................................................................. 15
7 Equipment Design Requirements .............................................................................................. 15
7.1 Lockout Isolation Points ....................................................................................................... 15
7.2 Equipment Drawings ............................................................................................................ 16
7.3 Stored Energy ...................................................................................................................... 16
8 Abbreviations and Definitions.................................................................................................... 16
9 References .................................................................................................................................. 18

1 Purpose
The purpose of the Vestas Standard for Control of Hazardous Energy is to establish standardized
requirements for Vestas Business Units (BU) to develop their Control of Hazardous Energy Program.
The primary purpose of the BU Control of Hazardous Energy Program is to prevent fatalities and
injuries to personnel from the unexpected energising, startup or release of hazardous energy while
performing work on equipment.
The program is also to be used to prevent unexpected environmental releases and damage to property
and installations.

2 Scope
This Vestas Standard for Control of Hazardous Energy specifies the minimum requirements for

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Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 3 of 18
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controlling hazardous energy. Hazardous energy is defined as any source of electrical, mechanical,
hydraulic, pneumatic, chemical, thermal, gravitational force or any other energy source that could cause
injuries to personnel.

2.1 Applicability of the standard

2.1.1 The parameters of the standard have to be taken into account when designing and drawing up
specifications for Vestas produced equipment, tools and turbines.

2.1.2 The parameters of the standard must be followed when defining purchase specifications for
new machines or equipment.

2.1.3 The standard is to cover installation, operation, maintenance and dismantling of machines and
building installations.

2.1.4 The standard is to cover installation, commissioning, operation, service and decommissioning
of wind turbines.

2.1.5 The standard establishes the minimum training requirements for employees executing the
Control of Hazardous Energy Program.

2.1.6 The Control of Hazardous Energy Program applies to all personnel working on behalf of
Vestas, including employees, customers, contractors, inspectors and visitors.

2.1.7 Deviations from the standard will require a formal risk assessment and management approval.

2.1.8 Personnel working where the unexpected energisation, start-up, or release of stored energy
could occur and cause injury are required to comply with the restrictions and limitations
imposed on them during the use of this program. Energy sources include, but are not limited
to, electrical, mechanical, pneumatic, and hydraulic.

2.2 Requirement for a Written Program

2.2.1 All Vestas Business Units (BU) shall develop a written Control of Hazardous Energy Program.

2.2.2 The BU Control of Hazardous Energy Program shall meet the minimum requirements set forth
in this standard.

2.2.3 The BU Control of Hazardous Energy Program shall also meet local legal requirements in the
country of operation.

2.2.4 The BU shall implement and manage the written BU Control of Hazardous Energy Program
with appropriate training, roles and responsibilities, and audits that will ensure the effectiveness
of this program.

3 Program Administration

3.1 Roles and Responsibilities

3.1.1 The BU Hazardous Energy Control Program shall define roles and responsibilities associated

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Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 4 of 18
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with the administration of this program. The following roles, at minimum, shall be assigned to
personnel suitably experienced in terms of safety awareness, technical competency, and sound
judgment. Each BU shall define in the written Hazardous Energy Control Program how the
responsibilities will be filled, and what training and qualification requirements shall be
implemented.

3.1.2 Escorted Visitor: a person escorted by the Person In Charge, who will apply their personal
lock(s) to an established lockout prior to accessing an area requiring this lockout.

3.1.3 Basic Lockout User: a person trained to Lockout Level 1 in accordance with Section 4.1, who
will apply their personal lock(s) to an established lockout prior to working on equipment. Only
Basic Lockout Users shall be permitted to work on equipment under a lockout or access areas
requiring lockout without being escorted by the Person In Charge.

3.1.4 Person In Charge: a person trained to Lockout Level 2 in accordance with Section 4.2, and who
is assigned responsibility for a particular lockout. A Person In Charge shall be designated for
every lockout.

3.1.5 Lockout Specialist: a person trained to Lockout Level 3 in accordance with Section 4.3, who
can review and approve lockout instructions. Lockout instructions shall only be approved by
Lockout Specialists who have detailed technical knowledge about the equipment that will be
locked out. Lockout Specialists shall not approve lockout instructions for equipment for which
they are not qualified or feel they have not received the appropriate training, unless they are
supported by someone qualified and with the appropriate training.

3.1.6 Energy Control Coordinator (ECC): a single point of contact for a site, responsible for the
overall execution of the Control of Hazardous Energy Program at the site. The ECC shall have
successfully completed ECC training in accordance with Section 4.4. Each physical location
shall have an ECC with responsibility for that site. Smaller sites may share an ECC provided
that the appropriate level of oversight is achieved. The ECC also has additional responsibilities
for Electrical Safety outlined in the Vestas Standard for Electrical Safety.

3.1.7 Vestas Senior Manager: a manager who can approve certain special actions outlined in this
program, where the level of risk and responsibility would exceed what is commensurate with
the management level of the Energy Control Coordinator (ECC).

4 Training

4.1 Lockout Level 1 – Basic Lockout User

4.1.1 Initial training will cover the principles and methods of lockout, the usage of lockout equipment
and forms, and the imperative to always lockout before commencing work.

4.1.2 Initial training is expected to last one hour and shall include a physical demonstration of lockout
on training equipment. The trainee shall be exposed to examples of lockout situations that they
may encounter. A video of this material is acceptable.

4.1.3 A short multiple choice test and a practical demonstration test shall also be included at the end
of the course. A passing grade shall be required on both the written and practical portions of the
test.

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Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 5 of 18
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4.1.4 Annual retraining for Lockout Level 1 is required. It can consist of the same material as the
initial training, but shall be augmented with lessons learned from lockout incidents the previous
year.

4.2 Lockout Level 2 – Person in Charge

4.2.1 Persons completing Lockout Level 2 shall be given additional training after completing the
Lockout Level 1 training. The additional material shall include execution and management of
complex and group lockouts, and transfer of responsibility to another Person in Charge.

4.2.2 Initial training is expected to last one hour and shall include a physical demonstration of lockout
on training equipment. The trainee shall be exposed to examples of lockout situations that they
may encounter. A video of this material is acceptable.

4.2.3 A short multiple choice test and a practical demonstration test shall also be included at the end
of the course. A passing grade shall be required on both the written and practical portions of the
test.

4.2.4 Annual retraining for Lockout Level 2 is required. It can consist of the same material as the
initial training, but shall be augmented with lessons learned from lockout incidents the previous
year.

4.3 Lockout Level 3 – Lockout Specialist

4.3.1 Prerequisites for Lockout Level 3 training include:

a. Prior completion of Lockout Level 2 - Person In Charge training.

b. Candidates for Lockout Level 3 shall have extensive knowledge of schematics (electrical
and hydraulic at a minimum).

4.3.2 Training for Lockout Specialist shall include reading and interpreting schematics (electrical and
hydraulic at a minimum), identification of hazardous energy, identification of lockout boundaries,
matching of lockout boundaries to specific tasks to be performed, and writing of lockout
instructions.

4.3.3 Initial training is expected to last 6 hours and shall include a physical demonstration of lockout
on training equipment. The trainee shall be exposed to examples of lockout situations that they
may encounter. A video of this material is not acceptable.

4.3.4 A comprehensive one-hour examination shall include multiple choice questions and two
practical problems applicable to the plant. A passing grade shall be required on both the written
and practical portions of the test.

4.3.5 Retraining for Lockout Specialists is required every two years. It can consist of the same
material as the initial training, but shall be augmented with lessons learned from lockout
incidents the previous year.

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Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 6 of 18
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4.4 Energy Control Coordinator

4.4.1 Prerequisites for ECC training include:

a. Prior completion of Lockout Level 3 – Lockout Specialist training

b. Designation by the BU as a Skilled Electrical Person in accordance with the Vestas

Standard for Electrical Safety

c. Selection by the BU Electrical Safety Sub-Committee for the ECC role.

4.4.2 Training for Energy Control Coordinators shall include administrative duties and relevant
complex work scenarios where coordination of lockout requirements between several parties is
required.

4.4.3 The Energy Control Coordinator (ECC) shall also continue to maintain certification as Lockout
Specialist as required in 4.3.5.

5 Energised Work

5.1 Normal Energised Work

5.1.1 Servicing and/or maintenance which takes place during normal production operations is
covered by this standard only if:

a. An employee is required to remove or bypass a guard or other safety device; or

b. An employee is required to place any part of his or her body into an area on a machine or
piece of equipment where work is actually performed upon the material being processed
(point of operation) or where an associated danger zone exists during a machine operating
cycle.

5.1.2 Minor tool changes and adjustments, and other minor servicing activities, which take place
during normal production operations, are not covered by this standard if they are routine,
repetitive, and integral to the use of the equipment for production, provided that the work is
performed using alternative measures which provide effective protection. Such alternative
measures include equipment guarding, protection through interlocks, and the use of applicable
Personal Protective Equipment, to ensure that the hazard is fully managed and controlled.

5.1.3 All other tasks shall require the complete deenergisation of the equipment, and the minimum
lockout requirements of Section 6 shall apply. Where the minimum lockout requirements of
Section 6 cannot be fulfilled, the requirements of Sections 5.2 and 5.3 shall also apply.

5.2 Energised Work That Normally Requires Lockout

5.2.1 Servicing and/or maintenance tasks shall not be performed on energised equipment, unless all
of the following conditions are met:

a. A formal risk assessment has been performed, comparing the option of locking out the
equipment to the option of performing the task on energised equipment.

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Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 7 of 18
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b. The hazards associated with performing the task live can be managed such that the
employee is kept safe through a combination of guarding, PPE and training.

c. A written work instruction is developed to fully describe the task to be performed, the
hazards associated with the task, and all precautions and protective measures to be
implemented during the performance of the task.

d. The Chief Operating Officer (SBU’s), the Production Unit Manager (PBU’s) or the relevant
vice president (other BU’s) have the authority to curtail operations so that the work may be
performed deenergized. If work will instead be performed energised, they must therefore
also approve the written risk assessment and the written work instruction for working
energised.

e. For electrical work, an Energised Electrical Work Permit shall be issued in accordance with
the BU Electrical Safety Program.

5.3 Partial Energy Reduction

5.3.1 Certain tasks may require a partial reduction in the hazard exposure without being able to
achieve full deenergisation under the requirements of Section 6. The BU will implement control
protocols to govern work under partial energy reduction conditions. The protocols shall ensure
that the work is performed using alternative measures which provide effective protection. Such
alternative measures include equipment guarding, protection through interlocks, and the use of
applicable Personal Protective Equipment, to ensure that the hazard is fully managed and
controlled.

5.3.2 Partial energy reduction includes:

a. Testing of hydraulic systems at reduced pressures

b. Testing of electrical systems at reduced arc flash energy, using an Arc Reduction
Maintenance Switch or similar device

5.4 Interlock Bypass

5.4.1 No interlock shall be bypassed without establishing a method to provide equal or greater
protection. This method can consist of prohibiting access, prohibiting operation, or allowing
such access or operation while following a special instruction written for the tasks required. The
written instruction will establish safe boundaries and constraints such that the level of protection
provided is equivalent to that provided by the interlock.

5.4.2 Provided the requirements of 5.4.1 are met, bypassing an interlock shall require written
authorization from the Energy Control Coordinator. Interlock bypass authorization shall use a
form with the following entries:

a. Reason the interlock bypass is required.

b. A list and description of all disabled devices, their purpose, the impact of disabling the
interlock to equipment, and the impact of disabling the interlock to personal safety.

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c. Method used to provide equal or greater protection while the interlock is bypassed.

5.4.3 While an interlock is bypassed, the interlock bypass form shall be posted at the equipment
control panel. Once the interlock is restored, the form is returned to the Energy Control
Coordinator for record keeping.

6 Lockout Program

6.1 Compliance

6.1.1 NO PERSON SHALL OPERATE ANY ENERGY-ISOLATING DEVICE TO WHICH A LOCK

OR “DO NOT OPERATE” TAG IS ATTACHED, OR REMOVE ANOTHER PERSON’S LOCK
OR TAG WITHOUT AUTHORIZATION.

6.1.2 No person shall attempt to operate any equipment when it is locked out other than during the
initial check for a zero energy condition.

6.2 Basic Lockout Rules

6.2.1 Lockout is the process of isolating all sources of energy, releasing stored energy, verifying that
the isolations deenergised the equipment, and locking the isolation devices in accordance with
a written lockout instruction.

6.2.2 All personnel working on the equipment shall be personally locked out. Working on includes
access to areas where it would not be safe to be unless the equipment were shut down and
deenergised.

6.2.3 Anyone working on the equipment must work under his or her personal lock. Except under the
restrictions of Section 6.12 (Absent Person Lock Removal), no person is ever authorized to
apply or remove another person’s lock.

6.2.4 It is not permissible to rely on communications only (verbal, visual, written or radio) to perform a
lockout.

6.3 Energy Isolation

6.3.1 Lockout Isolation Point Requirements

a. All lockout isolation points must consist of positive isolation devices such as disconnect
switches, circuit breakers, block valves, and blocking pins.

b. All energy-isolating devices used as lockout points should be capable (or made capable) of
accepting an approved lockout device that physically prevents the actuation of the energy-
isolating device. Where this is not achievable, follow the tagout requirements of Section 6.8.

c. There can be no interlocks, contactors, diodes, check valves, or automatically controlled

devices between the isolation device and the test point used for verification of
deenergisation of the lockout point.

d. Each lockout point must be labelled clearly and uniquely, such as with an alphanumeric

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designator or a word description of its function.

e. Control points such as the emergency stop or the equipment controller shall not be used as
lockout isolation points.

6.3.2 Lockout Boundary

a. The Lockout Boundary encloses the entire zone where it is safe to work. It is defined by the
lockout isolation points selected for the lockout procedure.

b. The Lockout Boundary must completely deenergise the equipment to be worked on.

c. The Lockout Boundary must also completely deenergise adjacent systems that would pose
a hazard to the worker, as required by the particular tasks to be performed. The Lockout
Boundary is not only equipment-specific; it is also task-specific. Determining the proper
Lockout Boundary requires a careful examination of the tasks to be performed and the
conditions of the surrounding equipment. Some tasks introduce greater risk and therefore
must have a more expansive Lockout Boundary.

d. The person writing the lockout instruction may find it necessary to consult circuit or piping
diagrams, operational manuals, and in some cases may have to physically inspect the work
area to determine what should be locked out.

e. When the work area shifts or expands to an area outside the Lockout Boundary, the work
must stop until a new lockout is established that includes the new work area.

f. All personnel performing work under a lockout must clearly understand the extent of the
particular Lockout Boundary. The Lockout Boundary shall be specifically identified on all
written lockout instructions.

6.3.3 Stored Energy

a. Accumulated or stored energy sources that could supply a system that is locked out must
be identified and dissipated by an appropriate means.

b. If there is a possibility of the equipment accumulating energy over time after the application
of the lockout, then the lockout must include an energy-releasing device capable of
continuously releasing the energy without the buildup of hazardous conditions.

6.4 Verification of Deenergisation

6.4.1 Because of the possibility of interlocks and other automatic devices in the circuit, the verification
of deenergisation requires the following steps.

a. Verification of deenergisation at each isolation

b. Verification of deenergisation at the point of work and surrounding area

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c. Where possible for rotating equipment: verification that the equipment will not start on
command

6.4.2 The method of verification shall be established in the lockout instruction.

6.5 Requirement for Qualified Persons

6.5.1 A Qualified Person is someone designated by the BU management and who, by virtue of their
training, knowledge and experience with equipment design, construction and operation, can
safely shut down or startup the equipment. Qualification criteria will depend on the type of
equipment and energy involved.

6.5.2 Only Qualified Persons may establish the lockout. This includes equipment shutdown,
operation of isolation devices, releasing stored energy, and verification of deenergization. When
work is finished, this requirement also includes restoration, reenergization, and startup of the
equipment.

6.5.3 In many cases, the Person In Charge is also a Qualified Person. Where this is not the case, the
Person In Charge shall designate Qualified Persons to establish the equipment lockout. The
Person In Charge shall observe that the equipment is properly isolated and verified
deenergized, and apply the control locks per the chosen lockout method.

6.6 Locks

6.6.1 Personal lockout locks shall all be keyed differently, and the keys shall be kept by the employee
who owns the locks.

6.6.2 Control locks shall all be keyed differently, and when the locks are in use the keys will be kept
either by the Person In Charge or locked in a lockbox.

6.6.3 Lockout locks shall be substantial enough to prevent removal without the use of excessive force
or unusual techniques, such as with the use of bolt cutters or other metal cutting tools.

6.6.4 Master keys for lockout locks are not permitted. Duplicate keys issued with the locks by the
manufacturer shall be destroyed and discarded.

6.6.5 Each individual lock will be identifiable as a lockout lock as follows:

a. Personal locks shall always be tagged with “DANGER – DO NOT OPERATE”. The tag shall
include first and last name, company name, and telephone contact number identifying the
worker. Vestas employees’ tags shall have first and last name of the employee, telephone
contact number, and a colour picture of the employee permanently printed on the tag.

b. Control locks shall always be tagged with “DANGER – DO NOT OPERATE” and shall
include the permanent marking “VESTAS CONTROL LOCK”.

c. Where applicable, equivalent translation or the legally required statement in the local official
language shall also be used.

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6.6.6 Lockout tools and equipment shall not be used for any other purpose. They shall not be used
on equipment not under lockout (e.g. lockers, toolboxes, doors, or containers).

6.7 Lockout Methods

6.7.1 All lockouts will follow one of the established methods in this section:

a. Individual control

b. Single point lockout

c. Complex lockout

d. Group lockout (lockbox)

6.7.2 Individual Control

a. Individual Control is allowed for plug-in equipment with power cords. A lockout is not
required as long as the plug is within arm’s reach of the individual performing work on the
equipment. Where the plug is not within arm’s reach of the individual performing work, the
plug will be locked out with a suitable device.

b. Individual Control is allowed on breakers with door-mounted handles when opening the
door defeats the lockout applied to the door handle. When working under this isolation
inside of this cabinet, a lockout is not required. If work location moves outside of the cabinet
or if it is necessary to leave the location for any reason prior to the work being completed,
the door must be closed and the lockout applied.

6.7.3 Single Point Lockout

a. Where the equipment is powered from a single energy isolation point, and there is no
capacity for stored energy, the equipment may be locked out without the use of a written
lockout instruction.

6.7.4 Complex Lockout

a. This method is used whenever the individual control or single point lockout methods cannot
be applied according to 6.7.2 or 6.7.3.

b. In all cases, a Complex Lockout will require a written lockout instruction that identifies every
isolation point.

c. The lockout instruction shall be approved by a Lockout Specialist.

d. The lockout instruction shall include the sequence for the safe shutdown, lockout, clearing
of lockout, and startup of the system.

e. The Person In Charge shall establish the lockout in accordance with the lockout instruction,
using control locks. The Person In Charge keeps possession of the control lock keys.

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f. After the lockout is established, the completed lockout instruction form is handed to any
Basic Lockout User who wishes to perform work under the lockout. The Basic Lockout User
then hangs personal locks at every isolation point in accordance with the lockout instruction
form.

g. If the Person In Charge is also working on the equipment, then personal locks must be
applied in addition to the control locks. The Person In Charge may choose to apply personal
locks instead of control locks. However, if the Person In Charge decides to leave the
worksite and remove their personal locks, then they must apply control locks. Alternatively,
they may also turn over their responsibility to another Person In Charge who is staying at
the worksite and already has their personal locks applied.

h. Approved lockout instructions may be kept in electronic format and printed for use as
required. Prior to using a lockout instruction from a database, the Person In Charge must
ensure that their task matches the lockout boundary established by the lockout instruction.

i. Lockout instructions that have been prepared by someone offsite shall be reviewed by the
Energy Control Coordinator before use at the site. The Energy Control Coordinator shall
verify that the lockout instruction is completely sufficient for the equipment as installed at the
site.

j. A Complex Lockout can be converted to a Group Lockout at any time. The Person In
Charge is responsible for guiding all personnel through the transition.

k. After the Complex Lockout has been broken down, the lockout instruction shall be returned
to the Energy Control Coordinator for record-keeping.

6.7.5 Group Lockout (Lockbox)

a. The Group Lockout or Lockbox is another form of the Complex Lockout method. Instead of
requiring each Basic Lockout User to lockout at every isolation point, the Basic Lockout
User only applies one personal lock to a lockbox. The lockbox contains keys to controls
locks, which were applied to the equipment isolation points by the Person In Charge.

b. Once the equipment isolations have been locked, the Person in Charge place the control
lock keys into the Lockbox. The Person in Charge then locks the box with a single control
lock and retains control of the key.

c. The Group Lockout shall require the same lockout instruction as developed for the Complex
Lockout in section 6.7.4.

d. The completed lockout instruction form shall be securely attached to the lockbox so that it
may be clearly read by all personnel locking on the lockbox.

e. Any Basic Lockout User can request to put his or her personal lockout locks on each of the
lockout points of the Group Lockout, instead of just one lock on the lockbox.
 The Basic Lockout User shall be given an additional copy of the Group Lockout
instruction.
 The Person In Charge will assist the Basic Lockout User in locating all of the
lockout points.

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 The Basic Lockout User must lockout every lockout point identified in the Lockout
Form. Partial lockout of only some of the isolation points is not permitted.
 It is important that all control locks are applied with hasps, otherwise this process
will not be possible.

f. After the Group Lockout has been broken down, the lockout instruction shall be returned to
the Energy Control Coordinator for record-keeping.

6.7.6 Nesting:

a. It is permissible to reference one or more subordinate group lockouts from another master
complex or group lockout. This is called nesting. In this case, a control lock for the master
lockout is applied to the lockbox of the subordinate (nested) group lockout.

6.8 Tagout

6.8.1 Where possible a lock shall be used instead of a tagout. A reasonable effort shall be made to
design and build a suitable lockout device for future use, so that a tagout is not required.

6.8.2 A tagout is acceptable as a substitute for a lockout if and only if:

a. There is no physical means of attaching a lock to the energy-isolating device.

b. AND: The use of a tagout is specifically approved by the Energy Control Coordinator.

6.8.3 When the tagout method is used, it shall be supplemented by at least one additional safety
measure that will provide a level of safety equivalent to that of a lockout program. The particular
measure that is used must be documented in the lockout instruction.

6.8.4 All tagout points will be recorded as line items in the lockout instruction. In addition, the position
of the isolation shall be marked with “TAGGED” instead of “LOCKED”.

6.8.5 Personal tags shall include first and last name, company name, and telephone contact number
identifying the worker. Vestas employees’ tags shall have first and last name of the employee,
telephone contact number, and a colour picture of the employee permanently printed on the
tag.

6.8.6 Control tags shall always be tagged with “DANGER – DO NOT OPERATE” and shall include
the permanent marking “VESTAS CONTROL TAG”.

6.8.7 Where used in conjunction with a lockbox, control tags shall have a detachable stub to be
placed into the lockbox. The tag remaining on the isolation device, and the detachable stub,
shall be marked with matching and unique serial numbers.

6.8.8 Where used without a lockbox, every person working on the equipment shall attach a personal
tagout tag to the isolation device, just as they would attach their personal lockout lock.

6.8.9 Tags shall be attached on or as close to the device to be unquestionably apparent that that
device is not to be activated. Where possible, the tag attachment means shall impede the
activation of the device.

Vestas Wind Systems A/S · Alsvej 21 · 8940 Randers SV · Denmark · www.vestas.com

Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 14 of 18
Document: 0017-5309_V01

6.9 Extended Shutdown

6.9.1 In circumstances where equipment is taken out of service for extended time periods (more than
one shift change), the equipment shall remain locked out. The Person In Charge shall retain
possession of the control lock key(s). This requirement applies in any of the following
circumstances:

a. The equipment is left in a state where it should not be operated or started.

b. Starting the equipment could present a danger to persons nearby.

c. Starting the equipment could cause damage to the environment (e.g. oil spill).

d. Starting the equipment could cause equipment damage.

6.9.2 When a Person In Charge needs to turn over responsibility of a lockout, the control lock key(s)
is(are) physically handed over to the new Person in Charge. The new Person In Charge shall
record transfer details on the lockout instruction form.

6.9.3 Where equipment has been left in a locked out condition for several shifts without anyone
working under the lockout, the Person In Charge shall re-verify the lockout prior to allowing
work to resume. The Person In Charge shall confirm that the isolation of the equipment is still
effective by physically examining each control lock and lockout device. Verification of
deenergisation is not required unless a lockout device has been compromised.

6.10 Temporary Release for Testing or Repositioning

6.10.1 When it is necessary to temporarily release or reenergise part of the system under lockout, for
the purpose of testing or repositioning, it is acceptable to clear only the required isolations
without clearing the entire lockout.

6.10.2 The lockout instruction shall clearly identify the isolations to be restored for the purpose of
testing or repositioning.

6.10.3 Prior to restoring isolations for testing or repositioning, the Person-In-Charge shall require that
persons locked out on the equipment cease work, clear the area and remove their personal
locks.

6.10.4 Once the testing or repositioning is completed, the isolations that were temporarily restored
shall be once again deenergized, stored energy released, absence of energy verified, and
locked or tagged before resuming work.

6.10.5 Once testing or repositioning has been completed, the Person-In-Charge shall require that
persons who will perform work on the equipment apply their personal locks before resuming
work.

6.11 System Diagrams and Equipment Labelling

6.11.1 All fixed machinery shall be labelled with tags indicating their function and unique alphanumeric
designator.

Vestas Wind Systems A/S · Alsvej 21 · 8940 Randers SV · Denmark · www.vestas.com

Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 15 of 18
Document: 0017-5309_V01

6.11.2 All energy isolation points used for lockout shall be labelled with corresponding tags.

6.11.3 Lockout instructions shall be written to include both the alphanumeric designator and the word
function of the isolation. It is important that this matches the label on the physical isolation point.

6.12 Absent Person Lock Removal

6.12.1 In the event that a person is not available to remove their personal lockout lock(s), the Energy
Control Coordinator may have the lock(s) removed for them, subject to the restrictions in this
section.

6.12.2 BU’s shall develop a written procedure and checklist to control the removal of an absent
person’s lock(s).

6.12.3 Personal lockout tags applied instead of locks, in accordance with Section 6.8, are subject to
the same removal restrictions in this section as personal lockout locks.

6.12.4 Prior to removing someone else’s personal lock(s):

a. Verify that the absent person who applied their personal lock(s) is not present at the site.

b. Make all reasonable efforts to contact the absent person and inform them that their lockout
or tagout device needs to be removed.

c. Make all reasonable efforts to contact the absent person’s supervisor and inform them that
their employee’s lockout or tagout device needs to be removed.

6.12.5 Permission to remove an absent person’s lock must be obtained from the following managers:

a. In all cases, permission must be obtained from the Vestas Senior Manager.

b. At wind farms, permission must also be obtained from the customer, where required by the
customer’s Control of Hazardous Energy Program.

c. For subcontractors, permission must also be obtained from the subcontractor’s senior
manager, in accordance with the subcontractor’s Control of Hazardous Energy Program.

6.12.6 The Person In Charge shall remove the lock(s). The ECC shall physically witness the lock
removal and shall retain possession of the lock(s).

6.12.7 The checklist used for documenting the removal of the lock shall be retained by the ECC.

7 Equipment Design Requirements

This minimum standard requires certain features to be included in the design of new equipment used at
Vestas sites.

7.1 Lockout Isolation Points

7.1.1 Personnel involved in the design or purchase of equipment by Vestas shall take into
consideration how to lockout the equipment in compliance with this minimum standard.

Vestas Wind Systems A/S · Alsvej 21 · 8940 Randers SV · Denmark · www.vestas.com

Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 16 of 18
Document: 0017-5309_V01

7.1.2 Equipment shall be designed with every lockout point required to perform maintenance or repair
in a fully deenergised and locked out condition. All designated lockout points shall comply with
the requirements of 6.3.1.

7.1.3 Every designated lockout point shall be designed with a suitable lockout device that physically
prevents the operation of the device when a standard size lockout hasp is inserted, either
through a or b below:

a. The lockout device can be integral to the isolation

b. The lockout device can be attached to the isolation. Any commercially available or custom
designed lockout device required for use shall be specified in the equipment bill of materials
and supplied with the equipment.

7.1.4 Every designated lockout point shall be designed with a safe and efficient means to test for
deenergisation.

7.2 Equipment Drawings

7.2.1 All equipment designed or purchased by Vestas shall be accompanied with detailed drawings
to be used for troubleshooting and lockout. These can consist of single line circuit diagrams,
hydraulic schematics, piping and instrumentation diagrams (P&IDs), or mechanicals sketches.

7.2.2 Lockout points shall be designated in the operations & maintenance manual of the equipment.

7.2.3 Equipment drawings shall indicate every lockout point with their alphanumeric designator.

7.3 Stored Energy

7.3.1 All components that by their nature can retain stored energy shall be fitted with a means to
manually dissipate the energy. The means can be permanently installed or can consist of a tool
designed for the purpose.

7.3.2 The method of releasing the stored energy shall be fully described in the equipment operations
& maintenance manual.

7.3.3 A label shall be applied to the outside of the equipment warning of the potential for stored
energy.

8 Abbreviations and Definitions

Basic Lockout User: A trained person who can perform lockout in accordance with this program.
A Basic Lockout User can hang his/her personal locks on equipment that has already been locked
out by the Person In Charge.
Complex Lockout: Any lockout procedure that cannot be performed under Individual Control or
Single Point Isolation. Requires a written lockout procedure that lists all lockout points.
Control Lock: A lock applied by the Person In Charge to the lockout device. The control lock is
the first lock applied and the last lock removed. The purpose of the control lock is to signal to the
Basic Lockout User that the equipment was locked out by a Person In Charge in accordance with
this Control of Hazardous Energy Program.

Vestas Wind Systems A/S · Alsvej 21 · 8940 Randers SV · Denmark · www.vestas.com

Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 17 of 18
Document: 0017-5309_V01

Danger Zone: The immediate vicinity of a piece of equipment or machinery in which a person
could be in danger if said equipment or machinery was to become energised.
Energised: The state of being connected to an energy source or containing residual or stored
energy.
Energy Control Coordinator (ECC): The primary person in charge of the administration of the
Control of Hazardous Energy Program and the Electrical Safety Program at the site location.
Energy-Isolating Device: A mechanical device that physically prevents the transmission or
release of energy. These include manually operated circuit breakers, disconnect switches, blind
flanges, blocks valves, chains, and similar devices used to block or isolate energy.
Group Lockout: Any Complex Lockout procedure can be turned into a Group Lockout. All of the
control lock keys are locked into a lockbox by the Person In Charge. The workers then lock the
lockbox prior to performing work.
Hazardous Energy: Any source of electrical, mechanical, hydraulic, pneumatic, chemical,
thermal, gravitational force or any other energy source that could cause injuries to personnel.
Lockout: The process of isolating all sources of energy, dissipating stored energy, verifying that
the isolations deenergised the equipment, and locking the isolation devices in accordance with a
written lockout instruction.
Lockout Boundary: The safe limits of a given Lockout as determined by the lockout points for the
equipment and systems to be worked on. All the equipment within the Lockout Boundary is safe to
work on.
Lockout Device: A locking mechanism that provides a positive means for rendering an Energy-
Isolating Device inoperable. The device may be a padlock alone, or a padlock in combination with
a restraining bar, chain, hasp, or any device that positively prevents the Energy-Isolating Device
from being actuated.
Lockout Instruction: A form required to execute a Complex or Group Lockout. It lists the work
being performed, the lockout boundary, and all lockout/tagout points. The form also tracks who is
the Person In Charge for the lockout.
Lockout Specialist: A person who is trained to determine the appropriate Lockout methods and
Lockout Boundaries, and who is authorized to approve Lockout Instructions.
Person In Charge: A person designated to be in charge of a particular lockout procedure and
who has been trained in the practice of Lockout of all necessary devices to isolate the equipment
or system and to attach all locking devices and tags.
Qualified Person: One who has skills and knowledge related to the construction and operation of
the equipment and installations and has received safety training to recognize and avoid the
hazards involved.
Single-Point Isolation: A lockout with only one Energy-Isolation Device and no stored energy. It
does not require the use of a Lockout Instruction.
Tagout: The placement of only a tag on an Energy-Isolating Device, where it is not physically
possible to place a lock. Restrictions apply.
Vestas Senior Manager: In some cases the Energy Control Coordinator will need special
permission to perform certain activities. This responsibility is assigned to a manager designated
by the BU.

Vestas Wind Systems A/S · Alsvej 21 · 8940 Randers SV · Denmark · www.vestas.com

Author: MASCT Vestas Standard Date: 23 September 2011
Approver: JAL Control of Hazardous Energy Page 18 of 18
Document: 0017-5309_V01

9 References
[1] CSA Z460-05, Control of hazardous energy – Lockout and other methods, 2005
[2] CSA Z462-08, Workplace electrical safety, 2008
[3] EN 1037+A1, Safety of machinery – Prevention of unexpected start-up, 2010
[4] EN 50110-1, Operation of electrical installations, 2005
[5] EN 60204-1, Safety of machinery – Electrical equipment of machines – Part 1: General
requirements, 2006
[6] HTM 06-02, Electrical safety guidance for low voltage systems, 2006
[7] NFPA 70E-09, Standard for Electrical Safety in the Workplace, 2009

Vestas Wind Systems A/S · Alsvej 21 · 8940 Randers SV · Denmark · www.vestas.com