Lock

Out Tag Out Procedure - RTB Bor 2014

Lock Out Tag Out Procedure

(Area FSF)

Lock
Out Tag Out Procedure - RTB Bor 2014

Contents:
1.

Purpose..........................................................................................................................................................3

2.

Scope.............................................................................................................................................................3

3.

Definitions.......................................................................................................................................................4

4.

Construction and Pre-operational Verification...............................................................................................6

4.1

Pre-Operational Verification.......................................................................................................................6

4.2

System Isolations.......................................................................................................................................6

4.3

Energization...............................................................................................................................................7

5.

LOTO Personnel Responsibilities...............................................................................................................7

5.1

Isolation Authority.....................................................................................................................................7

5.2

Permit Issuer.............................................................................................................................................7

5.3

Permit Receiver........................................................................................................................................8

6.

Lock Out Tag Out (LOTO) Requirements......................................................................................................8

7.

LOTO Procedure............................................................................................................................................9

7.1

Detailed Lockout/Tag out Procedure..........................................................................................................9

7.2

Energy Isolation Devices Not Capable of Accepting a Lock....................................................................11

7.3

Removal of Authorized Employee Locks and Tags When Offsite.....................................................11

8.

Contractors..................................................................................................................................................11

9.

Personnel LOTO Training............................................................................................................................12

10.

Forms.......................................................................................................................................................12

Lock
Out Tag Out Procedure - RTB Bor 2014

1.

Purpose

The purpose of this policy is to ensure that before any employee performs any Pre- Operational
Verification (POV) or Commissioning of equipment, where the energization, start up or release of any
type of energy could occur and cause damage to equipment, injury, or worst case death, the equipment
will be rendered safe to work on by being locked and tagged out.
2.

Scope

This procedure is to be followed by all EPO personnel that lead, perform or participate in construction,
commissioning, operation and/or maintenance work.
The isolation procedure shall apply from the time equipment is connected to any source of hazardous
energy.
The procedures shall be adopted as the minimum acceptable standard by EPO personnel; being EPO
staff, contractors, consultants or persons under the direct and/or indirect supervision or guidance of EPO.
All EPO personnel shall understand and fully comply with this procedure. This procedure is a supplement
(addition) to local laws and regulations.
In a case where a clients procedures are to be used and do not meet the standard of this procedure,
EPO personnel shall still adopt these procedures as the minimum acceptable standard for EPO.
All relevant EPO personnel shall receive training in the use of this procedure.
Positive and secure isolation from energy sources shall be made when personnel are required to work on
or near equipment, which if live, started, running or contains stored/potential energy that could endanger
them.
This procedure covers all work in all areas of plants where isolation from one or more of the following is
required:

Electrical power
Mechanical energy stored or kinetic
Hydraulic or gaseous energy
Sources of dangerous heat
Radiation energy
Process fluids, poisons and chemicals; including steam, gases, liquids and solids.

Lock
Out Tag Out Procedure - RTB Bor 2014

3.

Definitions
Job Safety
Analyses
(JSA)
Isolation Authority
Permit Issuer
Permit Receiver
Work Group

Other Employees
Lock and Tags
Energy Isolation
Device
Lock Out Device

Personal Tag

Isolation Tag

Task specific risk analysis required prior to the commencement of work,

outlining potential exposure to hazards in completing the task.
The Process Engineer or Commissioning Engineer or authorized
person who is required to be informed of any work that requires work to
be conducted on a piece of equipment or a system.
A responsible person for initiating and controlling the Work Permit and
the Lock Out Tag Out (LOTO) procedure.
A responsible person who receives the permit to allow them to begin
work.
A person/persons who signs onto the relevant permit and applies their
lock and tags on machines, equipment and/or Systems (using a lock
box) and works under the protection of the Lock Out/Tag Out procedure
in order to perform a task on the piece of equipment or System.
Are employees whose work may be in the vicinity where energy control
procedures are in place.
Lock and Tags that are used to ensure the safety of the Authorised
Personnel performing the work.
A device that prevents the transmission of energy or hazardous
materials. These are typically, but not limited to Circuit breakers,
Disconnect switches, Slide gates, Valves and Blinding plates.
A mechanism that utilizes a physical block such as a Lock to hold the
energy isolation device in a safe position to prevent the energization of
a machine, equipment or system. Lock out devices include:
Valve hand wheel covers
Chain\Rope Locks
Hasps
Pad Lock
Danger Do not Operate Person
working
which will be securely fastened
to the
Personnels personal Lock. The
tag
should have the member of the
workgroups Name, a Contact
Number,
the Date the lock was placed
and the
Permit number they have signed
on to.
Danger Do not Operate which can be securely fastened to an
energy isolating device. The tag should have the Permit Issuers Name
and contact number, Equipment No. and System Scope number.

Lock
Out Tag Out Procedure - RTB Bor 2014

Commission Tag

Energy Sources

Live
Potential & Stored
Energies

Commissioning in Progress
This Tag is used to indicate that a particular piece of equipment is live and
meant to be so. These tags should be placed at the
piece of equipment and at its energy source eg/
Motor Control Centre and any other sources that
might feed or leave the equipment. The tag should
indicate the Equipment No., Description, who was it
placed by with a contact no. and the date.
Any source of potentially hazardous energy or materials. Energy
sources include Electrical, Mechanical, Hydraulic, Pneumatic,
Chemical, Radiation and Thermal as well as Potential energies that are
stored in springs, compressed gases and
suspended objects.
A reference to any electrical apparatus that is carrying a potential
difference to that of Earth or machinery that is pressurised, loaded or
operating.
Potential Energy is stored or suppressed or that exists because of its
position and the effects of gravity. Machines with large components that
raise and lower, such as a press, contain potential energy that becomes
kinetic energy when it is released.
Stored energy is energy that has not been used or dissipated. Stored
energy can take many forms, such as unused electricity pressurised
pipe or tension in a spring.

Double Block &

Bleed
Lock Out Tag Out
(LOTO)

Verification of DeEnergization
Construction
Pre Operational
Verification (POV)
Commissioning

The closure of a line, duct or pipe by closing, locking and tagging two
inline valves and by opening and locking/tagging the drain or vent to the
line between the two closed valves.
Installation of and locks and tags on energy isolation devices to ensure
that work can be performed safely. The locks and tags ensure that the
Energy Isolating devices and the machine, equipment or systems they
isolate and/or control, cannot be operated until the locks and tags are
removed.
The inspection or test of the system or component performed by the
Permit Issuer to ensure that the hazardous energy or materials are
controlled to prevent injury or accident.
A period of time where civil, structural, mechanical, piping and electrical
installation works are being conducted, without the possibility of them
being energised or charged.
Verification of equipment or system configuration prior to energization.
The period of time where equipment and machinery will be energised to
ensure correct function during the operation.

Lock
Out Tag Out Procedure - RTB Bor 2014

4.

Construction and Pre-operational Verification.

At the commencement of Pre-operational Verification all Construction and POV works will be required to
work under the Permit to Work procedure.
5.

Pre-Operational Verification
Before energization of any equipment or system, confirmation of the completion of the construction
activities for that piece of equipment and/or area is required. Detailed check sheets are to be sighted by
EPO and signed off. Additionally the equipment and/or systems are to be inspected by an EPO
representative. A walk through shall be conducted and the following must be:
Checked that all construction works are completed in accordance with the design.
Checked against Piping and Instrument Diagrams (P&IDs) and/or single line diagrams (SLDs)
The correct labelling is confirmed
Checked that all downstream valves and/or isolators are in the correct positions.

6.

System Isolations
Prior to initial energization of any system within the plant, all isolations for that system are required to be
in place.

7.

Energization
Upon initial energization EPO personnel will place the following stickers on the energised equipment
including, pipe work, switchboards, MCC buses, MCC modules, Transformers, Motors, Local Control
Switches etc, to indicate the potential for equipment to contain live energy.

Any equipment with the Caution Equipment Energised sticker placed on it shall be considered live
and any work on the equipment or system will require an isolation to be undertaken in accordance with
Section 7 LOTO Procedure of this document.
Full details of the energised equipment will be detailed on single line diagrams and P&IDs setup within
the main site office and maintained by EPO personnel.

Lock
Out Tag Out Procedure - RTB Bor 2014

Details of the commissioning activities will be posted daily identifying the areas of plant to be
commissioned and the equipment that is to be energised.
8.
9.

LOTO Personnel Responsibilities

Isolation Authority
It is the Isolation Authorities responsibility to identify all energy sources and hazards to a system,
machine or equipment necessary for safe isolation. The Isolation Authority is also responsible for coordinating with all Permit Issuers in approving and ensuring that all isolations for the particular system are
complete, correct and in compliance with this procedure.

10.

Permit Issuer
The Permit Issuer is responsible for initiating and controlling this procedure on shift, this ensures that the
proper procedures for isolating all energy sources have been controlled. The Permit Issuer also ensures
that the isolation procedures in accordance with the commissioning managers instructions have been
carried out and signs on to the appropriate permit prior to the work commencing. The Permit Issuer is to
conduct a walk down of the lines with the Permit Receiver and Workgroup to verify that all electrical,
piping and mechanical isolations are in fact in place.

11.

Permit Receiver
The Permit Receiver is the supervisor of the workgroup and is responsible to ensure that the workgroup
adheres to the Permit and to the LOTO procedure. The Permit Receivers personal lock is the last lock of
the workgroup to be placed first on the lock box and is the last to be removed from a lock box once the
job is completed.
12.

Lock Out Tag Out (LOTO) Requirements

This procedure establishes the requirements for the Lock Out/Tag Out of energy isolating devices.
1.

Only the Isolation Authority and the permit issuer can perform an Isolation of a piece of
equipment or system

2.

It is mandatory that all personnel comply with the Lock Out/Tag Out program and related
procedures.

3.

No individual shall attempt to start, energize, use, or operate a piece of equipment that has been
locked and tagged out after the safe condition check has been completed.

4.

No individual other than the individual who placed the lock and tag shall attempt to remove it,
except in the circumstance outlined in Section 7.3.

Lock
Out Tag Out Procedure - RTB Bor 2014

14.

5.

All locks and keys to be used will be stored in the appropriate storage with the exception of
members of the Workgroups personal locks, which will be controlled by him/her.

6.

The personal Lock Out Danger Do Not Operate tag signifies that there is a member of a
workgroup (single person per lock) working on a piece of equipment or system, and can only be
removed by that person immediately after their work is completed.

7.

The personal Danger Do Not Operate tag is reserved for the exclusive use of the member of
the workgroup identified on that tag. The identifying markings shall be made with a water proof
permanent marker. The tags shall be durable and weather proof and meet international
standards.

8.

No one shall authorize another person to ignore or violate this program and its procedures.

9.

At any time if any member of the workgroup believes that the isolation is incomplete or has been
compromised all work must cease and the permit issuer notified immediately.

10.

All employees shall receive the appropriate level of training based upon their LOTO duties.

11.

Any employee who observes any apparent violation of this program or related procedures shall
immediately notify their supervisor.

13.

LOTO Procedure

Detailed Lockout/Tag out Procedure

1.

The Permit Receiver will prepare the JSA for the works to be conducted prior to the request for a
Permit to work.

2.

The Permit receiver will submit the JSA and the work permit form with Section 1 completed to the
Permit Issuer and request the Permit to Work.

3.

The Isolation Authority and the Permit Issuer will determine all potential sources of hazardous
energies and verifying these with the use of P&IDs, Single Line diagrams and Schematics.

4.

The Permit Issuer will prepare the Permit required to conduct the work.

5.

The Permit Issuer will go to each energy isolation device in the order listed on Isolation Certificate
and deenergize that device using the Isolation lock/locks allocated to the lockbox.

Lock
Out Tag Out Procedure - RTB Bor 2014

6.

Once each of the isolations are in place and after each key is removed from each isolation lock,
the Permit Issuer will place them into the lockbox and will place a permit issuer lock on the lock
box.
The permit issuer will then copy the permit and hand a copy to the permit receiver to keep at the
work site at all times.
The Original Permit shall be kept in the control room and the key for that system isolation shall be
kept in a locked Permit display, displaying both the isolation and the isolation key.
The key for the permit display cabinet shall be kept by the Site Manager and the Permit Issuer on
shift.

7.

Members of the workgroup will then place their personal locks and tags on the lockbox. The
individuals that form the work group shall carry the key to their personal lock with them at all
times. Everyone that locks onto the Lock box must sign onto the Permit.

Lock
Out Tag Out Procedure - RTB Bor 2014

8.

Prior to commencement of work, all members that have signed onto the permit and have placed
their lock onto the Lock Box shall take part of a mandatory walking of the lines or Safety
Condition Check lead by the Permit issuer, this is a verification that all isolations have been put in
place and have been applied correctly and no isolations have been miss placed at the preliminary
stages and in fact that the line, system or equipment is de-energized.

9.

Work is now able to commence after all safety requirements outlined in the JSA and this
procedure have been met.

10.

In the case the work defined in a permit is required to span more than one shift a permit shall be
handed over from one shift Permit Receiver to the next shift Permit Receiver.
In order for the Permit to be handed over the permit receiver must ensure that all work groups
locks and tags have been removed including his own from the lock box and signed off on the
Work Permit.
The permit must be returned to the Permit Issuer by the Permit Receiver and signed over to the
Permit Issuer. The Permit Issuer then signs over the permit to the new shift Permit Receiver.

15.

11.

When all work on the system is complete, the Workgroup shall return to the lock box and remove
their personal lock, tags and sign off of the permit. Once all the personal locks have been
removed from the lock box, the Permit Receiver shall remove their personal lock and sign off of
the permit and hand over the lock box to the Permit Issuer.

12.

The Permit Issuer shall then remove the Permit Issuer lock from the lock box. The isolation keys
will then be removed from the lock box and all the isolation locks out in the field can be removed.
The Permit Issuer will make sure that all machines, equipment, systems, and areas are clear of
personnel and tools and redundant materials before energizing.

13.

The system or equipment will be de-isolated in the order noted on the isolation certificate.

Energy Isolation Devices Not Capable of Accepting a Lock

If an energy isolation device is physically incapable of accepting a lock or a lock out device, a tag
out system shall be used which will offer full employee protection similar to that of a lockout system .The

Lock
Out Tag Out Procedure - RTB Bor 2014

tag out system includes all of the steps of this lockout program except the actual use of a lockout device
on that particular energy isolation device. Additional means to be considered as a part of the
demonstration of full employee protection shall include the implementation of additional safety measures
such as the removal of an isolating circuit element, blocking of a controlling switch, opening of an extra
disconnecting device, or the removal of a valve handle to reduce the likelihood of inadvertent
energization etc.
16.

Removal of Authorized Employee Locks and Tags When Off site

There may be times when the work has been completed and the LOTO needs to be closed out, to put
equipment back into service, when a member of the workgroup has left his personal lock on the lock box and
left the site.
The removal of a personal lock and tag without the members signature on the Work sign off sheet will
require an authorisation from the EPO site manager.
The Site Manager will attempt to contact the individual to bring him/her back to site to complete the sign
off and the removal of his/her lock and tag.
If the individual cannot be contacted or cannot return to site, a site search must be conducted so that
the Site Manager can satisfy him or herself that the individual is no longer on site and cannot return to
the facility.
The member of the workgroup will be contacted by his/her Supervisor as soon as practical, to notify them
that they have been removed from the LOTO.
17.

Contractors

Outside contractors that will be performing work on site must follow, the LOTO Program and perform their
work in accordance with the instructions of the Issuing Authority.
18.

Personnel LOTO Training

Employees shall be trained so that they understand the purpose and function of the LOTO program and
procedures.
If any changes are made to the LOTO procedure retraining will be conducted.
Periodical audit will be conducted of the LOTO procedure to ensure its effectiveness.
A record of all training and re-training shall be maintained by the Permit Issuer. The training record shall
include the name of the employee, level of training(ie Permit Issuer Training, Permit Receiver Training,
etc) name of instructor and the date of the training (See Training Attendance Roster).

Lock
Out Tag Out Procedure - RTB Bor 2014

19.

Forms

Lock
Out Tag Out Procedure - RTB Bor 2014

20.

Work Permit

Lock
Out Tag Out Procedure - RTB Bor 2014

Lock
Out Tag Out Procedure - RTB Bor 2014

Lock
Out Tag Out Procedure - RTB Bor 2014

Lock
Out Tag Out Procedure - RTB Bor 2014

21.

Isolation Certificate

Lock
Out Tag Out Procedure - RTB Bor 2014

22.

Training Attendance Roster

Principles

ATTENDANCE ROSTER
Program Title: Lockout/Tag out Training

Instructor(s)

Date From Training_________to__________

Location

Name

1
2
3
4
5
6
7
8
9
1
0
1
1
2
1
3
1
4
1
5
1
6
1
7
1
8
1
9
2
0

Company

Position

Lock
Out Tag Out Procedure - RTB Bor 2014