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Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 1 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
1.0 PURPOSE/SCOPE
The purpose of this program is to ensure effective implementation, operation, and recordkeeping of the Westlake lock-out/tag-out program in compliance with 29 CFR 1910.147. The provisions of the Lock- out/Tag-out Program shall apply to all personnel at the facility.
2.0 APPLICATION
This program applies to the servicing and maintenance of machines and equipment in which the
unexpected energization or startup of the machines or equipment, or release of stored energy could cause
injury to employees. This program establishes minimum performance requirements for the control of such
hazardous energy.
A system that is to be opened for work and does not have valves (ie. instrument lines), has valves that
cannot be locked out (ie.. underground water valves) or any other deviation to this procedure requires
approved written procedures to document how the equipment shall be isolated.
NOTE:
It is the responsibility of the owner of the equipment, usually the operations group, to clean, clear,
de-energize and lock out all systems BEFORE allowing any work on the system(s). IF THE
SYSTEM(S) CAN NOT BE ISOLATED, A WRITTEN DEVIATION PLAN (per procedure
WGS-SAF-HSE-P103) IS TO BE EXECUTED WITH MANAGEMENTS APPROVAL AND
ACCEPTANCE FROM MAINTENANCE.
Exclusions can be found in section 5 (WRITTEN ENERGY CONTROL PROCEDURE) of this
procedure
At Westlake Vinyls, all personnel have the right to deny any job that they feel it is unsafe.
NOTE:
This procedure is not intended to cover switchgear and high voltage equipment at or above 480V.
This policy does NOT apply to work on or near exposed electrical conductors and circuit parts falling
within the scope of OSHA standard 1910.333 - Selection and Use of Work Practices. If work must be
performed on or near exposed electrical conductors and circuit parts, refer to the Maintenance Procedure
Electrical Equipment Lockout/ Tag out.
3.0 RESPONSIBILITY
This is a Life Critical Procedure and hence is critical to protecting life and limb. Deviation from this procedure is subject to disciplinary action up to and including termination.
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 2 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
Unit Manager or their designee shall: Identify equipment and create an equipment isolation list for each piece of equipment under his/her area of responsibility.
NOTE:
The Safety Standard 505_1 Lock Out Equipment Isolation List is a tool that shall be used to create LOTO work plans for each piece of equipment and complex LOTO's.
Participate in annual audit of the lock out procedure and field evaluation sheets in Safety Standard 505_3
Lock, Tag and Try Evaluation Form
Be responsible for purchasing, administration, and distribution of locks, keys, lockboxes and other isolation equipment to be used for LOTO during daily operations in the unit including all group locks.
Assist in determining if tags may be used in the place of locks as they relate to this procedure. This will only take place if a piece of equipment is not capable of being physically locked.
Ensure ultimate compliance and enforcement for all elements of the LOTO program.
Unit Operator shall:
Provide safe isolation, clearing, cleaning and energy control for all equipment in their area and ensure
equipment isolation through shift changes with verification by both incoming and off-going unit
operators.
Ensure an isolation list for each piece of equipment under their responsibility exists or is created and
provided to the unit trainer so the equipment isolation lists may be compiled.
Workers shall:
Remove their own locks and tags at the end of each job or the end of the shift, whichever comes first.
NOT leave the property without first removing their lock out tag out.
NOT remove any lock or tag other than his/her own.
Participate, upon request, in the annual evaluation procedure.
Purchasing Department shall: Purchase only valves and replacement equipment installed in the process must be capable of being locked out and provide direction to those requesting new valves to ensure all avenues have been reviewed before allowing the purchase of a valve without lock out capabilities.
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 3 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
Purchase only approved LOTO locks, tag and other equipment set forth in this procedure.
Safety Department shall:
Lead the annual procedure review to ensure OSHA compliance with the lock-out procedures.
Perform all LOTO training for Westlake employees and maintain records of said training.
Assist in determining if tags may be used in the place of locks as they relate to this procedure. This will only take place if a piece of equipment is not capable of being physically locked.
Shift Supervisors shall: Assist in determining if tags may be used in the place of locks as they relate to this procedure. This will only take place if a piece of equipment is not capable of being physically locked.
Assist with LOTO to investigate removal of LOTO in absence of the originator.
NOTE:
To determine if tags may be used in the place of equipment locks, two of the following must agree (Unit Manager or designee, Safety Department and/or Shift Supervisor).
4.0 RECIPIENTS
Westlake Vinyls Intranet http://gvcdocs/Default.asp?
5.0 WRITTEN ENERGY CONTROL PROCEDURE (UNIT MANAGERS)
The Unit Manager shall develop, document, and use energy control procedures to control potentially
hazardous energy before workers perform service/maintenance activities covered by the Control of
Hazardous Energy (Lock-out/Tag-out) Procedure.
These written, machine or equipment specific procedures (505_1) must identify the information that the
authorized employee(s) must know to control hazardous energy (steam, water, natural gas, compressed
air, chemical, electrical, hydraulic, mechanical, and others) during servicing or maintenance. If this
information is the same for various machines or equipment or if other means of logical grouping exists,
then a single energy control procedure may be sufficient. If there are other conditions, such as multiple
energy sources, different connecting means, or a particular sequence that must be followed to shut down
the machine or equipment, then the supervising department must develop separate, machine or equipment
specific, written energy control procedures to protect the employees
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 4 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
EXCLUSIONS
The purpose of this section is to identify activities that will not require LOTO or that are covered
by operational procedures.
GENERAL
Automotive maintenance
Loading and unloading hoses, utility hoses, railcars and general hoses for certain instrument systems
Service activity such as copy machines, soda machines, telephones, etc.
Working on potable water lines (2 inches or less) and replacing water filters with pressure less than 35 pounds.
INSTRUMENT
Sensing/ signal inputs to and signal outputs from instruments, indicating or control devices.
Examples are pressure taps to gauges or switches, impulse lines to transmitters, outputs from
controllers or transmitters, and inputs to valve positioners and actuators interconnecting signals
between instruments or within nest, etc. This does not include flange mounted devices, unless the
system has installed bleed rings for the instrument, or devices used in highly hazardous chemical
services such as sulfuric acid, chlorine, HCl, caustic, hydrogen, bleach, etc.
ELECTRICAL
Checks, tests, verifications, calibrations, etc. of electrical/ electronic circuit condition or
arrangement made during the course of normal repairs or maintenance performed by qualified
Instrument/ Electricians while energized. A large portion of the repair/ troubleshooting work
required in the Instrument/ Electrical discipline is not possible without energizing circuits due to
the nature of electrical circuits and their functions. Examples would include phase voltage level
of a multiple tap transformer, verification of voltage and current indicators, phase rotation tests,
pressure and level transmitters and switches, etc. Additionally, this will include such activities as
changing of lights bulbs fluorescent bulbs, and checking electrical grounds. Work on cord and
plug-connected electric equipment for which exposure to the hazards of unexpected energization
or startup of the equipment is controlled by the unplugging of the equipment from its single
energy source and by the plug being under the exclusive control of the one and only employee
performing the servicing. HVAC (Heating, Ventilation and Air Conditioning Systems Service
checks, additions, removal or transfer of fluids involved in the Freon circuits of building HVAC
units or process refrigeration units.
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 5 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
TEST EQUIPMENT
The use of test or calibration equipment, which utilizes various energies for test or calibration
sources. Examples would be hypots, meggers, transmations, pressure calibrators, etc. Similar to
using multimeter to generate a 4-20mA signal.
OTHER
Minor tool changes and adjustments, and other minor servicing activities, which take place during
normal production operations, if they are routine, repetitive, and integral to the use of the
equipment, provided that the work is performed using alternative measures which provide
effective protection. Hot tap work where the Hot tap procedure is followed.
CHECKING ROTATION/ BALANCING OF MOTORS AND FANS
Testing or positioning of machines, equipment, or components following this sequence:
a. Notify all Authorized and Affected Employees that the equipment is being tested.
b. Have all workers remove their respective locks from the lock box. c. Remove the Operations lock from the lock box. d. Operations shall remove the keys from the lock box and activate the energy source for
testing. e. Perform the test
6.0 DEFINITIONS
Affected employee - An employee whose job requires him/her to operate or use a machine or equipment
on which servicing or maintenance is being performed under lock-out or tag-out, or whose job requires
him/her to work in the immediate area in which such servicing or maintenance is being performed. Many
times this will be the unit operators.
Authorized employee - A person who locks or implements a tag-out system procedure on machines or
equipment to perform the servicing or maintenance on that machine or equipment. An authorized
employee and an affected employee may be the same person when the affected employee’s duties also
include performing maintenance or service on a machine or equipment, which must be locked, or a tag-
out system implemented.
“Capable of being locked out” - An energy-isolating device will be considered to be capable of being
locked out if either it is designed with a hasp or other attachment or integral part to which, or through
which, a lock can be affixed, or if it has a locking mechanism built into it. Other energy-isolating devices
will also be considered to be capable of being locked out if lock-out can be achieved without the need to
dismantle, rebuild, or replace the energy-isolating device or permanently alter its energy control
capability.
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 6 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
“Clearing House Locks” – Locks that are keyed-alike in group. Each set of clearing house locks will be
clearly identified on each lock and on each lockbox. Danger tags may be used but are not necessary on
clearing house locks as the lock can be tracked to the required LOTO checklist which will identify when
and why the lock out is in place. The clearing house locks will be RED (if used by the operations) and
GREEN (if used by the electrical department).
IDENTIFING LOCKS:
Energized - Connected to an energy source or containing residual or stored energy.
Energy source - Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other
energy.
Energy-isolating device - A mechanical device that physically prevents the transmission or release of
energy, including, but not limited to, the following: a manually operated electrical circuit breaker; a
disconnect switch; a manually operated switch by which the conductors and, in addition, no pole can be
operated independently; a slide gate; a slip blind; a line valve; a block; and any similar device used to
block or isolate energy. The term does not include a push button, selector switch, and other control
circuit-type devices.
Hot tap - A procedure used in the repair, maintenance, and services activities, which involves welding on
a piece of equipment (pipelines, vessels, or tanks) under pressure, in order to install connections or
appurtenances. It is commonly used to replace or add sections of pipeline without the interruption of
service for air, gas, water, steam, and petrochemical distribution systems.
Lock-out - The placement of a lock-out device on an energy-isolating device, in accordance with an
established procedure, ensuring that the energy-isolating device and the equipment being controlled
cannot be operated until the lock-out device is removed.
Lock-out device - A device that utilizes a positive means such as a lock, either key or combination type, to hold an energy-isolating device in a safe position and prevent the energizing of a machine or equipment.
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 7 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
Master Operations Control Lock - A Red lock with a wrap of yellow tape that is (individually keyed. ie..
one lock and only one key) used by the operations department to secure the lock boxes.
Normal production operations - The utilization of a machine or equipment to perform its intended production function.
Servicing and/or maintenance - Workplace activities such as constructing, installing, setting up,
adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These
activities include lubrication, cleaning or unjamming of machines or equipment and making adjustments
or tool changes, where the employee may be exposed to startup of the equipment or release of hazardous
energy.
Setting up - Any work performed to prepare a machine or equipment to perform its normal production
operation.
Tag-out - The placement of a tag-out device on an energy-isolating device, in accordance with an
established procedure, to indicate that the energy-isolating device and the equipment being controlled
may not be operated until the tag-out device is removed.
Tag-out device - A prominent warning device, such as tag and a means of attachment, which can be
fastened securely to an energy-isolating device, in accordance with an established procedure, to indicate
that the energy-isolating device and the equipment being controlled may not be operated until the tag-out
device is removed.
Worker - The person actually performing work on equipment. The worker can be either a contractor or
Westlake personnel. Each worker must have full control of all energy sources leading to the equipment
for the duration of the work.
7.0 PROTECTIVE MATERIALS AND HARDWARE
Operations shall provide locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware for isolating, securing, or blocking of machines or equipment from energy sources.
Lock-out devices and tag-out devices must be identified and the only device(s) used for
controlling energy.
LOTO locks used to protect workers while they are working shall be keyed different with
only one key for each lock.
“Clearing House” locks will be keyed the same, but are ONLY to be used by operations and the electrical department. RED (operations) and GREEN (electrical department).
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 8 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
Clearing House locks are to be keyed alike in small groups. No matter how many groups of
clearing house locks are used, the job MUST be protected by use of ONLY ONE Master
Control Lock.
DANGER:
No worker shall solely use clearing house locks to perform work. Clearing house locks are to be used to isolate the equipment and will not provide the required protection. Individually keyed locks are to be used by each worker providing work on a system that is locked out.
Westlake Vinyls LOTO lock specifications: American Padlock 1100 Series
LOTO locks shall NOT be used for other purposes such as on lockers, toolboxes, bicycles, golf carts etc.
Lock-out Locks and Tag-out tags shall be:
Durable and standardized and shall be capable of withstanding the environment to which they are exposed for the maximum period of time that exposure is expected.
LOCK DEFINITIONS:
RED locks, reserved for the Operations Department
There are TWO different types of RED locks. 1. Clearing house locks (keyed alike in small groups) 2. “Red Master Control Lock” having a ring of yellow tape and will be individually
keyed (one lock/ one key).
GREEN locks, reserved for the I&E Department
Clearing house locks (keyed alike)
Black locks, reserved for equipment under PERMANENT lock-out
Silver locks, individually keyed, to be used by ALL PERSONNEL.
TAGS must be used when using these locks.
CONTRACTORS will provide each of their workers with Silver locks and a tag with each lock.
TAG DEFINITIONS:
Each LOTO lock shall have the appropriate colored tag attached.
All tag writing must be legible and provide complete information.
Red tags will be primarily used for LOTO
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 9 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
Green tags, reserved for I&E Department, to signify the electrical work
Blue tags, reserved for in-house Maintenance including core contractors
Yellow tags, reserved for all outside contractors
All tags are located in warehouse stock and a photocopy of each tag can be found at the
end of this procedure.
Substantial - Lock-out devices shall be substantial enough to prevent removal without
the use of excessive force or unusual techniques, such as with the use of bolt cutters.
Tag-out devices, including their means of attachment, shall be substantial enough to
prevent inadvertent or accidental removal. Tag-out device attachment means shall be of a
non-reusable type, attachable by hand, self-locking, and non-releasable with a minimum
unlocking tensile strength of no less than 50 pounds having the general design and
basic characteristics of being at least equivalent to a one-piece, all-environment-
tolerant nylon cable tie.
The ONLY acceptable attachment to be used at Westlake Vinyls is a RED tie-wrap that is available in warehouse stock that meets the above criteria.
8.0 INSPECTIONS
Routine Inspections
The Safety and Operations departments shall continually monitor performance with regard to compliance with this program and shall correct any deviations or inadequacies observed.
Periodic Inspections
The site will conduct periodic inspections through housekeeping and JTO (Job Task Observation) audits.
Inspections shall:
1. Include review of isolation list(s) for specific equipment to ensure that the isolation lists are adequate to provide the necessary protection.
2. include observing the implementation of an energy control procedure(s).
An authorized employee other than the one(s) utilizing the energy control procedure being inspected shall
perform the periodic inspection.
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 10 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
The employee performing the periodic inspection does not have to observe every authorized employee
implementing the energy control procedure on the machine or equipment on which he or she is authorized
to perform servicing and maintenance.
However, each Westlake Vinyl's employee that utilizes lock out tag out shall be observed and the
observation is to be documented using Safety Standard 505_3 Lock, Tag and Try Evaluation Form.
This procedure must be reviewed annually.
9.0 TRAINING AND COMMUNICATION
Initial Training
The Safety department shall provide orientation and annual training to ensure that the purpose and
function of the energy control program are understood by employees and that the knowledge and skills
required for the safe application, usage, and removal of energy controls are acquired by employees.
Training shall include:
1. Each authorized employee shall receive training in the recognition of applicable hazardous energy
sources, the type and magnitude of the energy available in the workplace, and the methods and
means necessary for energy isolation and control. 2. Each affected employee shall be instructed in the purpose and use of the energy control program. 3. All other employees whose work operations are or may be in an area where energy control
procedures may be utilized, shall be instructed about the procedure, and about the prohibition
relating to attempts to restart or re-energize machines or equipment which are locked out or
tagged out.
Employee Retraining
Retraining shall be provided for all authorized and affected employees annually or whenever there is a
change in their job assignments, a change in machines, equipment or processes that presents a new
hazard, or when there is a change in the energy control procedure.
Additional retraining will be managed by the MOC Procedure
10.0 GENERAL PROCEDURE
Energy Isolation
Implementation of lock-out or the tag-out system shall be performed only by authorized employees.
The 505_1 LOTO Isolation List shall be completed and retained for future use. It shall also be maintained and reviewed by the Unit Trainer until it is no longer valid and a digital record is developed for each piece of equipment under their responsibility.
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 11 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
Notification of Employees
Affected employees shall be notified by the supervising department or authorized employee of the
application and removal of lock-out devices or tag-out devices. Notification shall be given before the
controls are applied, and after they are removed from the machine or equipment.
Tag-out
OSHA has determined that lock-out is a more effective means of ensuring the de-energization of
equipment; it is the preferred method. However, OSHA recognizes that tag-out must be used where the
energy control device cannot accept a lock or locking device. If the energy isolating device is capable of
being locked out, the standard requires that a lock-out be used.
When tag-out systems are approved (See Responsibilities Section of this Procedure), employees shall also be trained in the following:
1. Tags are, essentially, warning devices affixed to energy-isolating devices, and do not provide the
physical restraint on those devices that is provided by a lock. 2. Tags must be attached with a RED cable tie LOTO tie wrap to an energy-isolating means, it is
not to be removed without authorization of the authorized person responsible for it, and it is never to be bypassed, ignored, or otherwise defeated.
3. Tags must be filled out completely. Partially written information or a tag that can't be read due poor penmanship or no ink in pen is not acceptable.
4. Tags must have a means of attachment that shall be substantial enough to prevent inadvertent or accidental removal. Tag-out device attachment means shall be of a non-reusable type, attachable by hand, self-locking, and non-releasable with a minimum unlocking tensile strength of no less than 50 pounds having the general design and basic characteristics of being at least equivalent to a one-piece, all-environment-tolerant nylon cable tie.
5. A RED cable tie-wrap meeting the above requirements is available in warehouse stock.
NOTE:
To determine if tags may be used in the place of equipment locks, two of the following must
agree (Unit Manager or designee, Safety Department and/or Shift Supervisor).
Preparation for Lock-out or Tag-out
Make a survey to locate and identify all isolating devices to be certain which switch(s), valve(s) or energy-isolating devices apply to the equipment to be locked or tagged out. More than one energy source (electrical, mechanical, or others) may be involved.
Sequence of Lock-out Tag-out System Procedures
1. The safe work permit system is designed to notify all affected employees that a lock-out or tag-
out system is going to be utilized and the reason therefore.
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 12 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
2. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress
stop button, open toggle switch, etc.). 3. Operate the switch, valve, or other energy-isolating device(s) so that the equipment is isolated
from its energy source(s). Stored energy (such as that in springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, water pressure, etc.) must be dissipated or restrained by methods such as repositioning, blocking, bleeding down, etc.
4. Lock, Tag & Try the energy-isolating devices with assigned individual lock(s) and/or tag(s).
SHARED EQUIPMENT
Some jobs require that valves be isolated in multiple units. The area operator that writes the permit is
responsible for walking the line and identifying all isolation points and shall also be responsible for
notifying the "non-originating" unit(s), and for locking all isolation points involved. All keys for the job
shall be kept in the same lockbox. The lockbox must stay at the originating unit where the permit was
written. Any valves locked in the "non-originating" unit(s) shall have tags with the locks. The tag must
indicate what unit originated the lockout. This will allow the "non-originating" unit(s) whom to call,
should there be questions about the lock out. Locks and tags are to be returned to their "originating"
unit(s) upon completion of the lock out.
CAUTION: Operations and Maintenance Supervisor or Designee JOINTLY are to test
and verify the following steps;
a. After ensuring that no personnel are exposed to potential energy hazard and disconnecting energy
sources: b. Operate the push button or other normal operating controls to make certain the equipment will not
operate. c. Try to start or use the push button of the equipment at least TWO times or other normal operating
controls to make certain the equipment will not operate. d. Return operating control(s) to “neutral” or “off” position after the test.
ATTENTION: Contractors/ Maintenance shall NOT operate any start switch or valve at Westlake Vinyls. Only trained operators are authorized to operate valves
and start switches.
5. If the equipment may be operated from a remote station or computer control system the
authorized employee MUST verify that the equipment will not start remotely
WARNING: Some equipment is capable of being operated remotely and isolation must be verified.
CAUTION: Ensure interlocked equipment is properly isolated and not temporarily disabled by interlock
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 13 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
6. The equipment is now locked out and/or tagged out
NOTE: If more than one person is working on the equipment refer to the Group LOTO section below.
Starting up a piece of equipment that is partially repaired can be dangerous. Therefore, as a preventative
measure, the operator will leave the Master Operations Control Lock Red (red lock with a wrap of
yellow tape) on the lockbox until it is proven that the equipment is prepared for start-up. It is the
responsibility of the person performing the work to communicate to the operator the job status of the
equipment at the bottom of the safe work permit, under the section titled, “exceptions to completion”
section. The work permit will serve as the communication tool between the operator and worker
performing the work and will capture if the “WORK IS NOT COMPLETE" before the end of a shift.
Restoring Machines or Equipment to Normal Production Operations
1. After the servicing and/or maintenance is complete and equipment is ready for normal production
operations notify the affected employee(s) and check the area around the machines or equipment
to ensure that no one is exposed. 2. After all tools have been removed from the machine or equipment, guards have been reinstalled
and employees are in the clear, remove all lock-out and tag-out devices. Operate the energy- isolating devices to restore energy to the machine or equipment
11.0 GROUP LOCK-OUT/TAG-OUT
Group lock-out shall be utilized where complex. In such situations the supervising department may
designate a primary authorized employee, with the primary responsibility for a set number of employees
working under the group LOTO device(s). The primary authorized employee must implement and
coordinate the Westlake LOTO. The primary authorized employee shall place all keys to all locks utilized
in the lock-out inside of a lock box and A Master Operations "Red" control lock placed on the box. This
must be accomplished before a permit is written and before authorized employees participating in the
group LOTO affix their personal lock-out device to the outside of the group LOTO box and before
performing servicing/maintenance activities.
ATTENTION: Operations MUST be present when energy is tested, such as, pressing a "START" button.
In addition to the primary authorized employee, each authorized employee participating in the group
LOTO must be informed of their right to verify the effectiveness of the lock-out measures. Each
authorized employee must be allowed to personally verify that hazardous energy sources have been
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 14 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
effectively isolated, if they so choose. An authorized employee, who opts to verify the effectiveness of the
isolation measures, must perform this verification after affixing his or her personal lock-out device to the
lock box and before performing servicing/maintenance activities.
Each authorized employee shall affix a personal lock-out to the group lock-out device, group lockbox, or
comparable mechanism before he or she begins work, and shall remove those devices when he or she
finishes working on the machine or equipment being serviced or maintained or at the end of the shift,
whichever comes first.
It is imperative that each authorized employee understands the hazards of the work and how to control the
hazards. Furthermore, it is required that authorized employee(s) have knowledge regarding the type and
magnitude of the energy, the hazards of the energy to be controlled, and the procedure to be used to
control the hazardous energy.
12.0 LOCK AND/OR TAG REMOVAL
Each lock-out or tag-out device shall be removed from each energy isolating device by the person who applied the device.
EXCEPTION: Operators are assigned specific areas of responsibility and the RED MASTER CONTROL LOCK KEY will be passed off during each shift change. It is the responsibility of the off-going operator to communicate the LOTO status of each piece of equipment under their assigned responsibility and to ensure the on-coming operator is made aware of the LOTO. The key control will continue from shift to shift until the equipment lock out is removed.
WARNING:
No tag or lockout device shall be forcibly removed without proper authorization. Failure to follow rules may result in disciplinary action up to and including termination.
The supervisor of an employee may remove a lock out or tag out device using the process below.
The supervisor MUST identify the worker(s) whose tag(s) or lockout device(s) are on the equipment.
The supervisor MUST complete Westlake Vinyls' Safety Standard 505_2 Authorization for Removal of Tags / Locks.
An incident report is to be completed by the employee's supervisor and disciplinary action as needed to prevent future occurrence.
PERSONNEL ARE RESPONSIBLE FOR REMOVING THEIR LOCK OUT TAG OUT BEFORE THEY LEAVE THE PLANT PROPERTY
NOTE: If the worker is contacted he/she MUST return to the work site and remove the worker
tag(s) or lock(s). No overtime is provided for this duty.
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 15 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
Operations shall report the LOTO incident to the Unit Manager or the Shift Supervisor indicating what
failed during the incident.
The findings from the incident and recommendations to prevent reoccurrence will be reviewed with all affected personnel.
If the worker cannot be located, attempts shall be made to contact the worker’s supervisor.
PREPARING TO REMOVE THE TAG OR LOCKOUT DEVICE
Verify the equipment is ready to run. Such as, machine guards in place and tools removed.
Fill out “Authorization for Removal of Lockout Device”. (505_2 LOTO Cutting Locks Form)
Remove the tag or lockout device.
NOTE:
Keep the worker’s lockout device, so it can be returned
The lock and tag will be given to the worker’s supervisor. The supervisor will notify the
worker whose lock or tag has been cut and review the incident prior to returning to
work. The worker should get the tag or lockout device(s) and a copy of the removal
form as soon as possible upon returning to the plant property. The ultimate goal is to
ensure the worker’s supervisor (or designee) must notify the worker prior to the worker
commencing any work activity.
The Shift Supervisor is responsible for ensuring the completed Authorization For
Removal of Tags/ Locks form is to be delivered to the Safety Department.
13.0 SHIFT OR PERSONNEL CHANGES
This section is to explain the orderly transfer of lock-out or tag-out device protection between off-going
and oncoming employees, to minimize exposure to hazards from the unexpected energization or start-up
of the machine or equipment, or the release of stored energy.
When work is being performed, under group LOTO, outside the normal shift or working hours a primary authorized employee must be present at all times.
When changing shifts the supervising department may, through an orderly transfer, designate a new
primary authorized employee. This new primary authorized employee must assume the control of the
key(s) involved in the LOTO
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 16 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
It is the responsibility of the each authorized employee to verify effective isolation prior to beginning
work.
When work is performed over a period of time and is not continuous, the primary authorized employee
shall walk through the affected work area(s) to verify effective isolation prior to beginning work. It is not
sufficient for the primary authorized employee(s), to merely review tests in a job briefing and to rely on a
locked box. Rather, each applicable energy isolation device must be verified to assure effective energy
isolation.
14.0 ATTACHMENTS
505_1 LOTO Equipment Isolation List 505_2 LOTO Authorization For Removal of Tags/ Locks 505_3 LOTO Evaluation Form
15.0 REFERENCES
OSHA 29 CFR 1910.147
16.0 APPROVAL
Electronic approval on file in MOC HSE-15-22
Revision History
Rev Changes Approved Date
Added new header 2/6/2020
Document Number: 505 Revised By: G. Thorn Manager Approval: N/A Revisions noted in italics
Current Rev: 2/6/2020 Review Cycle: 1 year Revision No. 3 Page 17 of 17
HEALTH AND SAFETY PROCEDURE 505 – Lock Out Tag Out
Example: Photocopy of Danger Tags used at Westlake Vinyls
WVC Safety Standard #505_1(Lock Out Tag Out) 505_1
LOCKOUT EQUIPMENT ISOLATION LIST IN CASE OF EMERGENCY, CONTACT UNIT CONTROL ROOM or ANNOUNCE OVER CHANNEL 1
505_1
EQUIPMENT NO. TIME DATE: OPERATOR: LOCK BOX No. Master Lock No.
JOB DESCRIPTION:
TYPES AND LOCATION OF ENERGY ISOLATING DEVICES
Lock Number
Energy
Type *
Valve
Position
: O or
List Valves, Breakers, Etc.
Time On
Date Off
Time Off
NOTE: If tag only is used, record "Tag" in the "Lock Number" column.
NOTE: By signing the permit, you verify that you have been offered the opportunity to observe all isolation points and that you understand the type
and magnitude of hazards that have been isolated.
NOTE: Replacement shifts may sign on back.
PRINT CONTRACTOR EMPLOYEE NAMES:
On completion of job, Sign this form complete here:
Operations
Name & Signature of Maintenance Supervisor or Designee
WVC Safety Standard 505_2 (Lock Out Tag Out) 505_2
AUTHORIZATION FOR REMOVAL OF TAGS / LOCKS TO BE COMPLETED BY PERSONNEL REMOVING ANY WORKERS’ LOCKOUT DEVICES
DATE TIME UNIT LOCK BOX NO.
EQUIPMENT NUMBER/DESCRIPTION
Name(s) and Employer(s)
1. Reason for Requesting LOTO Removal
2. Was The Above Employee Contacted? Yes No If yes, list precautions/instructions needed to make equipment ready. If no, contact the employee’s supervision as per the Procedure to remove the LOTO. List all contacts made or attempted and any precautions or instructions.
3. List Work Completed to Make Equipment Ready, Such as: Reinstating Valves, Reinstating Breakers, Opening Blinds
4. We Have Inspected This Equipment and it Appears Ready for Service. The Above Employee’s Tag Shall Be Removed.
Name and Signature of Worker’s Supervisor / Date (if the Supervisor is available)
Name & Signature of HSE Manager or “IF OCCURING IN OFF-HOURS” Name & Signature of Shift Supervisor on site / Date
Note: A copy of this document shall be given to the Employee’s Supervisor. The supervisor is responsible for obtaining the signature of the employee and notification prior to the employee commencing any work activities.
Signature of employee whose LOTO was Removed. Date, & Time of notification.
NOTE: The Shift Supervisor shall ensure this completed form is forwarded to the Safety Department for recordkeeping.
MULTIPLE ATTEMPTS SHOULD BE MADE AND DOCUMENTED TO CONTACT THE LOTO OWNER! REMOVING A LOCK IN THE ABSENCE OF THE ORIGINATOR SHOULD BE THE LAST RESORT. PERSONNEL ARE TO REMOVE THEIR LOTO BEFORE THEY LEAVE THE PLANT PROPERTY.
Rev Date 2/6/2020
WVC Safety Standard #505_3 (Lock Out Tag Out) 505_3
LOCK, TAG, AND TRY
EVALUATION FORM Equipment Locked Out: Date: Time:
Reason for Lockout:
Audit conducted by
Persons Locking Equipment: Immediate Supervisor:
Were all involved employees able to answer procedural questions satisfactorily?
YES NO N/A
Equipment properly Locked Out?
YES NO N/A
DANGER - LOCKOUT Tag Installed/Properly Completed?
YES NO N/A
Are Keys Under Proper Control?
YES NO N/A
Was Equipment Tried and Verified to be De-energized?
YES NO N/A
Procedure discrepancies Reviewed with Affected Employees?
YES NO N/A
Comments:
Signature: ___________________________________________
Supervisor or Designee
Signature: ___________________________________________
Technician
DO NOT ASSUME ANYTHING
Completed Form should be sent to:
Lead Operator/ Day Superintendent Safety Department Unit Manager