Lock Out Tag Out Procedure - RTB Bor 2014
Lock Out Tag Out Procedure(Area FSF)
Contents:
31.Purpose
32.Scope
43.Definitions
64.Construction and Pre-operational Verification.
64.1Pre-Operational Verification
64.2System Isolations
74.3Energization
75.LOTO Personnel Responsibilities
75.1Isolation Authority
75.2Permit Issuer
85.3Permit Receiver
86.Lock Out Tag Out (LOTO) Requirements
97.LOTO Procedure
97.1Detailed Lockout/Tag out Procedure
117.2Energy Isolation Devices Not Capable of Accepting a
Lock
117.3Removal of Authorized Employee Locks and Tags When
Offsite
118.Contractors
129.Personnel LOTO Training
1210.Forms
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.3. Definitions
Job Safety Analyses
(JSA)Task specific risk analysis required prior to the
commencement of work, outlining potential exposure to hazards in
completing the task.
Isolation AuthorityThe 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.
Permit IssuerA responsible person for initiating and controlling
the Work Permit and the Lock Out Tag Out (LOTO) procedure.
Permit ReceiverA responsible person who receives the permit to
allow them to begin work.
Work GroupA 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.
Other EmployeesAre employees whose work may be in the vicinity
where energy control procedures are in place.
Lock and TagsLock and Tags that are used to ensure the safety of
the Authorised Personnel performing the work.
Energy Isolation DeviceA 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.
Lock Out DeviceA 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
Personal TagDanger 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.
Isolation TagDanger 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.
Commission TagCommissioning 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.
Energy SourcesAny 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.
LiveA reference to any electrical apparatus that is carrying a
potential difference to that of Earth or machinery that is
pressurised, loaded or operating.
Potential & Stored EnergiesPotential 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 & BleedThe 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.
Lock Out Tag Out (LOTO)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.
Verification of De-EnergizationThe 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.
ConstructionA period of time where civil, structural,
mechanical, piping and electrical installation works are being
conducted, without the possibility of them being energised or
charged.
Pre Operational Verification (POV)Verification of equipment or
system configuration prior to energization.
CommissioningThe period of time where equipment and machinery
will be energised to ensure correct function during the
operation.
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.4.1 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.
4.2 System Isolations
Prior to initial energization of any system within the plant,
all isolations for that system are required to be in place. 4.3
EnergizationUpon 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.
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.
5. LOTO Personnel Responsibilities
5.1 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 co-ordinating with all Permit Issuers in approving
and ensuring that all isolations for the particular system are
complete, correct and in compliance with this procedure.
5.2 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.
5.3 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.
6. Lock Out Tag Out (LOTO) RequirementsThis 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 system2.
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.
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.7. LOTO Procedure
7.1 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.
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.
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. 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.
7.2 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 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.7.3 Removal of Authorized Employee
Locks and Tags When Offsite
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.
8. 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. 9. 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). 10. Forms10.1 Work
Permit
10.2 Isolation Certificate
10.3 Training Attendance Roster
PrinciplesATTENDANCE ROSTER
Program Title: Lockout/Tag out TrainingInstructor(s)
Date From Trainingto
Location
NameCompanyPosition
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
