The Practical Safety Guide

To

Lock Out and Tag Out

Isolation Pocket Book

Wayne G Herbertson, MSc

Practical Safety International

Copyright © 2002 by Wayne G Herbertson
Revised 2016

All Rights Reserved

Published in Australia by Practical Safety International Pty Ltd, PO Box 689 Nelson
Bay, NSW, Australia, 2315

No Part of this book may be reproduced, transmitted, or stored in any form or by any
means, electronic or mechanical without prior permission from the publisher. Exception
is made, and permission here granted, for the copying of information for personal
research use. Commercial distribution of such information is forbidden.

Photos:
© Large cover photo - Jupiter Images,
© Locks, Hasp, Group Box, and Out Service
Tags - Brady Worldwide Inc.,
© Information Tag – Westlake Printers
© Personal Danger Tag – lockouttag.com
© Out Service Lock – Master

National Library of Australia Cataloguing-in-Publication Data Author: Herbertson,

Wayne, 1961
Title: Practical Safety Guide to Lockout and Tagout: Isolation Pocketbook / Wayne G
Herbertson
ISBN: 978-1542599726
Subjects: Industrial Safety – Management
 Contents

1.0 Introduction 4

2.0 Lockout and Tagout System Equipment 7

2.1 The Use of Personal Locks and Danger Tags 8

2.2 Equipment Out of Service Locks and Tags 11
2.3 Information Tags 13
2.4 Isolation Clasps and Isolation Boards/Boxes 14

3.0 Isolation Process 15

4.0 Role of the Isolation Leader 19

5.0 Training and Competency 24

6.0 Points to Remember 26

 Introduction
The Lock Out and Tag Out process (LOTO) described here should be seen as part of an
integrated safety system designed to support the delivery of Zero Harm outcomes. The
Practical Safety Process® cannot be described here in detail (see The Practical Safety
Guide to Zero Harm – Available at amazon.com) but it’s important to understand the
core process steps and support mechanisms that need to be in place to create such a
safety system. See Figure 1

Figure 1- Practical Safety Process®

The LOTO process is part of this safe system of work i.e. Step 5. As such the pre-
requisites of Steps 1 to 7 must be completed prior to any work being carried out. This
includes:
1. Identification of Hazards and Risks through- Job Safety Analysis – JSA
2. Identification of People Requirements through - Job Person Analysis –
JPA
3. Identification of Compliance issues
4. Ensuring equipment and workplace preparations are completed
5. Ensuring safe systems of work are in place – e.g. Work Permits,
isolation plans
6. Training of personnel
7. Monitoring systems are in place

These hazard and risk control processes are integral to any isolation procedures to
ensure hazards are identified and appropriate risk controls are put in place to reduce
risk to acceptable levels where work can be performed safely. The process may include
several planning steps as shown in Figure 2. These procedures ensure that all hazards
are identified and that control measures are planned, documented and authorized prior to
the work being conducted. These support systems must be in place before any LOTO
work can be carried out.

2.0 Lockout and Tagout System Equipment

There are two types of locks required for Isolation

PERSONAL LOCKS (Red)
EQUIPMENT OUT SERVICE LOCKS (Brass or Yellow)
And there are three types of tags that could be used
PERSONAL DANGER TAGS (Red)
OUT OF SERVICE TAGS (Yellow)
INFORMATION TAGS (Blue)
LOCKS AND TAGS ARE USED TO INDICATE THE REMOVAL OF AN
ENERGY SOURCE SUCH AS ELECTRICITY, PRESSURE, MECHANICAL,
GRAVITY ETC FROM EQUIPMENT OR PLANT SO THAT IT CAN BE
SAFELY WORKED ON.
And lastly there is also a requirement for
Isolation Multilock Hasps
Group Isolation Boards or Box’s
Isolation Devices Toolkit
 2.1 The Use of Personal Locks and Danger Tags

THEY ARE FOR YOUR OWN PROTECTION

YOU MUST ENSURE THAT PERSONAL LOCKS AND DANGER TAGS ARE
PERSONALISED IN A LEGIBLE FASHION TO ENSURE POSITIVE
IDENTIFICATION OF THE OWNER.

YOU WILL BE ISSUED WITH ONLY ONE PERSONAL LOCK AND DANGER TAG.

IN SITUATIONS REQUIRING THE ISOLATION OF MORE THAN ONE ENERGY

SOURCE A GROUP ISOLATION SYSTEM SHOULD BE IMPLEMENTED.

It is important that before placing your personal lock and tag and entering a
restricted area that you are satisfied that:

1. There is a completed JSA and isolation plan with all isolation points listed
with proof of isolation procedures agreed.
2. All isolators have been switched to the safe position and the Isolation
Leader has proved each isolation is safe.
3. Ensure that there is no possibility of accidental dislodgment of isolation
devices.
4. Isolation Leader has inducted you into all the required risk assessments and
that you have signed the appropriate documentation acknowledging your
understanding of controls
5. You are the only person to place or remove your own Personal Lock and
Danger Tag.

2.1.1 Unfinished Work

If you leave a job unfinished, for example the end of a shift or lunch break etc., you must
remove your Personal Lock and Danger Tag and leave the “OUT OF SERVICE LOCK
AND TAG” in place to maintain the isolation.
2.1.2 Recommencing Work
You must REAPPLY YOUR PERSONAL LOCK AND DANGER TAG ONCE
AGAIN.

REMEMBER YOUR PERSONAL LOCK AND DANGER TAG

 REMAIN WITH YOU WHEREVER YOU ARE.

2.1.3 Removal of Personal Locks and Danger Tags

PERSONAL LOCKS AND DANGER TAGS CAN ONLY BE

REMOVED BY THE PERSON WHO PLACED THE LOCK AND
TAG.
Where a person has left the site or has lost their key the personal lock and danger tag
may be removed only after the person concerned has been positively located, and where
possible has returned to the site or the key is found. Such removals shall be documented
and repeat offenders should be reviewed regarding their suitability for this type of
work.
 2.2 Equipment Out of Service Locks and Tags

Equipment Out of Service Locks and Tags are used when performing isolations of
energy supplies to plant and equipment.

They are also placed on isolators when isolation is required but personal protection is
not needed. e.g. maintaining isolations.

You are required to write the reason for the isolation on the Out of Service Tag and then
attach the tag to the equipment at the same point as the EQUIPMENT OUT OF
SERVICE LOCK.

Equipment Out of Service Locks and Tags are also used by isolation leaders to secure
isolations.

Remember… you will need a Personal Danger Tag and Personal Lock if you are
working on the equipment.

2.2.1 Removal of Equipment Out of Service Locks and Tags.

EQUIPMENT OUT OF SERVICE LOCKS AND TAGS CAN BE

REMOVED BY THE PERSON WHO PLACED THE LOCK AND
TAG OR AN AUTHORISED PERSON.

Where a key is lost, the removal of an Equipment Out of Service Lock can only take
place by securing the area and ensuring all personnel are accounted for and only after a
thorough search has been conducted. The process shall be recorded and corrective
actions put in place to prevent a recurrence
 2.3 Information Tags

Information Tags are used to communicate important information to team members. The
most common use is on barricades.
INFORMATION TAGS ARE NOT FOR PERSONAL PROTECTION
An Information Tag cannot be used in place of a Personal Danger Tag or Out of Service
Tag.

An INFORMATION TAG IS USED to GIVE SAFETY ADVICE ONLY

2.3.1 Removal of an Information Tag

Where the information Tag is no longer required it can be removed by:

The person who attached it

OR
The Isolation Team Leader
 2.4 Isolation Clasps and Isolation Boards/Boxes
1. Multilock hasps are used in single isolation situations to enable an isolation
to be put into place using initially an equipment lock and tag. This allows
anyone requiring protection under the isolation to freely move in and out of
the isolation area by placing and removing their personal lock and tag as
appropriate whilst entering or exiting the isolation area.

ONLY A SINGLE CLASP IS PERMITTED ON ANY ISOLATOR

2. Isolation Boards and Boxes are used where there are multiple isolation
points and people involved in the isolation that needs to be put into place.
They provide for the use of just one personal lock and tag which simplifies
isolations considerably. See group isolation section 3
 3.0 Isolation Process
One of the most important things with any effective isolation system is to “KEEP IT
SIMPLE!” Whilst it is preferred to exclusively use locks for isolation an integrated
logout and tagout system is described here to cover all situations. The system described
here has been used across all industries and is both effective and simple to implement.
Here 2 isolation systems are explained to provide an integrated system that can be used
in most situations. The following flowchart gives and overview: See Figure 3 page 18

1. Single isolation – Applied in situations where there is one isolation point and no
more than 5 people. In this situation the process involves:
1. An Isolation Leader is appointed and this person ensures that all hazard and
risk processes have been carried out and that a suitable isolation plan has
been formulated.
2. The Isolation Leader is responsible for maintaining all documentation and
induction records for the isolation process.
3. The Isolation Leader then places a Multilock hasp and out of service lock
and tag on the isolation point and proves the isolation by testing and then
inducts all personnel involved in the work. This places the isolation in
place.

4. Up to 5 people can then be protected by placing their personal lock and tag
on the Multilock hasp prior to starting any work on the equipment or
entering the work area.
5. As work is completed all personnel protected then remove their personal
locks and tags and leave the area. The isolation leader then removes the out
of service lock, tag and the hasp and returns the area to normal operations.
2. Group Isolation – Applied where there is multiple isolation points or more than 5
people. In this situation the process has some additional steps:
1. An Isolation Leader is appointed and this person ensures that all hazard and
risk processes have been carried out and that a suitable isolation plan has
been formulated.
2. The Isolation Leader is responsible for maintaining all documentation and
induction records for the isolation process.
3. The Isolation Leader then places Out of Service Locks and Tags on each
isolation point and proves each isolation by testing.
4. All keys for the Out of Service Locks are then placed in a Group Isolation
Box or Board. These keys are secured with a further Out of Service Lock
and Tag placed by the Isolation Leader on the group box or board.
5. The Isolation Leader then inducts all personnel involved in the work. This
places all isolations in place. It is also good practice to have a suitable
location to have all the documentation available to team members in the
area. This can be either attached to Group Isolation Boxes or Boards or be
placed in a known location in the area.
6. Individuals can then be protected by placing their Personal Lock and tag on
the Group Isolation Box or Board before starting any work on the equipment
or entering the work area.
7. As work is completed all personnel protected then remove their Personal
Locks and tags and leave the area. The Isolation Leader then removes the
Out of Service Lock and Tag from the Group Isolation Box or Board and
accesses the keys for the individual isolation points. The Isolation Leader
then removes the Out of Service Locks and Tags from each individual
isolation point and returns the area to normal operations.
Figure 3 Isolation Process Overview
 4.0 The Role of the Isolation Leader
The role of the isolation leader is to:
1. Ensure all hazard and risk identification processes have been carried out.
This should include an isolation plan. See page 21
2. Carry out or supervise the isolation process
3. Ensure all isolations are proven
4. Maintain all documentation
5. Ensure all personnel are inducted into the isolation system and that this is
recorded before anyone is permitted to place their personal Danger tags and
locks.

In supervising and/or carrying out the process of isolation the Isolation Leader isolates,
proves and secures each isolator with an OUT OF SERVICE Lock and Tag. Note: The
leader may gain assistance from others but must supervise each isolation as it is
performed to ensure each isolation is proven. The Isolation Leader must ask themselves:

1. Do I understand the job and the correct isolation procedure and is this
documented in JSA or work instruction.
2. Have I identified and removed or reduced to an acceptable level, the risk
associated with identified hazards.
3. Am I satisfied my test equipment works

4. Have I positively identified the equipment to be worked on?

5. Have I correctly identified and isolated all known power supplies with an
equipment lock and tag?
1. Remembering that in some situations multiple supplies and
voltage levels may exist
2. And by referring to all known drawings and procedures
6. Have all other energy sources been isolated and locked out and tagged.
Remembering hydraulics, oil, gas, water, gravity.

7. TEST BEFORE YOU WORK

IS THE ENERGY SOURCE CONTROLLED?
CAN I PROVE IT’S CONTROLLED?
NOT SURE ASK!
DON’T ASSUME ITS SAFE, PROVE IT!
 Figure 4 – Isolation Plan

8. In the case of Group Isolation, the Isolation Leader must ensure that all
Out of Service Lock Keys are placed in the Group Isolation Board/Box with the
Isolation plan and the Board/Box is secured with an equipment lock and tag.
The isolation leader must retain the key to this equipment lock at all times
whilst the Group Isolations are in place.
9. The Isolation Leader must ensure that any team members requiring entry to
the isolation area have placed their Personal Lock and Danger Tag either on
clasp (single isolation) or on a group isolation board/box.
10. The Isolation Leader must ensure that the appropriate equipment is
available for the isolations to be performed. In permanent environments
isolation boards can be useful by placing them strategically within the
workplace. In maintenance and service environments isolation toolkits are
common.
11. The Isolation Leader must respect the right of each individual to confirm
the isolation/s for themselves prior to undertaking any work.

12. The Isolation Leader must ensure that all team members have the
 appropriate training and that records are maintained.

13. The Isolation Leader should ensure all emergency equipment is available
at the point of need.

NOTE
NO TEAM MEMEBER IS PERMITTED TO ATTACH A PERSONAL DANGER
LOCK AND TAG UNLESS THEY HAVE BEEN PROPERLY INDUCTED INTO
THE AREA CONCERNED AND UNDERSTAND THE ISOLATIONS.

PERSONAL LOCKS AND DANGER TAGS SHOULD ONLY BE ATTACHED

WHILST INDIVIDUALS REMAIN IN THE AREA BOUNDED BY THE
ISOLATION.
 5.0 Training and Competency
With respect to isolation there can be no compromise on training and competency
assessment. It is an area where mistakes cannot be tolerated and a high degree of
discipline is required. Therefore it is incumbent upon any organization to ensure that
there is appropriate training carried out that should include:

1. The use of Job Safety Analysis – JSA tool

2. The application of work permits
3. Hazard identification and risk assessment
methodologies
4. Identification of energy sources including
stored energy
5. Single and group isolation processes
6. The formulation of an isolation plan
7. Use of tags and the disciplines with respect
to removal
8. Use of isolation devices and equipment to
enable lockout
9. Testing of test equipment
10. Proving isolations
Once training is completed competency must be assessed through demonstrated
performance. This can be done in the field or can be simulated using isolation training
boards. It is of paramount importance that this demonstrated performance is assessed
due to the unforgiving nature, of particularly, electrical energy.
In order to give transparency to competency on the job an “Isolation Licence” can be
quite useful to ensure all involved in the isolation processes have been assessed as
competent.
 6.0 Points to Remember
1. ALWAYS TEST CONTROLS BEFORE YOU WORK

2. PERSONAL LOCKS AND DANGER TAGS ARE FOR THE

PROTECTION OF YOURSELF ONLY!

3. YOU ARE THE ONLY PERSON WHO CAN REMOVE YOUR

PERSONAL LOCK AND TAG

4. EQUIPMENT OUT OF SERVICE LOCKS AND TAGS ARE FOR THE

PROTECTION
5. OF EQUIPMENT AND OTHERS, AND CAN ONLY BE REMOVED
BY AN AUTHORISED PERSON.

6. INFORMATION TAGS ARE USED TO GIVE SAFETY ADVICE

ONLY AND ARE NOT USED FOR ISOLATION PURPOSES

7. ISOLATION HASPS ARE TO BE USED WHERE THERE IS A

SINGLE ISOLATION POINT AND LESS THAN 5 PEOPLE

8. GROUP ISOLATION BOARDS/BOXES

9. ARE TO BE USED WHERE THERE IS MORE THAN ONE
ISOLATION POINT.

THERE ARE STRICT DISCIPLINARY MEASURES TO ENSURE THAT THE

LOCK AND TAG SYSTEM CONTINUES TO PROTECT ALL TEAM
MEMBERS.
NOTES
NOTES