CONTROL OF HAZARDOUS ENERGY AND

LOCK-OUT / TAG-OUT/ TRY-OUT

(LOTOTO)

By: ENGR. ALEXANDER B. TRILLANA

OSH CONSULTANT
• Work with machinery, equipment and process
systems where energization or release of stored
energy could result in injury.

• Work involving energy sources:

– Electrical
– Pneumatic
– Hydraulic
– Stored (such as gravity, spring or compressed gas)
– Chemical
– Thermal
– Radiation.
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Nov. 2, 2003 Rig Floor 7
Running at 130 rpm

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 Don’t
ignore the
“LOTOTO”

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Lockout/Tagout
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Electrical LOTO Mechanical LOTO

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 “NOBODY GETS HURT”

Lockout/Tagout Devices

• Locks

• Tags

• Lockout Boards

• Multi-Hole Hasp

• Cables

• Blinds/Spades

• Blind Flanges

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Electrical Lockout Devices

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Valve Lockout Devices

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Mechanical Lockout

WHEN there is a potential to be exposed to rotating equipment or machinery .

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Thermal Energy Lockout

WHEN there is the potential to be exposed to

residual heat or high temperatures.

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Chemical Energy Lockout

When the potential exists for chemical exposure

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Physical Blocks

Truck bed Lockout Punch press blocks

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Pneumatic Lockout

These devices prevent compressed air from flowing through lines and moving
some part of the machinery.The locks prevent anyone from hooking up the
lines while maintenance is being done.”

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Pipe Lockout

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Spades And Blinds

A physical block in a pipeline prevents steam, gas or liquids from flowing through the pipe to the area
where work is being done. For example, the pipe to a chemical tank must be blocked or disconnected
before someone goes in to do repair or maintenance.”

Ensure positive isolation of piping systems (Operation , Mechanical )

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Blind Flange or ‘End Blank’

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Spectacle Blind

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“ EVERY ONE , EVERY DAY , EVERY TASK “
 “NOBODY GETS HURT”

Blocks

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“ EVERY ONE , EVERY DAY , EVERY TASK “
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Types of Lockout/Tagout Devices
LOTOTO BOX
Types of Lockout Devices
Types of Lockout Devices
Types of Lockout Devices
Types of Lockout Devices
Types of Lockout Devices

Step 1: Step 2:
Verify circuit breaker is de-energized. Turn the toggle set screw knob and
Place PSL-CBL lockout device over tighten firmly against the breaker
breaker with the handle centered in handle.
lockout opening.

Step 3: Step 4:
Rotate and flip toggle set screw Install lock and tag and test for
upwards. security. Verify that the lockout device
secures the disconnect in a safe or off
position.
Types of Lockout Devices
 Scope
• Applicable to all operations (manufacturing,
distribution and offices) worldwide with potential for
work where energization or release of stored energy
can result in injury.
Definitions
• Energy source: any source of electrical, mechanical,
hydraulic, pneumatic, chemical, thermal, or other
energy.
 Definitions
• Energy isolating device: a mechanical device that
physically prevents the transmission or release of
energy
• Hazardous energy: any electrical, mechanical,
hydraulic, pneumatic, chemical, thermal or other
energy, which if inadvertently applied to a machine or
worker can cause injury.
 Definitions
• Lock-out: the placement of a lock on energy isolating
device ensuring the equipment cannot be operated
until the lock is removed
• Tag-out: the placement of a tag on an energy isolating
device ensuring the equipment may not be operated
until the tag is removed.
 1.0 Administrative controls

1.1 Compliance

• Establish local legal regulations and Company

requirements
• Implement management practices and controls
whichever is stricter of the two.
 1.2 Hazard ID and Risk Assessment

• Conduct and document initial assessment to ID

machinery and equipment in which energization or
release of energy could result to injury to workers
• Part of safety aspects and impacts analysis of the
Company’s Safety Management System
• To be reviewed annually and modified as necessary.
 1.3 Energy Control Procedures

• Document specific procedures for control of hazardous

energy for each piece of machinery and equipment where
energization or release of energy could result in injury
 1.3 Energy Control Procedures

• The machine-specific CoHE procedures must include how

to:
– Shut down the machine and location of controls
– Isolate energy sources and location of energy isolation devices
– Relieve any stored or residual energy
– Place lock-out and tag-out devices
– Verify energy isolation
– Release the machine from lock-out and tag-out.
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 1.4 Training
• All employees whose job requires them to operate, use,
or be in the area of equipment or process systems during
LOTO activities must receive documented initial training
– A review of energy sources present in facility
– Overview of purpose and use of CoHE
– Types of energy isolating devices they will see in use
– Prohibition of removing locks or tags or trying to start
equipment with LOTO
– Prohibition in using LOTO unless trained.
 SAFETY TALKS!

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 1.4 Training
• Disciplinary policy for violating CoHE program
• Retraining must be conducted when:
– Employees are assigned to a job in which they have not been
trained in CoHE
– Change in equipment with new hazards
– Change in CoHE procedures
– Audits or accidents reveal deficiencies in employees knowledge
or implementation of CoHE procedures.
 1.5 Working with Contractors

• The site is responsible for ensuring Contractors use CoHE

procedures
• Before work, site and contractor, review all applicable
hazardous energy sources and CoHE procedures
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 2.0 Scope of Line break processes

• CoHE during line breaks to prevent exposure to hazardous

chemicals causing injury on contact such
– Fluids above 55oC (130oF)
– Compressed air or gas >5.5bar (>80psig)
• These procedures do not apply where written SOPs are in
place e.g., making clean in place (CIP) connections.
 2.0 Line break processes
2.1 Line breaking permit
• The site must establish a permit program to control and
monitor line breaking work
• Minimum information to be documented
– Date, time and location of work
– Description of work to be done
– Date, time and expiration of work
– Required PPE
– Procedure to clear the line
– Potential sources of energy and CoHE
– Signature of authorizer, attendant and people doing the work
that above have been completed and verified.
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 2.2 Control measures

• Use hazard analysis and recognition to identify potential

control measures such as:
– Removal of chemicals from system
– Use of PPE based on MSDS
– Confirm safety equipment appropriate for the hazards
– Review piping flowsheet
– Confirm and physically check LOTO of pumps, blowers,
compressors to prevent inflow of hazmats
– Confirm work area is isolated or guarded with signs and warning
tape to prevent exposure of others not involved in the linebreak
work.
 2.3 Attendant
• Presence of (standby) attendant familiar with the system,
its hazards and CoHE procedures who is wearing
appropriate PPE for initial line break
 3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.1 Lock-out process

– 1. Stop equipment using normal push button

– 2. Isolate each energy source
– 3. LOTO each energy source
– 4. Verify each energy source is isolated. Call “Stand
Clear” then attempt to re-start the equipment. Return
controls to “neutral”, “stop”, or “OFF” positions after
the test
– 5. Do the required work.
 3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.2 Tag-out

• If the person who installed a lock-out must leave the site

before it is safe to re-energize the equipment, he must
install a tag-out
– “Warning: Do not operate”
– Name and signature of person doing the LOTO
– Reason for the tag
– Date
– Equipment which is de-energized.
 3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.3 Tag-out in lieu of lock-out

• If energy isolating device is not capable of being

locked-out, a tag-out may be used
• Additional energy control measure must be used
such as removal of isolating circuit element, or
blocking a controlling switch
• Sites must upgrade to lockable isolating devices as
soon as practicable.
 3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.4 Group LOTO

• Some works may require multiple individual isolations

with several people working on the same equipment or
process
• A multiple hasp or lock box can be used so each
individual worker can attach his own LOTO.
 3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.5 Release from LOTO

• Once work is complete, procedure to repower:

1. Inspect work area to verify all components are safe to
operate, GHK done, all personnel stay away
2. Remove LOTO. Each person removes his own.
3. Re-energize equipment. Call out “Stand Clear” visually
verifying all personnel are clear. Switch on, standing to
the side of each electrical disconnect (baka sumipa o
sumabog).
 3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.6 Personnel or Shift changes

• One of two procedures is acceptable

– 1. Incoming employee places his LOTO, after which leaving
employee removes his LOTO
– 2. Designated Company supervisor places department
LOTO in addition to the LOTO placed by individual
employees. Authorized employees remove their LOTO at
end of their shift. The designated supervisor keeps control
of the keys of the department LOTO.
 3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.7 LOTO removal when owner is off-site
• No one is authorized to remove another person’s LOTO
while he is on site
• In exceptional circumstance when he cannot be located:
– His supervisor to verify he is not on site
– Attempt to contact the owner before removal of LOTO
– Inform owner his LOTO is removed before he starts work
– A designated employee to verify that removal of LOTO will not
endanger anyone before removal.
 3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.7 LOTO removal when owner is off-site

• In exceptional circumstance when he cannot be

located (continuation):
– The employee removing the LOTO to document
the action. Document kept for 1 year.
– Supervisor investigates why employee left
without removing LOTO devices. Appropriate
disciplinary measures.
 3.0 Electrical, Pneumatic, Hydraulic Powered
Mechanical Equipment
3.8 LOTO Devices

• Standard durable lock hardware throughout the

site
• Tags printed and constructed to be weather
resistant
• Each tag to have secure means of attachment.
 What is Lock-Out / Tag-Out (LOTO)

• Lockout devices can include:

 Locks
 Blocks
 chains
that are applied to energy isolating devices:
 Switches
 Valves
 etc
 Activities That Require Lock-Out/Tag-Out

• Machinery and equipment that require...

Lubrication Un-jamming
Cleaning Repairing
Adjustments Servicing
Retooling Inspection
 Systems that require Lock-Out/Tag-Out

 During service and/or repair

Steam Boilers Electrical

Air Handlers Plumbing

Vehicles Pumps
Motorized equipment
Hydraulic

Pneumatic
• Lockout/Tagout prevents injuries during work
involving:
Repairs
Replacements
Modifications to machines or equipment
Maintenance
During normal operations, Lock-Out/Tag-Out is
needed whenever an employees must:
 Remove or bypass a guard or other safety devices.
 Place any part of his or her body into a machine’s
point of operation.
 Or a danger zone associated with machine’s
operation cycle.
• Authorized employees
can physically lock or tag out machines to
do service or maintenance work as
outlined in lockout/tagout procedures.
• Affected employees

 either operate equipment that can be locked

or tagged out or work in an area where
lockout/tagout is used. They must understand
and comply with the lockout/tagout program
Other employees

are those work operations are or may

be in an area where lockout/tagout
may be used. They must be instructed
about lockout/tagout and know that
they are never to attempt to restart
equipment that has been locked or
tagged out.
Valve Covers
Locks

Plug Covers

Switch Covers

Kits
Preventing Accidents
Requires

Team Effort