Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

LOCKOUT&TAGOUT PRACTICE

DOCUMENT NO. 1414-HSE-PRO-009-00

1.12.19 00 Information YDL WXJ LJW

Date Revision Issued For Prepared by Reviewed by Approved by

Ref : 1414-HSE-PRO-009-00 Lockout & tagout Practice Page 1 of 19

 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

REVISION UPDATE RECORD

Revisio Issue Date Developed By Reviewed By Approved By Remarks

n
00 2019-07-31 Ye Daolei Wang Xinjin Li Jiuwei For Information

Ref : 1414-HSE-PRO-009-00 Lockout & tagout Practice Page 2 of 19

 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

TABLE CONTENTS
1 PURPOSE................................................................................................................................1
2 SCOPE......................................................................................................................................1
3 APPLICATION..........................................................................................................................1
4 DEFINITIONS..........................................................................................................................1
5 LOTO APPLICATION FLOW CHART..................................................................................3
6 PRINCIPLES OF LOCKOUT/TAGOUT...............................................................................4
7 GENERAL REQUIREMENTS...............................................................................................5
8 AUTHORIZED WORKER LOCKOUT/TAGOUT PROCESS...........................................6
8.1 AUTHORIZED WORKER LOCKOUT/TAGOUT APPLICATION............................................................7
8.2 ABNORMAL LOCK CUTTING AND REMOVAL..................................................................................8
9 CO LOCKOUT/TAGOUT PROCESS...................................................................................8
9.1 ENERGY CONTROL PREPARATION................................................................................................8
9.2 CO LOCKS AND TAGS APPLICATION..............................................................................................9
10 AFFECTED WORKER LOCKOUT/TAGOUT PROCESS..............................................10
11 TRAINING...............................................................................................................................11
11.1 AFFECTED WORKER.....................................................................................................................11
11.2 AUTHORIZED WORKER.................................................................................................................11
11.3 CONTROLLING ORGANIZATION LOCKOUT/TAGOUT ADMINISTRATOR........................................12
11.4 REFRESHER TRAINING.................................................................................................................12
12 ATTACHMENTS....................................................................................................................12

Ref : 1414-HSE-PRO-009-00 Lockout & tagout Practice Page 3 of 19

 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

1 PURPOSE

This practice establishes the requirements for locking and tagging

equipment and systems to protect personnel, property, and the
environment from events that may be caused by the unexpected release
of hazardous energy or materials, the unexpected startup of machines or
equipment, or the unexpected release of stored energy.

2 SCOPE

This practice includes the following major sections:

 LOTO application flow chart
 Principles of Lockout/Tag out
 General Requirements
 Authorized Worker Lockout/Tag out Process
 Controlling Organization Lockout/Tag out Process
 Affected worker lockout/tag out process
 Training:

 Affected Worker
 Authorized Worker
 Controlling Organization Lockout/Tag out Administrator
 Refresher Training

3 APPLICATION

This practice applies to work activities and employees under the control of
EPC contractor of IBRI Ⅱ 500MW Solar PV Independent Power Project
and its subcontractors. The “this project” will stand for “IBRI Ⅱ 500MW
Solar PV Independent Power Project” in the following.

4 DEFINITIONS

Affected Worker – A person whose job requires him or her to be in an area

where equipment or system(s) have been de-energized under the lockout/tag

1
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

out program. The affected worker cannot perform work under a lockout/tag
out.
Authorized Worker – A person who locks out and tags out machines,
equipment, or systems to perform servicing or maintenance on that machine
or equipment. This person must have completed the mandatory training to
qualify as an authorized worker. Only an authorized worker installs and
removes his or her own lock(s) and “Danger-Do not operate Tag(s)” as
required by this program.
Boundary – The safe limits of a given lockout/tag out as determined by those
components that are configured to provide a safe condition where the work is
to be performed.
Controlling Organization (CO) – The organization or individual responsible
for the implementation and documentation of the lockout/tag out process,
including identifying the hazards, controlling the boundaries, understanding
the impacts, and directing the authorized workers. The designated controlling
organization may be a contractor responsible to install a system or equipment;
the facility owner or manger; or the construction management contractor. The
Project/Site Manager designates which organization(s) or individual(s) acts as
the CO.
Controlling Organization Lockout/Tag out Administrator – The CO trained
worker who is responsible to perform the duties of the controlling organization.
These duties include performing the technical review, providing approvals,
completing appropriate documentation, and installing/removing tags.
Danger – Do Not Operate Tag: The tag that is used by the controlling
organization, authorized workers and affected workers to set the boundaries
for the purpose of hazardous energy control. No work may be performed
under this tag unless an Authorized Worker Danger Tag has also been
installed.
Energy Source – Any source of hazardous energy or materials. Sources
include electrical, mechanical, hydraulic, pneumatic, chemical, radiation, and
thermal energies; as well as various forms of potential energy such as that
stored in springs, compressed gases, or in suspended objects (gravitational).

2
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

Isolating Device – A device that prevents the transmission or release of

hazardous energy or hazardous materials. Examples include restraint blocks,
electrical circuit breakers, disconnect switches, slide gates, slip blinds, or line
valves. For lockout / tag out purposes, isolating devices that provide visible
indication of the device's position are desirable.
Lock box – A device that is capable of being locked in which the key(s) for
the energy control boundary lock(s) is stored.
Lock(s) – A device that requires a key to operate (not a combination lock)
and holds an isolating device in the required position for the protection of
employees. The lock(s) used for control of hazardous energy must be single-
keyed and singularly identified by color, shape, or size. This lock(s) shall be
the only device used for controlling hazardous energy and shall not be used
for other purposes.
Lockout Device – A device that utilizes a positive means such as a lock, key
type to hold an energy-isolating device in the safe position and prevent the
energizing of a machine or equipment. Blank flanges and bolted slip blinds
are Included.
LOTO Control Board - A key& lock-controlled board that contains the Master
Control Hasp, documentation of all project keys and their locks in the process
of hazardous energy control.
Lockout/Tag out – Installation of lock(s) and tag(s) on the isolating device(s)
to ensure that work can be performed safely. The lock(s) and tag(s) ensure
that the isolating device(s) and the equipment or system(s) they isolate or
control cannot be operated until the lock(s) and tag(s) are removed.
Safe Condition Check – The inspection or test of a system or component
performed by the controlling organization, authorized worker and affected
workers to ensure that the hazardous energy or materials are controlled
adequately to prevent injury or accident.

5 LOTO APPLICATION FLOW CHART

Based on the nature of the system, the complexity of the work, complexity
of the system, number and types of the energy sources, number of
authorized workers, and the duration of the work project, the application of
LOTO on different projects may vary from one to another, the following
LOTO application flow chart is a general process for reference:

3
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

6 PRINCIPLES OF LOCKOUT/TAGOUT

The following 14 principles provide the fundamental basis for successful

employee protection while performing hazardous energy control/lock out-
tag out:
 Each authorized worker will/may install his/her personal lock(s) and
Danger Tag(s) before starting work and will remove them when
completing that work assignment. The personal lock and Authorized
Worker Danger Tag signify that an authorized worker is working on a
component.

4
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

 The Authorized Worker Danger Tag is for the exclusive use of the
authorized worker identified on that Danger Tag. Information on the
tag must include the following:

 Name and telephone number of the authorized worker

who installed the Danger Tag (use permanent ink).
 Name and telephone number of the authorized worker’s
supervisor.
 Name of the authorized worker’s organization.
 A safe-condition check is always required. ( Lock, Tag, Test and Try)
 No one will remove a lockout or tag out device when an unsafe
condition exists until that condition has been made safe or another
lockout device has been installed. No one will operate any equipment
on which a lockout / tag out device is installed.
 No authorized worker will install a lock/tag on any system without
notifying the controlling organization, unless the work control system
specifically addresses this issue. This is to ensure the controlling
organization knows the status of its equipment/systems.
 Only single-keyed locks are authorized for lockout.
 The authorized worker will maintain control of the key(s) for any
lock(s) he/she applies.
 Locks and Authorized Worker Danger Tags can only be removed by
the worker who originally installed them. When the authorized worker
is not on site, the device(s) may be removed under the direction of the
authorized worker’s management after all reasonable efforts have
been taken to reach the worker. A phone conversation with the
original authorized worker is considered adequate when documented.
 When an Authorized Worker Danger Tag(s) used in a radiological or
hazardous chemical control zone cannot be released, it must be
destroyed or defaced to prevent reuse and disposed of in accordance
with appropriate disposal procedures.
 Any employee required to work on any system with hazardous energy
sources will receive hazard energy control training.
 Compliance with this hazardous energy control program and its
requirements is mandatory. To maintain consistency, use only the
Danger - Do Not Operate Tag (Attachment 01).

5
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

 Tags used for hazardous energy control will not be used for any other
purpose.

7 GENERAL REQUIREMENTS

Prior to starting work, operations involving hazardous energy control will

be assessed by using the JSA form or equivalent. The JSA and the other
equivalent are required for this and other Life Critical operations to ensure
that all hazards associated with the work are identified, the likelihood and
severity are understood, and control measures are defined that will
effectively reduce the risk.
Workers will identify and control all hazardous energy sources and stored
hazardous energy before commencing work on a system/equipment.
Work on energized systems/equipment is prohibited except in
circumstance where such work must be performed “live” e.g.
testing/troubleshooting.
Each employer may supply uniquely identified locks and associated
hardware for use by their authorized workers. The locks may be issued on
a permanent basis or on an as needed basis.
If an isolating device has the physical capability of being locked out, it will
be locked out and an Authorized Worker Danger Tag installed with each
lock. If the isolating device cannot be physically locked out, it will be
tagged out.
If an isolating device cannot be locked, then protection equivalent to that
provided by locks must be established and a tag(s) will be used to ensure
that the equivalent protection is maintained.
Safe condition checks will be performed by the authorized worker before
commencing work on the system/component.
Pieces of equipment will not be removed from their installed location with
locks or tags attached. If a locked/tagged component must be removed
(such as during demolition, replacement, or rework), then reset or readjust
the isolation boundaries so that any locks and tags may be properly
cleared from the component that is to be removed.
Locks that are used for control of hazardous energy will be single-keyed
and singularly identified by color, shape, or size; these locks will not be
used for any other purpose.

6
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

Lockout devices will be used that are substantial enough to prevent

removal without excessive force (bolt cutters) or unusual techniques
(metal cutting tools).

8 AUTHORIZED WORKER LOCKOUT/TAGOUT PROCESS

The method described below will be used to achieve authorized worker

lockout/tagout. The controlling organization will determine the method of
application depending on factors such as complexity of the work,
complexity of the system, number and types of the energy sources,
number of authorized workers, and the duration of the work project.
Authorized Worker Danger Tag(s) and lock(s) will be applied in one of the
following two ways:
 Using as a management lock/tag of the controlling organization’s lock
and tag.
 Using as a personal operation lock/tag of a machine-specific or
system energy control process (ECP).
The detail authorized worker lockout and tag out application process
refers to section 5.0 of this practice.

8.1 Authorized Worker Lockout/Tagout Application

The authorized worker will perform the following in the process of

hazardous energy controlling (LOTO):
 Develop the hazardous energy control plan or method statement
 Conducted relevant job safety analysis
 Develop energy controlling process drawings if necessary
 Develop the work emergency response plan or take proper
emergency response preparation measure
 Prepare the LOTO permit to work (PTW) and its attachments.
 Submit the LOTO PTW for internal and CO for approval.
 Prepare for the hazardous energy system for the oncoming isolation.
 Cooperation with CO and affected worker/workers to assess and
confirm the isolation devices, locks and tags, task related method,
hazards, precautions etc.
7
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

 Install Authorized Worker Danger Tag(s) and lock(s) on each energy-

isolating device for the component to be worked on after that the
LOTO PTW is approved by the CO administrator.
 Perform safe condition checks. Personally check that no hazardous
energy exists as follows:
 Before starting work on machines or equipment that have been locked
or tagged out, verify the isolation and deenergization of all energy-
isolating devices for the machine or equipment involved in the work
scope.
 Perform or witness a field walkdown on the identified boundary each
time an Authorized Worker Danger Tag is hung, to ensure proper
isolation specific to the equipment, machinery, or process undergoing
servicing or maintenance.
 Perform the assigned work.
 Prepare for the hazardous energy system recovery after the
completion of assigned work, and then apply lock and tag removal
from CO.
 Cooperate with CO and affected workers to assess and confirm the
system recovery preparation.
 Remove their Authorized Worker Danger Tag(s) and lock(s) after the
approval from CO.
 Close the LOTO PTW.

8.2 Abnormal Lock Cutting and Removal

In the event it becomes necessary to remove an authorized worker’s lock

or tag, due to his/her absence from the project site, this lock cutting and
removal process must be strictly adhered to the below requirement:
 The device(s) may be removed under the direction of the
authorized worker’s management after all reasonable efforts to
reach the worker have been taken. A phone conversation with the
original authorized worker is considered adequate when
documented.

8
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

9 CO LOCKOUT/TAGOUT PROCESS

The controlling organization will ensure that locks and Danger – Do Not
Operate Tags or Authorized Worker Danger Tags are used for personal
safety when employees are performing maintenance, service,
commissioning, repair, construction, or demolition on a hazardous energy
system.

9.1 Energy Control Preparation

9.1.1 Lock and Tag Logbook

The controlling organization shall maintain a lock and tag logbook to

provide summary information about lockouts and tag outs. This
information, as a minimum, includes a Tag out Index.
9.1.2 Lockout and Tag out Logbook

The controlling organization shall maintain a lockout and tag out logbook
to supervise and monitor the status of the project hazardous energy
controlling (LOTO) activities.
9.1.3 LOTO Equipment

The employer or designated CO shall prepare the project standard LOTO

equipment which will be used in the process of hazardous energy control,
the LOTO equipment include but not limit to the following:
 Locks
 Tags (Danger - Do Not Operate Tag)
 Lock boxes
 LOTO Control Board
 LOTO scissors
 Other necessary lockout devices
9.1.4 Lock Boxes

Lock boxes are an option that can be used for single or multiple isolation
points to simplify lockout/tagout or to reduce the hazards of applying lock
and tag. The principle of lock box use is the security of the lock key(s) and
control of the key(s) by the authorized worker. The most practical location

9
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

for the lock box is at the job site. This allows the authorized worker to
easily confirm the integrity of their lockout/tagout.
Typical situations where lock boxes may be used include the following:
 Multiple isolation points: Apply lock(s) and Danger – Do Not Operate
Tag(s) to the isolation points and place the key(s) in the lock box. All
authorized workers who are intended to work on the system(s) apply
their Authorized Worker Danger Tags and lock(s) to the lock box.
 If the isolation point may not support or accept multiple locks/tags.
 If the isolation points are in an area of radiation, chemical, or other
hazards, use the lock box to keep the authorized workers from being
exposed to the hazard.
 In areas of poor or restricted access (such as confined space), one
person enters to perform lockout/tagout and places the key(s) in the
lock box located adjacent to the hazardous area.

9.2 CO locks and tags application

The detail CO lockout and tag out application process refers to section 5.0
of this practice.
The controlling organization and the controlling organization administrator
will perform the following in the process of hazardous energy controlling:
 Determine the method of LOTO application according to the factors
such as complexity of the work, complexity of the system, number and
types of the energy sources, number of authorized workers, and the
duration of the work project.
 Review the LOTO PTW and its attachments (method statements,
JSA, drawing etc.) which are submitted by authorized worker to
ensure the isolating boundaries have been properly identified,
documented, and verified through the use of accepted as-built
drawings, specific written procedures, or routine walk-downs and are
included as a part of each specific work package instructions.
 Evaluate the impact of the isolating boundaries with respect to work
scope, employee safety, facility operability, configuration control,
public and environmental protection, and compliance with safety
requirements of the system.

10
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

 Inform the affected worker about the oncoming lockout and tag out of
the energy system.
 Organize the CO administrator, authorized worker and affected
worker to conduct joint site energy system isolation devices
confirmation and site safety assessment.
 Approve the LOTO PTW submitted by authorized worker
 Install the CO administrator system management locks and tags
 Confirm the effectiveness of the isolation jointly with authorized
worker and affected worker.
 Record the LOTO task on the LOTO logbook
 Monitor and supervise the authorized worker’s maintenance, service,
commissioning, repairing, construction, or demolition activities.
 Organize the CO administrator, authorized worker and affected
worker to conduct the joint site safety review and assessment after
receiving the locks and tags removal application.
 Remove the locks and tags, recover the energy system if the safety
status is confirmed by the joint site review team.
 Close the LOTO task on the LOTO logbook
 Close the LOTO PTW

10 AFFECTED WORKER LOCKOUT/TAGOUT PROCESS

The detail affected worker lockout and tag out application process refers
to section 5.0 of this practice.
The affected worker will perform the following in the process of hazardous
energy controlling:
 Attend the joint site isolation devices review, confirmation, and
safety assessment which are organized by the CO before the
implementation of LOTO.
 Help to conduct the subsystem influence analysis which will be
created by the oncoming system isolation, and subsystem is
under his control.
 Prepare subsystem for the oncoming isolation

11
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

 Install the affected worker’s lock and tag when it is necessary, and
it is decided by CO administrator.
 Attend the joint site safety review and assessment after the
completion of authorized worker’s maintenance, service,
commissioning, repairing, construction, or demolition work.
 Prepare for the subsystem which will be affected by the oncoming
system recovery.
 Remove the affected worker lock and tag under the instruction of
CO administrator.

11 TRAINING

11.1 Affected Worker

Lockout/tagout orientation for affected workers includes the following

elements:
 Instruction on the definition of an affected Worker and Authorized
Worker.
 Instruction that the installation and removal of a lock and tag is
conducted only with proper authorization as required by this practice
 Instruction on limitations of tag out
 Discussion of the disciplinary actions that may result from violation of
requirements specified in this practice

11.2 Authorized Worker

Lockout/tagout training for authorized workers includes the following

elements:
 All elements in the affected worker orientation
 The Hazardous Energy Control program as described in this practice
 Limitations of just “tagging out” a component
 Methods for recognizing types and magnitude of hazards existing in
their work area
 Means to control and isolate these hazards

12
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

 Proper performance to determine the safety of the area where the

work is to be performed, as identified in this practice

11.3 Controlling Organization Lockout/Tagout Administrator

Lockout/tagout training for controlling organization lockout/tagout

administrator includes the following:
 All elements in the affected worker orientation
 All elements in the authorized worker training
 Application of this practice
 Facility systems, controls, and configuration processes appropriate to
the work involving the lockout/tagout

11.4 Refresher Training

Employees required to be trained by the provisions of this practice

must be retrained or pass a challenge test annually. Employees will
be provided appropriate retraining whenever there is a significant
change in work assignment, a new hazard is identified, or there is a
revision to this practice.
12 ATTACHMENTS
Attachment Attachment Title
No.
Attachment 01 Danger tag
Attachment 02 Lockout and Tagout log

Attachment 01

13
 Lockout & Tagout Practice

Project : IBRI II Solar PV Independent

Power Project

DANGER TAG

FRONT BACK

14
1414-HSE-PRO-009-00 LOCKOUT&TAGOUT PRACTICE

Attachment 02
LOTO Logbook

LOTO
NO. LOTO job description Applied by Approved by validity status date remarks
team

15