Isolation, Lockout and Hold Tags: Participant Handbook

Isolation, Lockout
And Hold Tags
PARTICIPANT HANDBOOK
CORPORATE SAFETY TRAINING

Job Skills Curriculum & Testing Unit, PD&QAD
Training & Development
Saudi Aramco — © 2012
This publication is the exclusive property of the Saudi Arabian Oil Company.
Distribution, reproduction, or any use of this material outside of the Company, without the
express written consent of the General Manager,
Training & Development, is strictly prohibited.
Participant Handbook Isolation, Lockout And Hold Tags
ISOLATION, LOCKOUT AND

HOLD TAGS
July 2012 3
Isolation, Lockout And Hold Tags Participant Handbook
INTRODUCTIONS
COURSE OBJECTIVES
At the end of this course you will be able to:

Identify equipment, energy and/or systems
that require the application of L.O.T.O.
Identify and apply the correct isolation
methods to make systems safe before work
can be performed.
Return equipment to operational state for safe
operations
4 July 2012
SAFETY MANAGEMENT SYSTEM (SMS)
World class safety starts with a vision

LP policy is “action plan” to achieve vision
SMS magnifies policy, defines management
system
Points to expected programs, safety work
processes, standards, GI’s 6.012
To produce desired safe work behaviors and
results
The Saudi Aramco Safety Management System (SMS) includes a comprehensive

plan for maintaining a safe and healthful work environment. The system includes a
vision to be the recognized industry leader in safety. The telescope model depicts
segments of the system which work together to achieve the vision. Remember, a
system is all of the activities put together to carry out a higher goal – like world class
safety.
Loss Prevention policy states that “Saudi Aramco will conduct its business in a
manner which prevents incidents or accidents which cause loss of life, bodily injury
or illness, or damage to assets or the environment.” Lock-out and Hold Tags
procedures support workplace safety by enabling equipment to be maintained and
serviced without suddenly or inadvertently becoming energized.
SMS plan elements state that Saudi Aramco will “Evaluate, identify and eliminate or
manage safety risks prior to beginning any operation or activity and continue to
review such risks, complying with all applicable laws and regulations.” Lock-out and
Hold Tag procedures are designed to _____________ and _____________ the
risks of servicing energized equipment.
Loss Prevention also addresses safety training. Saudi Aramco will “Train employees
and provide resources to maintain job competencies, including loss prevention
responsibility and accountability.” Your training today is part of the vision to maintain
your safety and the safety of individuals that work with you.
You have a part to play in the SMS vision and making the vision a success. You
need to follow Lock-out and Hold Tag procedures and all safety procedures to
protect yourself, your coworkers, contractors, and the community and company
assets. The SMS achieves its vision when all workers make safety a top priority.
July 2012 5
NEED FOR LOCK-OUT TAG-OUT
As you can see from the bar graph, a high percentage of injuries are classified as
mechanical in nature. The Lock-out and Hold Tags procedure, also called
_____________ or _____________ , describes procedures which make mechanical
service and repair jobs safe.
L.O.T.O. programs describe how to de-energize and isolate equipment and systems
for maintenance and service. Energy isolation is required to ensure that a piece of
equipment does not become energized during repair. For example, L.O.T.O.
prevents a pump from becoming suddenly energized during repairs thereby
protecting the electrician or maintenance worker from electric shock.
6 July 2012
NEED FOR LOCK-OUT TAG-OUT
L.O.T.O. is designed for the protection of workers,

when maintenance work is performed on equipment.
Needed to prevent unexpected or uncontrolled
energizing of systems
G.I. 6.012, Isolation, Lock-out and Use of Hold
Tags governs L.O.T.O.
Over time all installed equipment will require maintenance and servicing. This work
is normally done by a maintenance crew. Operators need to hand over the
equipment in a safe condition for service work to be performed. This means shutting
down the equipment and removing all sources of energy. L.O.T.O. procedures
describe how to safely accomplish and ensure continued safe conditions for
maintenance and service work.
G.I. 6.012, Isolation, Lock-out and Use of Hold Tags, requires that operations or
controlling organizations develop isolation, lock, and hold tag procedures for their
operations and equipment. Specific L.O.T.O. procedures must be developed for any
energized equipment or processes and incorporated into departmental Operating
Instruction Manuals (OIM's).
G.I. 6.012 also states that each department that uses a lock-out and hold tag
procedure must train personnel in all elements of the program. Operations and
maintenance organizations are required to provide necessary lock-out equipment to
employees.
Operations personnel need to work as a team with the maintenance and service
crews for work to be accomplished safely.
July 2012 7
WATCH OUT!
The Occupational Health and Safety Administration (OSHA) is a division of the

Department of Labor in the United States Federal government. OSHA develops
standards for workplace safety and health including L.O.T.O. standards.
OSHA estimates that Control of Hazardous Energy procedures prevent 120 fatalities
and 50,000 injuries annually.
L.O.T.O. programs can also significantly cut operating costs by minimizing lost time
and insurance costs. Businesses can maintain equipment safely to save on
operating costs.
L.O.T.O. programs can also improve productivity by minimizing equipment downtime

during maintenance.
8 July 2012
FIVE FATAL FAILURES
Failure to …
Stop equipment
Disconnect from power source
Remove residual energy
Prevent unexpected re-starting
Clear area before re-starting
To successfully implement a L.O.T.O. procedure you must follow all of the details of
the procedure. You must be thorough and follow set procedures and ensure that all
risks are identified and controlled.
There are five fatal failures that are the main causes of injuries related to failing to
lock-out and tag-out correctly:
Failure to stop equipment.

Failure to disconnect from power source.
Failure to remove residual energy.
Failure to prevent unexpected re-starting.
Failure to clear area before re-starting.
July 2012 9
Isolation, Lockout And Hold Tags
10 July 2012
ACTIVITY 1
In the previous slide the five fatal failures associated with Lock-out and Tag-out was
discussed. Recall these and write the five fatal failures below.
10
July 2012 11
12 July 2012
LOCK-OUT & TAG-OUT DEFINITIONS
Energy control program

Lock-out Tag-out
Authorized employees
Affected employees
Other employees
11
Important L.O.T.O. terms and their definitions are listed below.
Energy control program. All procedures, including L.O.T.O. programs, which are
established and implemented to prevent unexpected energizing, startup or release
of stored energy during maintenance or service on equipment. Key elements of an
energy control program are written procedures, employee training, and periodic
inspections.
Lock-out. The placement of a lock on an energy isolating device ensuring that the
isolator and the equipment being controlled cannot be operated until the lock-out
device is removed.
Tag-out. The placement of a tag on an energy isolating device to indicate

equipment being controlled must not be operated. Tags provide essential
information about the lock-out such as the reason for the lock-out. When a tag is
attached to an energy isolating means, it is not to be removed without the
permission of the authorized person responsible for the tag. Tags are never to be
bypassed, ignored, or otherwise defeated.
Authorized employee. An authorized employee is a person who has been trained

in L.O.T.O. and has official permission to lock-out and tag-out equipment as part of
a L.O.T.O. procedure. Authorized employees are trained in the recognition of
applicable hazardous energy sources, the type and level of energy available in the
workplace, and methods of energy isolation and control.
Affected employee. An affected employee is one whose job requires the operation
or use of a machine or equipment on which servicing or maintenance is being
performed, or someone who works in the area and is impacted by such servicing or
maintenance. Affected employees must be instructed in the purpose and logistics of
the energy control procedure.
Other employees are workers whose work operations are near or adjacent to where
energy control procedures are to be implemented. These workers must be
instructed about the procedure, and trained not to restart or re-energize machines or
equipment that are locked and tagged out.
July 2012 13
ISOLATION
Isolation is the process of:

Removing the possibility of an unexpected start up
of equipment or machines
Eliminating all stored energy
Isolation is dependent on:
The nature of the energy
The specific work to be conducted
The equipment and configuration
12
Isolation as part of a L.O.T.O. procedure means to de-energize and render

inoperative by cutting off energy to the machine or equipment. De-energizing can
include releasing stored energy to the equipment. For example, to completely de-
energize a compressed air line, after you lock-out and tag-out the switch to the
compressor you may have to bleed residual air still pressurizing the line.
Isolation is ensured, and inadvertent re-energizing is made impossible, by applying a

lock to energy source controllers such as switches. Tags are applied to
communicate information about the L.O.T.O. in progress.
After a lock-out, attempts are made to operate the locked switches to verify that they
are inoperative. Other tests and measurements may be taken to make sure that
complete de-energizing has been achieved.
_____________ procedures generally include the following steps:
1. Identify the energy source.

2. De-energize equipment.
3. Lock-out and Tag the energy controllers (switches, valves, circuit
breakers etc.).
4. Verify that the equipment is isolated.
14 July 2012
WHEN TO ISOLATE
13
Equipment isolation, as part of a L.O.T.O. program, must be completed and

_____________ before a work permit can be issued. The work permit issuer must
physically verify the L.O.T.O. and document the verification on the permit.
STEPS TO PERFORM ISOLATION
Identify what needs to be isolated or controlled

Communicate with affected personnel
Turn everything off, specialized PPE may be
required
Remove and dissipate all stored energy
14
Applicable L.O.T.O. procedures in the OIM and G.I. 6.012 must be followed.
L.O.T.O. workers must be comprehensive in their approach to a L.O.T.O. job. All
aspects of the work must be planned and all scenarios considered. L.O.T.O. work is
not a place to take chances or shortcuts.
Preparations include identification of all energy sources to the equipment. All energy
sources, including any secondary power supplies, must be isolated. Applicable
energy controllers are identified and a plan for appropriate locks and tags is
developed. Affected personnel and other personnel are informed about the
L.O.T.O. procedure.
July 2012 15
STEPS TO PERFORM ISOLATION
Apply isolation devices and record on list

Clear area
Verify effectiveness of isolations, try each isolation
point and operate all controls.
Ensure that all equipment isolated cannot be
moved to the “on” or “open” position.
15
Service crafts must apply approved lock-out and tag-out devices. Each person
working on the repairs should apply his own unique lock. Operations will list the
types of isolation devices and places where the isolation devices have been
installed. Operations will ensure that isolation points are tagged and that tags are
completed correctly.
All sources of energy must be removed and dissipated. This may include releasing
the tension on springs, blocking, blinding or blanking pipe lines, releasing hydraulic
and pneumatic systems, bleeding lines, and opening valves.
Prior to L.O.T.O. verification tests, non-essential personnel and equipment must be

cleared from the area. Tests are then run on each energy isolation device to ensure
that the equipment is locked out.
L.O.T.O. - OPEN AND SHUT CASE
16
16 July 2012
ENERGY THAT REQUIRES ISOLATION
Machinery/equipment under repair, service or

maintenance work that contains energy/substances that
requires L.O.T.O.
Electrical
Mechanical
Steam
Hydraulic
Pneumatic
Chemical
17
At Saudi Aramco many types of equipment and energy sources are controlled with a
L.O.T.O. program. Energy sources include electricity, steam, hydraulic power,
pneumatic power, chemical energy, and mechanical power. The type of equipment
and energy sources determine many aspects of a L.O.T.O. procedure such as the
type of locks, type of tags, and energy dissipation procedures.
EQUIPMENT ISOLATION
Examples of equipment that requires L.O.T.O.

Pipe lines
Electrical breakers
Pumps
Motors
Compressors
Vessels & Tanks
Confined spaces
Hydraulic presses
18
The type of equipment and energy sources determine many aspects of a L.O.T.O.
procedure. For example, a valve on a fluid line can be securely locked out with a
suitable _________ and _________ through the hand wheel to prevent the wheel
from being turned.
July 2012 17
18 July 2012
ACTIVITY 2
Discuss the types of energy that you are familiar with in your workplaces that would
require L.O.T.O. and list them below.
19
July 2012 19
STEPS TO SUCCESSFUL L.O.T.O.
20
L.O.T.O. procedures must be performed by an authorized person. Under all

circumstances the authorized person must follow the L.O.T.O. procedure in G.I.
6.012 or the OIM.
Prepare Shutdown. Prepare for shutdown means to plan the details of the
L.O.T.O. project and consider all possible impacts of the procedure on equipment
and personnel in the area.
Isolate. Isolation means to cut off energy to the machine or equipment. All
applicable energy isolating devices must be located and used to isolate the machine
or equipment. Equipment must be shut down using established procedures to avoid
any additional or increased hazards to affected employees as a result of the
equipment stoppage. For example, prior to shutting down a cooling water pump for
an A.C. plant, the standby pump may have to be checked and started to maintain
cooling capability.
Apply Lock. Lock and tag devices must be affixed to each energy isolating device
by an authorized person. Lock-out devices must be affixed in a manner that will
hold the energy isolating devices in a "safe" or "OFF" position. After the energy
isolating devices have been locked and tagged out, all potentially hazardous stored
or residual energy must be relieved, disconnected, restrained, or otherwise rendered
safe.
Tag. A tag (Saudi Aramco Form 525) must be installed on each lock indicating plant
number or location, equipment name, badge number, organization, contact phone,
signature of the individual who installed the lock, and the reason for the lock.
Clear. Clear means to remove all unnecessary personnel and equipment from the
area in preparation for a test of the lock-out. This is done to avoid injury to
personnel or damage to equipment in the event that the lock-out was unsuccessful
and the equipment energizes creating a hazardous situation.
Try. Try means to verify the isolation of the equipment by operating all controls on
the equipment to make sure the equipment cannot be started. All applicable energy
disconnect points must be tested and verified as locked out.
20 July 2012
L.O.T.O. REMOVAL PROCEDURE
21
Lock removal and re-energizing can create safety risks that must be identified and
eliminated or controlled. Re-energizing of equipment procedures must be performed
by an Authorized Person. Under all circumstances the authorized person must
follow the L.O.T.O. procedure in G.I. 6.012 or the OIM.
Step 1 - Restore the Work Area. Authorized personnel must make sure that
serviced equipment has been returned to a functional condition. This includes
ensuring that panel covers and doors that may have been opened for maintenance
and service are closed correctly. Items such as machine guards and warning signs
are returned to their proper places. Repair items such as tools and equipment are
removed from the area and stowed. Affected personnel must be cleared from the
area.
Step 2 - Notify All Personnel. Affected personnel who must remain in the area
must be notified that the L.O.T.O. is ending and equipment is about to be re-
energized. All non-essential workers must be cleared from the area.
Step 3 - Remove L.O.T.O. Devices. The operations supervisor must make sure
that locks are removed according to procedure. Under almost all circumstances, the
worker who placed a lock must be the worker who removes the lock. This lock and
tag must not be removed until operations personnel have checked and examined
the equipment to ensure safe re-energizing.
July 2012 21
L.O.T.O. DEVICE REMOVAL
When can L.O.T.O. devices be removed?

When the job is complete
When the L.O.T.O. device owner permanently
leaves the job
Operations shall always be the first to install and
the last to remove L.O.T.O. devices
Supervisors shall verify that the equipment is safe
to power back up.
Shift changes
22
When a craftsman completes his work, or leaves the job site permanently, his tags
and lock-out devices must be removed. The craft foreman or supervisor shall advise
the operations supervisor that the craftsman has completed his work and is
removing his locks and tags. Locks and tags must not be removed until operations
personnel have checked and examined equipment to ensure the equipment can be
safely energized. The requirements for shift changes can be found in the
"ISOLATION, LOCKOUT AND USE OF HOLD TAGS, GI 6.012."
NORMAL L.O.T.O. DEVICE REMOVAL
Ensure that all isolation devices have been

removed in proper sequence
Communicate with all affected
personnel/departments
Inspect the L.O.T.O.locations to confirm the work
is complete
Confirm all L.O.T.O. devices have been removed
Follow normal or appropriate start up procedures
23
The removal of ___________ devices must be done according to established

procedure and in the proper sequence to make sure the job is done safely. L.O.T.O.
procedures will often require locks to be removed following a specific sequence.
Operations supervision must ensure that service work is complete and the area is
restored before re-energizing.
22 July 2012
EMERGENCY L.O.T.O. DEVICE REMOVAL
Requirements for emergency removal of L.O.T.O. devices

The shift superintendent:
May remove the lock(s) and tag(s) confirming it is
safe to do so.
Advise the operations division superintendent
Record removal of lock-out device in the
operations log book
Document incident in a written memo to
Operations Division Superintendent
24
Suppose a craftsman places a lock and becomes unavailable to remove the lock
(perhaps he has a seizure or medical emergency). A need to remove a lock on an
emergency basis, such as when the person who placed the lock is unavailable, calls
for a high level authorization. Sometimes, under extreme circumstances, the lock
must be cut off or forcefully removed due to an unavailable key.
Permission from the lock owner's superintendent or the operations shift

superintendent is required when a lock will be removed by someone other than the
worker who placed the lock. The operations shift superintendent will attempt to
contact the individual who installed the lock, or his supervisor, to confirm that the
work is complete and that the lock can be removed.
If the individual, his supervisor, or superintendent cannot be contacted, the shift

superintendent may remove the lock(s) and tag(s) only after reviewing the
equipment or process to be energized, to ensure that personnel and equipment are
safe from injury or damage.
The shift superintendent must verbally advise the operations division superintendent
of the action taken and record the removal of the lock-out device in the operations
log book. He must then document the incident in a written memo to the operations
division superintendent stating why the lock-out device was removed, the original
purpose of the lock-out device, and names of workers involved.
July 2012 23
LOCK/HOLD TAG
26
The purpose of a _____________ _____________ is to record and document

information about the L.O.T.O. work in process. Hold tags should be legible and
attached in a conspicuous location near the lock. The large hole on the tag is to
hang the tag on a padlock.
The following information must be clearly recorded on the hold tag:
Date and time

Equipment location and plant number
Equipment name and number
Reason for the tag
Operator name
Organization
Badge number
Telephone number
Signature
Hold tag forms are revised periodically. Be sure to use the most recent revision.
Check the Saudi Aramco number and date on the hold tag before filling it out.
24 July 2012
ACTIVITY 3
Transfer the information below to the tag at the back of your workbook. Check your
tag with the model answer.
Date and time 19/1/2011

Equipment location and plant number Ras Tanura liquid recovery
Equipment name and number Pump Motor G-55
Reason for the tag Maintenance to replace bearing
Operator name Participants name
Organization Participants organization
Badge number Participants badge number
Telephone number Participants phone number
Signature Participants signature
27
July 2012 25
ELECTRICAL ISOLATION
Identify isolation points

Type of isolation devices to be used
Isolate equipment
Lock and tag at point of isolation
Clear work area of equipment and personnel
Try to start - switch(es) of equipment to verify
isolation
De-energize equipment
Ensure that it contains no residual energy
29
An electrical L.O.T.O. job requires the identification of all applicable isolation

devices. This requires methodical consideration of the electrical energy sources and
circuitry to the equipment that is scheduled for service. Common electrical isolation
points include switches and electrical swithgear. Some switches have a built-in
feature to hold a lock for L.O.T.O. purposes.
ELECTRICAL 'EQUIPMENT' ISOLATION
If lock-out or chain & lock is not possible

Remove fuses
Disconnect electrical cables
Physically remove a component
NOTE: These methods are not as secure as L.O.T.O.
30
Sometimes an electrical switch cannot easily be locked out, simply because of the
design of the switch. For example, a pushbutton switch may be used to start a
motor. By design, a pushbutton leaves little possibility for the application of a lock.
When application of a lock is not possible, procedures will permit alternatives for
achieving electrical isolation. Alternatives include removing electrical components
such as fuses and circuit breakers, and disconnecting electrical wires that supply
power.
The physical removal of a component of the system supplying energy to the

equipment. The point of physical interruption shall be identified with a fully
completed _____ _____.
26 July 2012
MECHANICAL ISOLATION
Removal of pressurized fluid and/or gas from

system
Locking or closing valves
Use of blinds
Physical removal of piping
31
In mechanical systems, consideration must be given for the different types of energy
sources, for example hydraulic, pneumatic, stored/potential, steam.
An extreme form of piping isolation is to physically remove a section of the pipe.
PIPING & EQUIPMENT ISOLATION
Four primary methods for isolating process pipe

lines and equipment
Single block valve
Double block and bleed
Disconnecting piping
Blinding
Method of isolation is determined by the
task to be performed
32
In Saudi Aramco there are four primary methods used for isolating process pipe
lines and equipment.
Single block valve

Double block and bleed
Disconnection of piping
Blinding
The method is determined by the task to be performed, for example for “confined
space entry” only blinding or ______________ is acceptable to do this work safely.
July 2012 27
PIPING & EQUIPMENT ISOLATION - OPERATIONS
Single block valves

Fully close the valve
Attach chain, lock, and tag
Safely drain fluid from pipe line
Test the valve for leakage
Not a preferred method in Hydrocarbon
service
33
Single block valves are often used as a minimum isolation procedure for certain
routine maintenance operations where no open flame work is required. Examples
include changing a gauge or sock filters. The block valve is fully closed, locked with
a chain and padlock and tagged. The fluid shall be removed from the system safely
and the valve shall be tested for leakage before work begins. Single block valves
are not a desirable method for lock-out of hydrocarbon service.
28 July 2012
Double block and bleed

Lock and tag the two consecutive valves on
the same line, Open drain valve, Check for
passing
Not acceptable as isolation method for
confined spaces
34
Double block and bleed is achieved by _________ and __________ of two

consecutive valves on the same line with a drain valve installed between them that
can be opened as a drain to determine if the locked valves are passing.
While superior to a single locked and tagged valve situation for open flame work or
long-term construction or maintenance activity, a double block and bleed setup may
not always guarantee total isolation and safety. For example, the bleed valve may
be plugged or cannot handle the flow or pressure that may be passing through the
upstream valve.
Also, flammable or toxic gases or liquids potentially vented through the bleed valve
can present a safety hazard especially for nearby hot work. Certain fluids may need
to be securely piped or hosed away to a safe location. Other work in the area may
have to be suspended if flammable or toxic gas is vented nearby.
Double block and bleed isolation is considered unacceptable for confined space
entry jobs.
July 2012 29
Disconnect
If a fully rated blind cannot be used
Drain and purge the line
Check for hazardous materials leak
Long term maintenance method
35
A less frequent method of isolation for long term maintenance activities. The act of
dropping out a spool piece to form a physical disconnect in the piping, often
because the piping design will not allow the insertion of a fully rated blind. Steps
shall be taken to ensure no hazardous materials can leak or be discharged from the
open ends of piping, e.g. Blind flanging.
This isolation technique requires steps to prevent hazardous materials from leaking
or being discharged from the open ends of the pipe. The open ends of the pipe are
often sealed by blind flanging and tagged.
It is often not possible to physically disconnect piping and insert a fully-rated blind.
This method is seldom used for routine maintenance and is mostly utilized for long
term maintenance activities.
30 July 2012
Blind
Solid metal plate between two pipe flanges or on
the end of a disconnected pipe
Blinds must be rated for potential internal
pressures
Three important criteria the are size, rating and
location
36
Before starting an isolation using blinds, a procedure and sketch showing blinding
locations for each piece of equipment requiring more than two isolation blinds must
be made. The blinding procedure must include precautions to complete the work
safely such as: proper line entry, lock and tag locations, blind rating, location and
size of blind, etc.
A blind is a solid metal plate that is inserted between two flanges or at the end of a
disconnected section of pipe. Blinds must be the appropriate size and pressure
rating for a successful isolation.
Blinds manufactured in a factory are normally stamped with a pressure rating and
are preferred over facility built (fabricated) blinds. Facility built (fabricated) blinds
may be used after approval by engineering inspection for service and rating and the
results must be documented.
July 2012 31
Blind
Individually identify blinds on list
Protect blind mating surfaces
Only use matching gaskets
Blinds are the only acceptable method for confined
space entry
37
A _____________ _____________ must be prepared when blinds are used to

isolate equipment. The list is kept to track important information including blind
number, date of installation, location, blind rating, installer name, date of removal,
and remover name.
In addition to a blind list, a procedure and sketch showing blinding locations for each
piece of equipment is made. The blinding procedure must include precautions to
complete the work safely such as proper line entry, lock and tag locations, blind
ratings, and blind locations and sizes.
Blinding or disconnection are the only acceptable methods of equipment isolation for
entry into confined spaces.
Blind installation requires an appropriate matching gasket to ensure effective

isolation when all stud bolts are in place and properly tensioned. Slip blinds must be
equipped with a tail or T-handle drilled with a hole to attach a tag. Blinds must be
properly stored to protect mating surfaces when not in use.
32 July 2012
BLIND SELECTION
Based on hazards due to

Temperature
Pressure
Flammability
Reactivity
Corrosion
Toxicity of materials and cleaning/purging agents
38
Blinds are designed and manufactured based on the intended service and use.
Begin blind selection by considering the hazards that may exist or develop to include
temperature, pressure, flammability, reactivity, corrosivity or toxicity of material in
the piping and reactions that could occur with cleaning or purging agents, as well as
any physical hazards.
Blinds must be selected carefully to ensure that they are appropriate for the isolation
job.
July 2012 33
APPLICATION OF LOCKS AND TAGS
40
L.O.T.O. procedures apply to all situations where unexpected energizing or startup

of machines or equipment is possible during servicing and maintenance. Since
equipment must be regularly maintained and serviced throughout Saudi Aramco,
L.O.T.O. procedures are critical to employee safety.
For example, routine maintenance of a pump requires a maintenance worker to

remove the pump from service and deliver the pump to a repair shop location. If the
pump suddenly became energized during the removal procedure the worker could
be exposed to electric shock and probably injured hands from impact wounds and
fluid flow. The safest way to prepare to remove a pump from service is to lock and
tag-out all energy sources prior to maintenance tasks.
There are exceptions to the application of L.O.T.O. procedures. Due to the nature
of our industry it can be necessary, for example, for an electrician to work on a live
electrical circuit. It may also be necessary for certain service work to be performed
on fluid lines where shutdown is impractical. In such cases, extra precautions must
be taken and written procedures and special equipment must be used which will
provide complete protection for employees.
Another exception to L.O.T.O. procedures involves simple plug and cord equipment.
Minor adjustments such as changing the speed of a drill or changing a saw blade
are permissible as long as the plug is under control of the user. A carpenter can
perform routine maintenance such as changing a blade without a lock-out and tag as
long as he has full control over the plug. Still, the carpenter could ensure isolation
by using a mechanical device that fits over the plug which prevents insertion into a
wall socket, thus locking the saw out.
34 July 2012
ISOLATE CONFINED SPACE
Prevent flammable, toxic, irritating, or oxygen

displacing gases and vapors from entering the space
Utilize blinding, disconnection, or removal
Purge dead-space between isolation and confined
space
Check for interconnected equipment
Confirm adequate lock-out or tag-out
41
Maintenance or service work in a confined space presents a unique set of

_____________. Confined space entry procedures apply and require many
safeguards including gas testing and standby attendants. L.O.T.O. procedures also
apply and are critical to a safe working environment.
Blinding with pipe disconnection is a preferred method for isolating fluids to a

confined space such as a tank or vessel. Pipelines between the confined space and
the first valve, blank or associated equipment may contain material or hazardous
contaminants and must be cleaned or purged. Inter-connected equipment, vessels
or machinery must be evaluated as energy sources that need to be isolated.
Drains, vents or piping left open must be checked and evaluated for potential
reversal of flow. Reverse flow could contaminate a confined space with fumes from
adjacent processing equipment.
July 2012 35
HYDRAULIC EQUIPMENT ISOLATION
Stored energy (Potential energy)

Isolate fluids under pressure
De-energize and relieve pressure
Proper safety supports
Never take a chance
42
_____________ power/energy is a form of stored or potential energy. Hydraulic

energy involves fluids under pressure, sometimes very high pressure. High
pressure fluids present a unique set of hazards and therefore L.O.T.O. procedures
apply.
Like other energy sources, hydraulic energy must be locked out at energy isolation
points (switches). Care must be taken to bleed residual energy (pressure) from
hydraulic lines prior to performing service work. Hydraulic lines can remain
pressurized even with the power sources locked out and switches locked open.
Stored hydraulic energy can cause unexpected movement. A hydraulic line can
break and spray flammable liquid, resulting in fires and explosions. If a line fails or is
disconnected while under pressure, machine components can drop down and cause
injury due to hose failure or accidental movement of operating levers or removal of
incorrect hoses.
For example, consider a fork truck with the forks raised. Even with an ignition in the
off position and a disconnected battery, the hydraulic lines are under great pressure.
It is unsafe to work on the hydraulic lines without bleeding off this residual energy. It
is unsafe to work near or underneath the raised forks as this mechanism can
36 July 2012
GROUP L.O.T.O.
43
L.O.T.O. jobs often require multiple crafts to be involved in the service work. A
single authorized employee must coordinate the lock-out and ensure related job site
safety. A group lock box can be utilized when several crafts are involved in a service
or maintenance job.
The group lock box helps to ensure that energy sources cannot be restored until all
workers have completed their tasks and retreated from the hazardous area. This is
accomplished by locking the key to a main switch into the group box, which is
secured by the lock of each craftsman. Only when each craftsman removes his lock
from the group box can the key to a main shutoff lock be accessed.
When a group of service workers represent a single craft such as electricians, a

single lock can represent the entire trade group. The lock should be place by a
group leader, usually a foreman or supervisor.
CONTRACTORS AND L.O.T.O.
Working with Contractors

Must adhere to L.O.T.O.
Must follow Saudi Aramco procedure
Must follow the ARAMCO G I 6.012
44
Contractors and other outside servicing personnel that perform tasks covered by
L.O.T.O. must adhere to the Saudi Aramco General Instruction 6.012, as stated in
schedule ‘D’ of their contract with Saudi Aramco.
Sub-contractors also must follow Saudi Aramco L.O.T.O. procedures. Contractors

are responsible for ensuring that sub-contractors under their contract follow Saudi
Aramco L.O.T.O. procedures.
July 2012 37
RESPONSIBILITIES - SAUDI ARAMCO
Department Managers
Division Heads
Supervisors
Employees
45
Department managers, division heads and supervisors are responsible for ensuring
compliance with General Instruction 6.012, Isolation, Lock-out and Use of Hold
Tags.
Employees, contractors and subcontractors must follow all L.O.T.O. procedures as

necessary to perform their jobs.
38 July 2012
ACTIVITY 4
In this activity, you must search for information that is required to identify and
correctly list the responsibilities of operations, maintenance and maintenance crew
in your workbook. You are encouraged to discuss this with your fellow participants
and record these responsibilities in your workbook. (Ask the Instructor for a copy of
the GI. 6.012 for use in class.)
46
July 2012 39
RESPONSIBILITIES - OPERATIONS
Develop program or adopts GI 6.012

Develop program procedures
Identify isolating locations
Identify types of isolating devices
47
Operations or controlling organizations have the responsibilities of developing

isolation, lock, and hold tag procedures for their operations or adopting GI 6.012
instruction as written if it will satisfy their lock and hold tag requirements.
Alternatively operations can develop their own L.O.T.O. procedures specific for their
area and equipment.
For example, operations are responsible for developing specific isolation, lock and
hold tag procedures for any complex equipment or processes and incorporate these
procedures into departmental Operating Instruction Manuals (OIM's).
Operations is responsible for identifying isolating locations and types of isolating

devices required for a L.O.T.O. job, and installing the locks and tags.
40 July 2012
RESPONSIBILITIES - OPERATIONS & MAINTENANCE
Implement lock-out procedures (GI 6.012)

Provide L.O.T.O. training
Provide lock-out equipment
Verify lock-out
48
Operations and maintenance organizations that are responsible for implementing

General Instruction 6.012 must train affected personnel on L.O.T.O. These groups
must also provide the equipment for L.O.T.O. work.
Operations also has the responsibility for verifying lock-out before maintenance work
can begin. Each organization issuing locks shall have a system of uniquely
identifying locks. Acceptable methods include color coding, stamping or engraving
locks appropriately. Each lock shall be keyed separately, with no duplicate key, to
ensure removal only by the authorized user.
Verification tests are conducted by operations on each isolating device and on each
piece of locked out equipment. Operations can include other affected parties in
verification tests including equipment operators and maintenance and service
supervisors.
Each isolating device, such as a switch, must be physically tested by moving its
operating mechanism against the padlock, multiple lock-out clip, or chain, to confirm
that it cannot be operated.
July 2012 41
RESPONSIBILITIES - MAINTENANCE CREW
Verify isolation
Multiple or group-lock-out
Leave worksite
Temporarily
Shift change and the work is incomplete
Job completed
49
Verify isolation - Each isolating device, such as a disconnected switch, shall be

physically tested by moving its operating mechanism against the padlock, multiple
lock-out clip, or chain, to confirm that it cannot be operated.
A _____________ lock box can be utilized when several crafts are involved in a
service or maintenance job. When implemented correctly a group lock-out will
afford each craft protection while avoiding the need for large numbers of locks and
tags at isolation points. A sample group lock-out procedure follows:
An operations representative shall lock and tag each isolation point with single
keyed locks as per written isolation procedure.
The maintenance Supervisor/Foreman shall also lock and tag the isolation
points with single keyed locks.
The maintenance Supervisor/Foreman's key(s) to these locks are placed in a
Group Lock-out box.
Multiple lock clips (hasps) are then attached on the closed group lock-out box.
The operations representative shall place his lock and tag on the box/hasp first
and maintain possession of his key(s) until job is complete.
Each member of the maintenance crew shall then place his lock and tag on the
multiple lock clip and maintain possession of his key(s) until job is complete.
If a craftsman leaves the job-site temporarily but intends to return to complete work,
his locks and tags may be left installed provided this is acceptable to the controlling
organizations. Operations may require craft locks and tags to be removed. Upon his
return to work, the worker shall verify his locks and tags are still in place ensuring
the equipment is still isolated prior to restarting his work.
When a shift change occurs, the operations supervisor shall review locations and
placement of isolated equipment, locks and tags. These operations tags and locks
may be left installed and do not require endorsement at each shift change. Keys to
locks shall be transferred at the time the review is made.
At craft shift change the oncoming shift has two options. Crafts can remove and
hang new locks or simply transfer keys to existing locks.
Crafts can install their own locks and tags at locations where the
42 July 2012
previous shift had them; in which case the off-going shift shall remove
their tags and locks.
Crafts can effect a transfer of keys between shifts. This transfer requires
the craft foremen or supervisors to conduct a detailed review of installed
locks and tags. Craft tags may be endorsed by the oncoming shift or new
tags may be installed.
When a craftsman completes his work, or leaves the job site permanently, his tags
and lock-out devices shall be removed. The craft foreman or supervisor shall advise
the operations supervisor that the craftsman has completed his work and is
removing his locks and tags.
Operations or controlling organizations must always be the first to install a lock and
tag on a piece of equipment and the last to remove them. The operations lock and
tag shall not be removed until operations personnel have checked and examined
equipment to ensure the equipment can be safely energized.
July 2012 43
44 July 2012
ACTIVITY 5
You are required to prepare a procedure for Isolation, Lock-out and use of Hold
Tags (L.O.T.O.) using the form and carry out L.O.T.O. simulation in your groups.
The pump has:

Inlet valve
Outlet valve
Breaker in substation
Start button in field
Can be started from control room console
The local start button will have a hold tag only
Number of locks required and responsibilities:

Electrical Systems Operator (ESO), 1 lock.
Operations Supervisor, 4 locks.
Maintenance Supervisor, 3 locks.
There are two metals mechanics Sunil and Khan they have one lock each.
GM-55A is the motor in this activity.
50
July 2012 45
51
Five commonly observed _____________ lead to incidents. A failed L.O.T.O. job

can have devastating consequences. A machine or piece of equipment under
service should never become unexpectedly energized.
Remember these general steps to a L.O.T.O. procedure:
Stop equipment
Disconnect power source
Make sure that there is no residual energy in the system that can cause injury
Lock the system/equipment out
Tag the system or equipment
Clear the area
Double check on the L.O.T.O. by trying to start the equipment to ensure the
equipment will not start.
Once maintenance work has been completed, conduct proper housekeeping and
clear the area of any unnecessary tools and materials.
46 July 2012
SUMMARY
Need for L.O.T.O.

Definitions
L.O.T.O. procedure(s)
Isolation of Electrical / Mechanical equipment
Responsibilities
Five Fatal Failures
Lock, Tag, Clear and Try
54
OTHER RESOURCES
55
QUESTIONS
56
July 2012 47
Participant Workbook L.O.T.O. in Saudi Aramco
July 2012 A-1

LOTO in Saudi Aramco Participant Workbook
TSU/TAD&AV Print Shop.October 2016.

A-2 July 2012

Isolation, Lockout and Hold Tags: Participant Handbook

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Isolation, Lockout and Hold Tags: Participant Handbook

Uploaded by

Copyright:

Available Formats

Isolation, Lockout

And Hold Tags

CORPORATE SAFETY TRAINING

ISOLATION, LOCKOUT AND

At the end of this course you will be able to:

SAFETY MANAGEMENT SYSTEM (SMS)

World class safety starts with a vision

The Saudi Aramco Safety Management System (SMS) includes a comprehensive

NEED FOR LOCK-OUT TAG-OUT

NEED FOR LOCK-OUT TAG-OUT

L.O.T.O. is designed for the protection of workers,

The Occupational Health and Safety Administration (OSHA) is a division of the

L.O.T.O. programs can also improve productivity by minimizing equipment downtime

FIVE FATAL FAILURES

Failure to stop equipment.

LOCK-OUT & TAG-OUT DEFINITIONS

Energy control program

Important L.O.T.O. terms and their definitions are listed below.

Tag-out. The placement of a tag on an energy isolating device to indicate

Authorized employee. An authorized employee is a person who has been trained

Isolation is the process of:

Isolation as part of a L.O.T.O. procedure means to de-energize and render

Isolation is ensured, and inadvertent re-energizing is made impossible, by applying a

_____________ procedures generally include the following steps:

1. Identify the energy source.

Equipment isolation, as part of a L.O.T.O. program, must be completed and

STEPS TO PERFORM ISOLATION

Identify what needs to be isolated or controlled

STEPS TO PERFORM ISOLATION

Apply isolation devices and record on list

Prior to L.O.T.O. verification tests, non-essential personnel and equipment must be

L.O.T.O. - OPEN AND SHUT CASE

ENERGY THAT REQUIRES ISOLATION

Machinery/equipment under repair, service or

Examples of equipment that requires L.O.T.O.

STEPS TO SUCCESSFUL L.O.T.O.

L.O.T.O. procedures must be performed by an authorized person. Under all

L.O.T.O. REMOVAL PROCEDURE

L.O.T.O. DEVICE REMOVAL

When can L.O.T.O. devices be removed?

NORMAL L.O.T.O. DEVICE REMOVAL

Ensure that all isolation devices have been

The removal of ___________ devices must be done according to established

EMERGENCY L.O.T.O. DEVICE REMOVAL

Requirements for emergency removal of L.O.T.O. devices

Permission from the lock owner's superintendent or the operations shift

If the individual, his supervisor, or superintendent cannot be contacted, the shift

The purpose of a _____________ _____________ is to record and document

The following information must be clearly recorded on the hold tag:

Date and time

Date and time 19/1/2011

Identify isolation points

An electrical L.O.T.O. job requires the identification of all applicable isolation

ELECTRICAL 'EQUIPMENT' ISOLATION

If lock-out or chain & lock is not possible

NOTE: These methods are not as secure as L.O.T.O.

The physical removal of a component of the system supplying energy to the

Removal of pressurized fluid and/or gas from

An extreme form of piping isolation is to physically remove a section of the pipe.

PIPING & EQUIPMENT ISOLATION

Four primary methods for isolating process pipe

Single block valve

PIPING & EQUIPMENT ISOLATION - OPERATIONS

The purpose of a _ _ is to record and document

Double block and bleed is achieved by _ and __ of two

A _ _ must be prepared when blinds are used to