GE Energy

LOTO
PROGRAM

2013 - Rev1
CONTENT
1. Objectives
2. Applicable reference documentation
3. Definitions and responsibilities
4. Preparation of LOTO process on site
5. Specific LOTO areas
6. LOTO process
7. Obligations
8. Authorized material
9. Manual of ‘Permit To Work in LOTO Area’
 Objectives and
applicable reference
documentation
1 – OBJECTIVES OF LOTO PROGRAM
This program was designed to prevent injuries and damages caused by energization,
unexpected start-up or release of hazardous energy during all the steps of a project
(construction, pre-commissioning, commissioning or maintenance).

All works on energized systems have to follow GE LOTO Program.

2 – APPLICABLE REFERENCE
DOCUMENTATION
GE LOTO Procedures: GE Energy – Construction EHS Plan – Module 7 Rev.2
 Definitions
&
Responsibilities
3 – DEFINITIONS ET RESPONSIBILITIES
3.1 – Remind of some definitions and rules of LOTO Program
(cf. GE Energy - Construction EHS PLAN – Module 7 – Rev2 / 2. Definitions)

 LOTO ( Lockout / Tagout):

The placement of a lockout device and associated tags on an energy isolating device in accordance with an
established procedure for ensuring that the equipment being controlled by the energy isolating device, cannot be
operated until the lockout device and associated tags are removed.

 HRA : High Risk Areas: Areas where potentially energy exists

HRA are areas where potentially electric, gas, fuel, water or other energy can create high risks.

 HRA Safety Signs:

A visual alerting device in the form of a sign, label, decal, placard or other marking that advises the observer of the
nature and degree of the potential hazard(s) that can cause injury or death in the area, or that identifies the area as
requiring application of LOTO permit.

 Turnover process (TOP):

Documented procedure for a formal handover of equipment, area or circuits from the responsibility of construction
to commissioning. Equipment that is ‘turned over’ is typically ready to be energized, and would have LOTO
applied at the turnover, to prevent unplanned energization.
 3.1 – Remind of some definitions and rules of LOTO Program
(cf. GE Energy - Construction EHS PLAN – Module 7 – Rev2 / 2. Definitions)
 Energization
Connection to an energy supply or containing residual or stored energy.

 Dissipation
The process of removing stored energy from a machine, equipment, process or circuit. The energy source steadily
declines to a zero value after the energy source has been shut off and locked.

 De-energization
Physical isolation from all energy sources and not containing residual or stored energy. A zero energy state is
verified as existing.

 Energy Isolating Device

A mechanical device that physically prevents the transmission or release of energy, including, but not limited to,
the following: a manually operated electrical circuit breaker, a disconnect switch, a manually operated switch by
which the conductors of a circuit can be disconnected from all ungrounded supply conductors and, in addition, no
pole can be operated independently, a line valve, a block and any similar device used to block or isolate energy.
A device that utilizes a positive means, such as a lock, to hold an energy isolating system in a safe position and
prevent the equipment from being energized.
Energy isolating devices also include blank flanges and bolted slip blinds. The authorized employee applying the
device will have exclusive control of the device.
NOTE: Locks and multiple lock adapters are Lockout Devices, not Energy Isolating Devices
WARNING: The term does not include a push button, selector switch, and other devices.
3 – DEFINITIONS ET RESPONSIBILITIES
3.2 – Roles and responsibilities
(cf. GE Energy - Construction EHS PLAN – Module 7 – Rev2 / 3. Responsabilities)

 Site Manager

Has overall responsibility for site safety within GE Scope of the project, and for all GE/contractor personnel on site
Will order stoppage of any work performed in an unsafe manner
Will order corrective actions for any unsafe condition
Approved roles and responsibilities
Will order the review and issuance of revised LOTO procedures.
Will assign the responsibility for weekly LOTO inspections of the LOTO log and procedures.

 EHS Manager

Checks and/or validates Risk Assessment

Makes sure that specific work permit associated are correctly full filled and signed (hot work, confined space…)
Updates and communicates safety LOTO documentation (plan, notifications, safety signs…)
Makes sure that all safety rules concerned by LOTO Program are respected
Performs a general weekly LOTO inspection with LOTO Administrator
 Commissioning Manager

Shall be responsible for:

 Establishing and implementing the LOTO program
 The periodic review and revision of the LOTO procedures as required
 Training site personnel and contract employees in the rules and regulations contained within these procedures
 Conducting periodic inspections of the LOTO log and reporting to the Site Manager the results
 Authorization of locking out system or remove lockout devices. He is responsible of the keys management
He will order stoppage of any work performed in an unsafe manner.
He shall be knowledgeable in all plant systems, and trained in the practice of LOTO.
He is responsible for authorization of all LOTOs.
He shall be the central focal point for the coordination of all work and test activities, during plant commissioning.
He may also act as a System Authorized Employee for those plant systems that he is responsible.

 System Authorized Employee

(Other name: Lead Commissioning Engineer…)

He shall be knowledgeable in the specific plant systems that they have responsibility for.
He may physically operate all necessary devices to isolate the equipment or system and attach all locking devices and
tags to the systems and equipments that have been assigned to him .
He Employee is trained in the practice of LOTO. The System Authorized Employee shall ensure that all Affected
Employees are notified of activities within their respective areas or on equipment under their scope of control/operation.
He can be the LOTO officer.
 LOTO Officer

Shall be responsible of the 6 steps of LOTO Program. He can be:

- The Commissioning Manager
- The System Authorized Employee
- The Lead Authorized Employee
- The LOTO Administrator
- An Authorized Employee
…only if he has completed all trainings required for LOTO Program and if he has the written authorization
from the commissioning manager.

 LOTO Administrator

He shall be responsible for maintenance of LOTO documentation including, the Logbook, the LOTO index, active and
inactive LOTO Work Permit. He shall monitor active LOTOs for compliance with the procedure.
He received all LOTO Program Trainings.

 LOTO Trainer

He shall create and develop specific LOTO training template under control of Commissioning Manager.
He shall train Affected, Authorized, Lead Authorized, System authorized workers to the site specificities.
He updates training files.
 Lead Authorized Employee

Shall be responsible for:

 Preparing interventions that have to be done
 Asking the work permits associated to these interventions
 Overseeing or leading a group of workers (authorized employees or affected workers)
He is trained in the practice of LOTO for a group of person. He is authorized to remove LOTO Work Permit.

 Authorized Employee

He is trained in the practice of LOTO.

He is an employee who performs tasks assigned to him on equipment under the supervision of a Lead Authorized
Person.

 Affected Employee

An Affected Employee is an employee whose job requires him/her to be in an area where work is being performed
under LOTO. Any site personnel who even work in the general vicinity of equipment or systems under LOTO must be
trained as an Affected Employee.

LOTO Organization Site LOTO

Chart responsibilities sheet
Preparation of LOTO
process on site
4 – PREPARATION OF LOTO PROCESS ON
SITE
4.1 – Steps to follow before pre-commissioning and commissioning:
1. Specific site LOTO protocol must be completed, validated, communicated, posted and joined in
annexe of the LOTO program (Appendix A).
2. All companies which are impacted shall approve and sign the LOTO Program (Appendix B).
3. The Permit to Work in LOTO area must be validated by GE and operational (Appendix C).
4. The responsible persons are designated and validated. They know their role and their
responsibilities and approve it (Appendix D).
5. High risk areas must be located on site map which is posted and clearly visible by all concerned
persons.
6. All systems under LOTO must be indicated on site (tag, safety signs…)
7. All systems under LOTO must be the subject of a “Turn Over declaration” signed by both
construction team and commissioning team (Appendix E).
8. All material used for Lock out program must be listed and in accordance with GE standards.
9. The LOTO log book is prepared and operational (daily posted and signed by both the
Commissioning Manager and the GE EHS Manager in the GE meeting room). (Appendix F).
10. The weekly inspection check list must be validated and operational (Appendix G).
11. A toolbox talk is animated for all persons susceptible to work in the HRA.
12. The persons concerned by LOTO procedure have to follow a specific training (Appendix H).
4.2 - APPLICABLE REFERENCE DOCUMENTATION

Reference
Step Appendix Documentation Link

1 A LOTO Protocol

2 B Acceptance of LOTO Program

3 C Permit to Work in LOTO Area

4 D Designation of LOTO Responsibilities

7 E Turn over Declaration

9 F LOTO log book

10 G Weekly LOTO Inspection Check List

12 H LOTO Training register

ALL requested document are available and updated.

Specific LOTO Areas
5 – SPECIFIC LOTO AREAS

 High risks areas have to be clearly communicated to all people on site.

This communication is done by:
 the Turnover declaration,
 specific site map with all concerned areas,
 the identification on site of all equipment and areas concerned,
 flash information distributed and posted.

 The Turnover declaration is required.

It must be communicated at least 7 days before to :
 Site Manager,
 EHS Manager,
 Commissioning Manager,
 All companies on site.
Acknowledgment forms are followed and archived in order to be sure that all received the information.
 Each high risk area is identified on site (signs on each door isolation of each areas…).

 A site map that identifies all high risk areas is updated and posted.

Example: this site map carte represents all high risk areas.
All these areas including forbidden areas and dangers associated are
clearly identified with pictograms.
If an area is not defined as “high risk area”, no LOTO procedure are
required.
If change, a daily update of this plan is done with a written
acknowledgment signed by GE (Commissioning Manager and EHS
Manager)

 Tool-box and Flash information are communicated to all persons on site.

 Each entry of a person in high risk area requires a LOTO work permit.
All implicated persons in a LOTO work permit are named and their trainings/certifications verified.
Support function persons (quality, EHS…) who want an access to all areas are named by the Site Manager after
completing all required trainings.
LOTO Process
 Tasks 1 Task planning with risk assessment
+ Risk assessment associated by Lead authorized employee (GE
supervisor) and the performer.
1
2 If the task is located in specific high risk
Task must be LOTO area, a request of LOTO work permit is
realized in specific high risk
LOTO area ? done by the Lead authorized employee.

NO YES 3 The Lead authorized employee fills the part

2 « Permit Request  » and joins the concerned
Request of work risk assessment (JSA), work permits and
Construction work permit others associated documents. Then he
authorization and/or LOTO
communicates all these documents to EHS
3 Manager.
Description of work, operator, date…
4 & 5 The EHS Manager identifies the co-
activity problems, analyses and validates the
4
Co-activity indentification all documents (JSA, work permits…). Then he
transfers all the documents signed to the
LOTO administrator.
5 Analysis and validation of JSA documents,
permits… 6 LOTO Administrator updates the LogBook.
He shall ensure that all identified companies,
Update of which can be impacted by the tasks, know
LOGBOOK
6 Approval / Refusal of activity what tasks will be done with a written form.
Preparation of LOTO Then he transfers to Commissioning Manager
and to System Authorized Employee the
permit for approval/refusal of activities and
definition of LOTO devices if required.
 7 If wok request is refused, the work is
forbidden. The request returns to the LOTO
Wait Administrator who updates the LogBook and
for validation REFUSED
close the permit.
APPROVED 7
Update of 8 If work authorization is approved and work
WITH LOTO LOGBOOK
doesn’t need to lock out equipment, the work is
No work possible after the Lead authorized employee
9 received the work authorization (go to step 12).
9 If authorization is approved and work needs to
1/ Shutting down planning lockout some equipments, work will be
10 possible when lockout devices asked on permit
2/ Shut down equipment are applied (LOTO officer) and the Lead
authorized employee received a copy of the
3/ Isolate equipment 8 validated work permit .
4/ Apply LOTO devices APPROVED 10 6 steps of LOTO (LOTO Officer)
WITHOUT Verification of lockout devices (LOTO Officer2
5/ Control of stored energy LOTO or System authorized employee)
6/ Verify zero energy Update of The LOTO LogBook is updated including the
LOGBOOK
number of padlock and the concerned locked
system (LOTO Administrator)
Verification of lockout devices 11 The work can start, LOTO Administrator
communicates the LOTO permit to the Lead
Authorized Employee who signs it.
Update of
LOGBOOK
Work is possible
11
 During the work:
 Repartition of Permit to Work and associated copies:
 LOTO Administrator keeps imperatively the original
 The copy 1 is for the Lead Authorized Employee 1
Current work
 The copy 2 is for the Lead Authorized Employee 2 (team working)
 Other copies can be given to EHS and Commissioning departments
Attention : The original, the copy 1 and the copy 2 are required to close the permit.

 Date and hour of the closure of permit must be strictly respected.

IMPORTANT !!!
 On activity location:
 Work permit and risk assessment are available and directly accessible.

 If activity happens with different teams (day/night):

 Each Lead Authorized Employee has to get his permit from the LOTO
Administrator, and signs in the correct part (day/night).
 He must have the copy of permit associated to his team (day/night).
 The lead Authorized Employee 2 (night) cannot work with the permit of team 1
(day) and conversely.
 12 When work is finished, the Lead Authorized Employee
shall indicate the work completion in the section 4 of
« Permit to Work in LOTO area ». In case of day and
Work completed night shift, both Lead Authorized Employees shall
indicate the end of work for their own team.
12 The original, the copy 1 and the copy 2 have to be
Update of imperatively grouped.
Fill authorization and
LOGBOOK
return Signatures for the work completion declaration have to be on
the three documents..
13
The LOTO Administrator updates the LogBook and
transfers it to Commissioning Manager and the System
Removal of all padlocks Authorized Employee in order to authorize removing
and tags lock and tag. If locks doesn’t exist, go to step 16 directly.
14
13 The System Authorized Employee/Commissioning
Manager control that work is completed and all work
teams have validated the work completion. Then they
Inspection before
authorize to remove locks and tags.
re-energization
15 14 The LOTO Officer removes all lockout devices
(including padlocks and tags).
Update of 15 The LOTO Officer inspects and control system before
End of Permit to work in LOGBOOK re-energization, then transfers to LOTO Administrator.
LOTO area
16 The LOTO Administrator close the permit and
16
updates the LogBook (permit and padlocks)

• Weekly LOTO/EHS inspection will be done during the pre-comissioning and the commissioning.
Obligations
7 – Obligations
A One only key per padlock. A padlock refers to one permit only.
B One tag per padlock indicating the lock number, the permit number, the reference of
equipment locked, its lock position (open/closed) and the name of the System Authorized
Employee.
C Copies of “LOTO work permit” and risk assessment are directly available in the concerned
work places and the original is in the LOTO Administrator office.
D All parts of the permit are correctly and clearly fulfilled and all requirements are respected.
E The “LOTO work permit” are required for all activities which take place in high risk area
(energy…). The oral instructions are forbidden (lock and tag, remove padlock and tag,
startup…)
F The presence of employees and the equipments are checked/controlled after the work
completion. The work completion confirmation on permit is signed by all concerned
employee and all copies have to be transferred to the LOTO Administrator before the
authorization of removing padlock and tags.
G Traceability of LOTO work permit and padlocks including their location on equipment.
(Logbook is permanently updated)
H If LOTO Program can’t be applied, works can’t be authorized. EHS and Commissioning
department must be informed as soon as possible in order to find and validate an
alternative.
Authorized material
&
Keys management
8.1 – Authorized Material
Usual LOTO material Specific material

Tags in accordance with GE Padlock with an only key

requirements MATERIAL associated with a number MATERIAL

HASP

Breakers
LockBox
 8.2 – Keys management
 LOTO keys are always under supervision.
The Commissioning Manager has the final responsibility of the keys.

 Once the Padlocks are placed on site, the associated keys are immediately placed in LockBox that is in
accordance with GE requirements.

 Once LockBoxes returned to the office:

 Either LockBoxes are given to the Commissioning Manager or the keys of LockBoxes (in that
case be careful of traceability in LogBook)

 Or the padlock keys are given to Commissioning Manager who stores them in a specific LOTO
cabinet. The Commissioning Manager is the only person who has the only key of this LOTO
cabinet (possibly his deputy can have the key in case of team working (day/night)).

It is STRICTLY forbidden for anybody (including LOTO Officer, System Authorized Employee
and Commissioning Manager) to move with keys which are not in a LockBox in accordance with
GE requirements.
Presentation of Permit to
Work in LOTO Area
9 – Presentation of work permit g Permit to Work
in LOTO Are a
Site :
Unit :
for Work
for Te st

 Date / Time :
Expiry date of the permit Number

Permit Re que st

Date / Time : Estima ted duration : Compa nies : Nb of workers :

Lea d Authorized Employee (Name ) JSA N°:

Exe cution responsible (Name )

Form divised in 4 parts System / Equipe me nt De scription of work to be carrierd out

Ide ntification of dange rs Pe rmit approval

Fluid No Yes : Pre ssure No Yes : 0 EHS Manage r Approval

Heading Voltage
Fire
No
No
Yes :
Yes :
Chimical No
Mechanica l No
Yes :
Yes :
Initials + Visa

Explosion No Yes : Other No Yes : JSA Valide  Ye s - n°  YES - n°

Pe rmits
Confined S.  Yes - n°  Yes - n°
Identification of companies impacte d by work
Hot Work  Yes - n°  Yes - n°
Repre sentant of
Impa cte d : 1 Approval for be ginning the LOTO process
Compa ny the company Function Visa
YES / NO
(name) LOTO re quire d  YES  NON
Commissioning
Initia ls Date /Time Visa
Ma nage r

Permit request If your activity is impacted, ple ase list all the what lockout device s are
require d
S ys te m
Autho rize d
Em plo ye e
Initia ls Date /Time Visa

De tails of lockout de vices and intructions 2 LOTO applied by LOTO Officer

N° Ide ntification Condition/state Padlock N°
LOTO Officer 1 Initia ls Date /Time Visa
LOTO Officer 2
(in c ha rge o f Initia ls Date /Time Visa
c he c k)
3 Permit reception by Lead Authorized Employee

Da te / Time
Identification of dangers
Coactivity Nom / Initials

Lockout devices Visa

4 Work completion de claration

Da te / heure

Nom / Initiales

Visa

Permit approval 5 Removal of LOTO de vice s authorization

Commissioning
Initia ls Date /Time Visa
Ma nage r
S ys te m
Autho rize d Initia ls Date /Time Visa
Em plo ye e
6 Re moval of LOTO de vice s done by LOTO Officer

LOTO Officer Initia ls Date /Time Visa

7 Closure of permit by LOTO Administrator

Initia ls Da te / Time Visa

 Heading

g Pe rmit to Work
in LOTO Are a
Site :
Unit :
for Work
for Te st
 Expiry date of the pe rmit
 Date / Time :
Number

Time and date of the permit

Site name closure defined by the
Indicate which part of the Commissioning Manager or
plant is involved (ex: TG 1, possibly by LOTO
Bat . Elec ….) Administrator or EHS Manager

Number of permit defined

Indicate if the permit is for
by LOTO Administrator in
work or for test
accordance with LogBook
 To be completed by Lead Authorized Employee
Permit request
Risk assessment and associated work permits and are enclosed to this permit
(Confined Space, Hot Work…), a map can be added to locate the intervention
Permit Request

Da te / Time : Estima te d duration : Companie s : Nb of worke rs :

Le ad Authorize d Employe e (Name ) JSA N°:

Execution re sponsible (Name)

System / Equipe ment De scription of work to be carrierd out

Fill date and time of permit request (not the beginning of work)
Fill the foreseeable duration of work
Fill the name of companies and the number of workers who will carry out the task concerned by this permit

Indicate the name of Lead Authorized person of each team (day and night)
Indicate the name of the execution responsible (usually the subcontractor supervisor) of each team.

Indicate the number of JSA ‘Job Safety assessment” (risk assessment) associated to the work.

Indicate the system and/or the equipment impacted or that can impact on the work to be performed.
Describe shortly and clearly what work will be performed.
 Identification of dangers To be filled by the Commissioning
Coactivity
Lockout devices Manager and the System Identification of dangers

Authorized Employee Fluid

Voltage
No
No
Yes :
Yes :
Pre ssure
Chimical No
No Yes :
Yes :
Fire No Yes : Me cha nical No Yes :
Explosion No Yes : Othe r No Yes :
Before validating the permit, the Commissioning Manager and the Identification of companies impacted by work
System Authorized Employee shall identify all dangers associated to Represe ntant of
Impacted :
Company the company Function Visa
equipment or system involved by the work; (name)
YES / NO

If several companies are responsible of equipment or system, they have to If your activity is impacted, please list all the what lockout devices are
indicate if they will be impacted by the work associated to this permit. required
Details of lockout devices and intructions
Otherwise, the companies have to lock and tag or give instructions so that
N° Ide ntifica tion Condition/state Padlock N°
the wok can be performed safely.
Remind: The oral instructions are forbidden. They have to be
communicated following the LOTO Process.

The Commissioning Manager and the System Authorized Employee shall

identify the lockout device required and define the associated padlocks.
The padlocks are given by the LOTO Officer to System Authorized
Employee or the Commissioning Manager (depending of the Site LOTO
Program).
 Pe rmit approval

Permit approval 0 EHS Manage r Approval

Initia ls + Visa

JSA Valide  Ye s - n°  YES - n°

P e r m it s
0/ The EHS managers of each team verify the validation of risk assessment and Confine d S.  Ye s - n°  Ye s - n°
work permits associated, then they give their approval for their respective team. Hot Work  Ye s - n°  Ye s - n°
1 Approval for be ginning the LOTO proce ss

1/ The commissioning Manager and the System Authorized Employee indicate if LOTO re quire d  YES  NON
lockouts devices are required, define them (cf previous page), then authorize the Commissioning
Initia ls Da te / Time Visa
Ma na ge r
activation of LOTO to LOTO Officer and the start of work; S ys te m
Autho rize d Initia ls Da te / Time Visa
Em plo ye e
2/ The LOTO Officer locks out systems and equipments indicated by the System 2 LOTO applie d by LOTO Office r
Authorized Employee and the Commissioning Manager. LOTO Office r 1 Initia ls Da te / Time Visa
An other LOTO Officer check if lockout and tag are correctly installed. LOTO Office r 2
(in c ha rge o f Initia ls Da te / Time Visa
c he c k)
3/ When the 3 previous parts of the LOTO Permit are validated, the Lead Authorized 3 Pe rmit re ce ption by Le ad Authorize d Employe e

Employee can get the copy of work permit associated to his team. Da te / Time

Nom / Initia ls
4/ When work has been completed, each Lead Authorized Employee indicates it on
the permit and signs the declaration of work completion associated to his team. Visa

4 Work comple tion de claration

5/ The Commissioning Manager and the System Authorized Employee check if all Da te / he ure
Lead Authorized Employees have declared the work completion they were
responsible and authorize the removal of all concerned lockout devices. Nom / Initia le s

Visa
6/ The LOTO Officer removes all lockout devices and validates it on the permit.
5 Re moval of LOTO de vice s authorization
Commissioning
Initia ls Da te / Time Visa
7/ The LOTO Administrator closes the permit. Ma na ge r
S ys te m
Autho rize d Initia ls Da te / Time Visa
Em plo ye e
6 Re moval of LOTO de vice s done by LOTO Office r

LOTO Office r Initia ls Da te / Time Visa

7 Closure of pe rmit by LOTO Administrator

Initia ls Da te / Time Visa

THE ONLY RESPONSIBLE OF
YOUR SAFETY : YOU !
Be aware
of DANGERS and RISKS associated
to your job