LOTO Training

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Lock Out Tag Out (LOTO) Lockout Tag out Authorized Employees Training

Transcript of LOTO Training

Page 1: LOTO Training

Lock Out Tag Out (LOTO)

Lockout Tag out

Authorized Employees Training

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Why is LOTO important?

• The Lock Out/Tag Out procedure prevents the unexpected start up or release of stored energy that could cause injury to employees by placing a lock and/or warning tag on an energy isolation device.

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LOTO Program Enforcement

• Any employee not using LOTO program• Employees tempering the LOTO lock and

Tag• Removing the LOTO program

Must be brought to the notice of Plant Manager, EHS Manager and HR

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Hazardous Energy SourcesEnergy Type

Description

Mechanical Relating to springs, rotating parts etc, produced by machine

Radiation Energy released from unstable nuclei, nuclear reaction or charged particle acceleration

Magnetic Energy stored in magnetic fields, found in capacitors & superconducting magnetic storage

Gravity Found in machine/equipment parts that might descend, slide or fall if left unblocked

Electrical Present in transmission lines, transformers, circuit breakers or motors- AC or DC

Hydraulic Involving fluid under pressure, in cylinders, pipes & tanks

Pneumatic Involving compressed air or gas, in cylinders, lines or pipes

Thermal Hot or Cold, Heat generated from machine or cooling system (<5°C & >60°C)

Chemical Produced as a result of chemical reaction

Steam Water vapour kept under pressure

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What is LOTO?

LOTO is a technique to prevent the release of hazardous energy during servicing or maintenance

LOTO is performed by physically putting lock & tag at the energy isolation points

LOTO DOES NOT apply to single plug & cord equipment when the equipment is unplugged under the exclusive control of the person performing the work

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Category of Employees under LOTO Program

1) LOTO Authorized Employees Whose job responsibility include servicing and

maintenance on the machine Example: Fitter, Electrician, Technician, plumber etc..

2) Affected employees Employees whose does not require servicing and

maintenance on machine. Example: Passers by, office employees, supervisors ,

employee sitting in the area etc..

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Why LOTO?

• To prevent bodily harm caused by uncontrolled hazardous energy

• To prevent accidental equipment startup• To guarantee that equipment stays shutdown

Personal Barriers- Lack of knowledge, overconfidence, pride, other prioritiesOrganizational Barriers- Production pressure, poor enforcement, lack of LOTO procedures/equipmentsEnvironmental Barriers- Machine design, poor housekeeping

Why some people ignore LOTO Safety

Remember: there are no good reasons for not performing LOTO

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Types of LOTO Locks & Tags

Red Lock & Red Tag

(Individual LOTO lock, AD Employee)

Black Lock & Red Tag with Black Stripes(Group LOTO lock)

Blue Lock & Red Tag

(Individual LOTO lock, AD Contract Person)

Yellow Lock & Yellow Tag with Blue Stripes

(Transition LOTO lock)

Individual LOTO locks have only one key

Red Tag-

AD employee or Contractor employee is actively working on the equipment/machine

Red Tag with Blue Stripes-

Group of persons are actively working on equipment/machine

Yellow Tag with Blue Stripes

Nobody is actively working on the system but the equipment is unsafe to operate (Transition Period)

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EID and Lockout Devices

• The devices which help to lock out and prevent the energization of a machine, equipment or process are called LOTO devices

Plug Box-largePlug Box-small

Hood locking Component

Valve Locking Component

HT Panel Locking Component

Valve Locking Component

Group LOTO Box

Hasp Hood locking Component (small)

MCB locking Component

Chain

Cylinder locking Component (Large)

• Energy isolation devices (EID) is a device which prevents the transmission of energy e.g. MCB, MCCB, ball valve etc.

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Affected and Authorized Persons & Training Requirements

An individual who operates equipment on which maintenance or servicing is being performed under LOTO, or an individual who works in the area where such maintenance or servicing is being performed. This individual is not authorized to perform LOTO.

A person who is having appropriate technical background, has successfully completed this training and given the successful demonstration of practical skills is authorized to perform LOTO

What are the LOTO Training Requirements?

Who is Authorized Person(s) ?

Who is Affected Person(s) ?

Affected Individual Authorized IndividualInitial training Required Required

Required(must be observed and verified by another authorized employee, i.e. "hands on")

Annual refresher trainingRecommended RequiredRequired(must be observed and verified by another authorized employee)

Training Requirements & Frequency

Not applicable

Not applicableAnnual demonstration

Initial demonstration

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Time/Duration of LOTO Lock

• LOTO lock can be used for duration of work or end of shift whichever is shorter.

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Equipment Specific LOTO procedure

A/B/C/D/E

A- Department

B- Room or sub area

C- Equipment ID

D- Energy source

E- LOTO Point ID oP1/GF, B2 lab/ HAO-1/E/LPS-1

Labeling of Energy Isolating Points

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Applying LOTO- Six Step Process

• Plan & Prepare for

shutdown

• Shutdown the Equipment

• Isolate the Equipment

• Apply lockout/tagout

devices

• Control stored energy

• Verify isolation: Zero

Energy

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Step-1 Prepare for shutdown

• Understand the problem– What need to be fixed?– What are the types of hazards involved?– Equipment specific LOTO procedure– Consider downstream effects– Will another piece of equipment be also affected?

• Plan– Are proper tools available?– Are proper technical persons available?– Have all affected employees been informed?

• Prepare– Is the area clear & warning posted?– Is the person performing LOTO ready physically and

mentally?– Have all hazardous energy sources and disconnect points

been located?

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Step-2 Shutdown the Equipment

• Use established procedure

• Involve the worker who normally shuts down

the equipment

• If the work is being performed at customer’s

site, customer should shutdown the equipment

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Step-3 Isolate the Equipment

• Have a qualified person disconnect the

equipment

• Wear appropriate PPE

• Use common isolation techniques – closing

valves, opening electrical disconnects

• While opening electrical disconnect, stand to

one side in the event an electric arc occurs

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Step-4 Apply Lockout Tagout Devices

• Use only approved locks and tags

• Never lend or borrow locks or keys

• Never use LOTO locks & tags for any other

purpose

• Clearly mention the required details on tag

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Step-5 Control stored or Residual Energy

• Mechanical Motion- Stop any motion

• Gravity – Use blocks & pins • Thermal Energy- Allow for heat up

or cool down• Stored Mechanical Energy- block,

tag & lock springs• Stored Electrical Energy- Drain

power from capacitors, release or neutralize potential energy

• Pressure- Bleed pressure carefully and slowly

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Step-6 Verify isolation: zero energy

• Verify that your testing equipments are working properly

• Try to turn the equipment on• Test for voltage• Check gauges• Check double block and bleed• Check temperature with an independent

device• Return to switched OFF after verifying zero

energy• Notify affected person in the area that the

work is to begin

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Release of Lockout Tagout

• Communicate to all affected employee

• Verify the safety of the area

• Ensure that the safety devices &

guards in place

• Return system functions

• Remove your lock & tag

• Communicate the system energization

• Reenergize and test the equipment

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Sl No

Shut Down Procedure Check list YESSl No

Release from Lockout / Tagout Checklist YES

1 2 3 1 2 31 Do the equipment has LOTO procedure? 1 Is the visual verification & personnel count performed

to verify that personnel are clear from equipment/system and any material/tools are removed ?

2 Has the authorized person read the LOTO procedure, understood isolation points location and LOTO verification (Try Out) procedure ?

2 Are all the operational control such as guards / interlocks made operational before release of equipment ?

3 Has the affected personnel been informed that the LOTO will be applied to equipment which belongs to them or located in their vicinity ?.

3 Are the LOTO devices removed from each isolation point ?

4 Has the equipment/system requiring servicing/maintenance released by the owner of equipment?

4 Have the following sequence of activities followed, where the equipment require test ?

Y/NA

5 Has the equipment been shut down using shut down procedure ?

4(a) Clear tools and materials from equipments.

4(b) Clear and notify affected personnel

4(c )Remove the LOTO devices

4(d)

Proceed with the test4(e)

De-energize all systems & relock & retag the controls4(f) Re-verify de-energization by try out4(g)

Proceed with the work9 Is the operating control returned to neutral (OFF)

position after try out.

5

In case of supervisory approach, outside service contractor has been explained all the steps and LOTO is applied on First On Last Off basis

Y/NA

7 Has the equipment /system examined carefully to detect & release, disconnect any stored energy?

Name & Signature of the Authorized person Remarks:

8 TRY OUT - Is the equipment attempted to operate by pressing the start button. Where switches are not provided, other means of verification as per LOTO procedure used for try out.

6 Are LOTO devices applied to the all energy isolation points? (Refer the note overleaf for type of lock and tag required)

Machine/ Equipment: Date:

NOTE- For each servicing & maintenance, use this check list for Lock out & Tag Out. All the questions in column A(3) must have answer -Yes before start working on equipment. Similarly, all questions in column B(3) must have answer Yes except point no. 4 & 5

Cloumn A Column BNOTE- Write against each check point 'Y' for Yes and 'NA' for Not Applicable.

LOTO Check-List

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LOTO ProgramOffice of Design & Construction

Responsibilities• Notify contractors to

bring their LOTO program to preconstruction meeting; and

• Include LOTO as an agenda item & allow contractors & EHS dept. to discuss

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LOTO ProgramSupervisor’s Responsibilities

• Complete equipment specific LOTO procedures;• Conduct annual & periodic inspections;• Keep a list of authorized employees;• Issue LOTO devices to employees;• Ensure all affected employees are properly

trained on LOTO procedures;• Enforce compliance with AD’s LOTO program;

and• Provide employees with copies of the LOTO

Program upon request.

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LOTO ProgramAuthorized Employee Responsibilities

• Attend EHS’s required training;• Follow all LOTO procedures;• Assist supervisor’s in completing

equipment specific LOTO procedures;• Consult supervisors when questions or

concerns arise; and• Notify all affected employees of LOTO

activities.

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LOTO ProgramContractors

• Contractor & on-site employer must exchange LOTO info

• AD employee must place his lock first the contractor employee and remove his lock after contractor employee remove his lock under supervisory approach

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LOTO ProgramEquipment

• Must be singularly identified;

• Must be the ONLY devices for controlling energy; and

• Must NOT be used for any other purposes.

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LOTO ProgramEquipment

• LO devices must be durable & withstand the environment to which they are exposed. TO devices must be constructed & printed so they do not deteriorate or become illegible;

• LO/TO devices must be standardized by color, shape or size;

• LO/TO devices must be substantial enough to prevent early or accidental removal and removal without excessive force.

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LOTO ProgramEquipment

• Lock out will be accomplished using a lock and key. Chains, or other hardware, may be used in conjunction with the lock to isolate the energy source.

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LOTO ProgramEquipment

• One key will be issued to the authorized employee applying the lock.

• Additional keys will should be destroyed

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LOTO ProgramRequired TO Device Information

• Name of authorized employee who locked out equipment;

• Authorized employee’s radio or phone number, including contractors;

• Date and time of lockout; and• Brief description of work being performed.

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LOTO ProgramEquipment

• An approved warning tag will accompany all lockouts. The warning tag will be attached directly to the lockout device by a nylon tie.

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LOTO ProgramEnergy Isolation

• LO & TO energy isolating sources with assigned locks and tags. Usually requires locking out electrical disconnect.

• Be sure to isolate ALL energy sources (secondary as well as primary).

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LOTO ProgramApplication of Devices

• Use valve covers, plug locks, etc. if the lock can’t be placed directly on the energy control.

• When LO is used, every employee in the work crew must attach their personal lock.

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LOTO ProgramApplication of Devices

A TO system alone is not acceptable at any time unless the equipment is not capable of

being locked out. The tag must be placed at the same location

that the lockout device would have been attached, and additional measures must be

taken to ensure the level of safety is equivalent to that obtained by using a lock.

This includes: blocking of a controlling switch, removal of an isolating circuit element,

opening of an extra disconnect device, or removal of a valve handle ONLY.

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LOTO ProgramRelease of Stored Energy

• Inspect the system to make sure all parts have stopped moving.

• Disperse stored energy (springs, hydraulic systems, air, gas, water pressure, or steam).

• If stored energy can build up again, monitor it to make certain it stays below hazardous levels.

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LOTO ProgramVerifying Equipment Isolation

• Make certain all dangerous areas are clear of personnel.

• Verify that the equipment cannot be turned to the “on” position. Press all “start” buttons and activating controls on the equipment.

• Return all controls to the “off” position after certain that LO is effective.

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LOTO ProgramRemoving LOTO Devices/Restoring

Equipment

• Safeguard all employees by making certain everyone is clear of the equipment. Also notify affected employees of impending re-energization.

• Verify that all tools have been removed and all guards reinstalled.

• Remove LOTO devices. Each device must be removed by the person who put it on.

• Energize equipment.

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LOTO ProgramTroubleshooting

• Remove all tools & personnel from the area.

• Notify affected employees of impending re-energization.

• Authorized employees remove the LO device but MUST leave tag in place.

• Energize equipment.• When finished, de-energize & reapply LO

device.

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LOTO Program- Shift Changes• If servicing lasts more than one shift, LOTO

protection CANNOT be interrupted.• The original authorized employee will remove

their lock & the incoming employee will place theirs on the isolating device. If the first employee leaves prior to the replacement’s arrival, first employee must place transition lock to ensure safety and handover transition key to supervisor.

• The incoming authorized employee must place his own personal lock and MUST VERIFY that ALL energy sources are locked out prior to beginning work.

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LOTO ProgramAbandoned Lock Procedure

• Verify authorized employee has left the worksite & notify them that their lock is being removed.

• LOTO devices may ONLY be removed if supervisor is present and committee is formed which authorizes removal.

• After all communication attempts are complete & the equipment has been inspected, energy can be restored.

• An abandoned lock procedure form must be filled out & filed in the Lock Shop.

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LOTO ProgramEquipment Specific Procedures

Procedures must be updated when:• New equipment is installed; or• New energy sources are added to a facility

or individual equipment; or• Magnitude of an energy source changes;

or• Designated isolation points change.

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LOTO ProgramAlternate Procedure

When LOTO can not be applied under certain situation like calibration, trouble shooting etc where power has to be kept on, an alternate method should be adopted:

• Develop list of all activities where LOTO can not be applied.

• Conduct risk assessment and develop a procedure.

• Train employees who will work on machine