This document discusses lockout/tagout (LOTO) procedures for controlling hazardous energy sources. It covers the purpose of LOTO, which is to prevent injuries from unexpected equipment energization. Requirements include written procedures, training, locks/tags, and verifying isolation. Hazardous energy types are electrical, mechanical, chemical, thermal, hydraulic, and pneumatic. The 6-step LOTO procedure is outlined as preparing for shutdown, shutting down equipment, isolating energy sources, placing locks and tags, releasing stored energy, and verifying isolation. Stored energy must be assessed and relieved before work. Only authorized employees who have gone through training can perform LOTO procedures.
2. We shall discuss…
Purpose of Lockout-Tagout
Requirements for LOTO
Types of hazardous Energy
Procedures for LOTO
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3. Purpose of LOTO
To prevent injury to maintenance
and/or servicing employees due to –
unexpected energisation of machine or
equipment,
inadvertent start-up of machine or
equipment, or
release of stored energy.
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4. Requirements for LOTO
Written procedure for LOTO
LOTO training of concerned employees
Lockout hasp (scissors clamp)
Padlocks with keys/locking devices
Tags
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5. Types of Energy
1. Electrical
2. Mechanical
3. Chemical
4. Thermal
5. Hydraulic
6. Pneumatic
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6. Electric shock can kill
As low as 30 volts can carry enough
current to kill a person.
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7. Use Safe Electrical Practices
Use non-conducting tools.
Check circuits are dead before working.
Lock and Tag the source breakers, not switches.
Ensure all control power is de-energized.
Discharge all capacitors after Lockout.
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8. Mechanical Energy Hazards
Two types:
Kinetic – in motion
(Example: A moving shaft)
Potential – stored
(Example: Compressed air)
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9. Kinetic Energy Hazards
Energy of moving machinery
can cause:
– Amputations
– Lacerations
– Fractures
– Loss of life
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10. Potential Energy Hazards
Energy stored in machinery
Weights
Springs and cables under tension
Pistons under pressure
Vessels or gas cylinders under pressure
Hydraulic controls
Stored potential energy can be
released during work, causing injury
or death. 10
12. Chemical Energy Hazards
Chemicals have energy that can –
start fires;
cause skin burns;
generate harmful gases or fumes.
Before working – release/vent or drain
chemicals safely.
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13. Thermal Energy Hazards
Energy of Heat (and cold)
Hot equipment and fluids can burn you
Cold fluids can also cause cold burns
Quick release of compressed or
liquefied gases can freeze your skin
Allow equipment to reach a safe
temperature before starting work.
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HOT
14. Hydraulic Energy
Energy of Liquids Under Pressure
Pressure can cause equipment to move
Rapid release can cause injury, or
Ejection of the system parts
Relieve pressure by draining liquid
slowly into a proper container.
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15. Pneumatic Energy Hazards
Energy of Compressed Gases
Uncontrolled release can cause injury.
Rapid de-pressurization can create
extremely low temperatures.
Excessive pressure may rupture the vessel
or piping
Properly depressurize and vent the entire
system before starting work.
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16. First Step in LOTO
Know your equipment and
systems:
Hazards
Isolation points
Procedure for lockout and tagout
(LOTO)
Working on unfamiliar machinery
is a hazard.
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17. First Step in LOTO
A clear policy and written
procedures and instructions
are essential and address:
1. Scope
2. Purpose
3. Authorization
4. Rules
5. Techniques
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LOTO is essential for doing a job safely.
19. Items needed for LOTO
Written LOTO Procedure – workers trained
Locks & Tags – identified to the workers
Hasps – for placing multiple locks and tags
Breaker Clips – for electrical LOTO
Blank Flanges (Pancakes) – for fluid lines
Valve Covers – for LOTO of valves
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20. Use of Locks & Tags
Use only those issued to you
Ask your supervisor if you need more
LOTO equipment
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21. 6-Step LOTO Procedure
1. Prepare for shutdown
2. Shutdown the equipment
3. Isolate all energy sources
4. Place locks and tags
5. Release stored energy
6. Verify equipment isolation
(attempt normal startup)
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22. 1. Prepare for Shutdown
Understand equipment hazards.
Notify other workers of shutdown.
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Hasp
23. 2. Shutdown Equipment
Use normal shutdown procedure.
Turn all switches to “OFF” position.
Shut all control valves.
Disable all sources of energy.
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24. 3. Isolate All Energy Sources
Shut valves
Open breakers and disconnect
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25. Stored Energy
Lockout procedure must address Stored Energy
Awareness of how energy is transferred and
potentially stored is essential
An assessment of the systems involved is
required
Simply locking out a particular machine or
equipment is not enough
All stored energy must be relieved
Verify that there is no potential for re-accumulation
Assessment of related equipment
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26. 4. Place Locks and Tags
Place locks and tags on –
Valves
Breakers / electrical disconnects
Positive isolation –Block or disconnect all lines
Carry out required spading/blinding
Maintain a “Spade/Blind Register”
Double block-and-bleed system
Tag the spades/blank flanges
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28. Customised
attention-grabbing
tags to place
emphasis on
locked-out
equipment
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Circuit-Breaker
lockout device
featuring a bar
clamp design
Customised LOTO Tags
Customised LOTO Tags
29. 5. Release or Block
all Stored Energy
Discharge capacitors
Block or release springs
Block elevated parts
Stop rotating flywheels
Relieve system pressure
Drain fluids
Vent gases
Allow system to attain ambient
temperature (cool down /warm up) 29
30. 6. Verify Equipment
Isolation
Check all other workers are clear
Check locking devices securely placed
Check isolation
Attempt normal startup
Return controls to OFF/Neutral
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31. Release from LOTO
Inspect area and equipment
Ensure all machine guards are in place
Move tools away from equipment
Inform others of startup
Remove spades/blinds (Record in register)
Restore system connections
Remove locks and tags
Restore equipment to normal (energise)
Conduct normal startup
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32. Who can remove
Locks and Tags?
Only the employee who
placed the tag
or
a supervisor, after obtaining
permission from the worker
who placed the tag.
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33. A piece of equipment already has
a lock and tag.
Do I have to place my own locks
and tags?
YES.
All persons working on the
equipment must place their
own locks and tags to ensure
their safety.
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