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- 1. Credit: Rudy Ricciotti (Architect) / Jae-Seong E. (Photograph) © Copyright 2006, Lafarge SA All rights reserved. No part of this document may be reproduced, stored in a retrieval system, translated, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of Lafarge SA. LOTOTO Advisory
- 2. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 2 HSE KOHAT CEMENT COMPANY LIMITED Every Employee will attend 3 Training Sessions this Year. 1. Fire Safety 2. LOTOTO 3. Personal Protective Equipments. Training Objective: •Safety should become second nature While performing any task. • Work safely Because •Improving Safety Culture at Plant./Discuss Safety.
- 3. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 3 Since January 2006, Lafarge has experienced 22 fatal injuries related to working on machinery, equipment, or processes due to uncontrolled energy
- 4. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 4 Bottom line is ALL the 22 fatalities could have been avoided
- 5. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 5 Recent fatality in Cameroun • Moundi Moussa, 24 years lost his life. • He was digging to remove a wall, during the job the jack hammer cut 380V power cables was buried. • Cable was noticed but was not isolated
- 6. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 6 Purpose of the Advisory To build one way for all product lines, regarding to LOTOTO terminology and principles Sites Workers contractors To mobilise all sites to re-assess to eliminate incidents related to the control of hazardous energy In November 2008, the Group published LOTOTO Advisory
- 7. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 7 Hazardous Energy is any type of energy that, if released unexpectedly, can cause a damage. Key Terminologies Variable Stored Electrical Current Batteries, capacitors Mechanical Turning shafts, gears, chains Tensed springs Hydraulic Moving cylinder pistons Pressure in accumulators Pneumatic Moving actuator pistons Pressure in tanks and lines Steam Flowing steam Trapped pressure Chemical Flowing liquids, gases Trapped gases, liquids Gravity Downward moving components Elevated counter weights, etc. Radiation Released energy Contained source material
- 8. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 8 Energy Isolating Device Mechanical device that physically prevents the transmission or release of hazardous energy (e.g. manually-operated electrical circuit breakers, disconnect switches, line valves, blinds and blocks). Zero Energy State Completely isolated from all energy sources and does not contain residual or stored energy or the potential to re-accumulate residual or stored energy. Residual or Stored Energy Energy that remains in machinery or equipment after it is shutdown (e.g. compressed air inside a receiver tank (pneumatic), elevated/lifted components (gravity), pressurized hoses and components (hydraulic), stored electrical energy/capacitors (electrical)). Energy Isolation – Definitions
- 9. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 9 MEP Machinery, Equipment and Processes Arc flash Explosive release of energy caused by passage of electrical current through ionized gases and vapors between 2 energized conductor or energized conductor to ground Task a job activity that includes but is not limited to: erecting, installing, commissioning, repairing, adjusting, inspecting, un-jamming, troubleshooting, testing, cleaning, dismantling, demolishing, servicing, maintaining or other similar work on machinery or equipment HERA Hazardous Energy Risk Assessment, perform to > All types of conveyors > Tasks requiring a LOTOTO permit HECP Hazardous Energy Control Procedure, for each MEP where HERA was performed Energy Isolation – Definitions
- 10. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 10 Lockout / Tagout / Tryout (LOTOTO) is the primary and preferred method to Control hazardous energy Achieve zero energy state before performing tasks on MEP LOTOTO is required when: Guarding or safety devices on MEP need to removed/bypassed Individuals may be exposed to hazardous energy when performing tasks on MEP (e.g. pressurized systems). Scope
- 11. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 11 5 Key Principles There are five key principles to control of hazardous energy – Controlling Risk (Hierarchy of Controls) – Lockout + Tagout + Tryout (LOTOTO) – One Lock, One Worker, One Energy Source – Mandatory LOTOTO Sequence; and – Training & Hazard Awareness LOTOTO Advisory
- 12. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 12 Group standards requires sites to manage risk through HOC Principle 1: Controlling Risk Barriers Planning Guarding Permits Training Tools Housekeeping What is Risk? Risk = Hazard x Exposure
- 13. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 13 Hazard Risk Eliminate Engineer/Redesign Isolate the hazard Administrative Use PPE HOC Hierarchy of Controls
- 14. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 14 Isolation Isolate the workers from hazard HOC Hierarchy of Controls
- 15. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 15 Engineering Reducing the potential for exposure to hazardous energy, by installing engineering controls (e.g. physical guarding, infra red beam trap key interlock system, installation of local disconnect, etc.) HOC Hierarchy of Controls
- 16. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 16 Administrative Minimizing the potential for exposure to hazardous energy through • The use of administrative controls (e.g. conducting risk assessments, establishing safe work procedures, training, etc). • Warning signs are an important means to support and ensure the effectiveness of each level of the HOC. • Define a safety perimeter as appropriate HOC Hierarchy of Controls
- 17. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 17 PPE Using proper PPE to minimize exposure to hazardous energy during forming the tasks on MEP Mandatory PPE Special PPE upon the task risk assessment “e.g. arc flash PPE , etc” HOC Hierarchy of Controls
- 18. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 18 EXERCISE 3 Men working in the Crusher. Q. What are the HAZARDS?
- 19. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 19 Principle 2: Lockout + Tagout + Tryout (LOTOTO) LOTOTO is the primary and preferred method to control hazardous energy/achieve zero energy state > LO (Lockout) means to physically lock the machine or equipment controls > TO (Tagout) means to attach an information tag with the lock to identify the owner of the lock and the date it was applied to the machine or equipment > TO (Tryout) means to verify by testing that the machine or equipment has been properly de- energised and will not operate before beginning a task on the machine or equipment LOTOTO Advisory
- 20. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 20 Principle 3: One Lock, One Person, One Energy Source All personnel who perform tasks on Machinery, Equipment and Processes (MEP)’s must be issued personal locks and tags > Lafarge employees > Contractors (should have their own locks) > Third party (Visitors, suppliers, etc..) Two Types of LOTOTO (LOTOTO methods) Simple LOTOTO > Each worker must apply his own lock(s) to all energy source(s) Complex LOTOTO > Each worker must ensure his personal lock and tag is attached to the group lockbox. LOTOTO Advisory
- 21. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 21 1)Simple method When One or more authorized individual One or more energy source Each authorized individual shall place a personal lock and identification tag on all energy isolating devices > Use multi clasps (hasps) if needed All authorized individuals shall perform mandatory LOTOTO sequence or the MEP-specific HECP. LOTOTO Methods
- 23. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 23 2)Complex method When several authorized individuals perform task(s) on MEP under the following conditions A large number of energy isolation devices or authorized individuals are involved The period of energy isolation is extended (e.g. more than one shift) The energy isolation devices are relatively inaccessible There is interdependence and interrelationship of the MEP components One responsible individual shall be assigned the overall responsibility and authority and shall ensure continuity of lockout protection LOTOTO Methods
- 24. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 24 2)Complex method All keys to the designated MEP locks are placed in one lockbox or complex isolation board One responsible individual shall be assigned the overall responsibility and authority and shall ensure continuity of lockout protection The lockbox or complex isolation board shall be locked by the responsible individual with a single controlling lock and key All authorized individuals shall affix their personal lockout device on the lock box hasp and keep their personal lock key under their exclusive control LOTOTO Methods
- 25. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 25 2)Complex method LOTOTO Methods
- 26. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 26 Principle 4: Mandatory LOTOTO Sequence The following 9 steps outline the mandatory LOTOTO sequence that shall be followed prior to performing any task on machinery or equipment. > 1. Prepare > 2. Notify > 3. Turnoff / Shutdown > 4. Isolation > 5. Apply Locks. > 6. Zero Energy State > 7. Tryout > 8. Perform Task or Activity > 9. Inspect and Restore LOTOTO Advisory
- 27. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 27 1. Prepare Preparation required by the authorized individual: > reviewing the work order > performing a pre-job briefing > reviewing the MEP-specific HECP > registering the task in the LOTOTO logbook or completing the LOTOTO Permit Mandatory LOTOTO sequence Step1
- 28. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 28 2. Notify Authorized or responsible shall notify all that the MEP will be isolated Mandatory LOTOTO sequence Step2
- 29. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 29 3. Turnoff / Shutdown The authorised individual shall: Turnoff/ shut-down/ de-energize per the MEP-specific HECP or the site specific energy isolation program Mandatory LOTOTO sequence Step3
- 30. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 30 4. Isolation Isolate the energy sources in positive way Positive isolation shall be achieved by using: > energy isolating devices – disconnect switches – line valves blocks – Blinds – Etc The MEP operating controls (i.e. on/off button, emergency stop button) shall not be used for isolation Mandatory LOTOTO sequence Step4
- 31. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 31 5. Apply Locks Locks shall be applied to the energy isolating device Each authorized individual working on the MEP use his personal lock(s) and information tag(s) Lockout of each energy isolating device shall be done with the approved lockout device Mandatory LOTOTO sequence Step5
- 33. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 33 6. Zero Energy State must be achieved so all energy shall be: Relieved Blocked Restrained Mandatory LOTOTO sequence Step6
- 34. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 34 7. Tryout After ensuring that all individuals are clear of the MEP, Authorized individual should attempt to operate the normal operating controls to ensure the correct MEP > Has been de-energized > will not operate The operating controls shall be returned to the neutral or off position after the tryout testing. If the equipment operates, it shall be shutdown and the supervisor notified. Mandatory LOTOTO sequence Step7
- 35. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 35 8. Perform Task Mandatory LOTOTO sequence Step8
- 36. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 36 9. Inspect and Restore The authorised individual shall: Visually inspect the area > ensure that all tools have been removed > guards and other safety devices are in place Notify all affected individuals that power is to be restored Verify that all individuals are clear of the MEP Remove all lockout devices and tags from energy sources Restore all isolating devices to the “On” position Mandatory LOTOTO sequence Step9
- 37. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 37 LOTOTO Advisory
- 38. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 38 Lockout / Tag out Tools 38
- 39. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 39 Lockout / Tag out Tools 39
- 40. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 40 40 Multi Clasps ( Hasps )
- 41. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 41 41 Padlocks
- 42. Building World-class Foundations Living Safety Learning and Sharing Sustaining Local Improvement Leadership & Accountability May 2011 - 42 42 Valve Lockouts