Purpose:
The purpose of the procedure is to provide you with correct actions to prevent risk of death or injury during equipment/ factory inspections, repairs/ maintenances and assessments.
Location of Lockout Station
- Lockout Station is located beside the Retort bench at the front of the factory.
Items at the LOTO Station
- Lockout devices / 3 Phase Plugs
- Out of Service Tags
- Do Not Operate Tags
- Information Tags
Lockout Devices: Locks are used to isolate equipment / machinery so that no unexpected energization or activation of equipment or movement can take place.
Out of Service Tag: This tag is to be placed with the lock and indicates that the equipment being controlled must not be operated until the tag out device is removed by the person who placed the tag or by a technician following the repair of the equipment and before it is placed back into service.
Do not Operate: A signed and dated label that is attached to energy isolation points of equipment , plant, pipes or lines by the person responsible for undertaking commissioning, repairs, maintenance, service alteration or cleaning.
Information Tag: It is used to provide instructional information only. It should clearly describe the equipment it is referring to and be attached in a conspicuous situation for its intended purpose. It can be placed by anybody who feels there is a need to supply information to other users of the equipment or asset.
Lockout devices and tags can only be removed by the personnel that placed them on the equipment/ energy source.
Lockout Tagout Process
- Survey the equipment for sources of energy (e.g., electrical, pneumatic, fluids and steam; hazards such as biological, chemical and environmental etc.).
- Perform the shutdown of the equipment and disconnect it from the energy source(s).The authorized person performing this action needs to be able to locate all primary energy sources (it can be electricity, steam, water, gas, compressed air…) and know how to disconnect them.
- Notify the maintenance team to perform the Lockout tagout and inform all affected employees and tell them the reason why.
- Locks, Tags or plugs will be fitted and be visible on the equipment or energy supply. The Maintenance team will fill out the tags with clear & correct information required on the tag.
- Equipment should now be safely locked down. There might be some residual energy that needs to be blocked or released. Draining fluids, venting gases, heat or air supplies.
- Test the effectiveness of the isolation : It is important to ensure that the system is properly isolated. Trying to start equipment to test the energy source(s) has been isolated.
- Locks, Tags or plugs are not to be removed by everyone other than maintenance team or a licensed contractor.
Removal of Lockout Tagout
- Ensure that nonessential items are removed from equipment
- Ensure that equipment components are intact
- Check area to ensure that all affected employees are safely positioned or removed from the area
- Notify all affected employees and site manager/supervisor before reenergizing the equipment
- Remove lockout / tagout devices
- Reenergize equipment to ensure safe operation
