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Lock Out Tag Out & Try Out Training Module

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-POSITIVE

-ISOLATION
 Why Lock Out / Tag Out?

Lockout / tag out is performed to prevent injury to personnel

or damage to property and or environment by the
unexpected release of energy / materials. When planning a
lockout, it is important to consider the nature of all energy /
materials that may be present.
 Principles Governing LOTOTO
 Identification of the equipments & all possible energy sources
 Preparation of Lockout / Tag out
 Methods of isolation
 Restoration & Re-energisation
 Lock out and tag out devices
 Any Specific requirements
Examples of removing or controlling hazardous energy
1. Disconnecting power and discharging any capacitance
2. Isolating pressure sources and releasing the pressure
3. Stopping rotating devices and securing them from further movement
4. Releasing stored hazardous energy
5. Lowering or securing equipment to prevent movement caused by gravity
6. Protecting equipment from external forces (e.g., wind) that may cause
movement
Energy Source Identification (Having Single energy source)

• In the Method of Isolation the details of Isolation (Like

breaker to be racked out, discharging to be done,
permanent earthing to be done at particular location,
Valve to be closed etc.) .
• The type of job may be categorized based on the
basic philosophy which may affect the method of
Isolation method. Like the jobs which may not require
or require direct exposure to electrical parts, released
energy.
• If the single source energy is electrical then panel
no/MCC or S/S should be mentioned other than that
Valve no, location or any other details giving
information about the location should be given
Energy Source Identification (Having multiple energy source)

Note:
• In the Method of Isolation the details of Isolation
(Like breaker to be racked out, Valve is to be
closed, pump is to be switched off) to be done.
 Principles Governing LOTOTO

• The Person In-Charge/ permit issuer shall be responsible for

Preparation for Lockout / Tag out and shall
 Identify type of energy that the System or equipment utilizes,
 understand the hazards of the energy,
 know the methods to control the energy.
 In cases of multiple energy sources, generate an energy source
identification sketch (a computer generated, hand written or in any
other form) to properly identify all energy sources.
• Electrical Technician / Mechanical Technician shall
Identify electrical / mechanical energy source(s).
Switch off the source(s) / depressurise /purge / put slip plates ,
as the case may be
Test the absence of voltage / fluid to equipment.
 Put lockout device (Hasp) and DANGER (Electrical Isolation) tag
 Principles Governing LOTOTO

• Working agency / person shall put his lock on the Hasp and retain the key
to the lock till the job is over.
• In case of group isolation involving multiple energy sources, the key of the
equipment lock shall be placed in group isolation box,

• The key to the lock shall be retained by locking individual till the end of the
job.
• Executing person shall also verify effectiveness of the isolation by TRY OUT
before putting people on job.
• After job completion, the work permit shall be returned to issuer who in turn
will verify site for job completion and in his presence lock will be removed.
• In case of key missing, it will be reported in writing to HOD who in turn will
take UH/Plant head approval to use duplicate key.
 Principles Governing LOTOTO
• Before starting work, each individual working on a task must determine, to
his or her satisfaction, that appropriate isolations are in place and the
isolations are secure for the task in which he is involved.
• Where a lock can be applied, tag out alone shall not be used to control
exposure to sources of hazardous energy.
• An energy source shall be considered energized until the source is removed
and the energy isolation is verified according to the Lockout / Tag out
Procedure.
• An effective verification (try) step must be performed. All interlocks that may
prevent an effective try step must be accounted for. A test for the absence
of voltage must be performed for all electrical hazards
-LOTO Procedures and

Requirements
 ISOLATION PROCESS
Isolating Person isolates
ON ON and verifies and attaches
a relevant colour
OFF equipment lock to the
OFF isolator.
U The key is placed in the
Group Isolation Board.

GROUP ISOLATION BOARD -GROUP ISOLATION

Isolation Coordinator
U -BOARD secures key in
Group Isolation
Board with a
Relevant colour
Protected Person secures a group lock
relevant colour personal lock and retains the key.
to the board and retains the
key.
Start of Permit Issuer (PI)
Identify Equipment No & PI will handover permit to
LOTO isolating agency (Mech/ Elec)
Isolation Source on a permit
Process

PI will remove his personal locks

Isolating agency shall match
from group isolation box &
equipment ID & No.
handover keys to the isolating
agency to complete restoration
of energy. Executing person
/agency provide Isolating agency will carry out &
After job completion, Executing his lock on the complete isolation process &
person will handover permit to hasp & retain the Lock Out
permit issuer & remove his key till the job is
respective locks on isolation box. over
Isolating Agency mention the
Permit executor / working agency For lock no. and tag no on
shall put their respective lock on Individual respective permit & Sign off
isolation box/ hasp & start
Isolation
maintenance activities
Isolating agency return this
Permit issuer will keep this keys permit to PI (in case of group
in isolation box & put his lock & isolation) respective keys will
hasp & issue permit to Permit For group isolation be handover to PI for group
executor/ working agency isolation
-Isolation from

Electrical Energy
Electrical Isolation From Energy

Lock Placement -- Locks must be placed on main

disconnect switches
NOT on control circuits
 Electrical Energy Isolation Method
Sr Electrical Energy Location of LO / LO / TO Isolation method
No Source TO point
1 110kV, 6.6KV source Breakers on Lock Out & Tag Out Rack out
respective panels
2 415V Source MCC / PDB/PCC Lock Out & Tag Out Rack out / Fuse removal
/MLDB feeder
3 415V or less Source DB / Power points Lock Out & Tag Out Fuse removal
with LO provision / Control Panels
4 415V or less Source DB / Power points Tag Out Switching OFF power from
without LO provision / Control Panels MCB/ELCB/ Isolator
5 Lighting circuit LDB Tag Out Switching OFF power from
Distribution (230V) MCB/ELCB/ Isolator
6 415V / 230V sockets Socket Tag Out Removal of plug

7 110 V and below with Control Supply Lockout&Tagout Switching OFF power from
LO provisoin MCB/ Isolator
8 110 V and below Control Supply Tag-out Switching OFF power from
without LO provision MCB/ Isolator
 -Isolation from

Mechanical Energy
 Isolation From Mechanical Energy

• Prior to any work being performed on any mechanical

equipment such as a pump, agitator, compressor, blower,
fan, etc.
 The motor or driver must be isolated from its
source of energy.
 The source of energy could be electrical, steam
compressed air, etc.
 The source of energy must be locked out.
-Isolation from Plant

Processes
 Isolation From Process Energy

• Prior to any work being performed on any piping or

vessel system that could have any process materials
introduced into it (including water or compressed air)
through the operation of an isolation device such as a
valve….
• the isolation device must be placed in the closed or off
position and locked in that position.
 Isolation From Process Energy
• Category I materials include:
 Chemicals
 Flammables (liquid or gas)
 Toxic Materials
 Radiation Exposure
 High pressure, regardless of material (e.g., air,
water)
 High temperature, regardless of material
Isolation From Process Energy

Isolating Devices
-Isolation from Stored

Energy
 Isolation From Stored Energy

Hazardous energy may exist as stored energy.

Stored energy must be relieved prior to working on
such equipment.

Examples of stored energy are springs, elevated

weights, Bucket Elevators, contained pressure,
flywheels, capacitors, Blowers, Fans, Impeller etc.
-LOTO – Procedure &

General Requirements
 LOTOTO - Requirements
All sources of hazardous energy shall be removed or
controlled prior to potential exposure to the hazards.
Examples of removing or controlling hazardous energy are as
follows:
 Disconnecting power and discharging any capacitance
 Isolating pressure sources and releasing the pressure
 Stopping rotating devices and securing them from
further movement
 Releasing stored hazardous energy
 Lowering or securing equipment to prevent movement
caused by gravity
 Protecting equipment from external forces (e.g., wind)
that may cause movement
 LOTOTO – Requirements(Contd..)

 Each and every person working on the equipment must

have his or her own individual lock and tag installed. Both

 LO/TO devices must be identified with the name of the

person applying the device.

 The lock and tag must be placed only by the person whose
signature appears on the danger tag.

 Keys must remain in control of the individual placing the

lock.
LOTO - Devices
Lock Out / Tag Out - Devices

Caution Tag

-Front -Back
Lock Out / Tag Out - Devices
Danger Tag (Non Electrical)

-Front -Back
 LOTO - Requirements

Multi-lock devices shall be used, as needed, for

additional lockout locks.
-LOTO – Examples
 Summary
 All those responsible to implement and follow LOTO
must be trained in the procedures and inspections of
LOTO to assure all workers are protected from energy
sources
 Lock/tag must include name of person placing it
 All Employees engaged in work on de-energized
systems must place their own lock and/or tag
 Lock/tag must be removed by person placing it.
 Identify all tasks and circumstances under which work
is permitted in close proximity to energized
components
LOTO- Electrical Examples
LOTO- Electrical Examples
LOTO- Mechanical Examples
THANK YOU