[Alex] COHE LOTO [Instructor]

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7/25/2019 [Alex] COHE LOTO [Instructor]

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CONTROL OF HAZARDOUS ENERGY AND

LOCK-OUT / TAG-OUT/ TRY-OUT

(LOTOTO)

By: ENGR. ALEXANDER B. TRILLANAOSH CONSULTANT

• Work with machinery, equipment and processsystems where energization or release of storedenergy could result in injury.

• Work involving energy sources:

– Electrical

Pneumatic – Hydraulic

– Stored (such as gravity, spring or compressed gas)

– Chemical

– Thermal – Radiation.

7Nov. 2, 2003 Rig Floor

Running at 130 rpm

Don’t

ignore the “LOTOTO”

Lockout/Tagout

Electrical LOTO Mechanical LOTO

“NOBODY GETS HURT”

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Lockout/Tagout Devices

• Locks

• Tags

• Lockout Boards

• Multi-Hole Hasp

• Cables

• Blinds/Spades

• Blind Flanges

NOBODY GETS HURT

“ EVERY ONE EVERY DAY EVERY TASK “

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Electrical Lockout Devices

NOBODY GETS HURT

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Valve Lockout Devices

NOBODY GETS HURT

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Mechanical Lockout

WHEN there is a potential to be exposed to rotating equipment or machinery.

NOBODY GETS HURT

“ EVERY ONE , EVERY DAY , EVERY TASK “

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Thermal Energy Lockout

WHEN there is the potential to be exposed to

residual heat or high temperatures.

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Chemical Energy Lockout

When the potential exists for chemical exposure

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Physical Blocks

Truck bed Lockout Punch press blocks

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Pneumatic Lockout

These devices prevent compressed air from flowing through lines and movingsome part of the machinery.The locks prevent anyone from hooking up the

lines while maintenance is being done.”

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Pipe Lockout

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Spades And Blinds

A physical block in a pipeline prevents steam, gas or liquids from flowing through the pipe to the area

where work is being done. For example, the pipe to a chemical tank must be blocked or disconnected

before someone goes in to do repair or maintenance.”

Ensure positive isolation of piping systems (Operation , Mechanical )

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Blind Flange or ‘End Blank’

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Spectacle Blind

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Blocks

Types of Lockout/Tagout Devices

LOTOTO BOX

Types of Lockout Devices

Step 1:

Verify circuit breaker is de-energized.Place PSL-CBL lockout device over

breaker with the handle centered in

lockout opening.

Step 2:

Turn the toggle set screw knob andtighten firmly against the breaker

handle.

Step 3:

Rotate and flip toggle set screw

upwards.

Step 4:

Install lock and tag and test for

security. Verify that the lockout device

secures the disconnect in a safe or off

position.

• Applicable to all operations (manufacturing,distribution and offices) worldwide with potential for

work where energization or release of stored energy

can result in injury.

Definitions

• Energy source: any source of electrical, mechanical,

hydraulic, pneumatic, chemical, thermal, or other

energy.

Definitions

• Energy isolating device: a mechanical device thatphysically prevents the transmission or release of

energy

• Hazardous energy: any electrical, mechanical,

hydraulic, pneumatic, chemical, thermal or other

energy, which if inadvertently applied to a machine or

worker can cause injury.

Definitions

•Lock-out: the placement of a lock on energy isolatingdevice ensuring the equipment cannot be operated

until the lock is removed

• Tag-out: the placement of a tag on an energy isolating

device ensuring the equipment may not be operated

until the tag is removed.

1.0 Administrative controls

1.1 Compliance

• Establish local legal regulations and Companyrequirements

• Implement management practices and controlswhichever is stricter of the two.

1.2 Hazard ID and Risk Assessment

• Conduct and document initial assessment to ID

machinery and equipment in which energization or

release of energy could result to injury to workers

• Part of safety aspects and impacts analysis of theCompany’s Safety Management System

• To be reviewed annually and modified as necessary.

1.3 Energy Control Procedures

• Document specific procedures for control of hazardous

energy for each piece of machinery and equipment where

energization or release of energy could result in injury

1.3 Energy Control Procedures

• The machine-specific CoHE procedures must include how

– Shut down the machine and location of controls

– Isolate energy sources and location of energy isolation devices

– Relieve any stored or residual energy

– Place lock-out and tag-out devices

– Verify energy isolation

– Release the machine from lock-out and tag-out.

Don’t

ignore the “LOTOTO”

1.4 Training

• All employees whose job requires them to operate, use,or be in the area of equipment or process systems during

LOTO activities must receive documented initial training

– A review of energy sources present in facility

– Overview of purpose and use of CoHE

– Types of energy isolating devices they will see in use

– Prohibition of removing locks or tags or trying to start

equipment with LOTO

– Prohibition in using LOTO unless trained.

S A F E T Y

T A L K S

1.4 Training

• Disciplinary policy for violating CoHE program• Retraining must be conducted when:

– Employees are assigned to a job in which they have not been

trained in CoHE

– Change in equipment with new hazards

– Change in CoHE procedures

– Audits or accidents reveal deficiencies in employees knowledge

or implementation of CoHE procedures.

1.5 Working with Contractors

• The site is responsible for ensuring Contractors use CoHE

procedures

• Before work, site and contractor, review all applicable

hazardous energy sources and CoHE procedures

2.0 Scope of Line break processes

• CoHE during line breaks to prevent exposure to hazardous

chemicals causing injury on contact such

– Fluids above 55oC (130oF)

–Compressed air or gas >5.5bar (>80psig)

• These procedures do not apply where written SOPs are in

place e.g., making clean in place (CIP) connections.

2 0 Li b k

2.0 Line break processes

2.1 Line breaking permit

• The site must establish a permit program to control andmonitor line breaking work

• Minimum information to be documented

Date, time and location of work – Description of work to be done

– Date, time and expiration of work

– Required PPE

Procedure to clear the line – Potential sources of energy and CoHE

– Signature of authorizer, attendant and people doing the workthat above have been completed and verified.

S A F E T Y

T A L K S

2.2 Control measures

• Use hazard analysis and recognition to identify potentialcontrol measures such as:

– Removal of chemicals from system

– Use of PPE based on MSDS

– Confirm safety equipment appropriate for the hazards

– Review piping flowsheet

– Confirm and physically check LOTO of pumps, blowers,

compressors to prevent inflow of hazmats

– Confirm work area is isolated or guarded with signs and warning

tape to prevent exposure of others not involved in the linebreak

2.3 Attendant

• Presence of (standby) attendant familiar with the system,its hazards and CoHE procedures who is wearing

appropriate PPE for initial line break

3 0 Electrical Pneumatic Hydraulic Powered

3.0 Electrical, Pneumatic, Hydraulic Powered

Mechanical Equipment

3.1 Lock-out process

– 1. Stop equipment using normal push button

– 2. Isolate each energy source

– 3. LOTO each energy source – 4. Verify each energy source is isolated. Call “Stand

Clear” then attempt to re-start the equipment. Returncontrols to “neutral”, “stop”, or “OFF” positions after

the test – 5. Do the required work.

3.2 Tag-out

• If the person who installed a lock-out must leave the site

before it is safe to re-energize the equipment, he must

install a tag-out – “Warning: Do not operate”

– Name and signature of person doing the LOTO

– Reason for the tag

– Date

– Equipment which is de-energized.

3.3 Tag-out in lieu of lock-out

• If energy isolating device is not capable of beinglocked-out, a tag-out may be used

• Additional energy control measure must be usedsuch as removal of isolating circuit element, orblocking a controlling switch

Sites must upgrade to lockable isolating devices assoon as practicable.

3 0 El t i l P ti H d li P d

3.4 Group LOTO

• Some works may require multiple individual isolations

with several people working on the same equipment or

process

• A multiple hasp or lock box can be used so each

individual worker can attach his own LOTO.

3 0 El t i l P ti H d li P d

3.5 Release from LOTO

• Once work is complete, procedure to repower:

1. Inspect work area to verify all components are safe to

operate, GHK done, all personnel stay away

2. Remove LOTO. Each person removes his own.

3. Re-energize equipment. Call out “Stand Clear” visually

verifying all personnel are clear. Switch on, standing tothe side of each electrical disconnect (baka sumipa o

sumabog).

3.6 Personnel or Shift changes

• One of two procedures is acceptable

– 1. Incoming employee places his LOTO, after which leaving

employee removes his LOTO – 2. Designated Company supervisor places department

LOTO in addition to the LOTO placed by individualemployees. Authorized employees remove their LOTO atend of their shift. The designated supervisor keeps controlof the keys of the department LOTO.

3.7 LOTO removal when owner is off-site • No one is authorized to remove another person’s LOTO

while he is on site

In exceptional circumstance when he cannot be located: – His supervisor to verify he is not on site

– Attempt to contact the owner before removal of LOTO

– Inform owner his LOTO is removed before he starts work

– A designated employee to verify that removal of LOTO will notendanger anyone before removal.

3.7 LOTO removal when owner is off-site

• In exceptional circumstance when he cannot be

located (continuation):

– The employee removing the LOTO to document

the action. Document kept for 1 year.

– Supervisor investigates why employee left

without removing LOTO devices. Appropriate

disciplinary measures.

3.8 LOTO Devices

• Standard durable lock hardware throughout the

• Tags printed and constructed to be weather

resistant

• Each tag to have secure means of attachment.

What is Lock Out / Tag Out (LOTO)

What is Lock-Out / Tag-Out (LOTO)

•Lockout devices can include:

Blocks

chainsthat are applied to energy isolating devices:

Switches

Valves etc

A ti iti Th t R i L k O t/T O t

Activities That Require Lock-Out/Tag-Out

Machinery and equipment that require...

Lubrication

Cleaning AdjustmentsR etooling

Un-jamming

RepairingServicing

Inspection

Systems that require Lock Out/Tag Out

Systems that require Lock-Out/Tag-Out

During service and/or repair

Steam Boilers

Air Handlers

Vehicles

Hydraulic

Pneumatic

Electrical

Plumbing

Motorized equipment

• Lockout/Tagout prevents injuries during work

involving:Repairs

Replacements

Modifications to machines or equipment

Maintenance

During normal operations, Lock-Out/Tag-Out isneeded whenever an employees must:

Remove or bypass a guard or other safety devices.

Place any part of his or her body into a machine’s

point of operation.

Or a danger zone associated with machine’soperation cycle.

• Authori ed employees

• Authorized employees

can physically lock or tag out machines to

do service or maintenance work asoutlined in lockout/tagout procedures.

Affected employees

either operate equipment that can be locked

or tagged out or work in an area wherelockout/tagout is used. They must understand

and comply with the lockout/tagout program

Other employees

are those work operations are or may

be in an area where lockout/tagoutmay be used. They must be instructedabout lockout/tagout and know thatthey are never to attempt to restartequipment that has been locked ortagged out.

Valve Covers

Switch Covers

Plug Covers

Preventing Accidents

Requires

Team Effort

[Alex] COHE LOTO [Instructor]

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