LOTO - Lock Out Tag Out of Plant and Equipment Procedure

LOTO - Lock Out Tag Out of Plant and Equipment Procedure

22:35:00

Purpose

To reduce the risk of injury when people are working on plant or equipment by preventing the item and its components from being set in motion and preventing the accidental release of stored energy.

Scope

This procedure applies to people (staff, contractor, sub-contractor, self-employed person, student, etc), working on plant or equipment on University premises.  Where several people are working on plant or equipment, this procedure applies to every person.

Actions

Unless specified otherwise, the following actions apply to any person planning to work on an item of plant or equipment at the University:
  • A. Shut Down the Plant / Equipment
  • B. Conduct a Job Safety Analysis
  • C. Isolate All Energy Sources: Lock Out / Tag Out
  • D. Release All Stored or Trapped Energies
  • E. Test for Effective Isolation
  • F. Complete the Work
A. Shut Down the Plant / Equipment
  1. Shut down the item of plant/equipment.  Simple items can usually be shut down by a single control, such as a switch or valve.  More complex items may have to be shut down in a set sequence or by shutting down several energy sources (e.g. electricity, pneumatics, hydraulics, fuel, etc).
  2. Place a completed Out of Service Tag on the controls of every energy source. 
B. Conduct a Job Safety Analysis
  1. Identify all sources of energy associated with the item of plant/equipment and their isolation points, including ones that may be remote or hidden.  Include electricity, compressed gases, fluids under pressure, stored energy, fuels, heat, steam, gravity, radiation, etc. 
  2. Identify all other hazards, including mechanical, chemical, falls, burns, asphyxiation, and impact.
  3. If the work and the item of equipment meet all the conditions listed below, proceed with the work:
    1. the item involves only one source of energy, and that energy source will be under the direct control of the worker throughout the work;
    2. the work involves only one worker;
    3. the worker is not working in isolation;
    4. the work and item are well within the technical competencies of the worker; and
    5. other safety requirements do not apply (e.g. permit-to-work).
  4. If the work or item of plant/equipment do not meet any one of the requirements in Item 3 above, record the findings on a Job Safety Analysis form and contact the Facilities Services office of the premises/campus where the work is being carried out. 
  5. If there is uncertainty about any aspect of conducting a Job Safety Analysis or if further information is required (e.g. plans or diagrams), contact Facilities Services. 
  6. Facilities Services will review the JSA, issue the necessary Locks and Tags, make the entries in the Lock and Tag Register, and determine the level of supervision and additional measures required. 
C. Isolate All Energy Sources: Lock Out / Tag Out
  1. Once Facilities Services have approved the JSA and have issued the necessary Locks and Tags, isolate every energy source by means of one Lock and one Danger Tag for every worker on every isolation point.  Where several workers are involved, use Safety Hasps (see Figure 1 below).  Contact Facilities Services to obtain these Hasps. 
  2. Except for simple electrical equipment connected via a plug and socket, an electrician* must isolate and disconnect all electrical supply to an item of plant/equipment.
    *Note: "electrician" in this procedure means a worker who holds either of the following electrical licences:
    - Disconnect/Reconnect Worker's Licence (D Licence/Restricted)
    - Electrician's Licence (A Class/A/E Licence)
D. De-energise All Stored or Trapped Energies
Take any of the following steps necessary to guard against energy left in the item of plant/equipment after its energy sources have been isolated:
  1. Inspect the plant/equipment to make sure all parts have stopped moving. 
  2. Install ground wires. 
  3. Block or brace parts which could fall due to gravity. 
  4. Release the tension on springs, or block the movement of spring-driven parts. 
  5. Block parts in hydraulic and pneumatic systems that could move from the loss of pressure. 
  6. Relieve trapped or stored pressure.  Bleed the lines and leave vent valves open. 
  7. Drain process piping systems and close valves to prevent the flow of hazardous material. 
  8. If a pipe must be blocked where there is no valve, use a blank flange. 
  9. Purge tanks and process lines. 
  10. Dissipate extreme cold or heat, or provide protective clothing. 
  11. If stored energy can re-accumulate, monitor it to make sure it stays below hazardous levels.  
E. Test for Effective Isolation
  1. After the item of plant/equipment has been shut down, locked out and tagged out, but before any person attempts to start work on the item, test all isolated power sources.  Test first with appropriate instruments and then by trying to activate the item.  Ensure the complexity of the plant (or parts of the plant, including control stations and computers remote from the plant) is understood.  If unsure, contact Facilities Services. 
  2. Only begin work on the item of plant/equipment when tests have confirmed it is safe to do so.  
F. Complete the Work
While performing the work, monitor the condition of the item of plant/equipment throughout the work to ensure unforeseen hazards or changing conditions do not cause injury. 
On completion of the work:
  1. Return the item of plant/equipment to a safe and serviceable condition. 
  2. Ensure each worker removes his/her own Safety Lock(s) and Danger Tag(s).  Note: Only the worker who was issued with a given Lock and Danger tag can remove them.  Anything other than this strict safety rule is absolutely prohibited.  Contact Facilities Services if for any reason it is impossible to comply with this rule (e.g. lost key).
  3. Ensure the person who fitted the Out of Service Tag(s) removes it(them). 
  4. Test the equipment for correct operation.
  5. Report to Facilities Services.  Return all the items on loan, including used tags.

Responsibility

  1. The Director – Facilities Services has ownership of this procedure and its implementation. 
  2. The Manager – Risk, Health and Safety is responsible for the maintenance of this procedure. 
  3. The Facilities Managers are responsible for including this procedure in contractor inductions and for ensuring that contractors/sub-contractors and Facilities Services staff comply with this procedure. 
  4. Deans/Directors are responsible for ensuring their staff and students comply with this procedure. 

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