Lockout/Tag out (LOTO) Procedure

Table of Contents

1. Introduction ................................................................................................ 3
2. Definitions and Interpretations ................................................................... 3
3. Lock-Out Tag-Out (LOTO)......................................................................... 4

3.1 General Requirements ...................................................................................................4

3.2 Permit Requirements for Lockout/Tag out ......................................................................4
3.2 LOTO Materials..............................................................................................................5
4. Lock-Out Tag-Out (LOTO) Procedures ..................................................... 5

4.1 Prepare for Shutdown..................................................................................................5

4.2 Shut Down and Isolate Equipment...............................................................................5
4.3 Apply Lockout/Tagout Devices ....................................................................................6
4.4 Control Stored (Potential) Energy ................................................................................6
4.5 Check Safe Condition ..................................................................................................6
4.6 End-Of-Shift Procedures..............................................................................................6
5. Lock-Out Tag-Out (LOTO) Procedure for Mobile Equipment .................... 7
6. Service, Maintenance, and Temporary Reactivation ................................. 7
7. Restoring Equipment to Service ................................................................ 8
8. Lock/Tag Removal by Other than Authorized Workers ............................. 8
9. Group Lock-Out Tag-Out (LOTO)........................................................... ..9

9.1 Group LOTO Procedure ............................................................................................ 9

10. Periodic Inspection ................................................................................ 9
11. Lock-Out Tag-Out (LOTO) Exceptions .................................................. 9
12. Training .................................................................................................. 10

12.1 Affected Employee................................................................................................... 10

12.2 Authorized Employee............................................................................................... 10
12.3 Other Employees ..................................................................................................... 11
12.4 Retraining ................................................................................................................ 11
13. Documentation....................................................................................... 11
13.1 Attached LOTO form.........................................................................................12
13.2 LOTO Work Permit ......................................................................................... 14

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1. Introduction
The purpose of this section is to introduce minimum requirements for Lockout-Tagout.
These requirements are intended to provide Consultants, Contractors and sub-
Contractors with guidelines and information for the planning and execution of
measures to prevent the inadvertent energization of equipment.

2. Definitions and Interpretations

 Affected Worker: Person whose job requires him to be in an area where the
equipment or system has been de-energized under the LOTO program. The affected
worker cannot perform work under aLOTO.

 Authorized Worker: Person who locks out and/ or tags out machines, equipment, or
systems to perform servicing or maintenance on that machine or equipment. This
person must have completed the mandatory training to be qualified as an authorized
worker. Only an authorized worker installs locks and/ or tags as required by this
program.

 Energy Isolating Device: Device that prevents the transmission or release of hazardous
energy or hazardous materials. Examples include restraint blocks, electrical circuit
breakers, disconnect switches, slide gates, slip blinds, or line valves. For LOTO
purposes, isolating devices that provide visible indication of the equipment/ system
status are desirable.

 Energy Source: The object, equipment or system which contains or has potential to
contain a form of hazardous energy.

 Exposure: Known, potential or accidental contact with a hazardous chemical, material,

energy, or physical hazard through any route of entry into/ onto the body, including
inhalation, ingestion, skin contact, or absorption.

 Hazardous Energy: Examples include electrical, mechanical, hydraulic, pneumatic,

chemical, radiation, and thermal energies, as well as various forms of potential energy,
such as that stored in springs, compressed gases, or suspended objects.

 Lockbox: A lockable container or location in which keys for the locks applied to energy
isolating devices are stored.

 Lock(s): Device that requires a key to operate (not a combination lock) and is capable of
holding an energy isolating device in the required position for the protection of
personnel.

 Lockout/Tagout (LOTO): Installation of a lock and/ or tag on the energy isolating

device(s) to render the energy associated with the tool equipment or system controlled
or safe. The lock and/ or tag provide physical and visual assurance that the tool,
equipment or system they are isolating cannot be operated until the lock and/ or tag
are removed.

 Safe Condition Check: An inspection and test of tool, equipment or system following
installation of the lock and/ or tag upon the energy isolating device to verify that the
lockout has successfully controlled the possibility of hazardous energy release.

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  Servicing and Maintenance: Workplace activities such as reconstructing,
installing, setting up, adjusting, inspecting, modifying, and maintaining or
servicing machines or equipment. These activities include lubricating, cleaning, or
un-jamming machines or equipment and making adjustments or tool changes
during which the employee may be exposed to the unexpected energization or
startup of the equipment or release of hazardous energy. This applies to all
personnel regardless of job title (operator, researcher, maintenance crafts,
engineer, or construction personnel).
 Tag(s)/Tagout: A “DANGER” tag or a “DANGER – DO NOT OPERATE” tag which
can be securely fastened to an energy isolating device in accordance with this
element to indicate to Affected Workers that the energy isolating device and the
equipment being controlled cannot be operated until the tag is removed.

3. Lock-Out Tag-Out (LOTO)

3.1 General Requirements

The Contractor shall ensure that LOTO Is used when an employee is performing service or
maintenance around any machine which, if suddenly set in operation or motion, could
cause injury. For example, unexpected startup of equipment or release of stored energy
could cause injury to any person near that machinery. LOTO is also required when work is
performed on electrical, hydraulic, thermal, pressurized, or chemical conveyance system
where failure to control the potential energy could cause injury, death, or equipment
damage.

 Locks and tags by themselves do not de-energize equipment; they must be

attached only after a machine has been isolated from its sources.

 Energy isolation and LOTO are applied only by authorized employees trained to
perform service or maintenance.

 No device is operated with LOTO attached, regardless of circumstances. No

person will remove a lock or tag without following proper procedures.

 Group lockout devices are used when multiple craftsmen or other contractors are
involved in the operation.

 Only individually keyed locks are used, and these locks are individually identified.

3.2 Permit Requirements for Lockout/Tag out

 Contractor employees planning to conduct work on any system which requires

LOTO are required torequest for a permit to work from their H&S Representative.
No LOTO work shall occur without first being reviewed by the H&S Representative
and a valid authorized permit being issued.

 Through use of the two-week look ahead planning process, Contractors are
expected to know the schedule of work activities which will require LOTO.
Contractors shall notify the Supervising Consultant a minimum twenty-four (24)
hours prior to start of work. The Supervising Consultant and Contractor H&S
Representative shall “walk down” the work area where LOTO will be performed.
 The Contractor shall describe the work activity planned via a Method Statement,
Activity Hazard Analysis (AHA), or similar. This work plan shall clearly identify all
controls planned, lockout devices which will be used, personnel involved, systems
affected, and a schedule of the planned work activity, at a minimum.

 Conditions which would automatically terminate the Permit include: completion

of the work and removal of LOTO devices, discovery of previously unknown
hazards, conditions, or exposures which are not addressed by the current permit,
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 or failure of the LOTO device(s) to adequate control the hazardous energy
source(s) present in the system, equipment, or tool.

3.2 LOTO Materials

The Contractor provides locks, tags, chains, wedges, key blocks, adapter pins, self-locking
fasteners, or other hardware for isolating, securing, or blocking machines or equipment
from energy sources.
 Locks and tags cannot be used for other purposes.
 Locks must meet the following requirements:
o Capable of withstanding the environment to which they are exposed for
themaximum period that exposure is expected
o Standardized in at least one of the following criteria: color, shape, or size
o Substantial enough to prevent removal without the use of excessive force
or unusualtechniques, such as bolt cutters or other metal cutting tools
 Tags must meet the following requirements:
o Standardized print and format and in at least one of the following
criteria: color,shape, or size
o Constructed and printed so that exposure to weather or wet and damp
locations does not cause the tag to deteriorate or the message on the tag
to become illegible
o Does not deteriorate when used in corrosive environments such as areas
where acidand alkali chemicals are handled and stored
o Attach securely using tie wraps (or equivalent) capable of withstanding 50
pounds offorce
o Indicate the date and identity of the employee applying the device(s) or
the identityof the group lockbox
o Contain identifying information about the person who applies it and the
controlpoint
o Contain a statement prohibiting operation of the disconnected
equipment andremoval of the tag.
o Warn against hazardous conditions and include a legend such as: “Do Not
Start, DoNot Open, Do Not Close, Do Not Operate.”

4. Lock-Out Tag-Out (LOTO) Procedures

4.1 Prepare for Shutdown

Notify all affected employees that servicing or maintenance is required on a specific

machine or equipment and that the machine or equipment must be shut down and
locked out to performservicing or maintenance.

4.2 Shut Down and Isolate Equipment

 If the machine or equipment is in operation, shut it down using its operating

controls or shutdown procedure (e.g., depress stop button, open switch, close
valve).

 If possible, lock out all electrical breakers (if applicable) first to prevent
unexpected startup of equipment while isolating valves, etc.

 Position the energy isolating device(s) so that the machine or equipment is

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 isolated from the energy source(s). Ensure that a disconnect switch, circuit
breaker, valve, or other energy- isolating mechanism is the SAFE or OFF position.

4.3 Apply Lockout/Tagout Devices

 Lock and tag each energy isolating device with assigned individual locks/tags.
Each authorized individual conducting maintenance or servicing must attach his
lock and tag to each energy- isolating source.

 If a tag cannot be affixed directly to the energy isolating device, attach the tag as
close to the isolating device as possible, in a position that will be immediately
obvious to anyone attempting to operate the energy isolating device.

4.4 Control Stored (Potential) Energy

 Inspect each system to ensure that all parts have stopped moving.

 Install ground wires.

 Relieve trapped pressure.

 Release the tension on springs or block the movement of spring-driven parts.

 Block or brace parts that could fall. Use jacks and jack stands under vehicles.

 Block parts in hydraulic and pneumatic systems that could move from loss of
pressure. Bleed the lines and leave the vent valves open.

 Drain process piping systems and close valves to prevent hazardous material
flow.

 If a line must be blocked where there is no valve, use a blank flange.

 Purge reactor tanks and process lines.

 Allow dissipation of extreme cold or heat. If time does not allow full dissipation,
wear protective clothing.

If stored energy can re-accumulate, monitor it to ensure that it stays below hazardous
levels.

4.5 Check Safe Condition

 Ensure that the equipment is disconnected from the energy source(s). First, check
that no personnel are exposed, then verify the isolation of the equipment by
operating the energy control device(s) or by testing (e.g., voltmeter) to make
certain that the equipment will not operate.

 Return operating control(s) to neutral or “off” position after verifying the

isolation of the equipment.

 The machine is now locked out.

4.6 End-Of-Shift Procedures

 If only one shift or individual is to work on the equipment, system, or machine,

the attachedlocks/tags remain in place until maintenance/servicing is complete.

 Where a second or third shift will continue maintenance or service initiated by

the first shift, the authorized individuals from transitioning shifts conduct a
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 turnover of the tasks, systems, etc. The off- going shift personnel remove their
locks and tags, and the on-coming shift personnel install their ownlocks and tags in
accordance with the LOTO procedure.

All works must follow the process model shown in Figure 1.

Figure 1. Process Model

5. Lock-Out Tag-Out (LOTO) Procedure for Mobile Equipment

To prevent injury from unexpected start-up of vehicles and powered industrial
equipment during servicing or maintenance operations, the authorized employee
performing the maintenance or service institutes the following procedures:
 Remove the keys from the ignition and maintain control of them throughout the
time theequipment is serviced.
 Attach a tag at the point of operation (the steering mechanism or control panel)
and in aneasily seen location on the vehicle or equipment being serviced.
 Take at least one other safety measure to make the vehicle or equipment
inoperable (e.g.,remove cables from the battery).
 Block the wheels of the vehicle to prevent accidental movement.
 Secure all hydraulic systems to prevent their accidental movement.
 Where possible, guard all sharp instruments or blades to prevent accidental injury.
 Permit only authorized personnel in the work area.

6. Service, Maintenance, and Temporary Reactivation

If equipment must be temporarily reactivated, the authorized employee performing the
maintenance or service institutes the following procedures:
 Safeguard all employees by conducting a headcount to make sure everyone is clear
of theequipment.
 Notify everyone in the area that LOTO is being removed.
 Check the machine or equipment and the immediate area around the machine to
ensure that nonessential items have been removed and that the machine or
equipment components are operationally intact.
 Remove all LOTO devices and re-energize the system.
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  As soon as the energy is no longer needed, isolate the equipment and reapply
LOTO.

If servicing equipment requires more than one work shift, do not interrupt LOTO
protection. Employees leaving work must not remove their locks until the next shift
arrives and is ready to lock out.

7. Restoring Equipment to Service

This procedure must be followed when removing LOTO:
 Safeguard all employees by conducting a headcount to make sure everyone is clear
of theequipment.
 Notify everyone in the area that LOTO is being removed.
 Check the machine or equipment and the immediate area around the machine to
ensure that nonessential items have been removed and that the machine or
equipment components are operationally intact.
 Check the work area to ensure that all employees have been safely positioned or
removedfrom the area.
 Verify the equipment or machine controls are in neutral.
 Remove LOTO devices and re-energize the machine or equipment. Note: The
removal of some forms of blocking may require re-energization of the machine
before safe removal.
 Notify affected employees that servicing or maintenance is completed and the
machine orequipment is ready for use.
 Remove the LOTO devices. Each device must be removed by the person who
attached it.

In some workplaces, the last person to remove a lock may have extra duties, such as
removing the hasp and lockout device, and removing tags, signing them, and turning them
in. The exception would be in some cases in which the client’s designated personnel
remove their locks and tags last.

8. Lock/Tag Removal by Other than Authorized Workers

Only the employee(s) who applied the LOTO device(s) is/ are authorized to remove that
device. If the person who applied the device is not available, the device may be
removed by the authorized employee’s supervisor if the following requirements are met
(the supervisor must submit a written report to the superintendent outlining the removal
of locks/tags and the reason for this action):
 The machine/equipment must be placed in service because of an emergency.
 If the employee is not available, the supervisor must:
o Verify that the authorized employee who applied the device is not at the
facility.
o Make all reasonable efforts to contract the employee to advise him that
the device has been removed.
o Ensure that the authorized employee knows that the device has been
removed before he returns to that job.
o Verify that task that was being performed is complete or that the task is
at a point where the equipment or machine can be put back in service
without damage to the equipment, machine, or personnel. Page 8 of 14
After verifying that the equipment is safe, the Contractor's Project Manager in charge of
the workdirects the removal of the lock.

9. Group Lock-Out Tag-Out (LOTO)

9.1 Group LOTO Procedure

The Contractor shall include a group LOTO procedure to address cases in which
equipment or machinery maintenance or servicing is provided by a group. The following
requirements apply to thegroup LOTO procedure:
 The group Supervisor has primary responsibility for all employees working under
the protection of a group LOTO.
 The group Supervisor ensures that the protection of each employee in a group
LOTO is equal to or better than that of individual LOTO.
 When more than one crew is involved, the responsibility of the overall job-
associated lockout or tagout control is assigned to an authorized employee
designated to coordinate affected work forces and ensure continuity of protection.
 Each authorized employee affixes a personal LOTO device to the group lockbox when
he begins work and removes those devices when he stops working on the machine
or equipment being serviced or maintained.
 The crew or group using a group lockout device places the keys to the locks in a
lock box and locks that box.

10. Periodic Inspection

 To ensure that procedures and requirements are being followed, a designated
authorized employee (other than those using the energy control procedure)
conducts a monthly inspection. The authorized employee submits the completed
inspection forms to the H&S Representative each month.
 Designated H&S or supervisory personnel conduct weekly inspections of locations
selected to verify the continued need for each lockout and to ensure lockout
devices and tags are still in place.
 The Contractor/Consultant reviews the inspection forms and monitors the
effectiveness of the program.

11.Lock-Out Tag-Out (LOTO) Exceptions

This element does not apply to work on cords and plug electric equipment where
exposure to the hazards of unexpected energization or startup of the equipment is
controlled by unplugging the equipment from the energy source and keeping the plug
under the exclusive control (within arm’s reach and line of sight) of the employee
performing the servicing or maintenance.

LOTO is not required when all of the following elements exist:

 The machine or equipment has no potential for stored or residual energy or re-
accumulationof stored energy after shutdown that could endanger employees.
 The machine or equipment has a single energy source that can be easily identified
and isolated,and
 The isolation and lockout of that energy source completely de-energizes and
deactivates themachine or equipment.
 The machine or equipment is isolated from that energy source and locked out
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 during servicingor maintenance.
 A single lockout device achieves a locked-out condition.
 The lockout device is under the exclusive control of the authorized employee
performing the servicing or maintenance and may not be used by or shared with
other employees.
 Servicing or maintenance does not create hazards for other employees.
 Servicing and/or maintenance activities that take place during normal operations
are coveredby this LOTO procedure only if:
 An employee is required to remove or bypass a guard or other safety device.
 An employee is required to place any part of his body into an area on a machine or
piece of equipment where work is actually performed on the material being
processed (point of operation) or where an associated danger zone exists during a
machine operating cycle.

Minor tool changes, adjustments, and other minor servicing activities that take place
during normal production operations are not covered by this procedure if they are
routine, repetitive, and integral to the use of the equipment for production, provided
that the work is performed using alternative measures to provide effective protection.

12.Training
 The Contractor trains affected and authorized employees in the project LOTO plan
to be used on theworksite.

 The Contractor arranges employee training at the time of their initial assignment
and whenever a new hazard is introduced to the jobsite. Supervisors are
responsible for identifying additional employee training needs during risk
mitigation planning (2-week look-ahead).

12.1 Affected Employee

An affected employee is an employee whose job requires him to operate or use a

machine or
equipment on which servicing or maintenance is being performed under a tag, lock, and
try procedure, or whose job requires him to work in an area in which such servicing or
maintenance is being performed.

Each affected employee is instructed in the purpose and use of the Lockout/Tagout
Procedure.

12.2 Authorized Employee

 An authorized employee tags, locks, or tries machines or equipment in order to
perform servicing or maintenance on that machine or equipment. An affected
employee becomes an authorized employee when that employee’s duties include
servicing or maintenance.
 Each authorized employee receives training in the recognition of applicable
hazardous energy sources, the type and magnitude of the energy available in the
workplace, and the methods and means necessary for energy isolation and control.
 Authorized employees are trained in the type and magnitude of energy and must
understand the hazards of that energy.

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12.3 Other Employees

The Contractor discusses the project LOTO procedure during the initial orientation with
occasional and business visitors, as well as Contractors whose work operations are or
may be in an area where energy control procedures may be used. Training includes
general information about the procedure and about the prohibition relating to attempts
to restart or re-energize machines or equipment thatis locked and/ or tagged out.

12.4 Retraining

Retraining is provided for all authorized and affected employees when there is a change
in their job assignments, a change in machines, equipment or processes that present a
new hazard, or a changein the energy control procedures.

Additional retraining is conducted when there are deviations from, or inadequacies in,
the employee’s knowledge or use of the energy control procedures. The retraining re-
establishes employee proficiency and introduces new or revised energy control methods
and procedures, as necessary.

13. Documentation
 The Contractor H&S Representative documents all LOTO instruction, training, and
retraining records. Records verifying completion of LOTO training are kept in the
individual employee’s training files.

 Lockout/Tagout Permits which have been closed out will be retained on file by

the Contractor.Contractor H&S personnel maintain the LOTO requests and logs.

 In each instance that a lock is removed by any person other than that applying the
lock, the supervisor submits a report to the Project Manager for review. The
Contractor maintains a file of these reports.

 The Contractor maintains a file for completed monthly LOTO inspection reports.
The Contractor also maintains LOTO project records at the site for the duration of
the project and archives them for a minimum retention time of 10 years from
creation date.

13.1 Attached LOTO Forms

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 TAMIMI GLOBAL CO. LTD.
LOTO PROCEDURES
Lock out/Tag Out procedures are to be completed before any service or maintenance work on equipment
or machinery, and/or before entry into any grain bin or other area where operating equipment poses a
hazard to the entrant. Failure to follow proper lockout-tag out procedures may result in disciplinary action
up to and including termination.
1. Each LOTO will follow the general process listed below.
2. LOTO will follow the specific instructions for each piece of equipment/machinery to identify,
disconnect, isolate, lock out and verify the lock out of the appropriate energy sources.
3. Ending LOTO – follow the general LOTO Release process listed below, using the specific instructions
for the equipment to activate energy sources.

General Lockout Steps

# Step Instruction Additional Information
1 Notify Employees Notify all affected employees what machine/equipment
will be shutdown and locked out.
2 Review Procedures Ensure each person performing LOTO (authorized
employee) understands the type and magnitude of the
energy present, the associated hazards and the proper
methods of control.
3 Shutdown Equipment If the machine or equipment is operating, shut it down by
the normal stopping procedure.
4 Disconnect & Isolate Disconnect/de-activate the energy isolating devices(s) so
the Energy Source the machine or equipment is isolated from the energy
source(s).
5 Lockout Controls Lockout and tag out the energy isolating device(s) as
indicated in the specific instructions
6 Release Energy Release and/or dissipate any stored or residual energy as
indicated in the specific instructions.
7 Try out Verify the energy source has been isolated as indicated in
specific instructions.
Lockout Release Steps
# Step Instruction Additional Information
1 Inspect Equipment Check the equipment to ensure the components are
operational.
2 Check Area Check the immediate area to ensure all employees have
been safely positioned, and tools and any nonessential
items have been removed.
3 Check Controls Verify that operating controls are off (not on).
4 Re-energize Remove the lockout device(s) and activate the energy
isolating device(s) to re-energize the equipment.
5 Notify Employees Notify affected employees the servicing or maintenance is
completed and the equipment is ready for use.
6 Startup Equipment Startup equipment and monitor for several operating
cycles to ensure it is functioning properly.

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 TAMIMI GLOBAL CO. LTD.
SPECIFIC LOTO INSTRUCTIONS
Company Name

Equipment ID: Date Created:

Description: Person:
Facility: Date Revised:
Location: Person:

#1 Lockout Points Identify where the lock out points are located.
Picture of lockout points goes here. Picture of lockout points goes here.

#2 Lockout Instructions Follow the lock out instructions below.

Any machine modifications must be shown in this procedure. Contact facility manager to update this
procedure.
Energy Source Device used Always
to performLocation
a machine stop before locking
Method out Try
De-energize disconnects. Out
Check to Verify
Equipment is De-
energized

# SPECIAL INSTRUCTIONS
1.
2.
3.
Reference: Typical minimal lockout procedure – 29 CFR 1910.147 App. A
Enforcement: Failure to follow proper lockout-tag out procedures may result in disciplinary action up to and including termination.

SAFETY IS YOUR RESPONSIBILITY – LOCK IT OUT!

*** End of Document ***

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