Lock-out & Tag-out

TRAINING

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Course Contents
 Purpose of Lock-out / Tag-out.
 Who is responsible for implementing Lock-out / Tag out?
 What is a Lock-out?
 What is a Tag-out?
 When do we need to perform Lock-out, Tag-out & Try?
 The Four E’s of Lock-out / Tag-out
 7 Steps on - How to Apply Energy Controls?
 5 Steps on - Removing Lock-out / Tag-out
 Fatal Case Studies
 Conclusion

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 Purpose of Lock-out / Tag-out

The objective of lock & tag-out is to

prevent any inadvertent activation or
energisation of any plant, machinery or
equipment while any person is involved with
any inspection, cleaning, repair or
maintenance on it.

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Purpose of Lock-out / Tag-out

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 Purpose of Lock-out / Tag-out
Statutory requirements under Section 24A
Lock-out Procedures of the The Factories
(Amendment) Act 2000.
To ensure that all energy sources to the
relevant plant, machinery or equipment will be
isolated, disconnected or discharged; &
to prevent any part of the plant, machinery or
equipment from being inadvertently activated
or energised.
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Who is responsible for implementing the Lock &
Tag out requirements at the work place?

Section Heads are to ensure that Staffs follow the

procedure (QP-038) strictly.

EHS Manager shall provide training & to staffs

identify by section head to perform LOTO. (Training
records to be kept for 5 years)

Facilities/ Equipment is responsible for conducting

LOTO briefing to Contractors before any works are
carried out.
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Who is responsible for implementing the Lock &
Tag out requirements at the work place?

• Section heads / Engineer / Technician in

charge of the equipment / machinery and
process.

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 De
Da
Na

pt
me What is a Lock-out?
te
Te
l

A process of keeping equipment

from being set into motion or re-
energised by using a locking device
A disconnect switch, circuit breaker is secured in a
safe or off position
A device is placed over the energy-isolating
mechanism to hold it in the safe or off position
A lock is attached so the device cannot be moved
and the equipment cannot be energised

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 What is a Lock-out?
A tag used as a warning for
equipment not be re-energise - it is
not a physical restraint
An energy-isolating device placed in the safe or
off position
A tag with a written warning, “Do Not Operate” is
SW DO
placed on the device IT NO
C T
Na H O
The tag is signed by the person locking outmetheN
De
equipment Da
pt
te
Te
l

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 When do we need to perform
Lock-out / Tag-out & try?
When performing inspection, cleaning, repair or
maintenance around any machine where the
following could occur :
Unexpected start-up of equipment
Release of stored energy
When a guard or other safety device must be
removed or bypassed.
When you must place your body where you
could be caught by moving machinery.
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The Four E’s of Lock-out / Tag-
out
Energy
Engineering
Education
 Enforcement

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 Energy
Energy is movement or the possibility of
movement
Energy is always present in any powered
equipment
Energy may be in motion (kinetic energy)
Energy may be stored (potential)
Pneumatic, mechanical, hydraulic,
electrical, thermal & gravitational energy

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 Engineering
Some examples of protective
engineering are :
 Machine guards
 Electrical disconnectors
 Mechanical stops (I.e. pins, valves, etc.)

Engineering Lock-outs, which provide

automatic protection against human
error
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 Education
2 ways to ensure that you understand
the LOTO Policy
Employee Training
to explain how the policy works
Documentation
a written energy control plan
proof of training

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 Enforcement
 Enforcement is necessary to ensure
workers do their part in protecting
their own safety
 An audit must be conducted once a year
to ensure energy control procedures are
being carried out
 Enforcement must be carried out by
managers. Penalties for failure to follow
written procedure

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 7 Steps on - How to Apply
Energy Controls?
 1st Step - Announce the shutdown
 inform personnel working on the plant, machinery or
equipment

 2nd Step - Prepare for shutdown

 know what the energy hazard is
 know how the energy is controlled
 have the right LOTO devices

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 7 Steps on - How to Apply
Energy Controls?
 3rd Step - Equipment shutdown
 proceed to shut down by normal operating procedure

 4th Step - Equipment isolation

 isolate all energy sources - main & secondary power
supplies
 never pull an electrical switch while under load
 never remove a fuse instead of disconnecting
 energy-isolating devices, such as manually operated
circuit breakers or isolating switches are used for
disconnecting energy sources.

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 7 Steps on - How to Apply
Energy Controls?
 5th Step - Application of LOTO
Devices
 all devices must be locked, tagged or both
 Tag-out should only be used alone when Lock-out is
impossible
 the lock should be placed directly on the energy control; use
a device if this is not possible
 every employee working on locked out equipment must put
their own lock on
 only the person who put the lock on can remove the lock
 tags must be put on with the locks
 if only tags,attached them where the lock would go
 fill out tags with name and date
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 7 Steps on - How to Apply
Energy Controls?
 6th Step - Control of Stored energy
 make sure all parts have stopped moving
 install ground wires
 relieve trapped pressure
 release tension on springs or block movement of parts
 block or brace parts that could fall due to gravity
 bleed lines and leave vent valves open
 drain process piping systems and close valves to prevent
the flow of hazardous materials
 use a blank flange to block a line where there is no valve
 purge process lines
 dissipate extreme cold or heat, or wear PPE
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 7 Steps on - How to Apply
Energy Controls?
 7th Step - Verify Equipment Isolation
Completion
 release any residual or stored energy in capacitors
 ensure all danger areas are clear of personnel
 verify the that main disconnect switch or circuit breaker
cannot be moved to the ‘on’ position
 use a voltmeter or other equipment to check switch
 press all start buttons & other activating controls on the
equipment itself to ensure start-up cannot occur
 shut off all machine controls when the testing is finished

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 5 Steps on - Removing Lock-
out / Tag-out
Ensure equipment is safe to operate
 be sure system is fully assembled
 remove all tools from work area
Safeguard all employees
 make sure everyone is clear from machine
Notify workers that the machine would
be turned on

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 5 Steps on - Removing Lock-
out / Tag-out
Removed LOTO devices & re-
energise machine
*If a worker who put on the lock forgets to remove it &
leaves, only the manager can remove the lock
Inform personnel assigned to operate
machine that it is ready for use.

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 Fatal Case Studies
 Case I
 Electrical technician caught between the retracting
arm of the aerobridge at Changi Airport
 Left behind a widow-45, two daughters-23 & 21

 Case II
 Production Superintendent crushed to 1/8 of an
inch by hydraulic press before Christmas !
 Left behind a family. He had 3 young children,
ages 5, 7, and 9

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Items inside Nepes LOTO KIT
3 x Long Shackle padlock
3 x standard shackle padlock

1 x PSL A
1 x PSL-MLD
Multiple locking device

3 x wall switch lockout

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Items inside Nepes LOTO KIT
PSL - MLD

PSL-CB
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 Conclusion
 What does Lock-out / Tag-out prevent?
 Accidental start-ups, electric shock, disabling injuries & death.

 Next Practical Lesson : -

 Using the LOTO kits, practice on locking out & tag out the
machine power supply and DB board power supply.

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