HEALTH AND SAFETY MANUAL

DHI-EHS-HSM-009

LOCK-OUT AND TAG-OUT

Copyright This document is the property of Doosan Heavy Industries and Construction and all rights are
reserved in respect of it. This document may not be reproduced or disclosed in any manner what so ever, in
whole or in part, without the prior written consent of Doosan.

Doosan expressly disclaims any responsibility for or liability arising from the use
of this document by any third party. Copies printed are UNCONTROLLED.

Revision Details Next Review: January 2015

Rev. Date Revision Status Checked Approved

00 31/03/2014 Draft Yonghyun Kim Seungmin Park

DHI-EHS-HSM-009 (March 2014), Page 1 of 7

PURPOSE AND SCOPE

The purpose of this procedure is to establish safe performance objectives for the protection of personnel in, on,
or around machines or equipment during construction, installation, pre-commissioning, commissioning, start-up,
repair, maintenance, operation, and associated activities, from injury due to unexpected energisation, start-up, or
release of stored energy from the equipment. This document describes the procedures for the lockout, tagging
and installation of energy isolating devices to systems and/or components for isolation, testing or temporary
operations. It includes the sequence to be followed for Electrical Isolation and shall be used as the project
construction, pre-commissioning and commissioning Lock-Out and Tag-Out procedure.
The objective is to accomplish the above by means of affixing appropriate locking and tagging to the energy
isolating devices of the machine or equipment/ process according to this procedure.

DEFINITION
Lock-Out and Tag-Out:
The placement of “DO NOT OPERATE” tags and locking devices with keys, on a system at points, whereby any
transmission or change in energy potential within the system or part of the system is isolated from the point of
endangerment to a worker and whereby a visible warning is placed indicating that the system shall not be
operated until removal of the locking and tagging energy isolating device in accordance with the procedure.

Lock-Out and Tag-Out Device:

A prominent warning device that is capable of being securely attached and locked by means of an Energy
Isolating Device for the purpose of protecting personnel. It prevents the operation of an energy isolated system
or device, or removal of energy isolating devices or Lock-Out and Tag-Out devices and identifies the applier or
authority who has control of the Lock-Out and Tag-Out.

Energy Source:
Any electrical, mechanical, hydraulic, pneumatic, chemical, thermal, gravitational, or other energy source that
could cause injury to personnel.

Energy Isolating Device:

A physical locking device that prevents the transmission or release of energy, including, but not limited to the
following:
 Manually operated electrical circuit breaker;
 Disconnect switch;
 Manually operated switch;
 Similar devices with a visible indication of the position of the device;
 Blinds and/or isolation valves;
 Locks and chains;
 Chains.
*Note: Push buttons, selector switches, and other control-circuit type devices are not energy isolating
devices.

Competent Person:
A person, who has undertaken specialized Training, is authorized to work on Process, Mechanical,
Instrumentation or Electrical Equipment and knows the effect of operating controls and/or equipment.

DHI-EHS-HSM-009 (March 2014), Page 2 of 7

Authorised Person:
A person, who will isolate the equipment to avoid the release of stored energy, noting the method of isolation
used, be it blinding lines / electrical isolation etc.
In the case of electrical equipment, the isolation must be carried out by personnel with electrical background who
has been trained and authorized by the Site Manager. The authorized person for lock-out and tag-out of
electrical equipment or installations shall be accredited for the voltage of the network.

Requester:
A person who requests a system, device, or component be isolated and/or secured by a means of a Lock-Out
and Tag-Out devices.

PROCEDURE

1.0 Responsibility

1.1 Lock-Out and Tag-Out Procedure

It shall be the responsibility of the EHS Manager to develop, document, and implement a procedure for Lock-Out
and Tag-Out. This procedure shall require all personnel to comply with the Lock-Out and Tag-Out procedure.

1.2 Authority and Responsibility

Implementation of this procedure shall be under authority and the responsibility of the Site Manager.

1.3 Auditing Inspections

It shall be the responsibility of the EHS Manager to verify compliance with this procedure via periodic auditing
inspections.

1.4 Procedure Implementation

All employees, once instructed on this procedure, shall be responsible for knowing and following the procedure.
Non-compliance with this procedure shall be grounds for disciplinary action and/or termination of the individual.

2.0 Requirement

2.1 Authorized Person

 Processes requests and co-ordinates Lock-Out and Tag-Out activities.
 Makes appropriate control log entries to control and track the Lock-Out and Tag-Out activities.
 Maintains up-to-date control logs, including checking the logs on a periodic basis for status of tags in
use.
 Issues and installs tags and energy isolating devices e.g., locks on requested systems, devices or
components.
 Designates who will maintain the tag stubs, keys for locks, and how they will be maintained and
controlled.
 Removes tags and energy isolating devices, locks on requested systems, devices or components.
 Remove locks per established procedures if the appropriate Lock-Out and Tag-Out tag stubs cannot be
found. No locks shall be removed without written and recorded consent of area Superintendent.
 Maintains a lockable safe box for padlocks and keys.

2.2 Requester
 Identifies the components, devices and/or boundaries of systems to be isolated by tagout and submits a
request to the Lock-Out and Tag-Out Authorized Person (with drawings/ P&ID’s/ Single Line Diagrams if
appropriate).
 Assures that the system status and configuration is appropriate for the requested Lock-Out and Tag-Out.
 Co-ordinates with the Lock-Out and Tag-Out Authorized Person for system and isolation activities that

DHI-EHS-HSM-009 (March 2014), Page 3 of 7

 affect multi-disciplines and/or subcontractors to ensure correct Lock-Out and Tag-Out and installation of
Energy Isolating Devices.

 Assists in the placement of Tags/locks and other energy isolating devices on appropriate components,
devices, and/or boundaries per the direction of the Lock-Out and Tag-Out Authorized Person.
 Returns and signs record of locks used to the Lock-Out and Tag-Out Authorized Person when the
requirement for the lockout is no longer required.
 Only the person putting the lock on a system has the authority to remove it.

2.3 Employee
 Verifies that the device, component or system is properly isolated with a Tagging/Lockout, and that the
work can be performed safely. Verification shall be accomplished by assuring that all circuit breakers,
switches, valves, etc. are in the proper position; all blinds are properly installed; and/or blocks are
properly installed to provide for safe working conditions.
 Performs work on a device, component, and/or system only after a lock(s) has been properly installed.

3.0 Safety Tag Description Use and Regulations

3.1 DO NOT OPERATE - Black and Red on White Tags.

The "DO NOT OPERATE" tag has the highest priority of all system isolation tags. The rules for using it include
the following:
 Tag-out/Isolation/Blinding incorporating the “DO NOT OPERATE” tag and locks shall be used to isolate
devices, components, or systems when there is a potential for personal injury or equipment damage.
 Do not operate, energize, remove locks, or otherwise disturb a component, device or system with this
tag installed on it.
 Only those craft, discipline or sub-contractor under direct supervision of the requestor may work on a
component, device or system that has been isolated by a lockout and tag-out. A separate lock and tag-
out shall be accomplished for each requestor.
 A device or component (switch, circuit, breaker, valve, blind etc.) shall remain in the specific position
designated by the requestor and approved by the Lock-Out and Tag-Out Authorized Person during the
time that an isolation device is in place.
 Use tag and its supporting boundary tags to identify limits of adjacent systems or components that are
not included in the clearance.
 When more than one craft or discipline is working on a system, the requestor for each craft must have
the system isolated. Separate tags and locks are issued for each craft by the tagging authority. The
tagging authority must not remove any tag without the corresponding numbered stub.
 A component (valve, blind, switch, or circuit breaker) must remain locked in a specific position during the
work activities, and its position must be written in the tag. Only the appropriate tagging authority may
enter special instructions or information on the back of the tag.

3.2 Caution in Test Tag

The "CAUTION IN TEST" tag may be used on systems or components that are undergoing preliminary testing.
The requestor must ensure that all personnel working in adjacent areas are pre warned of any possible danger.
The rules for using this tag and its supporting boundary tag must include, but are not limited to the following:
 This tag does not constitute a tag-out or lock-out
 Shall be used on devices, components, or systems that are undergoing preliminary testing (i.e. control
circuit verification, motor bumping, pressure testing, line blowing etc.)
 Shall be used for individual components or devices being operated under the direction of a Doosan
superintendent or designee.
 No construction work can be done on a device, component, or system with this tag installed.

DHI-EHS-HSM-009 (March 2014), Page 4 of 7

  Cannot be placed on a device or component that has a tag-out installed.
 Only authorized personnel, assigned by the Lock-Out and Tag-Out Authorized Person, can operate,
energize, or work on a system component or device once this tag has been installed, except if a
component or device has to be de-energized for safety or emergency reasons.
 Must remain on all devices and/or components until testing or operations have been completed and
items isolated with a tag-out.
 Permanent plant equipment being used during construction shall have this tag applied to indicate that
the device or component is being used.
 A lock(s) will also be attached.

3.3 In Service Tag

 The "IN SERVICE” tag applies to temporary construction services which facilitate general
construction activities (e.g. construction service water, construction air and gas, construction
power) as well as to any permanent plant component or system that has been pressurized,
energized, or otherwise placed in service by the appropriate Lock-Out and Tag-Out Authorized
Person.
 Any service or system must be locked and tagged with “In service" tags and a log of all systems
that have been tagged with “In service” tags maintained by the construction tagging engineer.
 If a personnel hazard exists, a “DO NOT OPERATE” tag and lock(s) must be used.

The rules for using the “In Service” tag include the following:

 The requestor must fully identify the component/system (by the use of a marked up P&ID or
Electrical Single Line Diagram) and specify all points to be locked/tagged. He must also stipulate
why the component/system needs to be tagged and locked.
 The appropriate Lock-Out and Tag-Out Authorized Person must evaluate the request and, if in
agreement, lock/tag the component/system as "IN SERVICE". The Lock-Out and Tag-Out
Authorized Person is the only individual who can physically lock and tag "IN SERVICE"
components/systems.
 The appropriate area engineer must determine that all pre-service test criteria have been met and
verify with the appropriate disciplines that all other technical requirements are met, including
approvals, before locking and tagging any system or component for the applicable operation.
 Construction work may not be performed on any component or system that is identified with an "IN
SERVICE" unless a "Construction Work Clearance" or "Construction in Test Clearance" is
obtained first.
 Once an "IN SERVICE" tag is attached to a system or component, it cannot be removed by
anyone except the Lock-Out and Tag-Out Authorized Person and only under the following
conditions.
 The "IN SERVICE" tag may be replaced by a Project jurisdictional (green) tag when the
component/system is released to the Commissioning group.
 The "IN SERVICE" tag must be removed when a component or a system is shutdown for
extended construction activities. In this case a request will be submitted to the tagging authority
stating:
 The full extent and description of the component/system.
 The reason for the request to take the component/system out of service.
 How long the component/system will be out of service.
 The appropriate Lock-Out and Tag-Out Authorized Person must review the request in detail with
the affected construction discipline. Only after agreement is reached can the component/system
be taken out of service and the tags removed and replaced with the other appropriate tags.
 Components/systems identified with an "IN SERVICE" tag may be operated, pressurised, or
energised only by personnel authorised by the requestor.

DHI-EHS-HSM-009 (March 2014), Page 5 of 7

3.4 Sequence for Tagging
The following sequence shall be followed from the time a Lock-Out and Tag-Out request is made until the
Lock-Out and Tag-Out Authorized Person has removed the tags.

REQUESTOR

Prior to starting work the requestor shall:

 Identify the devices, components or system boundaries to be isolated.

 Verify that the system boundaries and components can be isolated.
 Determine the extent of lock-out/tag-out required including blinding, purging etc.
 Co-ordinate discipline and subcontractor interface requirements.
 Request the Lock-Out and Tag-Out Authorized Person to install the lock(s) and tag-out(s).
 Install personal lock(s) devices (after the Tagging Authority has isolated the system).

After work has been completed the requestor shall:

 Review the work to make sure that all work has been completed and that removing the lock(s) and
tag-out(s) will not create a potential safety hazard to personnel, or potential for equipment
damage.
 Obtain the tag-out tag stubs; sign and date the tag-out stub and return to the Lock-Out and Tag-
Out Authorized Person.
 Remove any personal locking device(s).

LOCK-OUT AND TAG-OUT AUTHORIZED PERSON

Prior to starting work the Lock-Out and Tag-Out Authorized Person shall:

 Review the lock-out/isolation/tag-out request with the requester.

 Complete the appropriate entries in the control log for each lock and tag-out being issued.
 Install the lock(s) and tags on the designated devices, components, or system boundaries.
 Isolate the requested equipment and install locking device(s).
 Hold the isolating locking device keys when applicable in a secure key safe/box.

After work has been completed the Lock-Out and Tag-Out Authorized Person shall:

 Verify that the serial number of the DO NOT OPERATE tag stub being returned corresponds with
the serial number of the tag attached to the tag-out. No tag-out(s) and locks can be removed until
these serial numbers have been matched.
 Visually check that the work is complete and the workplace is intact.
 Once satisfied that all precautions have been met, remove the tag-out.
 Make appropriate Control Log entries.
 Inform requestor that the system is now live.
3.5 Removing Tags without Proper Matching Signatures.
If a tag-out or lock must be removed, and the corresponding tag-out tag stub lock serial # cannot be found,
only the Lock-Out and Tag-Out Authorized Person can remove the tag-out after the following steps have
been completed.

 Verify that all reasonable efforts have been expended to obtain the tag-out tag stub and key holder
of the lock.
 Verify that the requestor has been notified and has acknowledged that the tag-out and lock can be
removed.

DHI-EHS-HSM-009 (March 2014), Page 6 of 7

  Verify that it is essential to remove the tag-out and lock.
 Verify that the releasing boundaries, components or devices will not create an unsafe condition for
personnel or cause equipment damage.

After the lock and tag-out has been removed, the circumstances shall be recorded in the appropriate daily
and tagging control logs.

4.0 Padlocks
The Lock-Out and Tag-Out Authorized Person controls the use of padlocks. Padlocks must be used at all
times.

When padlocks are used to "Isolate or Lock-out" a particular system or component, they must be
accompanied by a "DO NOT OPERATE" tag.

After the tag and lock have been installed, the key is attached to the tag stub and locked within the Lock-
Out and Tag-Out Authorized Person key box.

The requestor can then attach his own personal lock to the System lockout device. Only personnel
assigned as tagging authorities can install or remove locks.

Padlocks shall be used when work or test activities require personnel to perform work on electrical
equipment, electrical driven equipment, motors, steam driven equipment, pressurized vessels etc.

DHI-EHS-HSM-009 (March 2014), Page 7 of 7