Health Safety and Environment Training Course

Isolation & Lock Out and Tag Out

(LOTO)

19 November
Domestics
For your safety & comfort…

▪ Fire alarm, means of escape & muster point

▪ First aid

▪ Toilets/ rest-room

▪ Refreshments/ lunch

▪ Smoking policy

▪ Mobile phones

▪ Fitness to undertake practical activities

In line with BP Golden Rules
AGENDA

▪ Introduction:
▪ Rules and Regulations:
▪ Hazardous Energy
▪ Competent Person
▪ Isolation
▪ Lockout
▪ Tag Out
▪ Requirements
▪ Isolation Confirmation Certificate (ICC)
▪ Isolation Categories
▪ Steps to Isolation and De-Isolation
Introduction

What is Isolation & LOTO?

Process of de-energizing equipment and making it safe for
maintenance, inspection, etc.

Isolation and LOTO procedures are in

place to ensure employees understand
sources of hazardous energy,
understand how to turn them off AND
lock out & tag out them to prevent
accidents
Introduction

Why Isolation & LOTO?

Large numbers of workers are killed or injured due to non-isolated
or unexpected starting of equipment

Statistics (USA and Canada)

▪ One of major cause of serious
injury and death
▪ 120 fatalities / year
▪ 50,000 electrical injuries / year
Introduction

Main Causes of LOTO injuries

▪ Failure to stop equipment

▪ Failure to disconnect from main energy source

▪ Failure to dissipate (bleed, neutralize) stored energy

▪ Accidental re-start of equipment during maintenance

▪ Failure to clear work area before re-starting

Rules and Regulations

CSTS applies “industry best practice” standards and

guidelines:
▪ UK HSE - “The safe isolation of plant and equipment” HSG253

▪ OSHA - “Standard for the Control of Hazardous Energy

(Lockout/Tagout)”

Specifics Site/Project procedures are in place

for different activities and types of energy
Rules and Regulations

Employer’s Duty:
▪ Establish an energy-control program - procedures for
removing the energy supply from machines
▪ Train employees on the energy-control program
▪ Inspect these procedures periodically
Rules and Regulations

Employees’ Duty:

▪ Follow all Isolation and LOTO procedures

▪ Must not either remove or bypass isolations, locks, tags,
machine guards or other safety devices
Hazardous Energy

Hazards associated to:

▪Unexpected Energization

▪Unexpected Start-up

▪Release of Stored Energy

Hazardous Energy Types and Discharge

Electricity
• Capacitors should be discharged and current
disconnected and/or removed

Mechanical
• High and low speed rotating elements need to be
run down and springs released



Pneumatic
• The system should be depressurized. If valves
could be operated by residual trapped air, the
line should also be disconnected 
Hazardous Energy Types and Discharge

Hydraulic
• Accumulators and pressurized pipework must
be depressurized

Chemical
• Acid, base, toxic substances, etc. must be
removed as far as practicable

Physical
• Heat/cold – time must be allowed to gain
average temperature
Competent Person

Designated Competent Person

Competent Person is nominated by the management through PTW
system to be responsible for the safe execution of Isolation & LOTO for
each specific case. He shall:

▪ Isolate & affix locks and tags

▪ Test and try equipment to prove “dead”
▪ Re-energize the system safely

No de-isolation of any points within Isolation shall commence until all

PTW have been signed off by the Permit Issuer
Competent Person

Designated Competent Person SHALL:

Know the specific Isolation methods
Where lockout equipment is and how to place it
Know how to compile a tag and how to use it
Know how to re-energize the equipment safely
Competent Person

Designated Competent Person SHALL NOT:

х Keep the keys for co-workers’ locks (if used)
х Remove co-workers’ locks
х Deviate from the energy control procedures
х Allow untrained workers to be involved with LOTO
procedures
х Underestimate the danger
Isolating Authority Training and Competencies

• Project HSSE Awareness

• Attend and Pass LOTO Isolation Training
• Attend and Pass Greenfield Control of Work
Training
• Electrical Competency Assessment (for Electrician)
• Appointed as Isolating Authority by LOD
• Read and Understand Energy Isolation Procedure
and Greenfield Control of Work Procedure

18
Energy Isolation

• BP Golden Rules of Safety define the minimum controls

to be put in place when working in certain higher-risk
situations including activities requiring energy isolation.
• The minimum controls associated with Energy Isolation
shall be applied whenever the work activity is carried
out:
• Mechanical • Gravitational
• Electrical • Chemical
• Process • Radioactive
• Hydraulic • Thermal
• Pneumatic • or other energy source that
could cause injury
Type of Isolation

• Electrical Isolation
• Mechanical Isolation
• Control Isolation
• Lock Out and Tag Out
Type of Isolation
Electrical Isolation
All electrical isolation that needs to take place shall be carried out with
Permit To Work. Electrical energy sources shall be isolated as follows:
Positive isolation and lock out of switches, circuit breakers, etc
➢ Circuit disconnection or removal of component
➢ Test circuitry using reliable test equipment
Workers involved in Energy Isolation activity shall wear PPE and the use of
insulated tools. This shall refer to “Personal Protective Equipment
Procedures”
Mechanical Isolation
Whenever work is schedule on mechanical equipment or pressurized systems
device such as circuit breakers, switches, valve handles, and other operating
mechanisms shall be locked out and tagged out to prevent their
manipulation or operation.
The normal methods of isolation for mechanical equipment may be classified
as:
➢ Positive Isolation
➢ Valve Isolation
➢ Single Valve Isolation
Control Isolation

Instrument Pneumatic/Electronic Control equipment

▪ The air supply or electronic signal to individual instruments
both in the control panel and in the field shall be isolatable by
suitable block valve
▪ The dual input filter regulators feeding instrument air to a
pneumatic panel or dual power systems shall be provided with
isolation both upstream and downstream of each filter
regulator set.

ESD System
For isolation that related to the safety protection system, then
the isolation should be made at a minimum impact to the safety
system or individual item that related to the energy isolation
work.

22
Isolation

Energy Isolation
Energy Isolation should occur through various means: Electrical
breakers, switch panels and relays

NOT THROUGH OPERATOR CONTROL PANELS

A control point for isolating energy (breaker,

valve, etc.) must be locked whenever
practicable to prevent accidental energising
Isolation

Isolation in process line

▪ Isolation of fluids, steam and pneumatic energy sources is usually
achieved by closing a valve.

▪ Care needs to be taken to ensure that isolation is effectively

achieved as some valves may be automatically or remotely
controlled by computers.

Examples of fluids that may be encountered include

caustic or acid solutions, gas, inert substances (i.e.
Argon or Nitrogen) at varying pressure or
temperature.
Isolation

Isolation of Confined Space

▪ All confined spaces to be entered shall be completely and
positively isolated from all energy sources (e.g. product lines,
steam lines, electrical circuits, etc.)
▪ Positive Isolation must be done at the nearest connection (pipe
flange, pipe spool, circuit breaker etc.) to the equipment or
confined space.
Lockout

Lockout device
The placement of a lockout device on an energy isolating device
ensures that the equipment being controlled cannot be operated
until the lockout device is removed
Lockout

Lockout devices
Many options exist:

▪ Locks & Tags

▪ Valve covers
Lockout

Lockout devices
Many options exist:

▪ Switch disconnection

▪ Cables

▪ Anything that prevents use

Tag Out

Tag out Devices

Tag out is the process of using a tag to convey important information
related to the LOTO activity and should be posted at the energy
isolation control point.

A Tag may be used by itself IF AND

ONLY IF it is impossible to affix a
locking device to an energy
isolation device OR a dedicated
energy isolation device does not
exist.
Tag Out
Two types of tags are to be used, the “Danger Do Not Operate” and the
“Danger In Test” tags.
• “Danger Do Not Operate” tag is applicable to all persons and can only
be removed by the installer
• “Danger in Test” tag applies to all persons except those involved in the
“Test” operation.

DANGER DO NOT OPERATE TAG IN TEST SIDE

Tags must include certain information: Tags must also be:

• Date and Name of person in charge. • Durable,
• What work is occurring. • standardized by color, shape or size,
• uniquely identified,
*NB: Only use Permanent Marker/Pen • difficult to remove or fall off.
General Requirements
• No attempt shall be made to operate equipment on which a lock-out device
has been placed
• No one shall remove another person’s lockout device
• Lock-out devices must be inspected before each use to ensure they are
working properly
• Locks for energy source isolation must have a means of identification that
distinguishes them from any other locking device on the project. A particular
color, shape, or size may be used as the means of identification. Locks should
also be numbered
• Lockout devices shall not be used for any other purpose other than to lockout
equipment.
• When a machine, equipment, or process must be isolated and locked out for a
long period of time, periodic inspections should be performed to verify that
locks and tags are still in place. The frequency of these inspections will vary
depending upon the circumstances, e.g., inspect prior to each shift for an
active operation or weekly for an inactive operation.

Warning
Due to the serious consequences of not following this procedure:
• Any person who operates an energy source isolation device to which
lock-out devices and tags are attached, or removes a lock-out device
or tag without authorization will be subject to IMMEDIATE
DISCHARGE.
Isolation Confirmation Certificate
 Isolation Confirmation Certificate

• The Isolation Confirmation Certificate supports the

Permit to Work by providing the means of:
▪ Recording the isolations which are required before the task
detailed on the associated Permit to Work is issued
▪ Confirming that the isolations have been made for the task
to proceed following a physical check performed by the AA
▪ Authorization and recording of de-isolations and isolations
which may be required to test equipment under a Sanction
to Test (STT)
▪ Authorization and recording of de-isolation on completion
of the task detailed on the associated Permit to Work

• Note: The Isolation Confirmation Certificate (ICC) must be completed before the
relevant Permit to Work can be issued
 Control of Certificate
Isolation Confirmation Work

Control of Work

Safe Isolation &

Permit to work System Reinstatement of
Plant
Risk Assessment
 Isolation Confirmation Certificate

The AIA, IA & OA involved must be fully informed of the plant, equipment or system
to be worked upon and the scope of work to be carried out under each permit where
isolations are required. Marked-up drawings, diagrams & site checks must be utilized
to ensure that the plant, equipment or system is clearly identified for isolation.
Isolation points must be clearly marked and numbered on the supplied drawings
corresponding to the points highlighted on the ICC.

When each isolation is complete to LOTO standards, the Isolating Authority enters
the isolation details onto the ICC. The certificate must be cross-referenced to the
initial permit and any subsequent permits that utilize the same isolations.

Note: The ICC is raised before the permit is issued, and remains in force until the
permit is cancelled. The ICC shall only be cancelled when “WORK is COMPLETE”.
Only then AIA can sign the “CANCELLATION” section.

A single individual may NOT define and approve the design of energy isolations.
The IA are responsible for designing the isolation but must liaise with the AIA,
and PH on the scope, content and application method of proposed isolations
 Isolation Categories

• Boundary Isolation
• Long Term Isolation (LTI)
• Personal Isolation
• Sanction To Test (STT)
 Boundary Isolation

• Where an area of plant is isolated such that several activities (typically construction work) can
safely take place within this common set of strategically placed isolation points then this can be
termed as a ‘Boundary Isolation’. It must be clearly identified that the isolation is appropriate for
all the individual tasks to be carried out within the Boundary Isolation and all individual Work
Permits are cross-referenced to this Boundary Isolation.
• All related permits to work and additional ICCs within the boundary isolation shall be cross-
referenced to the Mother ICC.
• If any of the proposed tasks require a level of isolation or implementation of control measures
greater than that covered by the Boundary then a separate ICC should be raised for this task. This
additional ICC will be classes as Child and shall be cross-referenced to the Mother ICC which is the
boundary isolation.
• Once work is in progress and subsequent Work Permits are applied for within the recognized
framework of the Boundary Isolation, they can be added providing it is clearly established that the
existing isolation is appropriate to the task. However, this should be avoided if possible and it is
preferable to identify all activities when the Boundary isolation is being planned.
• Any additional tasks on systems or equipment that is already part of boundary isolation shall be
assessed to consider any requirements for applying additional isolations and controls.
• Boundary Isolations shall not be removed until all applicable Work Permits have been cancelled If,
for any reason, work on a particular piece of plant within the Boundary needs to be suspended (e.g.
whilst awaiting spares) then a separate isolation shall be implemented and an ICC raised before the
Boundary Isolation can be cancelled and confirmation that the installation can be energized safely.
No STT should go to the Long Term Isolation.
• Where the de-isolation of the Boundary Isolation is proposed, the Area Issuing Authority (AIA) shall
ensure that all associated Work Permits have been cancelled. He/she should also ensure that
equipment within the boundary is in safe condition.
 Long Term Isolation (LTI)
Long-term Isolations (LTI) are defined as those that no longer have work performed
against them. LTIs shall apply to:
1. Discovery of repairs during isolation that would require long-term planning and
execution.
2. Parts and material delays that extend the isolation.
3. Isolations to be extended beyond the noted time duration (e.g., work package) on the
isolation procedure.
4. Equipment from abandon-in-place or demolition jobs.
5. Equipment that is taken out of service for a period of time.
Long-term isolations shall be subject to two levels of review:
• A weekly review of the register to check the status of the isolations in place by AIA
• A quarterly review to physically check all the isolation points to confirm their
security and integrity and that the keys to all locks are being adequately controlled
• LTIs that remain in place for more than 6 months should be subject to an
engineering review to consider the effectiveness and the need to change to a
permanent modification.
• Before any work is performed against a long-term isolation a full integrity check of
all isolation points is required and the point of work must be proven dead.
• Before an electrical LTI is removed a physical check of the equipment to be
energized will be made to ensure that the equipment is safe to energize.
 Personal Isolation

Personal isolations are intended for short-duration tasks of relatively low risk. Where the
completion of an ICC is considered to add no significant value in terms of risk reduction. The use of
personnel isolation may only be authorized by the AIA and MUST be recorded on the PTW. The
rules for approval of a personal isolation are as follows:
• The task shall be routine and risk assessed as low.
• The PA within one shift performs the task and isolation; he/she may receive assistance from
others but he/she shall be present at all times until the system is de-isolated
• Before approval, the AA must be satisfied with the competence of the PH and check that he
has sufficient authorization to both carry out the isolation and execute the work. Personal
isolations shall only be carried out by those deemed to be a competent IA for that trade
• The same isolating standards apply to personal isolations other than the completion of the ICC
• The isolation points shall be labelled with an isolation label (which includes the date, the name
of the person isolating and the task information) and locked (the PH must keep effective
control of keys to isolation locks) as a LOTO process
• The personal isolation is authorized on the work permit
• An ICC shall be raised if any of these conditions cannot be met or the isolation will exceed one
shift (12hrs)
• Personal isolations are not allowed on the following:
– High Voltage
– Safety systems e.g. Fire and Gas or Emergency Shutdown (ESD) panels or sections thereof
– Equipment fed from more than one source.
 Sanction To Test (STT)

Sanction To Test is used when the system or part of the system needs to be isolated for checks
or test then to be re-isolated to facilitate the completion of the work. An example could be an
installation of a new motor on the pump skid unit and a rotation test is needed to confirm the
polarity of the motor to ensure its rotating in the correct direction. Without STT the ICC would
need to be cancelled to facilitate the test then a new ICC to be raised to complete the job. To
avoid this the ICC can facilitate up to 4 tests. However the following rules apply:
• The need for Sanction To Test shall be identified during the planning stage, and should be
clearly identified to the AA during the site visit
• All linked permits to work that are cross-referenced to the ICC shall be suspended
• AA will give the request for sanction to test in the ICC
• During STT, the PH and the IA shall closely monitor the work site to verify that a
controlled shut down or ESD can be initiated, if required.
• Although STT should normally be applied for tests lasting less than one shift. If STT is
extended for greater than one shift, a specific handover shall be undertaken between
incoming and outgoing AAs
• When the STT is completed successfully and the work is complete then the permit shall be
cancelled as ‘The work is COMPLETE’. A request for full de-isolation of the unit can then
be requested by the AA. However if the test is un-successful or there is further work to be
carried out on the unit then the permit can be re-issued following e-isolation of the de-
isolated points. The unit shall be re-isolated to the previous standard of isolation before
the Sanction To Test 40
 IA Competency & Training

• CSTS Risk Assessment

• Energy Isolation Course 
• Competent as Permit Holder
• Electrical Competency Assessment
• First Aid Level 1 (Basic)
• Basic Fire Fighting
• Read& Understand CSTS Procedure for Energy Isolation
• IA Competency assessment

41
 Steps to Isolation

Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step7 Step 8

•AIA Identifies •IA is identified •IA plans the •IA Submits ICC •AIA gives the •IA Applies the •AIA confirms •IA then
the need for an & briefed on isolation & to AIA for request for isolation & the Isolation is communicate
isolation during the task prepares the review. Once Isolation and completes the in place & the ICC number
daily PTW required ICC attaching agreed issue ICC application for ICC in the field applied to CSTS PTW
coordination all the number and the PTW to the correctly and in coordinator to
meeting necessary sign PH during daily accordance to cross reference
documentation, acknowledgeme PTW the LOTO in the PTW
drawings & nt on the ICC. coordination standards. AIA register. IA shall
diagrams. And cross meeting. Once then release the identify that
reference the the PTW is PTW. isolation is short
ICC number on registered in or long term to
the PTW. PTW office, IA enable data to
counter sign the be included in
PTW to confirm the isolation
all documents register.
are attached.
 Steps to De-Isolation

Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step7

•After PTW •Once all •The AIA or •IA performs •AIA or OA •IA close the •PTW
completion PTW have OA request De-Isolation confirms De- ICC and PH Coordinator
PTW must been de-isolation and Isolation & return the close the
be closed canceled completes the system ICC and PTW and
and signed then the ICC the ICC. is energized PTW to the ICC and
off by PH & could be de- permit include the
OA. isolated office. detail in the
PTW & ICC
registers
How to Fill Up Isolation Certificate
Choose what kind of
Isolation needed
(Electrical, Mechanical, Fill up the Isolation
Instrumentation) Certificate Number

Fill up the date, time, what facility, Permit

Number applicable, describe the equipment
to be isolated and why it needs to be isolated

In case of any Blind, please fill up Blind Register:

• Blind No
• Identify the Isolation, • Description/location
• Drawing reference (put also the drawing as attachment) • Rating
• Isolating point (Electrical, Mechanical, Instrument) • Size
• Tag • Type (S or B)
• Lock No • Installed
• Status Position (Normal, Isolated, Initial) • Initial
• Removal (Removal Data, Initial) • Removal Data
• Initial
Isolation Flow
Any questions?