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EHS-WI.005 Lockout-Tagout Program (Eng Ver0)
EHS-WI.005 Lockout-Tagout Program (Eng Ver0)
005
Code EHS-WI.005
Previous ref EHS-PO.002
Index
1. Scope .......................................................................................................................................................................... 3
2. Application ............................................................................................................................................................... 3
3. Definitions ................................................................................................................................................................ 4
4. Responsibilities ...................................................................................................................................................... 6
4.1 GE Site Manager....................................................................................................................................................................................... 6
4.2 EHS Specialist ............................................................................................................................................................................................ 6
4.3 Work Executor ........................................................................................................................................................................................... 6
1. Scope
The purpose of this work instruction is to establish a comprehensive Lockout/Tagout program, designed to
prevent injuries caused by unexpected activation of hazardous energies, including any unintended motion,
energization, start-up, or release of stored energy.
This work instruction applies to all GS/TM sites, employees, temporary and contract employees, and
contractors performing work on GS/TM sites.
This procedure establishes GE Oil&Gas GS/TM expectations regarding safe methods of controlling energy
during site activities (i.e. installation, commissioning, and/or maintenance) of machines and equipment and is
consistent with GE corporate guidelines.
This program provides for decision-making flexibility regarding hazardous energy control methodology.
Alternative methods, when used, are based upon risk assessment. However, LOTO continues to be emphasized
as the primary hazardous energy control approach.
With activities developed at Customer site, and if GS/TM team is called to follow Customer’s procedures, such
instructions shall be put in comparison with GE Oil&Gas GS/TM ones in order to define the more stringent and
implement at site their use (procedures, work instructions, forms, templates, etc.). The verification and
comparison shall be made:
• by EHS/SER team during ITO review, or if these procedures are not present at ITO review stage,
• by GE Site Manager at activities start up; if verification identifies gaps and/or deficiencies, GE Site
Manager shall inform EHS/SER and EHS representative as well.
2. Application
Lockout/Tagout (LOTO) applies to all sources of energy, including, but not limited to, energy sources listed
below:
• Primary and Secondary Energy Sources
o Electrical o Water Steam
o Pneumatic o Chemical/Coolant
o Hydraulic o Radiation
o Gases o Magnetic
3. Definitions
Affected Employee - An employee whose job requires him/her to operate or use a machine or equipment on
which servicing or maintenance is being performed under lockout or Tagout, or whose job requires
him/her to work in an area in which such servicing or maintenance is being performed. This individual
is not authorized to perform LOTO.
Alternative Methods - Methods developed for work other than servicing and/or maintenance of equipment.
The methods guide personnel, utilizing the safest procedures for tasks not requiring LOTO. Methods
are developed based on risk assessment of the machine, equipment, process and circuit.
Authorized Employee - A person who uses a Lockout/Tagout system procedure on machinery or equipment to
perform service or maintenance on that machinery or equipment. This person has completed the
required training to be an Authorized Employee (ref. EHS-PG.002).
De-energized - Physically isolated from all energy sources and not containing residual or stored energy. A zero
energy state is verified as existing.
Dissipate - The process of removing stored energy from a machine, equipment, process or circuit. The energy
source steadily declines to a zero value after the energy source has been shut off and locked.
Energized - Connected to an energy supply or containing residual or stored energy.
EHS/SER – EHS team supporting GS/TM.
Energy Isolating Device - A mechanical device that physically prevents the transmission or release of energy,
including, but not limited to: disconnect switches, circuit breakers, line valve, etc. A device that utilizes
a positive means, such as a lock, to hold an energy isolating system in a safe position and prevent the
equipment from being energized.
Equipment Specific LOTO Procedure - A written outline of steps to follow to Lockout/Tagout and re-energize
specific equipment. This procedure should include: type and magnitude of energy, isolation location,
mechanism for isolation, and method to verify isolation.
Exclusive Personal Control - A means by which a single person controls equipment that may impact his/her
safety.
Facility/Maintenance Locks - Locks used in conjunction with a Yellow “Caution – DO NOT OPERATE” Tag to
render equipment inoperable by locking the energy-isolating device in the “off “ or safe position. To be
used for long-term shut down situations, when equipment is not actively being serviced or maintained.
General LOTO Lock - A key lock that is not assigned to an individual employee as an Individual LOTO Lock. This
lock has only one key and master keys are not available. This lock may be used to lock out individual
energy-isolating devices or energy sources when group or complex group LOTO is used. This lock may
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be left on for durations of greater than one shift. This lock is unique within the facility and is to be used
only for LOTO. The LOTO lock shall hold an energy-isolating device in the “off” or safe position and
prevent the energizing of a machine or equipment.
GE Site Manager – the person who’s managing or coordinating the activities at site, being him formally
appointed as Site Manager, or being the more experienced FSE, or having informal duties as activities
coordinator at site.
GS/TM – Global Services Operations / Turbomachinery Operations divisions of GE Oil& Gas.
Hazardous Energy Source - Any electrical, mechanical, hydraulic, pneumatic, chemical, nuclear, thermal,
gravity or other energy (including potential and/or kinetic) that could cause injury to personnel.
Individual LOTO Lock - A type of key lock that is unique, standardized, and distinct from all other locks in use at
the site, and is used for no other purpose in the facility/operation, having one key, and for which
master keys are not available. Such locks are individually assigned to authorized individuals, or can be
obtained from a central repository of LOTO devices, whereupon they become personal locks while in
use by an individual. LOTO Locks are typically colored red. LOTO locks must be weather & operating
environment resistant, and securely attached and able to withstand whatever unintended force that
may be applied. The LOTO lock shall hold an energy-isolating device in the “off” or safe position and
prevent the energizing of a machine or equipment. The Individual LOTO lock shall be removed at the
completion of the LOTO, or at the end of the employees work shift, whichever is shorter.
Lead Authorized Employee - The authorized employee who has primary responsibility for the implementation
and coordination of group Lockout/Tagout activities.
LOTO (Lock Out / Tag Out) - The placement of a Lock and Red Tag on the Energy Isolating Device in
accordance with an established procedure, to secure isolation points to prevent unexpected start-up
or release of hazardous energy.
Lockout Device - A positive means, such as a lock, a wheel valve cover with lock adapter, or the like that
secures an energy isolating device in the safe position and prevents the energizing of a machine,
equipment, process and circuit. Lockout devices must be weather & operating environment resistant,
and securely attached and able to withstand whatever unintended force that may be applied.
“Caution-Do Not Operate” Tag (Red Tag) - A safety tag to be used only for personnel protection to
Lockout/Tagout equipment where injury could result if the tagged equipment was operated. When
Red Tags are used, the energy-isolating device (primary switch or valve of the system, or equipment)
must be made inoperable by use of a LOTO lock, physical disconnection, or equivalent protection. A
sample of the tag is given in Appendix B. Red tags are used with every LOTO Lock (General or
Individual) to indicate that the energy source is locked out and an authorized employee is actively
working on the machine, equipment, process or circuit. Tags must be weather & operating
environment resistant, and securely attached.
“Caution-Do Not Operate” Transfer Tag (Yellow Striped Tag) - Transfer tags (must be yellow in color with a
striped border – see EHS-WI.005.Saf02) are used to indicate that a machine, equipment, process or
circuit is out of service or inoperable, but no one is actively working on the system. Transfer tags are
not to be used in place of red tags. No activity to the machine, equipment, process and circuit may
occur when a transfer tag is placed. Transfer tags are to be used only when energy control is needed
for servicing or maintenance. Transfer tags are not to be used as general "out of service" tags and may
only be applied by Authorized Employees.
Service and/or Maintenance - Any activities to machine, equipment, process and circuit that represent repairs,
preventive maintenance, modifications and installation. These activities require that the machine,
equipment, process or circuit, or their components, be at a “zero energy state”. The personnel
performing these activities shall apply LOTO in accordance with established procedures. When LOTO
of the machine, equipment, process and circuit cannot be performed, alternative methods such as risk
assessment shall be applied.
Tagout Device - A prominent warning, such as a tag and its method of attachment, that secures an energy-
isolating device in a safe position and prevents the energizing of a machine, equipment, process or
circuit.
Transfer Lock - A key lock for which multiple keys may be available and is used on equipment or processes
when they are not actively being serviced. Key control or access must be limited to a small, closely
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controlled group of authorized individuals. This lock must be used in combination with a Transfer Tag
“Caution Do Not Operate” (see EHS-WI.005.Saf02) to indicate an unsafe to operate condition. This lock
must not be used as an Individual LOTO Lock and may never be used on equipment that is being
actively serviced. This lock is also used with a Transfer tag for the transition of complex/group LOTO
when there is a gap between active work shifts.
Zero Energy State see De-energized
4. Responsibilities
All GE Oil&Gas or Contractors personnel are responsible for the application of present procedure and EHS
Manual.
5. LOTO Procedure
5.1 Isolation methods with fluids
The following scheme, based on The safe isolation of plant and equipment 2006, HSE-UK, reports various
isolation techniques, these methods do not all provide an equivalent degree of security. For example, there is a
hierarchy of mechanical security for the three isolation methods shown for Proved Isolation category – once
installed, the reliability of double block and bleed (DBB) is greatest while that for single block and bleed (SBB) is
least.
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For hazardous substances it is required to implement at least a DBB isolation (or higher); hazardous
substances are to be considered the Category I & II as per Chemicals (Hazard Information and Packaging for
Supply) Regulations 2005, HSE-UK:
• Category I - Very toxic (T+), Toxic (T), Carcinogenic, mutagenic, toxic for reproduction, Sensitizing
• Category II - Extremely flammable (F+), Highly flammable (F), Flammable gases (R10), Flammable
liquids (R10), Petroleum products, Oxidizing (O), Explosive (E), Steam, Pressurized gases > 0.5 bar,
Flashing fluids, Asphyxiants
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• Locking jaws;
• Blind flanges.
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• In case of activities, which take longer time than a shift, and which, for any reason, foresee that the
system will not be put in operation or given to the shift responsible of the following shift at the end of
the works, the red TAG must be changed with the yellow TAG.
6. Subcontracted companies
Subcontractors must receive information concerning LOTO procedure application, during specific coordination
meetings, and must apply and respect it.
The minimum content of above cited information shall include the “affected employee” training.
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7. Operative Instructions
7.1 Phase 1 – Prepare the shutdown (Customer ownership)
• Identify present energy sources
• Identify present risks
• Verify if an equipment specific isolation procedure exist
• Check P&IDs / drawings are updated
• Verify the need of carrying out activities/tests on not de-energized equipment
• Verify the suitability of tools
• Verify the suitability of personnel
• Verify that all personnel has been informed
• Segregate working area and post specific signals
• Identify interception and disconnection points (LOTO application points) and residual energy discharge
points.
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• Gravity
o Use blocks designed for machines
o Padlock and tag checks
• Mechanic energy stored
o Blocks, tags, padlocks on sources
or
o Let the energy release slowly
• Electric energy
o Apply correctly LOTO and grounding
o Neutralize the potential
• Pressure
o Decrease the pressure slowly and carefully
o Use LOTO
• Thermal energy
o Put in safe condition from heat source
o Cool or heat
o Use PPE
• Works on the plant
o Double check: Think before acting
o Machine double check: Switches and blocks
o Inform all personnel involved: Actions carried out by each operator can affect safety of other
personnel
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9. Training
All persons involved in LOTO shall be trained as per procedure EHS-PG.002 to the level of their responsibilities.
Affected employees will be trained prior to initial assignment, prior to a change in assigned duties, if a new
hazard has been created, or if special deviations have occurred.
Training documentation information will be tracked via the Gensuite Training Tracker module.
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Global Services / Turbomachinery Operations - Field Activities EHS-WI.005.Reg01
GE
Oil & Gas Lockout / Tagout Register