PTW & LOTO

Training
 Course Aim

To provide participant with basic knowledge of

lockout-tagout system and subsequently to
incorporate it in PTW system in place.
 Course Objectives

Upon completion of this training, participant shall

be able to;
• Understand what is lockout-tagout system
(LOTO).
• Describe various hazardous energy that
require LOTO system.
• Describe the PTW isolation procedures in
LOTO system.
• Explain the correct procedures in LOTO
system at workplace.
 Lockout & Tagout (LOTO) System

q Who needs training?

q What is hazardous energy?
q What is lockout/tagout?
q What are the different types of
lockout devices?
q What is the requirement for
tags?
q PTW and LOTO isolation
procedures.
 Who Needs Training?

q Authorized employees – people who lock or

tag out machines or equipment to perform
servicing.

q Affected employees –people who use

machines or equipment on which servicing
is performed under lockout/tagout.

q Other employees –people who work in the

area of locked out machinery or equipment
Hazardous Energy Source Examples
q Live electrical lines
q Electrical capacitors
q Lasers
q Engines that move
machinery parts
q Hydraulic lifts
q Pneumatic (air pressure)
lines
q Pressurized water lines
q Springs
 When is Lockout/Tag-out required?

When someone will be servicing,

maintenance or repairing of
machinery or equipment
AND
the unexpected machinery start-
up or release of stored energy
could cause injury
 Service and Maintenance Examples

Installing, constructing,

adjusting, modifying,

un-jamming, cleaning,

lubrication, inspecting,

setup - preparing for normal

function

These activities often require a worker to place all or part of

their body into the machine’s hazard zone (“the line of fire”).
 What is an energy-isolating device?

A device that physically prevents transmission

or release of energy such as:

An electrical circuit breaker,

A pipeline valve,

A machine block,
Anything else that positively blocks or isolates energy.
 What is a Lockout Device?

A device that positively:

prevents a machine from being started

up or turned on,

prevents a machinery part from moving,

prevents electrical energizing,

blocks a pipeline, steam line or air line

 Electrical Lockout Devices
Locked out
circuit breaker

Locked out
electrical plug

Locked out electrical panel

Fluid & Gas Lockout Devices
Pipe Lockout Examples
Pneumatic Lockout Examples
Physical Blocks – Hydraulic Press
 Group Lockout Devices

Used when more than one person

doing maintenance or repair on
same machine or equipment.

Machinery or equipment can’t be

started up until all locks are
removed.

Each person places and removes

their own lock.
Example of a bad lockout/tagout
 What is Tag-out?
Tags are warning devices only
They don’t provide the same level of protection as lockout devices.
We only use for information, along with a locked device.
They can only be removed by an authorized person.
They must be legible (use a sharpie), securely attached (e.g., zip-
tie not string) and resistant to degradation.
 Energy Control Program

Energy control program consists of:

1. Training for Authorized and Affected employees;
2. A current inventory of equipment requiring lockout;
3. A description of general energy control procedures,
4. Development and use of a specific written stepwise
procedure for all equipment on the inventory; and
5. Periodic inspection of the implementation of the
energy control procedures
 Lockout Procedures
Six Steps to Follow:

1. Notify affected employees (anybody in the

area) that the machine or equipment will be
shut down and locked out
2. Shut down the machinery or equipment
using normal procedure
3. Isolate energy sources with energy-
isolating devices
 Lockout Procedures
Six Steps to Follow:
4. Lock out energy-isolating devices with
assigned locks.

5. Release or restrain stored or residual energy

(capacitors, pressure, vacuum, blades, etc.)

6. Test machinery to make sure it can’t start

up (use the normal start procedure)
 Lockout Steps

Notify Shutdown Isolate

employees Equipment Energy

Attach Lockout Release

Verify Lockout
Device Stored Energy

Service &
Maintenance
 Examples of Release of Stored Energy

• “Slowly open the receiver tank port and

bleed off any internal pressure.”

• “Loosen both line valves to relieve all

pressure in the cooling circuit.”

• “Ground out capacitor…”

 Examples of Attempt to Operate

• “…adjust the temperature cycle

thermostat to check that all electrical
inputs have been shut off.”

• “Push the start function button to verify

that electric power has been removed.”

• “Crack the steam inlet and discharge line

outlet valves…”
 Start-up Procedures
Only Authorized employee can do startup
§ Warn everyone present to stay clear
§ Remove all tools, locks and tags
§ Remove, reverse, open or reactivate
isolating devices
§ Visual check that all is clear
§ Start up machine, process or line flow
 PTW & LOTO– Isolation
Procedures
• An essential ingredient of any safe system of work is the
method and integrity of the isolation procedure.
• The following points should be considered within the
isolation procedures:
o complex isolations should be planned and recorded
o ensure all isolation points are clearly understood and
agreed.
o it is essential that the isolation standard is commensurate
with the type of work being carried out.
o isolation procedures should include all energy sources,
i.e mechanical, electrical, hydraulic pressure etc.
 PTW & LOTO– Isolation
Procedures (cont.)
• the tag or key number should be recorded on the PTW
form.
• isolation should only be applied and removed on
instruction from the person issuing the PTW.
• if more than one task is to be carried out on part of a
plant or piece of equipment, there is a risk that on
completion of one of the tasks the isolations are
removed and the equipment is put back into service.
• controls should be in place to prevent premature de-
isolation where dual tasks are involved
 PTW & LOTO– Isolation
Procedures (cont.)
• if the work is not able to be completed within the shift
the site should be checked by both the person in
charge of the work.
• if the PTW is suspended, the status of the work site
should be left on display in a suitable location.
 PTW & LOTO - Confined Spaces

PTW & LOTO is important while

working in confined spaces since it is
easy to get trapped and hard to
escape.

Pipelines leading into tanks must be

blanked off before entering the
space.

All electrical and mechanical

hazardous energy must be addressed
and locked out or tagged as needed.