Zubair IPF Project Iraq

LOTO: Lock Out / Tag Out &

Energy Isolation
 LOTO- Course Objectives

• Understand the scope and purpose of the LOTO System at

WFT.
• Explain the different Roles and Responsibilities

• Discuss the Isolation Certificates Forms

• Understand How to fill step by step the Isolation Confirmation

Certificate and the de-isolation for test certificate.
• Discuss the Energy Isolation steps and procedure

• Be familiar with the LOTO devices

 LOTO- Overview

What is (LOTO)?
• Technically Known as the Control of Hazardous Energy

• Procedure/ Program used to control and prevents the unexpected

energizing, start up or release of stored energy in machinery or
equipment which could cause injury to employees
• Scope: Construction, Commissioning, Installation and set-up,
Adjustment or maintenance, Inspection, Modification, Routine
service.
 LOTO- Overview

• Gives the minimum requirements for energy isolation, monitoring

and reinstatement of plant or equipment
• Must be used in conjunction with Safe work system for the control
of hazardous energy
• Isolation Confirmation Certificate shall be used and attached to
the PTW.
• De- Isolation for Test Certificate should be used before the final
de-isolation
 LOTO- Why we use LOTO?

• Protect People, Equipment and the Environment.

• Positive isolation of hazardous energy sources

• Defines responsibilities, task and work location.

• Communication, documentation and tracking.

• Under multi-discipline control, Operations, Mechanical and I&E

• Consistency in application
What could happen if you do not follow LOTO?
 Piper Alpha!
Alpha

• Backup propane condensate pump needed to have its pressure

safety valve checked every18 months
• Valve removed, leaving a hole in the pump where it had been
• 6:00 pm, work not completed, they received permission to leave
the rest of the work until the next day.
• Later in the evening with the night shift, at 10:00 pm, the primary
condensate pump failed.
• People in the control room, decided to start the backup pump, not
knowing that it was under maintenance.
 On July 6, 1988, 167
lives perished on the
Piper Alpha Platform,
located in the icy North
Sea.
 LOTO- Energy Sources
• Electrical (electric motors, batteries, Sub Stations…)

• Hydraulic (Pressurized fluids in hoses/pipes)

• Pneumatic (Pressurized air, N2 in hoses/pipes)

• Mechanical (Gravity systems, spring energy, Rotating Equipment)

• Chemical (Storage vessels/ pipelines containing toxic/hazardous chemicals

and hydrocarbon/oil products)

• Thermal (Hot oil lines to heat heavy fuel oil tanks/pipe, Heaters, hot pipes)

• Pressurized Liquids/Gases (e.g. hydrocarbons/petrol, steam)

LOTO- Roles & Responsibilities

Area Authority (AA)

•Review and approve any isolation involved in his area

•Ensure that the equipment and system is safe for work

•Ensure safe and proper reinstatement of the equipment

•Ensure that all personnel involved with energy isolation is

competent and understand the energy isolation procedure
LOTO- Roles & Responsibilities

Performing Authority (PA)

•Ensure that the equipment to work on is de-energized and has
been brought to zero energy (Test and check the isolation).
•TBT to include the risk of hazardous energies.

•No work to be done without PTW, associated certificates and Docs

(PIDs, Drawings, RA..)
•Ensure all safety measures associated with the work to be done are
implemented
 LOTO- Roles & Responsibilities

Responsible Electrical Person (REP)

•Identifies suitable and competent persons to act as Authorized
Electrical Person (AEP).

Authorized Electrical Person (SAEP/AEP):-

•Designs the electrical isolation and submits it to the REP for approval

•Proves dead through testing, and applies earthling as required

•Responsible for the De-isolation to test certificate

•Reinstate the equipment electrically upon requested from the AA

LOTO- Roles & Responsibilities

Isolation Authority
•Identify and implement process and mechanical isolations

•Prove Zero energy through testing

•Reinstate the equipment upon completion of the work and the PTW
is signed off.
 PTW
Vs
Isolation Confirmation
Certificates (ICC) &
De- Isolation Certificate
- Before issuing the PTW (Hot or Cold), the
AA & PA must ensure that the equipment to
be worked on is safe and electrical power
isolated
- The AEI person completes the electrical
isolation part and complete the De-
Isolation for Test Certificate when required
- No work should be done without
implementing energy isolation procedure.
Isolation Confirmation Certificate
 LOTO- Isolation requirements
• Process and mechanical isolation should be done by Authorised
person.
• PID should be used accordingly. DBB or SVI will be used
depending on the pressure in the system to be isolated.
• Mechanical isolation can be through: RS, Spade, Spectacle Blind,
Blind flange, removal of coupler, removal of air fun belt, ….
• Each isolation should be tested and proved before works being
started
• The integrity of valves should be assessed
• Electrical isolation should be performed by an SAEP/AEP.
• All energy sources must be locked and tagged before work starts
• Any Isolation which don’t meet the minimum standard shall be risk
assessed
De- Isolation for Test Certificate
 LOTO- Procedure

• Energy Isolation Sequence to be followed at all time:

1. Lock
2. Tag
3. Clear
4. Try
 LOTO- Procedure

1. Lock:
• Lock out devices must be used to maintain isolated equipment
in a “safe” position.
• Lock out devices to be fixed and removed upon approval from
AA or delegate.
• Only Isolating Authority or SAEP/AEP are allowed to fix or
remove lockout devices. Any exception should be approved by
the Site Senior Operations Manager
• Lockout device is under the exclusive control of the authorized
employee performing the servicing or
maintenance
 LOTO- Padlocks

1- Lock:
•Red padlocks are used for electrical isolations.

•Yellow padlocks for process isolations.

•Each lock has a unique number stamped

on it and the same number is on the key.

•Lockout boxes to be used to secure the keys
 LOTO- Procedure
2.Tag:
•Are only warning devices, don’t provide physical restraint as
provided by Lock out devices.
•Have the same meaning when used alone, and force as a lock

•Tags should be used in addition to lockout devices

• Shall not be used alone unless it is infeasible to apply a lockout

device.
•Shall be attached at the same location
 LOTO- Procedure
2. Tag:

•Tag out device must state:

• “DANGER, DO NOT OPERATE”,
• Date.
• Isolation certificate number.
• Name of the person applying the lock.

• Must be legible and understandable

• Must withstand environmental conditions
• Must be securely attached
 LOTO- Procedure

3. Clear

•The area must be clear of non essential personnel and be sure to

remove all tools prior to attempting to start the equipment
 LOTO- Procedure

4. Try

•Verify that equipment is properly isolated and safe to work on

•Check that the equipment has no residual energy or pressure

(Stored Energy)
Energy
 LOTO- Procedure

Prohibition of restarting or reenergizing machines

that are locked or tagged out
 LOTO- Requirements

LOTO devices

• Padlocks.
• Ball valve lockouts
• Lockout hasps •Multi-Hole Hasp
and Locking Cable

• Circuit Breaker lockouts

• Gate valve lockouts
• Etc …
Is This identifiable?
Is This Correct?
Is This Correct?
 LOTO- Requirements

LOTO Installation/ Removal Order:

 Locks & Tags are normally to be installed in the following order:
• Electrician Lock
• Operator Lock
• Maintenance Lock
Locks & Tags are to be removed in the following order:
• Maintenance Lock
• Electrician Lock
• Operator Lock
LOTO- Application Controls

Sequence for lockout/tagout procedures

1. Preparation for shutdown

2. Machine or equipment shutdown
3. Machine or equipment isolation
4. LOTO device application
5. Release of stored energy
6. Verification of isolation
7. Release from LOTO
8. Inspection of machine or equipment work area
LOTO- Application Controls

1- Preparation for shutdown

•Understand your equipment and Systems: hazards, Isolation points,
Procedure for LOTO.

• Notify other workers of shutdown

Working on unfamiliar machinery is a hazard

LOTO- Application Controls

2- Machine/Equipment Shutdown

• Use normal shutdown procedure

•Turn off or shut down using established procedures
• Orderly shutdown to avoid additional or increased hazard(s)
LOTO- Application Controls

3- Machine/Equipment Isolation
• All energy isolating devices needed to control energy shall be
physically located to isolate the machine or equipment from the
energy source(s).
 LOTO- Application Controls

4- Lockout / Tagout Application

• Shall be attached to each energy isolating device by authorized employees

• Lockout devices
– Shall be affixed in a manner that will hold the energy isolating devices
in a "safe" or "off" position

• Tagout devices
– Shall be attached in a manner indicating that the operation or
movement of energy isolating devices from the "safe" or "off" position
is prohibited
•P
U
R
P
L
E
LOTO- Application Controls

5- Stored Energy

• After application of device, all potentially hazardous stored or

residual energy shall be relieved, disconnected, restrained, and
otherwise rendered safe.
LOTO- Application Controls

6- Verification of Isolation

•Prior to starting work on machines or equipment that have been

locked out/tagged out

– Authorized employee shall verify that isolation and de-

energization of the machine or equipment have been
accomplished
LOTO- Application Controls

7- Release from LOTO

•Before LOTO devices are removed and energy restored

– Permit to work must be signed off as complete
– Work area inspected to ensure that nonessential items have
been removed and to ensure that machine or equipment
components are operationally intact
– Work area shall be checked to ensure that all employees have
been safely positioned or removed
– Affected employees notified that LOTO devices are removed
LOTO- Application Controls

8- Testing or Positioning of Machines

• When LOTO devices must temporarily be removed for
testing/positioning:

– Clear machine or equipment of tools and materials

– Remove employees from area
– Arrange for a “De-isolation for Test” certificate with the Area
Authority.
– Remove lockout/ tagout device
– Energize and proceed with testing or positioning
– De-energize and reapply energy control measures
LOTO- Application Controls

Outside Personal

•Contractors and the on-site employees must exchange

lockout/tagout information

•On-site employees must understand and comply with rules used by

the contractor
 LOTO- Long Term Isolation (LTI)
Extended Period Isolation (EPI)
 Work completed or suspended beyond the work permit's period.
 AA judges the need to maintain the system isolation in place (electrical,
mechanical, safety or emergency)
The following provision should be followed, but not limited to:

• PA and AA shall sign off to close the original work permit

• Lead PTW Coordinator shall retain Isolation Confirmation Certificates/
de-Isolation Certificate in the EPI Register
• EPI register should be used to record details of all the EPI.
• EPI shall be checked and inspected once a week or as required by
the Area Authority.
 PTW – Personal Isolation

Used by a qualified tradesmen performing routine tasks.

MUST be stated on the PTW application.

Can only be in force during a shift and can never be carried over
beyond a shift change.

If the task will not be completed before a shift change:

The task must be stopped

The worksite left in a safe condition

A full ICC is applied for.

PTW – Safe System Overrides (SSO)

Safety System Overrides Controls:

Any device or system, whose primary function is to provide protection to
personnel and/or equipment, detection of hazardous situations, or mitigation of
accident event
Shall only be overridden or rendered inoperative by way of a properly approved.

Safety System Override: this include, but not limited to:

Fire and Gas detection systems
Fixed firefighting equipment
Process shutdown systems
Process shutdown valves
PA Systems
Pressure Safety Valves

•45
PTW – Safe System Overrides (SSO)

• SS Overridden means a layer of accident prevention is removed

• SSO should be kept as short as possible.
• Authorization should be given to override a SS by AA (Shift
Supervisor)
• SSO does not require the isolations remain in force whenever the
associated PTW is active.
• SSO can be raised independently of a PTW (for operational reasons
only: low level shutdown during a plant start-up)
• SSO is requested by the PA
• Implemented by the CCR Operator

•46
 Isolation Confirmation
Certificates (ICC) &
De- Isolation Certificate
Isolation Confirmation Certificate
De- Isolation for Test Certificate
Zubair IPF Project Iraq
Zubair IPF Project Iraq

•Thank You For Your Attendance