Energy Isolation Lock Out / Tag Out

Trainer Name: Bilal Zekri
Energy Isolation
Lock Out / Tag Out
Values
Petrofac is a culturally diverse, international company, united by shared values.

Petrofac people are:
• safe
• ethical
• innovative
• cost-conscious
• responsive to customers
and always focus relentlessly on delivering results.
Energy Isolation Lock Out / Tag Out

Hazardous Energy Control

Energy Isolation
• Any isolation of energy systems - mechanical, electrical, process,

hydraulic and others – will only proceed when:
– the method of isolation and discharge of stored energy are agreed and executed by a
competent person(s)
– any stored energy is discharged
– a system of locks and tags is utilised at isolation points
– a test is conducted to ensure the isolation is effective
– isolation effectiveness is periodically monitored

Energy Isolation
VERIFY ISOLATION BEFORE WORK You should:

BEGINS AND USE THE SPECIFIED LIFE • Understand the isolations that protect you
PROTECTING EQUIPMENT from danger
• Confirm with the Supervisor or the Person
in Charge of the work that isolations are in
place
• Confirm with the Supervisor or the Person
in Charge of the work that it is safe to start
work

OBJECTIVES
 Assist in protecting personnel against injury that may occur due to
the accidental start-up or release of energy from equipment
that is being serviced or maintained.
 This energy may be from mechanical motion, pressure, gravity, springs,

electricity, heat or other sources. These forms of energy must be isolated
by being turned off, eliminated, dissipated or controlled.
 They will be securely maintained in the safe or off position

until the servicing personnel are out of danger.
 When sub-contractors are working on site, the Project Manager
or designee will verify that there is a mutual understanding of,
and respect for lock out / tag out procedures between all parties.
 The Project Manager / Supervisor will ensure that the subcontractors
implement this lockout and tag-out procedure.

Petrofac
Permit To Work
system
(PTWs)
• The type of isolation used shall
depend on the level of risk associated
with the work to be performed.
• Positive Isolation; physical
disconnection and blanking of open
ends; the turning of spectacle blind;
the insertion of spades between flanges
or the replacement of a spacer with a
line blind. Blanks, spades (blinds),
bolting and gaskets shall conform to the
piping specification for the equipment.
• Double block & bleed, valve isolation

is the industry standard for isolating a
valve.
• The effectiveness of isolations must
be tested and proved. If an isolation
valve is passing, it may be necessary to
shut additional valves or take further
plant and equipment out of service

Prior to authorizing a ‘Work
Permit’ it is essential to ensure
that the equipment to be
worked on is safe and electrical
power isolated for the safe
conduct of authorized work. The
requirement for electrical
isolation shall be specified by
the Area Authority in liaison with
the Permit Applicant. The
authorized Electrical person as
appropriate completes the
electrical isolation and enters
the detail on certificate.

(Lockout/Tagout)
An Energy Control Program must consist of

– energy control procedures
– employee training
– periodic inspections
to ensure that machines & equipment are

isolated from their energy sources and
rendered inoperative.
(Lockout/Tagout)
The energy control

program prevents
the unexpected
energizing/start up
or release of stored
energy that could
occur and cause
injury.

Scope & Application
What are the three key elements of an energy control
program?
•Procedures
•Training
•Inspections

Scope & Application
Person who operates or uses a machine or

equipment which is being serviced or has
maintenance being performed is an…
Affected Employee

Scope & Application
Person who works in an area where lockout/tagout

procedures are being used is an…
Other Employee

Scope & Application
Person who services or performs maintenance on
machines or equipment is an…
Authorized Employee
Scope & Application
Procedures must be followed when...
...servicing and/or maintenance when unexpected

energization/start-up or release of stored energy could cause
injury.
Scope & Application
Servicing and/or maintenance of machinery and equipment can
include:
• Adjusting
• Inspecting
• Modifying
• Replacing parts
• Tool changes
• Removing jams
•Lubricating
• Cleaning

Sources of Energy
Potential Energy
Sources of Energy
Kinetic (Motion) Energy

Sources of Energy
• Pneumatic
• Hydraulic
• Mechanical
• Thermal
• Radiation
• Nuclear
• Electrical
• DC Voltage
Don’t Forget Gravity!

Scope & Application
This standard does not apply to:
• Installations under the control of

electric utilities.
• Exposure to electrical hazards from

work on, near, or with conductors or
equipment in electric utilization
installations.
Scope & Application
Normal production operations

 Unless guards/devices are removed/bypassed.
 Unless employees place themselves in the point of

operation or in other areas considered dangerous during an
operating cycle.

Scope & Application
Work on cord & plug connected equipment
– must be locked out

when the authorized
employee no longer
has exclusive control

Energy Control Plan
Your Energy Control Plan must outline the
• Scope.
• Purpose.
• Authorization.
• Rules.
• Techniques used to control hazardous energy.
• Methods to enforce compliance.

Energy Control Plan
1.A specific statement of intent

to use the procedures.
2.Specific procedures to
shutdown, isolate, block and
secure machines or equipment.

Energy Control Plan
3.Specific procedures to place,

remove and transfer
lockout/tagout devices
4.Assigning responsibility for

lockout and tagout devices

Energy Control Plan
5.Requirements and
procedures to test
machines and machinery
to determine and verify
effective lockout/tagout
devices, and other energy
control measures

Energy Control Plan
Why is a comprehensive written plan critical to
a successful lockout/tagout program?
• It holds people accountable.

• It establishes a “boiler plate”.
• It allows for effective procedures.
• It allows for effective training.
• It allows for effective periodic inspections.

Energy Control Plan
What are some reasons a lockout/tagout
program may not work effectively?
• People may not respect it.

• Leadership may be lacking.
• Accountability may not be clearly established.
• Training may not be effective and/or monitored.

Energy Control Plan
Steps to developing a successful program
1.List all equipment or machines that need servicing or

maintenance.
2.Identify those machines which could unexpectedly

start up or release stored energy while being serviced
or maintained.

Energy Control Plan
Steps to developing a successful program
3.Determine the steps in the

maintenance or servicing task.
4.Review each step for the

potential of a hazard from all
energy sources.

Procedures
Step 1 - Prepare for Lockout.
Step 2 – Shutdown.
Step 3 – Isolation.
Step 4 - Lockout & Tagout application.
Step 5 - Stored Energy.
Step 6 – Verify.
Procedures
Step 1 - Prepare for Lockout.
•Review the following:
• Types and magnitudes of energy.

• Hazards posed by that energy.
• Methods to effectively control the energy.

Procedures
Step 1 - Prepare for Lockout
Don’t forget energy such as

gravity, electrical, or
pressure that can be stored
or reaccumulate!

Procedures
Step 1 - Prepare for Lockout
Prior to shutdown, all

affected employees must be
notified to clear their work
area and/or any other area
that might be hazardous.

Procedures
Step 2 - Shutdown
Machinery and equipment

that is capable of being
locked out should be shut
down in an orderly manner
using normal shutdown
procedures.

Procedures
Step 3 - Isolation
All energy isolating devices

should be located and operated
to completely de-energize and
isolate the equipment.
An energy isolating device

physically prevents the
transmission or release of energy.

Energy isolating devices can include
• Circuit Breaker.
• Valves.
• Fuse.
• Block.
• Disconnects.

Procedures
Step 3 - Isolation
Are Pushbuttons,
selector switches and
other control circuit
type devices are energy
isolating devices???
False!!!!!!!
Procedures
Step 4 - Lockout & Tagout Application
• Lockout
–Placement of a lockout device.
–Ensures that the energy isolating device and
the equipment being controlled.
–Cannot be operated until the lockout device is
removed

Procedures
● Tagout
 Placement of a tagout
device.
 Indicates that the energy
isolating device and the
equipment being controlled.
 May not be operated until
the lockout device is
removed.

Procedures
• A “lockout device”
must use a positive means
such as a lock, to hold an
energy isolating device in
a safe position to prevent
machinery or equipment
from being energized.

Procedures
• Only authorized employees will affix

lockout/tagout devices.
• Lockout devices must be able to hold energy

isolation devices in a “safe” or “off” position.

Procedures
• Tagout devices are

prominent warning devices
which can be securely
fastened to an energy
isolating device.

Procedures
• Tagout devices are

used when machinery
or equipment is not
capable of being
locked out (vehicles).

Procedures
• Tags will clearly state

that moving energy
isolating devices from the
“safe” or “off” position is
strictly prohibited.

Procedures
•Machinery or equipment is
“capable of being locked
out” if:
– it has a hasp or other

means to attach a lock.

Procedures
•Machinery or equipment is “capable of being locked

out” if:
– It has a built-in locking mechanism.
– Does not have to be dismantled or altered to

achieve lockout.

Procedures
•Energy isolating devices must be designed to

accept a lockout device.
•Whenever new machines or equipment are

installed or replacement, major repair or
modification of a machine or piece of equipment
is performed.

LINE ISOLATION AND BLIND FLANGES
LINE ISOLATION AND BLIND FLANGES
Procedures
When can an employer use a TAGOUT system?
1.When an energy isolating device is not capable of

being locked out.
or
2. If employer can demonstrate (prove) that using a
tagout system will provide full employee protection.

Procedures
What must be met to demonstrate full employee
protection?
1.Tags can be placed where lockout devices would

have been placed.
and
2.The employer demonstrates equivalent protection
can be obtained with tags.

•How?
Procedures
How can the employer demonstrate equivalent
protection can be obtained with tags?
•Opening an extra disconnect.

•Removing a valve handle.
•Removing a circuit or fuse.
•Blocking a ram.

Procedures
Materials and hardware

must be provided by the
employer.

Procedures
Each lockout/tagout
device must be singularly
identified as being used
only for lockout/tagout.

Procedures
Lockout/tagout devices
must be standardized
within the facility.

Procedures
Lockout/tagout devices must

identify the user.

Procedures
Lockout devices must be

substantial enough to prevent
removal except with the use
of excessive force or unusual
techniques(bolt cutters).

Procedures
•Tagout devices must

be substantial enough
to prevent inadvertent
or accidental removal.

Procedures
What are some examples of lockout devices?
• Padlocks.
• Ball valve lockouts.
• Fuse lockouts.
• Plug lockouts.
• Lockout hasps.
• Circuit Breaker lockouts.
• Gate valve lockouts

Procedures
Step 5 - Stored Energy
•Immediately after applying lockout or tagout
devices, the authorized employee must ensure all
potentially hazardous stored or residual energy is:-
• Relieved.
• Disconnected.
• Restrained.
• Otherwise safe.

Procedures
Step 5 - Stored Energy
Remember!
If stored energy can be re-accumulated to a
hazardous level, authorized employees
must continually verify that the machinery
or equipment is safely isolated until the
possibility of re-accumulated energy no
longer exists.

Procedures
Step 6 - Verify
Before starting work on a

machine or equipment that is
locked or tagged out, the
authorized employee must
verify that the machinery or
equipment is actually isolated
and de-energized.

Procedures
Release from Lockout/Tagout
Make sure machinery or equipment is properly

reassembled.
Inspect machinery or equipment to make sure

nonessential items have been removed.

Procedures
Make sure all employees are safely positioned outside

danger zones.
Notify affected employees that lockout/tagout

devices have been removed and that energy is going to
be reapplied.

Remember
You work under your lock

only!
Only the authorized

employee who applied the
lockout/tagout device may
remove that device

Procedures
Exception
The employer can remove the lockout
device provided that specific procedures
and training for such removal have been
developed, documented, and incorporated!

Procedures
• Testing/Positioning Machines or Equipment.

– keep under lockout as much as possible.
• Contractors.
– share information.

Procedures
Contractors must not
begin work until the host
employer is satisfied with
their procedures.
The host employer must
also ensure company
employees understand and
comply with the
contractors procedures, if
used

Procedures
• Shift Changes
– Written procedures must be developed to

address lockout/tagout procedures during a
shift change.
– Ensure continuity of protection.

Training
•Training in lockout/tagout must be provided to all
employees who may be in an area where energy
control procedures are used.
Training can
prevent this

Training
•This training will make sure that the purpose

and function of the energy control program are
understood and that employees gain the
needed knowledge and skills to safely apply,
use, and remove energy controls.

Training
Authorized employees are the only ones to work

under lockout/tagout.
They must be able to recognize hazardous energy

sources, types and magnitudes of energy in the
workplace, and methods and means necessary to
isolate and control the energy.

Training
Affected employees must be
able to recognize the purpose
and use of energy control
procedures.
Other employees must be

able to recognize procedures
and prohibitions of the
energy control program.

Training
What are effective training strategies for each level of training?

Training
Further training on tagout systems need to emphasize that:
1.Tags are warning devices only and do not provide a physical

restraint that lockout devices provide.
2.Tags must not be removed without the authorized employee’s
approval, and should never be bypassed or ignored.
3.Tags must be legible, and understandable by all employees.
4.Tags must be able to withstand environmental conditions in
the workplace.
5.Tags may give employees a false sense of security.
6. Tags must be securely attached to prevent being
accidentally detached during use.

Retraining
Employees must be retrained when:
1. Change in job assignment.

2. Change in machinery or equipment.
3. Change in operating procedures.
4. You note deficiencies in their understanding or
performance!

Training
Documentation
A training certification must contain each
employee’s name and date(s) of training.
What’s missing?

Periodic Inspections
•An inspection of each energy control procedure

must be conducted at least annually.
•These inspections must at least include a

demonstration of the procedures (steps) and may
be implemented through random audits and/or
planned visual observations.

•These inspections must be conducted by

an authorized employee other than the
one(s) using the energy control procedure
being inspected.
•The purpose of the inspection is to

correct any deviations or inadequacies in
the procedures.

Where lockout is used,

the inspector and
authorized employee(s)
involved in the
procedure being
inspected must review
applicable controls and
responsibilities.

Where tagout is used, the inspector

and each authorized and affected
employee involved in the procedure
being inspected must review
applicable controls and
responsibilities, and the limitations
a tagout system provides.

These inspections must
document the:
 Piece of equipment or
machinery.
 Date of inspection.
 Employees included in the
inspection.
 Authorized employee
performing the inspection. What’s missing?

What questions would you consider when conducting
your inspection?
ALL energy sources are deenergized?
The level of protection is adequate?
All authorized employees know their

responsibilities?

Safety Observation Cards Your Line of Communication
The HSSE Observation Card is a tool accessible all over the project and is available
to the entire workforce, in fact anyone can pick one up and fill it in.
WHY SHOULD YOU DO THIS ???
• Observation cards allow you to communicate directly to the management
without an appointment.
• Because your opinion and observations are very important and may help save
a life.
• Safety observations are not only to report the bad things such as: Unsafe
Behaviour, Near Miss, Safety hazards and Non Conformance but also to praise
good working practice, inform management of ideas or even thank a
colleague for being safe.
• You can help and support your fellow workers by sharing your observations.
• Everyone should go home unharmed to their family and without having
caused harm to anyone else so they can go home to their family unharmed.
Remember you are responsible for your own safety and also the safety of
those around you while on this project.
Once you have filled in the card post it in the dedicated box
or hand over to HSSE representative/supervisor.
a
Ne
r s
s
Mi Non
Conforman
ce
Unsafe
Behaviou
r
English Version
Observation card
HSSE Safety
Idea Hazar
d
REPORTING DEFECTS

Energy Isolation Lock Out / Tag Out

Uploaded by

Copyright:

Available Formats

Energy Isolation Lock Out / Tag Out

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Energy Isolation Lock Out / Tag Out

Uploaded by

Copyright:

Available Formats

Trainer Name: Bilal Zekri

Petrofac is a culturally diverse, international company, united by shared values.

and always focus relentlessly on delivering results.