Doc. No. S-003 Page 1 of 11 Revision No. R-000

Table of Contents

1.Scope and field of application

1.1.Scope

1.2.Field of Application

2.References

3.Management Responsibilities

4.Definitions

5.Standards/Guidelines

5.1.General

5.2.Principles

5.3.Lockout Procedures

5.3.1.Overview

5.3.2.Procedure

5.3.2.1.Removing the source of hazardous energy and hazardous materials

5.3.2.2.Installing lockout devices

5.3.2.3.Verifying that the hazardous energy source has been removed

5.3.2.4.Trying the equipment to determine that the hazardous energy is under control

5.3.2.5.Releasing the equipment from lockout

5.4.Procedure Audit

5.5.Lockout Types

5.5.1.Prevention of exposure to electrical hazards

5.5.2.Simple lockout

5.5.3.Complex lockout

5.6.Lockout Locks

5.7.Danger Tags

5.8.Employee Training and Documentation

5.9.Line Breaks

5.10.Confined Spaces

6.Management Systems

6.1.Support Resources

6.2.Management Records

6.3.Audit Requirements

6.4.Standard Renewal Process

6.5.Deviation Process

6.6.Training and Communication Requirements

6.7.Contact

  1. Scope and field of application
  2. Scope

This standard specifies the minimum mandatory requirements and advisory guidance forcontrolling hazardous energy. It also describes how to achieve and maintain the security of anyisolation made.

Local and national regulations shall be used in conjunction with this standard.

Mandatory requirements in this standard are noted in italics.

1.2.Field of Application

See Company Safety manual and Corporate Policy.

  1. References

Corporate Policy

Confined Space Entry

Electrical Safety Management

Engineering Standards

Safe Practices Using Mobile Equipment in the Vicinity of Electric Lines and Cables

  1. Management Responsibilities

Line management in SBUs and Sites has the responsibility to implement this standard.

  1. Definitions

Affected person—any person who operates or maintains machinery or equipment that is periodicallycontrolled by lockout.

Authorized employee—an employee trained and authorized by his or her employer to make and try isolations.

Complex lockout—lockouts that may involve multiple:

  • Crafts/Disciplines
  • Employers/Contractors
  • Hazardous energy sources
  • Lockout points
  • People
  • Shifts

Control device—a device used to execute a system change by manual, remote, automatic, orpartially automatic means (e.g., push buttons, emergency buttons or stops, selector switches, andother control-circuit type devices).

Energy-isolating device—a mechanical device that physically prevents the transmission orrelease of energy, including but not limited to, the following:

  • A manually operated electrical circuit breaker
  • A disconnect switch
  • A manually operated switch that disconnects a circuit from all ungrounded supply conductors and prevents all poles from being operated independently.
  • A line valve
  • Slip plates, blanks, and physical disconnections
  • A mechanical block or any similar device used to block or isolate energy.

Hazardous energy—any source of electrical, mechanical, hydraulic, pneumatic, chemical,thermal, or any other energy that, if not controlled, could cause injury to personnel or damage to property

  • Electrical hazards are present when conductors or components that may be electricallyenergized could cause injury to personnel or damage to property.
  • Mechanical hazards are present when the unexpected start-up of the system, equipment, ormachine, or the release of stored energy while adjusting, maintaining, or servicing systems,equipment, or machines could cause injury to personnel or damage to property.
  • Process hazards are present when the unexpected release of gases, liquids, or solids couldcause injury to personnel or damage to property. These hazards can exist during such tasksas installation, fabrication, servicing, or maintenance of pipelines, vessels, or associatedequipment.

Isolation—separation of the area where work is to occur from sources of hazardous energy ormaterials in such a way that only a conscious and deliberate act can restore the connection.

Lock—one of three types of locking mechanisms:

  • Discrete—locks that are different from one another; each can only be opened by one key.
  • Personal—a discrete lock, individually keyed, issued to an individual for his or her use insecuring isolations.
  • Series or system—a group of locks that are opened by a single key and are used in area/complex lockouts. Various sets of locks may be in use; however, only one key can open anygiven lock in a particular set.

Locking—placing a lockout device on a hazardous-energy-isolating device at a point of isolation.

Lockout—isolation of a source of hazardous energy, including releasing any residual hazardousenergy that might be present, and securing an isolation point by locking it.

Lockout device—a piece of equipment that prevents the unauthorized or accidental operation ofa hazardous-energy-isolating device.

Person in charge—a qualified employee who is specifically appointed with overall responsibilityfor a lockout/tagout to place and keep all hazardous energy sources under lockout/tagout and toaccount for all persons working on the job or task.

Proprietor/owner/operator—the person or group responsible for the operation of a machine,system, or equipment.

Qualified person—a person familiar with the construction and operation of the equipment and thehazards involved.

Stored energy—hazardous energy that can continue to exist after equipment is isolated (e.g., thehazardous energy contained in springs, flywheels, pressurized fluids or gases, capacitors, orgravity).

Tagging—placing a tag on a lock or point of isolation to identify who placed the lock and when itwas placed.

Tagout—placement of a “Danger—Do Not Operate” tag (without a lock).

Testing—when a qualified person verifies the absence of voltage using a site-approved testing device.

Troubleshooting—a process for identifying malfunctioning components within a system that isdone in both energized and de-energized systems.

Try/trying—proving the effectiveness of anisolation by attempting to make a machine, system, orequipment operate without being inhibited by interlocks or other means that would impede the “try”step.

  1. Standards/Guidelines
  2. General

Lockout/tagout is performed to prevent injury to personnel or damage to property by theunexpected release of hazardous energy. When planning a lockout, it is important to consider thenature of all hazardous energy that may be present.

5.2.Principles

The following principles govern all lockouts/tagouts:

  • All sources of hazardous energy shall be identified prior to initiating any lockout/tagout.
  • All sources of hazardous energy shall be removed or controlled prior to potential exposure tothe hazards. Examples of removing or controlling hazardous energy are as follows:
  • Disconnecting power and discharging any capacitance
  • Isolating pressure sources and releasing the pressure
  • Stopping rotating devices and securing them from further movement
  • Releasing stored hazardous energy
  • Lowering or securing equipment to prevent movement caused by gravity
  • Protecting equipment from external forces (e.g., wind) that may cause movement
  • Before starting work, each individual working on a task must determine, to his or hersatisfaction, that appropriate isolations are in place and the isolations are secure for the task inwhich he or she is involved.
  • Where a lock can be applied, tagout alone shall not be used to control exposure to sources ofhazardous energy. Where a lock cannot be applied, site procedures shall address the use oftagout and the additional steps essential to help ensure a level of safety equivalent to thatobtained by using lockout. Other means shall be used to secure access to the device, wherepossible.
  • Each person potentially exposed to the hazardous energy must place a lock and tag, when alock can be applied. Individuals who enter the hazard zone of a lockout shall be consideredpotentially exposed to the hazard.

Note: An exception to this principle shall only be made when the site has a written procedure describing the method of controlling, accounting for, and recording an individual’s involvement in the lockout.

  • Each person potentially exposed to the hazardous energy must participate in thelockout/tagout.
  • Clear communication of the lockout’s/tagout’s status shall be ongoing.
  • An energy source shall be considered energized until the source is removed and the energyisolation is verified.

Note: Exposure to hazardous material shall be controlled in accordance with the mandatory provisions of TATA POWERStandard for LOTO and TATA POWER Safety Manual.

  • An effective try step must be performed. All interlocks that may prevent an effective try stepmust be accounted for.
  • A test for the absence of voltage must be performed for all electrical hazards.
  1. Lockout Procedures
  2. Overview

Each site shall establish written procedures for controlling and methodologies for isolatinghazardous energy. The procedures shall include the following information:

  • How the hazardous energy sources are to be controlled for the duration of the work
  • Who is responsible for determining that the hazardous energy sources are controlled for theduration of the work
  • The responsibilities of all personnel involved in the work
  • Mandatory training requirements
  • Procedure

At a minimum, each site’s lockout procedure must include details on the following elements:

  • Removing the source of hazardous energy and hazardous materials
  • Addressing exposure to hazards while performing the lockout/tagout
  • Installing lockout devices
  • Verifying that the hazardous energy source has been removed
  • Trying the equipment to determine that the hazardous energy is under control
  • Developing a method for helping ensure the continuity of lockouts across shifts
  • Releasing the equipment from lockout
  • Describing the specific measures to be used to enforce the procedure’s mandatoryrequirements
  • Identifying and listing lockout points for tasks with multiple lockout points
  • Removing the source of hazardous energy and hazardous materials

All personnel who use site lockout procedures must know the following information:

  • The specific hazardous-energy-isolating devices for the task to be performed
  • The type of hazardous energy supply or hazardous material
  • The type and location of the disconnecting/isolating device acceptable for the hazardousenergy source or hazardous material
  • The mechanics and hazards of operating the disconnecting/isolating device
  • The mechanics of installing a lockout device

Note: Push buttons, selector switches, and other control-circuit type devices are not hazardous-energy-isolating devices. Control and solenoid valves are not adequate means of providing isolation for fluids. Control valves that are designed for use as hazardous-energy-isolating devices and that provide an effective isolation from the hazardous energy may be used in alignment with the mandatory requirements of TATA POWERStandard on LOTO and the TATA POWER Safety Manual.

A method must be used to verify that the hazardous energy source or hazardous material hasbeen removed and that the hazardous energy isolation is complete. In some instances, the “try”step is sufficient; in other instances, only testing can verify the isolation is complete.

Where hazardous energy can reaccumulate due to system design, configuration, or installation, ameans of preventing this reaccumulation must be used. An example of possible hazardous energyreaccumulation is in a long electrical cable that has a high capacitance. When the system orequipment contains a source of stored hazardous energy (e.g., springs, flywheels, gravitationaleffects, or capacitors), the stored hazardous energy must be relieved or otherwise blocked withcomponents that control the potential hazard. The advisability of installing protective grounds incomplex or high-energy electrical systems should be considered (see TATA POWER Safety Manual).

Fuel-powered, engine-driven equipment (sometimes called portable equipment) must be renderedinoperable by secure means (e.g., by removing the battery cables or removing the spark-plug wire orequivalent).

5.3.2.2.Installing lockout devices

The lockout device must be installed in a way that helps ensure that inadvertent operation of thehazardous-energy-isolating device is impossible.

Each site must define in written procedures the method of controlling or securing the keys for thelockout devices for all lockouts.

Each person potentially exposed to the hazardous energy must place a lock and tag, when a lockcan be applied.

Note: An exception to this principle shall only be made when the site has a written procedure describing the method of controlling, accounting for, and recording an individual’s involvement in the lockout.

5.3.2.3.Verifying that the hazardous energy source has been removed

All isolations shall be verified to determine that the hazardous energy has been removed.

The following are examples of how to verify the removal of hazardous energy sources: openingdrains; viewing pressure gauges, site glasses, or level indicators; visually verifying that rotatingequipment has stopped; visually verifying that components have been disconnected (e.g.,couplings, belts, and chains have been removed); and verifying that stored hazardous energy hasbeen removed or is appropriately blocked.

Caution: Gauges should be viewed before the hazardous energy source is removed to confirm they are in working order. Drains can become blocked and not function as designed.

When verifying isolations, personnel should take precautions to avoid putting themselves at risk or creating additional hazards.

For tasks where there is exposure to electrical hazards, a break in the power conductors shouldbe visually inspected, where possible. All lockouts must include verification of a completephysical break in the power conductors by testing for absence of voltage with a site-approvedvoltage-detecting device.

Note: For information on “Test Before Touch” and testing for the absence of voltage, refer to TATA POWERSafety Manual.

5.3.2.4.Trying the equipment to determine that the hazardous energy is under control

When the equipment is “tried” (i.e., the control device operated) to verify its isolation from sourcesof hazardous energy or hazardous materials, the area surrounding the equipment shall be clearedof people and equipment that could be injured or damaged prior to attempting to start theequipment. “Try” procedures must help ensure the isolation of all sources of hazardous energyand the positive control of hazardous materials by trying to start or move the equipment. The “try”procedure must also account for all items (e.g., interlocks) that may prohibit the equipment fromstarting or moving.

5.3.2.5.Releasing the equipment from lockout

Before the equipment or pipeline is released back to the proprietor, the people working on it shalldetermine that it is safe to reintroduce the hazardous energy or materialto the equipment orpipeline. The equipment’s status shall be conveyed to the proprietor when the equipment isreleased from lockout. The proprietor shall inspect or otherwise verify the integrity of the pipelineor equipment before hazardous energy or hazardous material is reintroduced. This verificationmay include leak testing, pressure testing, or simple visual inspection.

Where work extends over multiple days or shifts, a lockout device may be permitted to remain inplace for the duration of the work period. However, the individual shall verify the lockout is in placeafter any absence from the work site. Each person who installed a lock should remove it when hisor herwork is complete.

Sites shall establish a procedure, including the mandatory level of authorization, for removing anabsentee’s lock. Once the installer’s unavailability (i.e., not on site) is confirmed, formalauthorization for removing the lock should be given. If someone other than the installer removes alock, the installer shall be informed immediately on his or her return to work that the lock wasremoved.

Where lockouts extend beyond one shift, the lockout/job plan shall address the continuity of thelockout across the shifts.

5.4.Procedure Audit

Each site shall establish an audit process to determine

  • How often to audit.
  • If the established procedure is being followed.
  • If there are deficiencies in the established procedure.
  • If there are deficiencies in understanding the established procedure.

The person responsible for the procedure and other knowledgeable personnel shall audit theprocedure.

5.5.Lockout Types

5.5.1.Prevention of exposure to electrical hazards

Where an electrical hazard is a possibility, caution should be exercised to verify that all possiblesources of hazardous electrical energy are controlled. Persons making the lockout shall besuitably qualified to assess and address the electrical hazards associated with the lockout.

Additional steps are taken for lockouts for work on or near potentially energized electricalequipment. For more information, refer to TATA POWER Safety Manual.

5.5.2.Simple lockout

A simple lockout is accomplished by individuals placing personal locks and tags directly on thepoints of isolation. This is the preferred method of lockout and should be used when appropriate.

5.5.3.Complex lockout

For complex lockouts, each site shall define the following in writing:

  • The person in charge shall be responsible for keeping all hazardous energy sources,hazardous materials, and electrical, process, and mechanical hazards under control as thework progresses.
  • When multiple employers are working on the same process, everyone involved in the workmust understand and observe the mandatory requirements of all the lockout procedures of allthe employers involved.
  • The lockout process must cover all issues identified in all employer procedures.
  • Lockout Locks

Lockout locks shall only be used to control hazardous energy. In certain situations, an individualemployee may apply multiple locks keyed to a single key. Locks are an essential element of alockout device. However, the lockout device may include other components if the assemblyeffectively contains the source of hazardous energy.

All lockout locks shall be identified as follows:

  • Series or system locks shall indicate the lockbox number, system, or equipment being locked out.
  • Personal and discrete locks shall indicate the individual who applied the lock.

The information may be on a danger tag attached to the lock or may be on the lock. The preferredmethod is to use a danger tag with the locks.

5.7.Danger Tags

Danger tags shall be designed to be different from all other tags available at the site. Each siteshall establish a mandatory requirement for danger tag design for all lockout applications. Thedanger tag shall be readily identifiable as a danger tag. The tags should include standardizedverbiage (e.g., “Danger—Do Not Operate” or “Danger—Do Not Remove Without Authority”). Thedanger tag must provide space for the name of the employee and the date the tag is installed. Itmay also provide space for other information (e.g., the craft or the reason for the tag). Danger tagsmust be able to withstand the environment in which they are used for the duration of the lockout.