Doc. No. P-003 Page 1 of 30 Revision No. R-001

Document Control Details

Document Issue / Issue Date / * Compiled By / Document Owner / Approved by
1 / Dec-2009 / Corporate Sub Committee on Rules and Procedures
Document Revision No. / Revision Date / Procedure Document No.
R-001 / 10th Feb-201210 / CS-PRO-01P-003

User Notes: - Corporate Sub Committee on Rules and Procedures at Tata Power is the custodian of this document and is responsible for the Administration and Authorization of this Procedure. Site Implementation Teams on Rules and Procedures in each SBU are responsible for confirming the accuracy and integrity of content and proposed changes to the Procedure.

Controlled copy of the current version of this document is held at TATA POWER on Sangam portal (Link : Site) Any printed / electronic copy of this document is uncontrolled. It is recommended that users verify that the version being used by them is the current version by referring to the controlled version

* Compiled By -

Location / Team Members
Jojobera / Rajesh Sharma

Table of Contents

  1. Introduction 5
  2. Intent and Purpose 5
  3. Scope and field of Application 5
  4. References 6
  5. Responsibilities6
  6. Policy7
  7. Definitions7
  8. Procedure of Lockout & Tagout10
  9. Preparation of Lockout and Tagout10
  10. Sequence of Lockout and Tagout11
  11. Re-commissioning / Taking back in line, of systems

after maintenance12

7.4.Lockout and Tagout Procedure involving more than

one Person/group13

7.5.Lockout and Tagout Procedures Involving Shifts13

7.6.Temporary Removal of Lockout/Tagout Devices14

7.7.Maintenance requiring undisrupted energy supply14

7.8.Lockout Devices and Locks15

7.9.Tagout and Tags15

7.10.Contractors16

  1. Exceptions16
  2. Review of LOTO Completion16
  3. Audit17
  4. Training & Record keeping17

Annexures

  1. Responsibility Matrix18
  2. Guidelines for Positive isolation & Special Precautions19
  3. Caution Tag22
  4. Release Tags23

4A. Operating Permit Tag26

  1. Electrical Isolation Method27
  2. Team Leader’s Declaration28
  3. LOTO Transfer in Shifts30

Document Issue

Procedure for Lockout Tagout is issued by the Corporate Sub Committee on Rules and Procedures , on behalf of The TATA POWER and forms a part of the TATA POWER HSE SHE Management System.

Name:

......

Signed: (Not appearing in soft copy)

......

Date:

......

This document contains proprietary and confidential information of TATA POWERand is intended solely for the internal use of authorizedPersonnel should be treated as BUSINESS CONFIDENTIAL and its external use or disclosure, unless specifically authorised, is strictly prohibited

Abbreviations

  • CSHE–Corporate Safety, Health and Environment
  • DB - Distribution Board
  • DOR- Direction of rotation
  • DCS_Distributed Control System
  • ELCB- Earth Leakage Circuit Breaker
  • FCO- Field Change Order
  • GMS- Group Manufacturing Services
  • HOD- Head Of Department
  • KV - Kilovolts
  • LCS- Local Control Station
  • LDB- Lighting Distribution Board
  • LO - Lockout
  • LOTO- Lockout Tagout
  • MCB- Miniature Circuit Breaker
  • MCC- Motor Control Centre
  • MOC- Material of Construction
  • MOV- Motorised Operated Valve
  • PDB- Power Distribution Board
  • PPE- Personal Protective Equipment
  • SHE- Safety, Health and Environment
  • TO - Tagout
  1. Introduction

This procedure is intended to be used for the protection of Personnel while servicing or performing maintenance on equipment / pipeline / vessel / process systems. This is a general procedure that shall be used as the minimum requirements for isolation of equipment, pipelines, machines, system from all possible sources of hazardous energy and / or material such as Steam, Hot Water, Compressed Air, any other process fluid / chemical energy /Mechanical energy or Electrical energy.

1.1Intent and purpose.

The intent of this procedure is to outline the general requirement to ensure that the hazardous energy sources are controlled and the Personnel working on the equipment / system ensure his / her Personal safety. The purpose of this procedure is also to ensure safety of equipment and prevention of inadvertent release of hazardous material to the environment.

This procedure has been developed by inter-site team with the expert guidance from DuPont Safety Resources.

Comments and feedback would be appreciated to further enhance this process. All such comments and feedback may be addressed to Chairman, Corporate Sub Committee on Rules and Procedures, Tata Power. The comments and feedback would be consolidated and shall be used during the review and revision of the future releases.

It covers role and responsibilities of all Personnel associated with Lockout / Tagout of hazardous energy sources / materialbefore work is undertaken on any equipment.

  1. Scope and field of application

This procedure specifies the mandatory requirements for controlling hazardous energy. It also describes

i)how to achieve and maintain the security of any isolation made and

ii)releasing the equipment from lockout.

This procedure applies whenever an employee is servicing or performing maintenance activities on machinery or equipment in a manner which requires the removal or bypass of guards or other safety devices or in a manner that requires the employee to place any part of his or her body into an area on a machine or piece of equipment where work is actually performed upon the material being processed (point of operation) or where an associated danger zone exists during a machine operating cycle, or in a manner that otherwise exposes the employee to electrical, mechanical, heat, radiation, chemical gas /liquid or steam hazards in the event the machinery or equipment or system is accidentally re-energized during maintenance or service work. Here are some examples;

1. Work on electric motors and circuits.

2. Work on Pumps, Tanks Vessels, Silos and reactors accessories.

3. Work on refrigeration and air conditioning equipment.

4. Work on steam lines/gauges/transmitters.

5. Work on permanently wired machinery or equipment.

6. Work on workshop and laboratory equipment.

7. Work on pressurized liquid or chemical lines.

8. Work on compressed air or gas (chemical) lines.

9. Work on hydraulic/pneumatic systems.

10. Work on elevators/hoists, etc.

11.Work On Conveyor Belts and related accessories.

Caution: All sources of hazardous energy / materials shall be identified prior to initiating any lockout / tagout.

Equipment specific procedures shall be made unless all of the following elements exist(s)–

  1. The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shutdown that could endanger Personnel.
  2. The machine or equipment has all energy sources that can be readily identified and isolated.
  3. The isolation of the energy source(s) will completely deenergize and deactivate the machine or equipment.
  4. The machine or equipment is isolated from the energy source and locked out during servicing or maintenance.
  5. The key to the lock iskeys to the locks are under the exclusive control of the Permit Acceptor , Permit issuer and employee performing the work.
  6. The servicing or maintenance does not create hazards for other Personnel.
  7. There has been no incidence involving the unexpected activation or restarting of the machine or equipment during servicing or maintenance.

The practices that have been identified here are applicable across all plants, sections within TATA POWER.

  1. References

TATA POWER Standard for Lockout Tagout

TATA POWER Permit to work procedure

TATA POWER Standard for Confined Space Entry

TATA POWER Safety Manual

  1. Responsibilities
  • All line managers and their teams dealing in LOTO shall be responsible for adhering to the procedure during job involving exposure to hazardous energy / materials. These include the contractors and their work force.
  • Plant HOD shall be responsible to ensure that a system is in place to ensure that all concerned (TATA POWER and contract employees) in the plant are trained in LOTO procedure.
  • Permit Acceptor shall be responsible to ensure that only trained and authorized people are deployed for the jobs.
  • Person In-Charge/Shift In-Charge (Permit Issuer) shall be responsible for identifying specific procedures for isolation/discharging / draining / blinding / venting of process equipment before releasing it for maintenance / inspection in their respective plantsareas.
  • Maintenance supervisors shall be responsible for arranging / preparing discharge rod/slip plates / blanks, etc., as per the process requirements and use of Personal protective equipments while carrying out discharging /blinding / de-blinding activities as per the specific instructions.
  • Person In-Charge/Shift In-ChargeElectrical Officer/Technician shall be responsible for electrical lockout and tag out (Danger).
  • Executing Personor Team Leader shall be responsible for provision of Locks.

Note :- Refer Annexure – 1 for details of Responsibility Matrix

  1. Policy

Lockout devices and Tagout devices shall be singularly identified; shall be the only device(s) used for controlling hazardous energy sources and shall not be used for any other purposes.

No Personnel shall perform job on any equipment or machine unless it has been locked out and tagged out, to prevent inadvertent release of hazardous energy sources.

No device to be operated or moved when a tag, Caution or danger, or lock is attached.

The steps outlined in this procedure shall be considered as the minimum requirements.

Note: - Refer section – 8.0 for exceptions to this procedure.

  1. Definitions

Affected Person— Any Personwho operates or maintains or works on machinery or equipment, which is subjected to lockout/ tagout. (Operating party and Working party)

AuthorizedPerson— A Person(TATA POWER employeeor contractor employee) trained and authorised in the lockout/tag out procedure to make and verify isolations.

Note–In some cases, the authorizedPersoncan be the executing Person.

Caution Tag – is placed with intent of warning the affected Personthat operation of the device will cause harm to the equipment / system / machinery/ personnel.

Complex lockout—Lockouts that may involve multiple:

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

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

Release Tag – is placed only on an energy-isolating device with intent of alerting the affected Person that operation of that energy-isolating device will cause harm to the life of the Personnel inside the hazard zone.

Electrical Engineer/Technician —A qualified Person(TATA POWER employee or contractor employee) trained and authorised in the electrical lockout/tag out procedure to make and verify isolations.

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

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

Executing Person/Maintenance Engineer– Affected Personwho is executing the job on the equipment which is subjected to lockout / tagout.

Operation Engineer /Field Operator—the Personwho is responsible for the operation of a machine, system, or equipment in the field.

Hazardous energy—Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, nuclear radiation or any other energy that, if not controlled, could cause injury to Personnel or damage to property and/or environment.

  • Electrical hazards are present when conductors or components that may be electrically energized could cause injury to Personnel or damage to property.
  • Mechanical hazards are present when the unexpected start-up of the system, equipment, or machine, 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 could cause injury to Personnel or damage to property. These hazards can exist during such tasks as installation, fabrication, servicing, or maintenance of pipelines, vessels, or associated equipment

Isolation—Separation of the equipment, machinery or area where work is to occur from sources of hazardous energy or materials 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 in securing 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 any given 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 hazardous energy that might be present, and securing an isolation point by locking it.

Lockout device— A piece of equipment that prevents the unauthorised or accidental operation of a hazardous-energy-isolating device. Locks are an essential element of a lockout device.

Maintenance - Workplace activities such as constructing, installing, setting up, adjusting, inspecting, modifying, and maintaining and/or servicing machines or equipment. These activities include, but not necessarily limited to, lubrication, alignment, cleaning or unjamming of machines or equipment and making adjustments or tool changes, where the Personmay be exposed to the unexpected energisation or startup of the equipment or release of hazardous energy.

Maintenance Engineer – A Personwho is solely responsible for the execution of the intended maintenance activity. Normally he will be the permit acceptor.

Person In-Charge/Shift In-Charge– A Personwho is the custodian or owner of the area or process and or associated equipment. He / Sheare authorized by the management to exercise his / her exclusive rights for the operation and use of the process and or its associated equipment in the designated area. Also referred as “Proprietor / Owner” in the TATA POWER LOTO Standard.

Permit to Work - The written or printed document that is issued by the Owner to execute job as per Permit to work procedure applicable at TATA POWER.

Qualified Person—A Persontrained and authorized to work with the equipment and who understands the hazards involved.

Stored energy—Hazardous energy that can continue to exist after equipment is isolated (e.g., the hazardous energy contained in springs, flywheels, pressurized fluids or gases, pneumatically controlled devices, capacitors, or gravity).

Tagging—placing Placing a specific tag on a lock or point of isolation to identify who placed the lock and when it was placed.

Tagout—Placement of Release tag (Release Order\Release Notice – “HOLD”. “MEN AT WORK”) (without a lock).

Team Leader— A qualified and authorizedPersonwho shall undertake overall responsibility for a lockout/tagout to place and keep all hazardous energy sources under lockout/tagout and to account for all Persons working with him on the job or task. He is normally expected to lead the executing team at the work location.

Testing —A process in which a qualified Personchecks the machine / equipment to verify whether its performance meets the intended need.

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

Try/trying—Proving the effectiveness of isolation by attempting to make a machine, system, or equipment operate with out being inhibited by interlocks or other means that would impede the “try” step.

Work Permit Issuer -A Person, but not necessarily limited to Person In-Charge/Shift In-Charge, who is authorized to verify that all conditions for carrying out the assigned job have been met, to define ongoing precautions to maintain safe working conditions during the work, to authorize the work to occur, and to cancel the permit.

Work Permit Acceptor – A Person, but not necessarily limited to Maintenance Engineer, who accepts the work permit and control s the overall execution of the job in the field, in compliance with permit to work procedure of TATA POWER.

  1. Procedure of Lockout & Tagout

This procedure covers the minimum requirements for lockout and tagout of energy- isolating devices to protect any Personfrom hazardous energy including electrical, mechanical, hydraulic, pneumatic, or other energy.

This shall be used as a general procedure for isolating all potentially hazardous energy (lockout/tagout) before energization, start-up, or release of stored energy that could cause injury. This procedure, when used in conjunction with specific information concerningindividual machines, provides the necessary information for lockout/tagout of machines with multiple energy sources.

This procedure shall be followed in conjunction with the requirements of the TATA POWERSafety Manual.

Caution - Specific individual procedures are required for all servicing and maintenance of equipment, machines or systems requiring lockout/tagout of more than one energy source.

The essential elements of Lockout and Tagout procedure is -

1.Preparation for Lockout / Tagout.

2.Tagging/Locking/Trying

3.Restoring Equipment To Service

7.1 Preparation of Lockout and Tagout

Before work is started on any equipment, System or process, the Person In-Charge/Shift In-Charge shall be responsible for Preparation for Lockout / Tagout .

He / She shall ensure that all hazardous energy sources are identified (Chemical, Electrical, Mechanical or other) to determine which switches, valves or other energy-isolating devices apply to machinery or equipment to be locked and tagged out.

Where stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.)

may be encountered, identification of such type(s) of stored or residual energy shall be ensured. Appropriate methods of dissipating or restraining such energy (by methods such as, but not necessarily limited to, grounding, repositioning, blocking, bleeding down, etc.) shall be ensured.

For equipment preparation, pertaining to plant operational processes involving line breaks, the prime consideration shall be of proving that isolations are intact giving a tight shut off.

Caution - Each case must be carefully considered by the Person In-charge/Shift In-charge, taking into account the hazardous properties of the materials involved and the details of plant design.

7.2 Sequence of Lockout and Tagout

  • Person In-Charge/Shift In-Charge shall ensure that all the type of energy that the System or equipment utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy. In cases where complex lockout or multiple energy sources are involved the Person In-Charge/ShiftIn-Charge shall generate an energy source identification sketch (a computer generated, hand written or in any other form) to properly identify all energy sources.
  • Field operator/OperationEngineershall ensure the equipment is not in operation and shall press switch off the equipment from LCSthe/ local Push Button/DCS/ remote pushbutton. She/he shall provide a CAUTION Tag on the LCS or other control device. (Refer Annexure – 3)

Person In-Charge/Shift in-charge shall submit Release notice tag for isolation of electrical energy. Operation Engineer shall identify electrical energy source(s). He / She shall switch off the source(s) and test the absence of voltage to equipment. All such energy isolation points shall be provided with lockout device (Hasp) and ‘Release Notice’ tag (Refer Annexure –4). Simultaneously the Maintenance Engineer or Team Leader shall provide his lock on the Hasp and retain the key to the lock till the job is over. Refer Annexure –5 for recommended LOTO methods for electrical energy sources.