Guinea Bauxite Export Handling Project

TRAINING ON LOTO PROCEDURE

04th Apr’ 2019 Job No. : 8513

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 Training on LOTO procedure

 At the end of this course, participants will be able to:

● Define and exemplify the Lockout/Tagout:
– Effectively discuss and apply the principles of
– Surveillance Program
Hazardous Energy Control (hereafter referred to
as Lockout/Tagout for the purpose of this – Periodic Inspection (Program Review)
training) ● Successfully classify specific training requirements,
– Cite the general requirements pertaining to the including periodicity, related to the following
application of Lockout/Tagout. Lockout/Tagout Program official positions of
authority and responsibility:
– Efficiently explain and illustrate the authority,
roles, and responsibilities of the Authorized – Authorized Worker
Worker as applied to the Lockout/Tagout – Affected Worker
program, including: – Controlling Organization Lockout/Tagout
• Authorized Worker Lockout/Tagout Administrator
Application
• Lockout Device Cutting and Removal
– Successfully explain and illustrate the authority,
roles, and responsibilities of the Controlling
Organization as applied to the Lockout/Tagout
Program, including
• Hazardous Energy Control Requirements
• Lockout/Tagout Preparation and
Prerequisites
• Installation and Removal Of
Lockout/Tagout Devices, and Closure
including documentation closeout.

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 Training on LOTO procedure

Before beginning this course, it is important that you have a full

understanding of the terms associated with the Fluor Hazardous Energy
Control Practice and the Lockout/Tagout program before you can fully
comprehend their association and importance.
♦ Affected Worker – A person whose job requires him or her to be in an area
where equipment or system(s) have been deenergized under the lockout/tagout
program. The affected worker cannot perform work under a lockout/tagout.

♦ Authorized Worker – A person who locks out and tags out machines,
equipment, or systems to perform servicing or maintenance on that machine or
equipment. This person must have completed the mandatory training to qualify
as an authorized worker. Only an Authorized Worker installs and removes his or
her own lock(s) and “Danger Tag(s)” as required by this program.

♦ Boundary – The safe limits of a given lockout/tagout as determined by those

components that are configured to provide a safe condition where the work is to
be performed.

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 Training on LOTO procedure

♦ Controlling Organization (CO) – ♦ Danger Tag – The tag that is used by

The organization or individual Authorized Workers to perform Authorized
responsible for the implementation Worker lockout/tagout. This tag is for the
protection of the individual employee.
and documentation of the
lockout/tagout process, including ♦ Danger – Do Not Operate Tag: The tag
that is used by the Controlling Organization
identifying the hazards, controlling
to set the boundaries for the purpose of
the boundaries, understanding the hazardous energy control. No work may be
impacts, and directing the authorized performed under this tag unless an
workers. The designated controlling Authorized Worker Danger Tag has also
organization may be a contractor been installed.
responsible to install a system or
equipment; the facility owner or
manger; or the construction
management contractor
♦ Controlling Organization
Lockout/Tagout Administrator –
The CO trained worker responsible to Danger Tag Danger - Do Not Operate Tag

perform the duties of the Controlling

Organization.

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 Training on LOTO procedure

♦ Energy Source – Any source of hazardous energy or materials. Sources include electrical,
mechanical, hydraulic, pneumatic, chemical, radiation, and thermal energies; as well as
various forms of potential energy such as that stored in springs, compressed gases, or in
suspended objects (gravitational).
♦ Isolating Device – A device that prevents the transmission or release of hazardous energy or
hazardous materials. Examples include restraint blocks, electrical circuit breakers, disconnect
switches, slide gates, slip blinds, or line valves. For lockout/tagout purposes, isolating
devices that provide visible indication of the device's position are desirable.
♦ Lockbox – A device that is capable of being locked in which the key(s) for the energy control
boundary lock(s) is stored.

 Lock(s) – A device that requires a key to operate (not a combination lock) and holds an
isolating device in the required position for the protection of employees. The lock(s) used
for control of hazardous energy must be single-keyed and singularly identified by color,
shape, or size. These locks shall be the only device used for controlling hazardous energy
and shall not be used for other purposes.

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 Training on LOTO procedure
♦ Lockout Device – A device that utilizes a
positive means such as a lock, key type to
hold an energy-isolating device in the safe
position and prevent the energizing of a
machine or equipment. Included are blank
flanges and bolted slip blinds.
♦ Lockout/Tagout – Installation of lock(s) and
tag(s) on the isolating device(s) to ensure
that work can be performed safely. The
lock(s) and tag(s) ensure that the isolating
device(s) and the equipment or system(s)
they isolate or control cannot be operated
until the lock(s) and tag(s) are removed.
♦ Overlock/Overtag – Lock(s) and Danger
Tag(s) installed by an Authorized Worker on
top of the CO’s Danger – Do Not Operate
Tag(s).
♦ Safe-Condition Check – The inspection or
test of a system or component performed by
the Authorized Worker to ensure that the
hazardous energy or materials are controlled
adequately to prevent injury or accident.
Note: This is a mandatory step to ensure
safety for employees.
♦ Servicing and Maintenance – Workplace
activities such as constructing, installing,
setting up, adjusting, inspecting, modifying,
maintaining, or servicing machines or
equipment. These activities include
lubrication, cleaning, or unjamming of
machines or equipment and making
adjustments or tool changes, where the
employee may be exposed to the unexpected
energization or startup of the equipment or
release of hazardous energy.
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 Training on LOTO procedure

♦ Simple Lockout/Tagout – A lockout/tagout activity that meets all of the following criteria
(also refer to HSE Practice 000.653.1302, Permit to Work):
1. The machine or equipment has no potential for stored or residual energy or reaccumulation of stored
energy after shutdown that could endanger employees.
2. The machine or equipment has a single energy source that can be readily identified and isolated.
3. The isolation and locking out of that energy source completely deenergizes and deactivates the
machine or equipment.
4. The machine or equipment is isolated from that energy source and locked and tagged out during service
or maintenance.
5. A single lockout device achieves a locked out condition.
6. The lockout device is under the exclusive control of the Authorized Worker performing the service or
maintenance.
7. The service or maintenance does not create hazards for other employees.
8. The employer has had no accidents involving the unexpected activation or reenergization of the
machine or equipment during service or maintenance.

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 Training on LOTO procedure

The following 14 principles help to provide the fundamental basis for successful employee
protection while performing lockout/tagout.
1. Each Authorized Worker will install his/her personal lock(s) and Danger Tag(s) BEFORE
starting work and will remove them when leaving that work assignment. The personal
lock and Authorized Worker Danger Tag signifies that an Authorized Worker is working on
a component.
2. The Authorized Worker Danger Tag is for the exclusive use of the Authorized Worker
identified on that Danger Tag. Information on the tag must include the following:
● Name and telephone number of the Authorized Worker who installed the Danger Tag (use
permanent ink).
● Name and telephone number of the Authorized Worker’s supervisor.
● Name of the Authorized Worker’s organization.
3. A safe-condition check is always required. (Lock, Tag, Test and Try)

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 Training on LOTO procedure

4. No one will remove a lockout or tagout device when an unsafe condition exists until that
condition has been made safe or another lockout device has been installed. Concurrently, no
one will operate any equipment on which a lockout/tagout device is installed.
5. No Authorized Worker will install a lock/tag on any system without notifying the CO, unless
the work control system specifically addresses this issue. This is to ensure the CO knows the
status of its equipment/systems.
6. Only single-keyed locks are authorized for lockout.
7. The Authorized Worker will maintain control of the key(s) for any lock(s) he/she applies.
8. Authorized Worker locks and Danger Tags can only be removed by the worker who originally
installed them. When the Authorized Worker is not on site, the device(s) may be removed
under the direction of the Authorized Worker’s management after ALL REASONABLE
EFFORTS TO REACH THE WORKER HAVE BEEN TAKEN.

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 Training on LOTO procedure

9. New designs include isolating devices for machines or equipment that accept a lock when
the machines or equipment are being replaced, repaired, renovated or modified, or when
new equipment is being installed.
10. When an Authorized Worker Danger Tag(s) used in a radiological or hazardous chemical
control zone cannot be released, it must be destroyed or defaced to prevent reuse and
disposed of in accordance with appropriate disposal procedures.
11. Any employee required to work on any system with hazardous energy sources will receive
documented Lockout/Tagout training. Annual refresher training will be provided and
documented.
12. The execution of the energy control and lockout/tagout processes to assess employee
understanding and compliance will be documented in an annual review and will include
interviews with affected and authorized workers.

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 Training on LOTO procedure

13. Compliance with this hazardous energy control program and its requirements is mandatory.
Furthermore, to maintain consistency only those forms and tags prescribed by the Practice
for implementation of the Lockout/Tagout Program.
14. Tags used for hazardous energy control will not be used for any other purpose. For
example, the Authorized Worker Danger Tag and the CO Danger – Do Not Operate Tag
cannot be used to identify equipment as “out of service” or “defective.” “Out of service” or
“defective equipment” tags must be substantially different.

Authorized Worker Danger Tag Danger - Do Not Operate Tag

(Form 000.653.F0280) (Controlling Organization) (Form 000.653.F0281)

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 Training on LOTO procedure

♦ During the lockout/tagout or before starting work, use test equipment to test the circuit
elements and electrical parts of equipment to which employees will be exposed, and verify
that the circuit elements and equipment parts are deenergized
♦ Check test equipment used on circuits with a nominal voltage rating greater that 600 V for
proper operation immediately before and after the test.
♦ In addition to the check with the test equipment, perform at least one of these steps to verify
that equipment has been deenergized.
● After the lockout/tagout is installed, attempt to operate the equipments using the operating controls, or
otherwise, to verify that the equipment cannot be started
● Check the position indicators on electrical isolation devices to verify that they are open
● Verify that all disconnects are open
● Verify that the equipment is deenergized by checking the position indicators on electrical isolation
devices, visually verifying that any disconnects are open, or by performing a voltage check to ensure
that there is no power available
♦ After the lockout/tagout is installed, verify that there is no pressure on the system by
monitoring vent and drain valves opened during the tagout process

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Review:
♦ An Affected Worker is a person whose job requires him or her to be in an area where equipment or
system(s) have been deenergized under the lockout/tagout program. The Affected Worker cannot perform
work under a lockout/tagout.
♦ An Authorized Worker is a person who locks out and tags out machines, equipment, or systems to perform
servicing or maintenance on that machine or equipment. This person must have completed the mandatory
training to qualify as an Authorized Worker. Only an Authorized Worker installs and removes his or her own
locks and tags as required by this program.
♦ A Safe-Condition Check is the inspection or test of a system or component performed by the Authorized
Worker to ensure that the hazardous energy or materials are controlled adequately to prevent injury or
accident. Safe-Condition Checks will be performed by the Authorized Worker BEFORE commencing work
on any potentially energized system or component.
♦ The 14 Principles of Lockout/Tagout help to provide the fundamental basis for successful employee
protection, while performing lockout/tagout.
♦ The Authorized Worker Danger Tag is for the exclusive use of the Authorized Worker identified on that
Danger Tag. The information on the tag must include:
● the name and telephone number of the Authorized Worker
● the name and telephone number of the Authorized Worker’s supervisor
● the name of the Authorized Worker’s organization Ap
● Facility

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Review:

♦ Locks that are used for control of hazardous energy will be single-keyed and singularly identified by color,
shape, or size; these locks will not be used for any other purpose. Only single-keyed locks are authorized
for lockout.
♦ Authorized Worker locks and tags can only be removed by the worker who originally installed them. When
the Authorized Worker is not on site, the device(s) may be removed under the direction of the Authorized
Worker’s management after all reasonable efforts to reach the worker have been taken.
♦ Work on energized systems/equipment is prohibited except in circumstances where such work must be
performed “live”.
♦ A machine-specific ECP must be developed when the machine has more than one energy source, AND the
machine is purchased, leased, rented, or provided by the client and used by Fluor or a Fluor-managed
contractor, subcontractor, or lower-tier contractor.
♦ If the Permit to Work process is in use, the CO will obtain a Permit to Work (Form 000.653.F0181) in
accordance with HSE Practice 000.653.1302.
♦ Employees required to be trained by the provisions of HSE MS Practice 000.653.3315 will be retrained or
pass a challenge test annually

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Review:
♦ The CO will:
● Ensure the isolating boundaries have been properly identified, documented, and verified through the use
of accepted as-built drawings, specific written procedures, or routine walk-downs and are included as a
part of each specific work package instructions.
● Install its locks and tags BEFORE the installation of the Authorized Worker’s locks and tags
● Ensure that TAFs that are to be active for 1 year or longer are identified and documented as long-term
tagouts on the TAF
● Conduct a field walkdown of installed locks and tags to verify:
– Proper placement of locks and tags
– Proper position of component or equipment
– Complete and accurate tags
– No tags are missing, mutilated, or illegible

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THANK YOU

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