LOTO STANDARDS TRAINING

CONTENTS
• Introduction
• Why LOTO?
• Scope & Purpose
• Definitions & Types of Potentials
• Roles & Responsibility
• Procedure & Guidelines
• LOTO Devices

LOTO Standards 2
 Why LOTO is required?
• To ensure safe operation /service on any equipment
/ plant having hazardous energies associated.

• To provide safe working environment for co-workers

to work in an equipment with peace of mind.

LOTO Standards 3
Section – 1

SCOPE & PURPOSE

LOTO Standards 4
 SCOPE
• This LOTO standards applies to all Hindustan Zinc
Limited business units.

• References
– Vedanta Isolation Standards
– GN 20 : Vedanta Lockout Tagout Guidelines
– Permit To Work Standards

LOTO Standards 5
 PURPOSE

• To prevent injury or harm from the unexpected start

up or release of energy from any type or sources
when work is performed during equipment service or
maintenance.

LOTO Standards 6
 When LOTO is required?
• Maintenance or Equipment servicing.
• Removal or bypassing of guards.
• Removal or bypassing of Safety devices.
• Exposure of any part of the body during Setup or
Troubleshooting of an equipment.
• Any exposure to Hazardous energy sources during
any activities.

LOTO Standards 7
 Few Facts on LOTO
• According to a study conducted by OSHAS,

– Compliance to Lockout Tagout procedures has prevented

approximately 120 fatalities and 50000 injuries in a year.

– Each injury on a job from exposure to hazardous energy

lose an average of 24 manday’s for recuperation.

– Almost 20% of the fatalities happened between 1973 to

1995 were attributed to inadequate hazardous energy
control, i.e., non-compliance of Lockout Tagout procedures

LOTO Standards 8
Section – 2

DEFINITION & TYPES

LOTO Standards 9
 DEFINITIONS
• LOCKOUT: The placement of a Lockout device on
an energy-isolating device, in accordance with
an established procedure, ensuring that the
energy-isolating device and the equipment being
controlled cannot be operated until the lockout
device is removed.
• TAGOUT: The placement of a Tagout device on
an energy isolating device, in accordance with an
established procedure, to indicate that the
energy-isolating device and the equipment being
controlled may not be operated until the Tagout
device is removed.

LOTO Standards 10
 DEFINITIONS
• Master Lock – A Lockout device which will be placed by an
Isolation Officer on the isolation point of any energy source.
Department Specific in nature.
• Personal Lock – A Lockout device which will be placed by
Affected Person(s) on the Site Lock Box. Individual specific in
nature.
• Master Lock Box (MLB) – A centralised Lock box placed in the
custody of Issuing Authority. It contains all the Master Lock
keys and locked over by Issuing authority himself and Permit
requester.

LOTO Standards 11
 DEFINITIONS
• Site Lock Box (SLB) – A Lock box which will be maintained by
Permit Requester. Permit Requester’s key will be placed inside
it which will be locked over by each and every Affected
Person(s).
Note : If Permit Requester himself is Affected
Person, he may not re-apply lock.

• Visitor – Any third party person who has not been inducted
under HZL safety policy. Such person may be a subject expert/
consultant/ OEM/ Supplier from other organization.

LOTO Standards 12
 Types of Energy Sources
Energy Types
Energy Source Kinetic Energy Examples Potential Energy Examples
Electrical Current, static, storage devices Batteries, capacitors, voltage
Turning shafts, gears, rotors, fan Moving parts, tensed spring,
Mechanical/kinetic
blades, conveyors flywheel
Hydraulic Pistons, motors Pressure in accumulators
Actuators pistons, pressure vessels,
Pneumatic Stored potential pressure/vacuum
gas tanks, lines
Steam Flowing steam Steam in pipelines, drums
Chemical Flowing liquid, gases, slurry, cake Trapped gases, Liquid, Slurry
Moving components, falling Elevated counter weights, Objects
Gravity
objects suspended at Height
Mechanical, Chemical Reaction,
Thermal High or low temperatures
Electrical Resistance
Ionizing/non-ironizing released
Radiation Contained source material
energy
LOTO Standards 13
 Types of Lockouts
• Prevention of Exposure to Electrical Hazards
– Lockout done for job carried on electrical panel or
equipment
• Simple Lockout
– An individual applies Personal lock and his tag on Isolation
point
• Complex Lockout
– Lockout that applies to protect multiple energy source or
persons or agencies working on a equipment

LOTO Standards 14
Section – 3

ROLES AND
RESPONSIBILITIES

LOTO Standards 15
 PERMIT REQUESTER (PR)
• Termed as “Initiator” in PTW Standards.
• An authorised person who takes Permit to carry out any
job on an equipment which requires LOTO.
• Accepts all required energy isolations and conduct a
TRYOUT to ensure zero energy state.
• Shall ensure work area is safe after job completion and
maintain good housekeeping.
• Ensures Lockout procedure been followed by Visitors.

LOTO Standards 16
 ISSUING AUTHORITY (IA)
• Termed as “Issuer” in PTW Standards.
• An authorised person who is having thorough knowledge
on system / process and authorises energy isolations for
the specified PTW.
• Ensures proper isolations done by Isolation Officer.
• Ensures area is safe to re-energise the equipment / plant
after completion of job and signs off PTW for restoration
of energy sources by Isolation officers.

LOTO Standards 17
 ISOLATION OFFICER (IO)
• Termed as Authorized Isolator” in PTW Standards.
• An authorised person who ensures equipment is de-energised
and isolate to achieve zero energy state.
• Applies Master Lock on the Isolation point.
• His/hers lock shall be the first to be applied and last to be
removed.
• Restores energy source after receiving a properly signed off
PTW.

LOTO Standards 18
 AFFECTED PERSON (AP)
• Everyone, including the Isolation Officer, who has to
perform work on the plant, equipment or system is
termed as Affected Person.
• All Affected Person working on the equipment shall apply
their individual Personal Lock along with Identification
tag.
• Person Locks shall never be removed by any other
person. If key goes missing, then the Custodian shall
direct to removal and dispose such lock from further use
in accordance with written procedure.

LOTO Standards 19
Section – 4

PROCEDURE AND
GUIDELINES

LOTO Standards 20
 ISOLATION PROCESS
NINE MANDATORY ISOALTION STEPS
1. Preparation for Isolation – PTW & Procedure to identify
energy sources, Lockout & Isolation devices,
communication with Concerned operators/persons.
2. De-energize the plant/ equipment.
3. Isolate all energy sources.
4. Drain / Block and bleed residual energy ,wherever
applicable, to achieve zero energy state.
5. Secure Isolation device with Lockout device (Locks) and
tags

LOTO Standards 21
 ISOLATION PROCESS (Contd.)
6. Verify Zero-energy state.
7. Perform the task / activity intended.
8. Inspect the site area and restore normalcy (re-energise
after task completion.
9. Start-up plant / equipment after restoring all safety
interlocks.

LOTO Standards 22
 ISOLATION GUIDELINES
• Assess all equipment’s for hazardous level of energy
through HIRA.
• Identify and categorise single and multiple energy
sources and types of hazardous energy.
• Identify task and activities that may expose workers to
hazardous energy.
• Identify isolation methods for all energy sources and
types of hazardous energy.
• Specify isolation devices to be used at all isolation points.

LOTO Standards 23
 Flowchart – Complex Lockout Case

Issuing Authority
Initiate PTW Permit
MLB Requester

Affected

Master Key sent to IA.

Initiate Isolation

Isolation

LOTO carried out,

Person-1 SLB
Officer-E

Isolation Affected Affected

Officer-P Person-2 Person-3

Isolation
Officer-I

LOTO Standards 24
 LOTO Principles
• An energy source shall be considered energized until the
source is removed and the energy isolation is verified
through Tryout.
• Each person potentially exposed to the hazardous energy
must participate in the lockout.
• Each individual working on a task must determine, to
his/her satisfaction that appropriate isolations are in
place.
• In case of Tagout alone is provided, energy source shall
be considered to be present in the system and
accordingly Risk Assessment shall be carried out.
LOTO Standards 25
 Training & Audit
• UIC Members shall identify the need for training and
assessment methods for Issuing Authority, Isolation
Officer, Permit Requester and keep record of duly filled in
Authorised list of foresaid positions.
• Training (Refresher) shall be planned by UIC for all
personnel.
• Audit shall be conducted by UIC periodically to assess the
effective implementation of LOTO and identify the
necessary gaps.
• Training Record Retention Period – 1 Year.

LOTO Standards 26
 EXCEPTIONS
• Any situation where the normal Lockout procedure may
be tedious, a well defined written procedure shall be
documented to ensure protection of all workers from
hazardous energy sources and duly approved by Plant
Apex Committee.
• During any condition, where more people works on a
task / activity by a single agency, then a written
procedure shall be documented to ensure protection of
all workers from hazardous energy sources and duly
approved by Plant Apex Committee.

LOTO Standards 27
 EXCEPTIONS
• Tagout alone shall be not be considered as hazardous
energy control method. Wherever Lockout cannot be
applied, well defined procedure shall be made to
mitigate / control different types and sources of
hazardous energies.
• In case of any projects where Isolation procedure is not
available, JSA shall be conducted to identify energy
sources and necessary isolations required and
accordingly PTW shall be taken.

LOTO Standards 28
Section – 5

LOCKOUT AND TAGOUT

DEVICES

LOTO Standards 29
 LOCKOUT DEVICES

Coloured Padlocks Personal Locks

LOTO Standards 30
 LOCK COLOURS – DEPARTMENT WISE

• Red – Electrical
• Yellow – Mechanical
• Green – Process
• Blue – Instrumentation
• White – Visitors
• Black – Personal Locks

LOTO Standards 31
 LOCK BOX

LOTO Standards 32
 ISOLATION DEVICES (E)

Feeder lockout MCB/MCCB Lockout

Using Hasp, Lockout & Tagout device

LOTO Standards 33
 ISOLATION DEVICES (I)

Pneumatic Lockout Pneumatic Lockout

LOTO Standards 34
 ISOLATION DEVICES (M)

Ball valve Lockout Gate Valve Lockout Cylinder Lockout

LOTO Standards 35
 TAGOUT DEVICES
Isolation Tags Personal Tags

LOTO Standards 36
LOTO Standards 37