LOTOTO PDF.pdf

LOTOTO ISOLATION

1. LOCK OUT
TAG OUT
TEST OUT
(LOTOTO)
Prepared By : Jailani

2. Lockout-Tagout-Testout (LOTOTO)
To protect employees from machines, equipment, or material capable of
causing injury due to unexpected energization, release of stored energy or the
start-up of equipment while an employee is performing maintenance or
servicing equipment by isolating the energy sources.
Purpose LOTOTO

3. Lockout-Tagout-Testout (LOTOTO)

4. LOTOTO vs Hierarchy of
Control
. Planning &
Preparation
1. Apply PTW
4. Initial Ventilation
2. Isolation
5. Pre-
entry gas
test
6. Continuous Ventilation
7. Equipment Preparation
8. Issue PTW
3. Initial Cleaning
9. Enter-Work
10. Job Complete
pass
fail
Standard 10 Steps
Procedure
LOTOTO
Hierarchy of Control

5. Lockout-Tagout-Testout (LOTOTO)
Type of Energy Sources
Electrical
Mechanical
Hydraulic
Pneumatic
Chemical
Fluid
Radiation
Positive pressure
Vacuum
Gravity
Thermal

6. Lockout-Tagout-Testout (LOTOTO)
LOTOTO Case Study: Pasir Gudang -Jun 2001
Nine workers killed shipyard blaze
Flammable gas introduced into the tank
through passing drain valve while workers
doing welding job.

7. LOTO EVOLUTION
Tag only Chain and Tag

8. Lockout-Tagout-Testout (LOTOTO)
Isolation Requirement
ICOP2010
7.3 Methods of isolation from hazardous materials
A confined space shall be isolated before entry is
permitted. The method of isolation shall be determined
based on the risk involved and in accordance with one of
the methods described below or by an alternative method
ensuring equivalent security.

9. Lockout-Tagout-Testout (LOTOTO)
Isolation Devices
Physical device that positively prevents release of energy.
•manually operated
✓electrical circuit breaker;
✓electrical disconnect;
✓electrical switch,
•blank(blind), cap;
•disconnect pipe (remove spool)
•valve; and
•any similar device used to block or isolate energy.
•Except: Pushbuttons, selector switches, DCS and other control
circuit-type devices
All Isolation Devices shall be identified, documentedand Tagged

10. Valve Isolation
•Isolation with pneumatic valves only is not allowed.
•Only "fail closed" shutdown valves is allowed. The
instrument airline has been disconnected, bled off, and
tagged out.
•Control valve shall not be used as an isolation device
ISOLATION DEVICES
LOTOTO Requirement
Control valve Pneumatic shutdown valve Manual valve

11. Positive Isolation: (full safe isolation)
ICOP 2010
7.2 The employer shall take positive steps to ensure the
following but not limited to –
a) positive isolation to prevent accidental introduction into
the confined space of materials, through equipment such as
piping, ducts, drains, conveyors, service pipes, or fire
protection equipment. Closing of a valve is not considered
as a positive isolation;
Lockout-Tagout-Testout (LOTOTO)

12. LOTOTO: POSITIVE ISOLATION
Where PostiveIsolation is required?
•Confined space
•Hot work
•Motor electric removal
Recommended method
•Blank/blind plate (end blind, spectacle blind, slip blind)
•physical disconnection/drop spool
•double block and bleed
•Rack out breaker

13. Ratedblank/blind:
standardblankflangeorfabricatedplate
accordingtoratedthickness/strength
Non-ratedblank/blind:
fabricatedplatethatnotaccordingtorated
thickness/strength.
Non-ratedblindisnotrecommendedunless
bothsidearedepressurizedandemptiedout.
Non rated blind
LOTOTO: POSITIVE ISOLATION

14. Non rated blind
LOTOTO: POSITIVE ISOLATION
7.3 Methods of isolation from hazardous materials
b) insertion of a suitable full-pressure spade (blank) in
piping between the flanges nearestto the confined space;

15. Lockout-Tagout-Testout (LOTOTO)
Why TESTOUTis crucial
Case Study:
A contractor experienced finger cut injury while
repairing a conveyor. The conveyor activated even
though it was “properly” rack-out by chargeman.
What is TESTOUT
The additional step taken to verify the energy was
positively isolated

16. Lockout-Tagout-Testout (LOTOTO)
Devices Isolation method TESTOUT Method
Electrical breakerRackout Activate local switch
Manualvalve Close Verifythe potential valve passing
PneumaticvalveDisconnect air lineStroke test from CCR
Radiation sourceIsolate the sourceverify using radiation detector
LOTOTO shall be completed prior to opening or commencing
maintenance work on pipes or equipments.
Example TESTOUTmethod

17. Danger Tag
Lockout-Tagout-Testout (LOTOTO)

18. Blank/Blind Tag
Lockout-Tagout-Testout (LOTOTO)

19. A device that is Tagged
1.shall not be operated, repositioned, energized,
modified, removed or change in any way while it
is Tagged.
2.A Tag shall not be removed, altered, or modified
in any way until all people doing work under the
isolation have removed their lock
LOTOTO REQUIREMENT

20. LOTOTO RECORD
Se ction 1-LOT O List
Name /sign Date Name /sign Date Name /sign Date Name /sign Date
Se ction 2-Blinding List. NR -Non Rate d
Se ction 2A-Ope ration Blinding List.
Maint (name /sign) Ope ration (name /sign) Maint (name /sign) Ope ration (name /sign)
Maint (name /sign) Ope ration (name /sign) Maint (name /sign) Ope ration (name /sign)
Ve rifie d By: (PIC)Ve rifie d By: (PIC)
Size Rating P&ID No
BLINDING
Note sBlinding point De scription
Ve rifie d By: (ARP)
LOT O INST ALLAT ION
(Are a Owne r Re pre se ntativ e)
TE M P ORARY RE M OV AL
(Are a Ow ne r Re pre s e nta tiv e)
Note s
Ve rifie d By: (ARP) Approv e d by (ARP) Ve rifie d by (ARP)
Rev : 02
Revision Date :
24/06/2020
G-HSE-4-39 LOTOTO & BLINDING CHECKLIST
Unit No:
Re mov e LOT O
T e mporary T ag Re mov al T ag Re instate d
Equipment No:
Equipment Name:
Lock Box No:
No Valv e No Lock No P&ID NoLOT O De scription
Me thod of Site Ve rification
(T ry Out)
No
Date
Ve rifie d By: (ARP) Ve rifie d By: (ARP)
Se ction 2B Blinding List for SPECIFIC T ASK :
Blind No
DE-BLINDING
No
Date
Blind No Blinding point De scription Note s Size Rating P&ID No
BLINDING DE-BLINDING
DateDate

21. MCC
Hand Switch
breaker
Switch
Outlet
Inlet
Scenario : Preventive maintenance for pump
open
open
close
close
Example of LOTOTO
Job Scope
1.Remove pump
2.Change motor
3.Welding leaking suction pipe
Leak

22. MCC
Hand Switch
breaker
Switch
Outlet
Inlet
Example of LOTOTO
1.LOTOTO initiated by Area Owner
•Isolate
•Decontamination
•Request chargeman to rack
out
•Testout
•Chain and lock the isolation
devices

23. MCC
Hand Switch
breaker
Switch
Outlet
Inlet
Example of LOTOTO
Red Tag
Red Tag
close
chain and
lock
close
open
open
Plug
remove
Plug
remove
Red Tag
Red Tag
Testout
Red Tag
Rack out breaker
LOTOTO Process
1.Close the main inlet outlet valves
2.Rack out breaker -electrician
3.Testout local switch
4.Check the drain and vent point for
any potential isolation leak

24. LOTOTO-Valve IsolationSection 1-LOTO List
Name/sign Date Name/sign Date Name/sign Date Name/sign Date
Section 2-Blinding List. NR - Non Rated
Section 2A-Operation Blinding List.
Maint (name/sign) Operation (name/sign) Maint (name/sign) Operation (name/sign)
Maint (name/sign) Operation (name/sign) Maint (name/sign) Operation (name/sign)
Verified By: (PIC)Verified By: (PIC)
Size Rating P&ID No
BLINDING
NotesBlinding point Description
Verified By: (ARP)
LOTO INSTALLATION
(Area Owner Representative)
TEMPORARY REMOVAL
(Area Owner Representative)
Notes
Verified By: (ARP) Approved by (ARP) Verified by (ARP)
Rev : 02
Revision Date :
24/06/2020
G-HSE-4-39 LOTOTO & BLINDING CHECKLIST
Unit No:
Remove LOTO
Temporary Tag Removal Tag Reinstated
Equipment No:
Equipment Name:
Lock Box No:
No Valve No Lock No P&ID NoLOTO Description
Method of Site Verification
(Try Out)
No
Date
Verified By: (ARP) Verified By: (ARP)
Section 2B Blinding List for SPECIFIC TASK :
Blind No
DE-BLINDING
No
Date
Blind No Blinding point Description Notes Size Rating P&ID No
BLINDING DE-BLINDING
DateDate
LOTOTO list -Valve info –
Method Tryout -P&ID# -Name/Sign

25. MCC
Hand Switch
Switch
Outlet
Inlet
Red Tag
Red Tag
Red Tag
breaker
close
close
open
open
Red Tag
Red Tag
Example of LOTOTO
2. Install blind
3. Area Owner place the blind tag
LOCK
Red
LOCK
Red
LOCK

26. Section 2-Blinding List
blinding list
▪Operator fill in Blind List –Section 2
▪Operation and Mechanical to sign LOTOTO and Blind Checklist

27. MCC
Hand Switch
Switch
Outlet
Inlet
Red Tag
Red Tag
Red Tag
breaker
close
close
open
open
Red Tag
Red Tag
Example of LOTOTO
•All job Owner to padlock the Lockbox
before start the job
•Once LOTOTO and Blinding Checklist
approved, NO ONE can alter or
remove the isolation devices or Red
Tag without an approval
Red
LOCK

28. THANK YOU
0166607132
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