PROCEDURE FOR THE IMPLEMENTATION

OF
HAZARDOUS ENERGY CONTROL
PROGRAM (LOCK OUT & TAG OUT)

REV 1 1st September, 2008

CONTENT
CONTENT........................................................................................................................................2
GENERAL SCOPE.........................................................................................................................1
1.0 OBJECTIVE...............................................................................................................................1
2.0 SCOPE AND APPLICATION...................................................................................................2
2.1 SCOPE............................................................................................................................2
2.2 APPLICATION..............................................................................................................2
erecting......................................................................................................................3
installing....................................................................................................................3
constructing...............................................................................................................3
repairing....................................................................................................................3
adjusting....................................................................................................................3
inspecting..................................................................................................................3
un-jamming...............................................................................................................3
setting up...................................................................................................................3
troubleshooting ........................................................................................................3
testing........................................................................................................................3
cleaning.....................................................................................................................3
dismantling................................................................................................................3
servicing....................................................................................................................3
maintaining...............................................................................................................3
lubricating.................................................................................................................3
3.0 RESPONSIBILITIES.................................................................................................................3
3.1 SITE/OPERATION........................................................................................................3
3.2 AUTHORIZED INDIVIDUALS....................................................................................3
3.3 AFFECTED INDIVIDUALS.........................................................................................4
3.4 OTHERS ........................................................................................................................4
4.0 Top Ten Safety Activities for LOTO.........................................................................................4
5.0 DESIGN.......................................................................................................................................6
TECHNICAL PROCEDURE FOR................................................................................................7
HAZARDOUS ENERGY CONTROL PROGRAM.....................................................................7
1.0 LOTO PROGRAM.....................................................................................................................7
1.1 Key Elements of the LOTO Program.............................................................................8
1.2 General Requirements for LOTO...................................................................................8
1.3 LOTO Placard ................................................................................................................9

2.0 LOTO METHODS......................................................................................................................9

2.1 FLOWCHART................................................................................................................9
2.2 Lock Application and Usage........................................................................................10
2.3 Provisions for Energy Control Interruption..................................................................10
2.4 Procedures for LOTO Device Removal without Authorized Employee......................10
2.5 Group LOTO.................................................................................................................11
2.6 Shift or Personnel Changes...........................................................................................12
2.7 Remote or Noncontiguous Locations ...........................................................................13
2.8 Outside Service or Contractor Personnel......................................................................13
2.8.1 Hazard Notification. .......................................................................................14
2.8.2 Program Coordination. ...................................................................................14
2.8.3 Communications. ...........................................................................................14
2.8.4 LOTO Supervisor for Contractor....................................................................14
2.8.5 Saint-Gobain China as the Outside Service. ..................................................15
3.0 COMMUNICATION AND TRAINING.................................................................................16
3.1 Communication.............................................................................................................16
3.2 Training Overview........................................................................................................16
4.0 PROGRAM REVIEW..............................................................................................................17
4.1 Auditing and Inspections..............................................................................................17
4.2 Performance Feedback..................................................................................................17
APPENDIX A RISK ASSESSMENT AND RISK REDUCTION.............................................19
A.1 RISK ASSESSMENT.................................................................................................19
A.2 RISK REDUCTION (IMPLEMENTATION)............................................................20
A.2.1 Risk Reduction by Design.............................................................................21
A.2.2 Risk Reduction by Use of Engineered Safeguards.......................................21
A.2.3 Risk Reduction by Use of Warning and Alerting Techniques......................21
A.2.4 Risk Reduction by Use of Administrative Controls......................................22
A.2.5 Risk Reduction by Use of Personal Protective Equipment...........................22
A.3 REVIEW THE RISK ASSESSMENT AND RISK REDUCTION............................22
APPENDIX B LOTO DEFINITIONS.........................................................................................23
APPENDIX C LOTO Placard......................................................................................................29
C.1 LOTO Placard Format:................................................................................................29
C.1.1 Lockout, release and blocking instructions.................................................29
C.1.2 Hazard Warnings.........................................................................................30
C.1.3 Troubleshooting..........................................................................................30
C.2 What are the Purpose and Limitations of LOTO Placards?........................................30
C.3 Which Machines must have an LOTO Placard?.........................................................30
C.4 Who is responsible for implementing the LOTO Placard system?.............................31
C.5 Who is permitted to make LOTO Placards?...............................................................31
C.6 Who may sign (authorize) LOTO Placards?...............................................................32
C.7 What Does Authorizing an LOTO Placard Mean?.....................................................32

C.8 Summary of the Steps in Making LOTO Placard.......................................................32

C.9 LOTO Safe Work Procedures.....................................................................................33
APPENDIX D LOTO Step-By-Step Process...............................................................................35
APPENDIX E TRAINING OVERVIEW....................................................................................38
E.1 Affected Individual Training.......................................................................................38
E.2 Authorized Individual Training...................................................................................39
E.3 Additional Training.....................................................................................................40
E.4 Demonstration of Training..........................................................................................40
APPENDIX F DESIGN.................................................................................................................41
F.1 Exposure Minimization..............................................................................................41
F.2 Partial Energization....................................................................................................41
F.3 ENERGY- ISOLATING DEVICES...........................................................................41
F.3.1 Location.........................................................................................................41
F.3.2 Identification..................................................................................................42
F.3.3 Capability.......................................................................................................42
F.4 SPECIAL TOOLS OR DEVICES..............................................................................43
F.5 WARNINGS AND SPECIAL INSTRUCTIONS......................................................43
F.6 COMPONENT ISOLATION.....................................................................................43
F.7 DOCUMENTATION REQUIREMENTS.................................................................43
F.8 STORED AND RESIDUAL ENERGY.....................................................................44
F.9 TOOL CHANGE, SET-UP........................................................................................44
F.10 PHYSICAL SAFEGUARDS....................................................................................44
APPENDIX G PRIMARY, SECONDARY ENERGY SOURCE & STORED ENERGY
SOURCE..........................................................................................................................................45
Electrical.................................................................................................................45
Pneumatic................................................................................................................45
Hydraulic.................................................................................................................45
Steam.......................................................................................................................45
Chemical/Coolant...................................................................................................45
Gases 45
Radiation.................................................................................................................45
Magnetic.................................................................................................................45
Water45
APPENDIX H VALIDATION CRITERIA FOR THE LOCKOUT & TAG OUT
PROGRAM IMPLEMENTED......................................................................................................46

GENERAL SCOPE
1.0

OBJECTIVE
The purpose of this program is to establish comprehensive Saint-Gobain China
Delegation Lockout and Tag out (LOTO) expectations and requirements. It establishes
Saint-Gobains expectations regarding safe methods of controlling energy during
servicing and/or maintenance of machines and equipment and during reenergizing of the
machine and equipment at the end of the servicing and/or maintenance. This program
was designed to prevent injuries caused by unexpected activation of hazardous energies.
Unexpected release of hazardous energy can include any unintended motion,
energization, start-up or release of stored energy, deliberate or otherwise, from the
perspective of the person(s) at risk.
The Saint-Gobain China Delegation LOTO program will help the facility or
operation/organization comply with country-specific regulatory requirements and the
company EHS policy.
This program constitutes the minimum Saint-Gobain China Company LOTO
expectations. The most important element of the program is that Saint-Gobain China
personnel and contractors shall not perform activities, as defined in Paragraph 2.2
Application, with equipment energized. In special situations, a risk assessment process
may be used to document the necessity to work on energized equipment (e.g., it is not
possible to perform the task while using LOTO). In these situations, alternative energy
control procedures providing equivalent protection to employees are required.
This program provides Saint-Gobain Chinas expectations regarding:

Responsibilities of all personnel involved in hazardous energy control;

Design issues that influence the methods of controlling energy sources;

Hazardous energy control program elements necessary for employee protection;

Special applications where traditional methods of hazardous energy control are

inappropriate or impractical;

Communication and training requirements for affected personnel;

Management review of the total hazardous energy control process to ensure its
functioning effectiveness.

2.0
2.1

SCOPE AND APPLICATION

SCOPE
This program establishes requirements for the control of hazardous energy associated
with machines, equipment, processes and circuits that could cause injury to personnel.
This standard covers maintenance and/or servicing of equipment when unexpected
energization or start-up of the equipment, or release of stored energy, could cause injury
to employees. In addition, this program establishes minimum performance requirements
for the control of hazardous energy. A key element of this program is the development
of equipment or process-specific LOTO procedures (Placard) for all equipment.

2.2

APPLICATION
This program applies to Saint-Gobain China operation/sites that belong to Industry.
Distribution entities are invited to follow strictly Saint-Gobain Group LOTO Standard
that has been designed in order to meet Distribution needs.
For operation/sites that already have a LOTO procedure, they have to check if their
procedure complies with the LOTO validation criteria and submit it to their respective
Sector for approval. If the operation/site does not have any LOTO procedure in place,
this program will be adopted after submission to their Sector. In addition, each
operation/site should complement this program with more detailed document to make it
closer to production reality.
This standard applies to, but is not limited to, activities that are performed on a machine,
a piece of equipment, a process or circuit. Primary, secondary, stored and single source
energy sources require a lockout when performing servicing and/or maintenance
activities. Primary energy sources are the main energy sources, such as electricity, gas,
fluids, etc., provided to machines, equipment, processes and circuits.
Secondary energy sources are downstream from the primary (or main) energy source.
For example, electricity, fluids, etc., secondary energy lockout points are used to isolate
a specific component of a system without the necessity of locking out the entire system.
Stored energy must also be taken into consideration. Stored energy, such as motion,
pressure, gravity, capacitance or temperature, is a potential hazard that still exists after a
primary energy source has been locked out. For example, a pump motor for a hydraulic
system may be locked out, effectively stopping fluid flow, but energy in the form of
pressure may still exist in an accumulator. This pressure in the accumulator should be
bled off before work proceeds. All stored energy must be controlled to ensure complete
machine safety.

Single source machines are machines, equipment, processes and circuits that can be
completely deactivated through the isolation and locking out of a single energy source.
Below is a listing of typical activities in which energy control procedures apply:
erecting
inspecting
cleaning
installing
un-jamming
dismantling
constructing
setting up
servicing
repairing
troubleshooting
maintaining
adjusting
testing
lubricating
LOTO applies to all sources of energy, including, but not limited to, those energy
sources: Primary, Secondary Energy Source & Strored Energy Source.

3.0
3.1

RESPONSIBILITIES
SITE/OPERATION
The site/operation shall be responsible for complying with the applicable provisions of
this program by establishing an effective program for the protection of individuals from
hazardous energy during activities listed in Paragraph 2.2 Application.
The site/operation shall fully implement the provisions of this program within six (6)
months from the date this document enter into force. New site/operations or
acquisitions shall fully implement this program within six (6) months of initial
operations as SAINT-GOBAIN CHINA.
When Saint-Gobain China is retained as a service provider at a customer site, SaintGobain China personnel will adhere to this program, although special circumstances
may require utilization of alternative actions. Upon request of the customer and approval
by a qualified Saint-Gobain China authorized employee, Saint-Gobain China personnel
may follow the customers LOTO program, provided the program ensures equal or
greater protection to authorized individuals and affected individuals.

3.2

AUTHORIZED INDIVIDUALS
Authorized individuals shall be identified by site/operation and be responsible for
performing hazardous energy control in compliance with the site-specific program,
procedures and detailed training provided to them by the Saint-Gobain China business
and/or site/operation (e.g. LOTO Champion).

3.3

AFFECTED INDIVIDUALS
Affected individuals consist of all personnel who are not authorized individuals and who
must receive LOTO awareness training, which will include the importance of not
attempting to start up a locked out machine, equipment, process or circuit. Affected
individuals need to recognize and understand LOTO procedures.

3.4

OTHERS

LOTO Champion

Advice GM/Plant Manager how to implement the LOTO

program.
Review requests for changes to this operating procedure. Any
change that deviates from this procedure must have prior approval
of Delegation China EHS and Sector EHS.
Make sure this procedure is reviewed and updated annually to
take account of any changes to local legal regulatory changes
and/or the SG safety standards.
Provide LOTO training to authorize individuals, affected
individuals.
Ensure that all powered machines are LOTO capable and have
authorized LOTO Placards (see APPENDIX C LOTO Placard).
Maintain a register of powered machines and their status on all
aspects of LOTO capability.
Authorize new & updated LOTO Placards for existing machines
together with the machine operator and supervisor.
LOTO Compliance Audits each time there is a maintenance which
requires LOTO in his area.
Participate in LOTO Placard verification meetings,
Double check if the LOTO procedure is updated with local legal
regulatory changes and/or the SG safety standards.
Participate in LOTO Placard verification meetings.
Make sure employees who are required to apply LOTO must be
trained in LOTO and receive the annual LOTO refresher training.
LOTO Compliance Audits each time there is a maintenance which
requires LOTO in his area.
Participate in LOTO Placard verification meetings.

Comply with all LOTO procedures.

Report damage or defects affecting LOTO.

Facility engineer

Maintenance Manager

Area manager

EHS Coordinator

Supervisor

Area Safety
Representatives
Maintenance
technicians

4.0

Top Ten Safety Activities for LOTO

The top ten core requirements for using LOTO to prevent injuries are:
1.

One Lock, One Key, And One Person: The basis of LOTO is that any individual
has total control of the lockout of the machine, equipment, process or circuit
that is being serviced and/or maintained. This concept assures the individual sole
lockout responsibilities.

2.

Effective Training: Understanding lockout responsibilities, processes, methods

and requirements result from effective LOTO training practices. The knowledge
attained through training is reflected by practices of the site/operation. Effective
training is proven by periodic inspection and includes provisions for
demonstration and performance feedback.

3.

Routine and/or Repetitive Activities: While a full LOTO is always preferred,

there may be some routine or repetitive tasks for which a risk assessment will
determine correct safety precautions.

4.

Authorized/Affected Individuals:
Authorized individuals must be
knowledgeable and able to perform all aspects of the LOTO process. Affected
individuals must understand and respect the LOTO and not attempt to modify or
remove LOTO done by others.

5.

The Proper Tools: LOTO is conducted with a specific set of tools. These tools
include keys, locks, multiple lockout devices and red tags. Proper use and
application of these tools is learned through this program and effective training.

6.

Equipment-specific LOTO Procedures: Equipment-specific LOTO procedures

provide detailed guidelines for safe lockout of each machine, equipment, process
or circuit that is being serviced and/or maintained.

7.

LOTO Verification: A Zero Energy State must exist in the machine,

equipment, process or circuit before servicing and/or maintenance activities can
begin. The best method possible must be used to verify that energy has stopped,
released, dissipated or drained completely. Verification provides certainty that
energization cannot occur while work is being performed. The verification (or
tryout) step must be included in each equipment or process-specific LOTO
procedure.

8.

Shift or Personnel Changes: The maximum permitted duration for a LOTO is

one shift or the end of the task, whichever is shorter. Continuity of the LOTO
process must occur as shifts or personnel change. This applies to both individual
and group LOTO. It is important to assure that the LOTO process remains intact
during these transition times by using direct LOTO hand-off or other approved
methods by your Sector in very special case.

9.

LOTO for Contractor Activities: Whether contractors are working at a

site/operation or Saint-Gobain China individuals are performing contract work, it
is of the utmost importance that all aspects of the Saint-Gobain China LOTO
policy are adhered to.

10. Risk Assessment: Risk assessment can help to find the best condition for
individual work. It establishes safety action to reduce the risk when normal LOTO
program is impossible to implement.

5.0

DESIGN
GENERAL ELECTRIC EQUIPMENT
All machines, equipment, processes and circuits that are to be delivered to Saint-Gobain
China shall be designed, manufactured, supplied and installed so that the site/operation
can comply with the energy control guidelines explained in this program. It is SaintGobain Chinas responsibility to review the suppliers product to ensure that safety
issues are addressed. The paragraphs in this section define what is expected of suppliers.
Modifications affecting energy isolation shall comply with or exceed these standard
requirements. Machine, equipment, process and circuit design should incorporate
employee safety as a priority. A risk assessment shall be performed during the
engineering design stage of development. The risk assessment performs two functions;
first, it determines the need for energy control devices and systems; second, it
determines the appropriate type of energy control that is required.

TECHNICAL PROCEDURE FOR

HAZARDOUS ENERGY CONTROL PROGRAM
1.0

LOTO PROGRAM
The site/operation/service organization shall establish a written program for hazardous
energy control that details the requirements of the LOTO program. The written program
shall be based on this LOTO program and the Saint-Gobain LOTO Standard. The
purpose of this program is to ensure that risk of exposure to hazards will be eliminated
or minimized before any authorized individual performs any activity where the
unexpected energizing, start-up or release of stored energy could occur and cause injury
(see Figure 1).
Task requiring access to
machine, equipment or process.

NO

Implement the LOTO

Placard

Exposed to hazard?

YES
Report your manager and
LOTO work team

Guards removed?
Interlocks bypassed?
YES
Perform
Lockout
Procedure

YES
Perform
Task

Perform Risk
Assessment

Improve the
LOTO device

Figure 1. Decision Matrix for Safeguarding and LOTO Hazardous Energy

7
YES

1.1

Key Elements of the LOTO Program

The LOTO program shall consist of the following elements to provide effective
protection of personnel:

1.2

survey and inventory of all hazardous energy (electrical, pneumatic, hydraulic,

etc.);

identification of all isolation points (i.e., by labeling each point or specifically

indicating the location of the isolation points in the LOTO Placard);

identification of energy-isolating devices needed;

selection and procurement of protective materials and hardware;

assignment of duties and responsibilities;

written procedures (site specific and equipment/process specific) documenting

the shut-down, de-energization, verification, re-energization and start-up
sequences; for machines, equipment and processes;

training, re-training and evaluation of personnel;

periodic inspections, it is strongly recommended to make inspection each time

servicing and/or maintenance requires to perform LOTO;

auditing of program elements.

General Requirements for LOTO

LOTO shall be used on all energy-isolating devices capable of being locked out. An
energy-isolating device is capable of being locked out if it has one of the following:

a hasp or other means of attachment to which, or through which, a lock can be

affixed;

a locking mechanism built into it;

a means to achieve lockout without the need to dismantle, rebuild or replace the
energy-isolating device, or permanently alter its energy control capability.

If a machine/equipment does not have energy-isolating devices capable of being locked

out, the facility should make engineering work in order to make it capable of being
locked (this case could happened just after new acquisition or when a
machine/equipment has not been designed with energy-isolating device capable of being
locked out). The site has to write a specific procedure and inform all the workers during
the time engineering improvement will be implemented.

1.3

LOTO Placard
A LOTO Placard is a laminated sheet or sheets that contain detailed LOTO information
for the specified machine system, workstation or a single machine. LOTO Placards are
usually posted on the main electrical panel. Based on an identification of the primary
energies (energies required to run (energize) the machine/s), it lists:
the main disconnects (lockout points used to isolate all energies to the machine
or machine system), and
secondary disconnects (lockout points that can be used to isolate energy to a
single workstation or a single machine),
the locations for energy dissipation or blocking and
other safety hazards in and near the machine.
For each of these, there is a description of lockout/control locations, lockout/control
procedures, and verification procedures. Most LOTO Placards will also include a plan
layout of the machine on which the lockout/control points and other LOTO-related
hazards are marked. Matching the symbols on the LOTO Placard, energy labels
attached at or near lockout/control disconnects on the machinery.

2.0

LOTO METHODS

2.1

FLOWCHART
STEP 1

STEP 2

STEP 3

ID Energy Sources

Notify Others

Shutdown Equipment

STEP 4

STEP 5

STEP 6

Isolate Equipment

LOTO Equipment

Release Stored Energy

STEP 7

STEP 8

STEP 9

Verify Isolation

Keep LOTO enforced while

performing intervention

Release from LOTO

The selected method of hazardous energy control depends on whether the task can be
performed with or without energized conditions. In all cases, the primary method of
control shall be LOTO as specified in Paragraph APPENDIX D.
2.2

Lock Application and Usage

Table 1 below summarizes the application and use of the 2 different types of locks
covered in this program.
Table 1. Lock Usage

Lock Type

Purpose

Duration of
Use

Lock Color

Key

Tags

Group Lock

Not assigned to an
individual employee
and used to lock out
individual energyisolating devices or
energy sources when
group LOTO is used.

One shift or
the end of the
task,
whichever is
shorter.

Specific lock
color is not
required but lock
must be unique
and used for
LOTO only.

Only one key;

master keys are
not available.

required

Single shift
use only.

Specific lock
color is not
required but red
is typically used.

Only one key;

master keys are
not available.

Red tags
required.

LOTO Box should be

combined into group
lock.
Individual

2.3

Assigned to and used

by authorized
individuals only.

Provisions for Energy Control Interruption

In situations in which LOTO must be temporarily removed from the energy-isolating
device(s) and the machine, equipment, process and circuit must be either fully or
partially energized to test, troubleshoot or position the machine, equipment, process or
circuit or a component thereof, the sequence of actions detailed in Paragraph D, Step 9
(Release from LOTO) shall be followed.
When the energy is no longer needed, re-apply LOTO according to the appropriate
instruction found in Paragraph D.

2.4

Procedures for LOTO Device Removal without Authorized Employee

When the authorized individual who applied the LOTO device is not available to
remove it, that device may be removed under the direction of the site/operation
leadership, provided that specific procedures and training for such removal have been
developed, documented and incorporated into the energy control program. This system
should be comprised of at least three individuals knowledgeable of the work being

10

performed, and the removal should be documented through the Risk Assessment and
Risk Reduction program outlined in . The site/operation-specific procedure shall
incorporate the requirements in Paragraph APPENDIX D, Step 9 in addition to the
following elements:

2.5

verification by the appropriate supervisory personnel that the authorized

individual who applied the device is not reasonably available or not at the
facility;

ensuring that the authorized individual has been informed before he/she resumes
work at that facility that his/her lockout or tag out device has been removed.

Group LOTO
Machine, equipment, process and circuit may require servicing and/or maintenance by
more than one authorized individual. Each authorized individual performing service
and/or maintenance must apply his/her Individual LOTO Lock. Every authorized
individual who applies an Individual LOTO Lock shall verify that the machine,
equipment, process or circuit has attained a zero energy state or observe the verification
process. Multiple lock application can be accomplished with the following:

Multiple lock devices (hasps) that accommodate several Individual LOTO

Locks;

The use of Group Lock and Lock Box. For example, if a machine with multiple
energy sources is going to be serviced by multiple personnel, it may be useful to
use General LOTO Locks at the energy sources. Keys for the General LOTO
Locks are held in lock box to which employees attach their Individual LOTO
Locks.

Lock box when an energy-isolating device can accommodate only one key. This
key is placed inside the lock box and all authorized individuals servicing and/or
maintaining the machine, equipment, process and circuit secure and attach their
Individual LOTO Locks.

11

2.6

Shift or Personnel Changes

The maximum permitted duration for a LOTO is one shift or the end of the task,
whichever is shorter. Specific procedures shall be utilized during shift or personnel
changes to ensure the continuity of LOTO protection. This includes provisions for the
orderly transfer of LOTO devices between off-going and on-coming authorized
individuals.
The immediate hand-off of LOTO in progress. Authorized individuals of the outgoing
shift remove their Individual LOTO Locks and red tags. Authorized individuals of the
next shift simultaneously apply and secure their Individual LOTO Locks and red tags at
the same energy-isolating device and verify that a zero energy state exists in the system
via the "tryout" process.
Figure 1. Sample of LOTO Shift or Personnel Changes:
SHIFT CHANGE
(CHANGE-OVER
PERIOD)

IMMEDIATE
HAND-OFF

Shift
A

Authorized individual from Shift

A removes his/her Red Tag
and Individual LOTO Locks.
Authorized individual from Shift
B immediately applies
his/her Red Tag and Individual
LOTO Locks and verifies "zero"
energy via the "try- out" process.

Shift
B

Communication is an important part of the shift or personnel change process. LOTO and
servicing and/or maintenance information must be exchanged between authorized red
tags, which have remark areas to provide additional information.
During the shift or personnel change process, every authorized individual who applies
an Individual LOTO Lock shall verify (or observe verification) that the machine,
equipment, process or circuit has attained a zero energy state.
NOTE
Field Service personnel must coordinate LOTO procedures at
the customers sites with their customer representative.
Generally, energy isolation devices cannot be secured without

12

permission from the customer and in concert with the site

personnel. Further, isolation devices are removed only after
communication with the customer representative.

2.7

Remote or Noncontiguous Locations

Where isolation devices are in remote or noncontiguous locations, special methods may
be used to provide protection. Written procedures shall be used in conjunction with
written authorizations and continuous communication between people performing the
LOTO and those performing the maintenance or servicing. These steps are necessary to
ensure that authorized individuals performing maintenance or servicing tasks verify the
isolation and de-energization or re-energization through direct communication with
those individuals who actually performed the de-energization and isolation. Examples of
remote or noncontiguous locations include:

2.8

Pipeline operations with widely spaced pump stations, including those

connecting offshore oil and gas production to onshore terminals.

Electric power transmission and distribution systems and gas transmission and
distribution systems, including underground gas storage systems, gas wells and
compressor stations.

Outside Service or Contractor Personnel

The LOTO program and procedures of outside services or contractors must provide
protection equal to or better than the Saint-Gobain China LOTO program. Saint-Gobain
China requires that LOTO programs for outside services or contractors are reviewed by
authorized Saint-Gobain China personnel. Saint-Gobain China and outside service or
contractor personnel shall each designate a representative responsible for determining
their relationship, responsibilities and obligations regarding hazardous energy control
prior to the outside service or contractor starting work or providing services.
As a best practice, the Saint-Gobain China authorized representative may perform the
LOTO step-by-step process (refer to Paragraph APPENDIX D). The outside service or
contractor will then be required to attach and secure Individual LOTO Locks and red
tags to the same energy-isolating devices that the Saint-Gobain China representative has
locked out.

13

2.8.1

Hazard Notification.

Saint-Gobain China personnel shall inform the outside service or contractor-designated

representative of any special or unique hazards that are related to the machinery,
equipment, process or circuit and that may endanger the outside service or contractor
employees.
2.8.2

Program Coordination.

All outside service organization or contractor programs shall be coordinated with SaintGobain Chinas hazardous energy control program when there is integration of job
tasks. Protection for all individuals within the facility who may be affected shall be
mutually understood, communicated and agreed upon between the parties.
2.8.3

Communications.

Saint-Gobain China personnel and outside services or contractors shall keep each other
informed of any activities or conditions that may adversely affect the application of
hazardous energy control or impact the normal operation of machines, equipment, or
processes and circuits. The Saint-Gobain China representative should supply the service
or contractor with a copy of the operation/site-specific LOTO program. The SaintGobain China representative should review with outside services and contractors all
expectations, rules and hardware involved in the LOTO process. All written copies of
the contractors LOTO program and all project safety information shall be kept on file
with the Saint-Gobain China representative for the life of the project.
NOTE
Examples of activities or conditions that warrant communication
between the parties include interruption of energy supply,
disabling a fire protection/security system, emergency alarm
systems, hazardous area ventilation and special equipment that
are needed for energy isolation.

2.8.4

LOTO Supervisor for Contractor

It is safer to rely on a single authorized individual to oversee LOTO for contractors,

rather than train all individual contractors in proper LOTO procedures. These
circumstances may occur when, due to individual contractor skill level and system
complexity, a greater hazard may occur when normal LOTO is practiced. These

14

contractors will be given locks by the LOTO Supervisor and shown where to place them
to assure their individual control of the energy source(s) while working. Any authorized
individual who is asked to serve in a LOTO Supervisor role must acknowledge that they
are accepting responsibility for the safety of all personnel to be protected by the LOTO.
Per the requirements listed below, a site/operation may implement a LOTO Supervisor
system when:
A risk assessment has been completed that documents the greater hazard that would be
controlled by using the LOTO Supervisor method, and the specific alternative
procedures to be implemented.
The Central EHS Manager or site EHS Manager has reviewed the risk assessment and
provided documented approval of the need for the use of the LOTO Supervisor
approach and the specific alternative procedures to be used. Such approvals may be in
the form of a blanket approval or procedure for LOTO Supervisor applications that are
expected to be repeated periodically.
All contractors to be protected by LOTO receive training on the procedures the
LOTO Supervisor follows. The employees have the right to either perform LOTO
verification or observe the LOTO Supervisor perform verification.
The LOTO Supervisor must be present on the facility at all times that the LOTO is
in place, and must be in possession of a list of all employees protected by the
LOTO.
Lockouts under the LOTO Supervisor method are limited to the length of the task
or the end of the shift, whichever is shorter.
Placement of a LOTO under the LOTO Supervisor method involves the following steps:
Place the LOTO following the procedures in APPENDIX D, and LOTO Placard
for the equipment or process being locked out.
Inform the contractors to be protected by the LOTO of their right to perform the
verification step, or observe the LOTO Supervisor perform verification, and
provide the contractors with the opportunity to exercise this right.

2.8.5

Saint-Gobain China as the Outside Service.

The responsibility of Saint-Gobain China personnel when involved in providing services

includes:

15

complying with the Saint-Gobain China LOTO program;

assessing and making determination (by a qualified Saint-Gobain China

Authorized Employee) that customer LOTO programs provide equivalent
protection as Saint-Gobain China programs where the customer wants/requires
adherence to their procedures; if not, SG will follow his own procedure.

communicating with the customer regarding LOTO requirements and

conditions;

reporting deviations and/or discrepancies to your EHS facilitator;

discontinuing work when presented with an unsafe condition.

Field service personnel should request customer equipment-specific LOTO procedures

when performing servicing and/or maintenance activities. Risk assessment must be
performed to establish energy control procedures when customer LOTO documentation
does not exist. Risk assessment on customer equipment should involve a customer
representative knowledgeable on the equipment whenever possible.

3.0
3.1

COMMUNICATION AND TRAINING

Communication
The operations leader for the site operation shall be responsible for ensuring that all
affected and authorized individuals are informed regarding the provisions of the
hazardous energy control program. The operations leader for the operation shall also be
responsible for ensuring that appropriate authorized individuals are apprised of aspects
of the hazardous energy control program such as changes in the program, incident
experience, progress against the plan, performance data, auditing results and other
pertinent details.

3.2

Training Overview
Authorized individuals shall be trained and pass the examination prior to performing any
type of LOTO activity. The examination should include written text and on-site
demonstration. Affected individuals shall also be trained per this program. In
APPENDIX E, Table 1 is a summary of the training requirements. Table 2 summarizes
the training frequency requirements.

16

4.0

PROGRAM REVIEW
The site/operation shall annually assess the condition and effectiveness of each of the
elements of the hazardous energy control program as described in Saint-Gobain
China Health and Safety Annual Review system. At a minimum, the assessment
shall include:

4.1

the written program;

specific machine, equipment, process and circuit procedures;

LOTO hardware;

energy-isolating devices;

communication and training.

Auditing and Inspections

The site/operation should determine the frequency of auditing (e.g., weekly) and an
appropriate sample size. The audits should be random and address all shifts (never
forget night shift), days of operation, groups, non-standard work situations and
individual personnel. Knowledgeable personnel should conduct visual observations of
authorized individuals performing specific procedures. Feedback and documentation
shall follow the observations.

4.2

Performance Feedback
The site/operation shall establish a documented system that inspects performance by
authorized individuals and also provides both positive and negative feedback to
appropriate individuals and supervisors regarding the hazardous energy control program.
Where deficiencies are found, corrective action shall be taken and appropriate
individuals informed of the required improvements.
Appropriate disciplinary actions shall be implemented when defects are identified
during the audit or when this Saint-Gobain China program is not being followed by
affected or authorized employees. When necessary, employee violations of this program
17

shall be documented and appropriate disciplinary action taken. The enforcement of this
program, and all safety regulations, can result in disciplinary procedures up to and
including termination.

18

APPENDIX A RISK ASSESSMENT AND RISK REDUCTION

A.1

RISK ASSESSMENT
Risk assessment is an analytical tool consisting of a number of discrete steps intended to
ensure that hazards are properly identified, that associated risks are evaluated and that
appropriate measures are taken to reduce those risks to an acceptable level. Elements of a risk
assessment process include the following steps:
1.

Identify all tasks: All tasks and activities should be considered. Examples of activities
for which tasks should be identified include set up, installation, removal, maintenance,
operating, adjusting, cleaning, troubleshooting and programming.

2.

Identify hazards: Hazards associated with each task, such as mechanical, electrical,
thermal, pneumatic, hydraulic, radiation, residual or stored energy, motion, fuels and
human factors should be considered. Associated hazards for a particular task not related
to hazardous energy release may also need to be reviewed. Consideration should
include human error, management system deficiencies and foreseeable improper use of
equipment.

3.

Assess the severity of harm: Severity of harm addresses the degree of injury or illness
that could occur. The degrees are based on extent of injury or illness (from death to no
injury), and extent of treatment involved. The following is an example of severity
levels:
Catastrophic - death or permanently disabling injury or illness (unable to return to
work)
Serious - severe debilitating injury or illness (able to return to work at some point)
Moderate - significant injury or illness requiring more than first aid (able to return
to same job)
Minor - no injury or slight injury requiring no more than first aid (little or no lost
work time)
(Note: When determining risk, the worst credible severity of harm is to be
selected.)

4.

Assess the probability of occurrence of harm:

Probability of occurrence of harm is estimated by taking into account the
frequency, duration and extent of exposure, training and awareness, and the
presentation of the hazard. The following is an example of probability levels:
- Very likely - near certain to occur
- Likely - may occur
- Unlikely - not likely to occur
19

- Remote - so unlikely as to be near zero

When estimating probability, the highest credible level of probability is to be
selected. The following factors are considered important in estimating the probability
of occurrence of harm:
- Exposure to a hazard;
- Personnel who perform tasks;
- Machine/task history;
- Workplace environment;
- Human factors;
- Reliability of safety functions;
- Possibility to defeat or circumvent protective measures;
- Ability to maintain protective measures.
5.

Evaluate the risk: Based on the results of Steps 3 and 4 above, the level of risk is
estimated by applying the level of severity of harm and the probability of occurrence of
that harm to Table A-.
Table A-. Risk Estimation Matrix
Severity of Harm

Probability of
Occurrence of Harm

Catastrophic

Serious

Moderate

Minor

Very Likely

High

High

High

Medium

Likely

High

High

Medium

Low

Unlikely

Medium

Medium

Low

Negligible

Remote

Low

Low

Negligible

Negligible

An example: a serious severity of harm and a likely probability of occurrence of that harm yield a high level
of risk.

A.2

RISK REDUCTION (IMPLEMENTATION)

Risk reduction is a hierarchical process employed to reduce or control risk by the following:

elimination through design;

use of engineered safeguards;

awareness means including warning and alerting techniques;

administrative controls including safe work procedures and training;

use of personal protective equipment;

training.

20

Often, for any particular machine, equipment, process and circuit, the solution may include
aspects of each of these elements. The risk reduction process should involve the affected
personnel, should be documented.
The following questions should be asked to determine the adequacy of the risk reduction
process:

Is the safety level adequate? Can the task be performed without causing injury or
damage to health?

Have appropriate safety measures been taken for all tasks or activities? Are the
measures taken compatible with each other?

Do the safety measures generate any new, unexpected hazards or problems?

A.2.1 Risk Reduction by Design

Risk reduction should first attempt to eliminate the hazard through design. The primary
objective in implementing design features is to eliminate hazards or reduce their risk by
substitution.
A.2.2 Risk Reduction by Use of Engineered Safeguards
Safeguards or safety devices should be used to protect personnel from hazards that cannot be
reasonably eliminated or sufficiently reduced by design.
Safeguards or safety devices and the safety control system (electrical, pneumatic, hydraulic,
etc.) should be of a suitable reliability for the risk reduction that is required.
NOTE
Examples of engineered safeguards include guards (both fixed and
interlocked), trapped key devices, and trip devices (light curtains, laser
scanners, pressure mats, safety rated switches, etc.). Safety devices
include, emergency stop buttons, enabling or hold-to-run devices, etc.

A.2.3 Risk Reduction by Use of Warning and Alerting Techniques

Warning and alerting techniques should be used to protect personnel from hazards that cannot
be reasonably eliminated or sufficiently reduced by design, engineered safeguards, or a
combination of these elements.
NOTE
Examples of warning and alerting techniques include attendants,
audible and visual signals, barricades, signs and tags.

21

A.2.4 Risk Reduction by Use of Administrative Controls

Additional risk reduction is achieved by the use of administrative controls including safe work
procedures, standard practices and checklists and training. These should be used to control
risk that cannot be reasonably eliminated or sufficiently reduced by the use of design,
engineered safeguards, warning and alerting techniques or a combination of these elements.
Training should be used as a complement to all the risk reduction methods described here.
NOTE
Examples of safe work procedures, practices and training include
standard operating instructions, illumination, pre-job review and
establishing safe distances from a hazard. Examples of types of
training that can be used to develop proficiency of authorized
individuals may include computer-based simulation, drills, classroom
programs or exercises.

A.2.5 Risk Reduction by Use of Personal Protective Equipment

Additional risk reduction is achieved by effective use of prescribed personal protective
equipment (PPE). Strong administrative procedures must be in place for the PPE to be an
effective safeguard.
NOTE
Personal protective equipment can include safety eyewear or shields,
footwear, protective gloves (insulating or cut resistant) and protective
headgear.

A.3

REVIEW THE RISK ASSESSMENT AND RISK REDUCTION

The risk assessment and risk reduction should be reviewed at the following times:

following its implementation to ensure solutions are effective and in place;

following an incident or near miss;

whenever new tasks or activities are required;

whenever there are modifications to the machine, equipment, process or circuit;

on a periodic basis.

22

APPENDIX B LOTO DEFINITIONS

23

Adjacent Equipment/
Process:

Adjacent machine energy sources are the primary and

stored energy sources of a machine, equipment, process
and circuit that, while not related to the primary machine,
their nearness may present a hazard to persons working on
the primary machine. To ensure safety, hazardous energy
from adjacent equipment/processes should be identified.

Affected Individual:

An individual who operates equipment on which

maintenance or servicing is being performed under LOTO,
or an individual who works in the area where such
maintenance or servicing is being performed. This
individual is not authorized to perform LOTO.

Alarm:

An audible or visual means to alert personnel to an

impending hazard, e.g., motion, or that a failure or
malfunction of a machine, equipment, process and circuit
has occurred.

Associated
Equipment/Process:

Associated energy sources are those energy sources that

interface with the primary piece of machine, equipment,
process and circuit, but whose power is not dependent
upon that machine, equipment, process and circuit. For
example, a drill fixture may receive parts from a robot that
takes parts off a conveyor, but removing power from the
drill fixture does not remove power from the robot or the
conveyor. The robot and conveyor may each be powered
independently, but their physical association with the drill
fixture is such that, for ultimate safety, these pieces must
also be locked out. Therefore, both the robot and the
conveyor have associated energy sources that must be
identified.

Authorized Individual:

A person who is properly trained and authorized to

perform hazardous energy control (LOTO).
The means of initiating or interrupting energy to a
machine, equipment, process and circuit; also the circuit of
a control apparatus or system that directs the performance
of a machine, equipment, process or circuit but does not
directly interrupt the flow of energy. Control headers or
circuits may be hydraulic, pneumatic, electric or electromechanical.

Control Header or
Circuit:

24

Control Reliability:

A method to ensure that a device or system will stop or

prevent initiation of hazardous motion in the event of a
single component failure within the device or system.

Control System:

Sensors, manual input and mode selection elements,

interlocking and decision-making circuitry, and output
elements provided to the operating devices or mechanisms
of the machine, equipment, process and circuit.

De-energized:

Physically isolated from all energy sources and not

containing residual or stored energy. A zero energy state is
verified as existing.

Dissipate:

The process of removing stored energy from a machine,

equipment, process or circuit. The energy source steadily
declines to a zero value after the energy source has been
shut off and locked.

Energized:

Connected to an energy supply or containing residual or

stored energy.

Energy-Isolating Device:

A mechanical device that physically prevents the

transmission or release of energy, including, but not
limited to, the following: a manually operated electrical
circuit breaker, a disconnect switch, a manually operated
switch by which the conductors of a circuit can be
disconnected from all ungrounded supply conductors and,
in addition, no pole can be operated independently, a line
valve, a block and any similar device used to block or
isolate energy.
A device that utilizes a positive means, such as a lock, to
hold an energy isolating system in a safe position and
prevent the equipment from being energized.

Energy Source:

Exclusive Personal
Control:

LOTO devices also include blank flanges and bolted slip

blinds. The authorized employee applying the device will
have exclusive control of the device.
A resource that produces power, or has the potential to
produce power, in forms of electricity, flow, pressure or
movement.
A means by which a single person controls equipment that
may impact his/her safety.

25

Guard:

A physical barrier or device that prevents access to areas

of the machine, equipment, process and circuit where a
hazard exists.

Hardwired:

Operates independently of any programmable logic

control devices.

Hazardous Energy:

Any electrical, mechanical, hydraulic, pneumatic,

chemical, nuclear, thermal, gravity or other energy
(including potential and/or kinetic) that could cause injury
to personnel.

Individual LOTO Lock:

A type of key lock that is used for no other purpose in the

facility/operation, having one key, and for which master
keys are not available. Such locks are individually
assigned (personal lock) to authorized individuals, or can
be obtained from a central repository of LOTO devices,
whereupon they become personal locks while in use by an
individual. LOTO Locks are typically colored red. We
recommend the individual information post in the lock,
such as photo, mobile phone number.

Integrator:

An entity that is responsible for assembling a group of

interrelated or interacting machine, equipment, process
and circuit components.

Interlock:

A device or system whereby the status of one control or

mechanism allows or prevents the operation of another.

Lockout Device:

A positive means, such as a lock that secures an energy

isolating device in the safe position and prevents the
energizing of a machine, equipment, process and circuit.

LOTO (lockout/tagout):

The placement of a lock and red tag on the energyisolating device in accordance with an established
procedure, indicating that the energy isolating device shall
not be operated until removal of the lock and red tag, in
accordance with an established procedure.

Manufacturer:

An entity that designs, fabricates, assembles or supplies

machines, equipment, processes and circuits.

Modifier:

An entity that changes or alters an existing machine,

equipment, process or circuit so that its operation is
affected in regard to the control of hazardous energy.

26

Red Tag Danger Do

Not OperateLife
Tag:

Red tags (must be red in color) are used with every

Personal LOTO Lock to indicate that the energy source is
locked out and an authorized employee is actively working
on the machine, equipment, process or circuit. The content
of the red tag must include the name, department, the
LOTO start time and date. All the authorized individuals
are required to fill in the red tag carefully.

Remanufacturer:

Any entity whose business is the

reconstruction of a machine or equipment.

Risk Assessment:

A comprehensive evaluation of the probability and the

degree of the possible injury or damage to health in a
hazardous situation. After making a risk assessment,
appropriate safeguarding can be selected to reduce the risk
of exposure. It is used to identify high risk and take
corrective actions to reduce the risk to an acceptable risk
level.

Safety Signs:

A visual alerting device in the form of a sign, label, decal,

Placard or other marking that advises the observer of the
nature and degree of the potential hazard(s) that can cause
injury or death.

Servicing and/or
Maintenance:

Any activities to machine, equipment, process and circuit

that represent repairs, preventive maintenance,
modifications and installation (refer to Paragraph Error:
Reference source not found). These activities require that
the machine, equipment, process or circuit, or their
components, be at a zero energy state. The personnel
performing these activities must employ LOTO in
accordance with established procedures.
An entity that utilizes machines, equipment, processes and
circuits covered by this procedure, and is responsible for
personnel associated with hazardous energy control. This
also includes customer locations where Saint-Gobain
China personnel may render services at the customers
request.

Site/Operation:

redesign

or

27

Tag out Device:

A prominent warning, such as a tag and its method of

attachment that secures an energy-isolating device in a
safe position and prevents the energizing of a machine,
equipment, process or circuit.

28

APPENDIX C LOTO Placard

C.1

LOTO Placard Format:

The LOTO Placard includes two main sections: a Procedures Section and The Machine
Layout Section.
The Procedures Section is used to
list and describe the main
disconnects, workstation Placards
(or secondary disconnects), stored
energy sources, LOTO-related
hazards and any useful advice for
troubleshooting.
The purpose of the layout is to show the location of all lockout/release points and other
specific hazards described in the procedures section.
The procedures section has three main parts:
Instructions on where and how to isolate the primary energies and where and
how to release or block the stored energies.
Associated hazards and safety precautions
Troubleshooting advice

C.1.1 Lockout, release and blocking

instructions.

ENERGY TYPE
AND
MAGNITUDE:
LOCKOUT
LOCATION:
ISOLATES
....
BLOCKS .
..
DISSIPATES
.
LOCKOUT /
CONTROL
PROCEDURES:
VERIFICATION
PROCEDURES:

The type of energy (electrical, hydraulic,

pneumatic, etc.) and the magnitude of
the energy (the voltage, or pressure) are
listed in this column.
The energy icon (i.e., E-1, H-1, H, P-1, P,
etc.) and a description of the location of
the lockout point are shown here.
The exact lockout point controls is
described by naming the machine or the
part of the machine that is isolated (e.g.,
station 3; automation loader; die (?)
protection enclosure; etc.), blocked or
released.
Specific instructions on how to lockout,
block or dissipate the energy.
These direct the user on how to verify
that the energy(s) has been controlled.

29

C.1.2 Hazard Warnings

The Hazard Warnings section is use to describe
machine hazards in close proximity to the machine
described in the LOTO Placard, and the precautions
that should be taken.

C.1.3 Troubleshooting

C.2

The Troubleshooting section includes a reminder of

the two main troubleshooting rules and space to
include any useful specific advice on troubleshooting.

What are the Purpose and Limitations of LOTO Placards?

LOTO Placards are a guide showing where energy sources are located and what they
control with a reminder to lockout and verify lockout each time lockout is used. LOTO
Placards do not give specific instructions for every task that may be performed on a
given piece of equipment. Specific sequential procedures may be described on SOP
(STANDARD OPERATION PROCESS) sheets for boilers and gas fired equipment; on
other equipment a SOP (STANDARD OPERATION PROCESS) or Safe Work
Procedure may be used.
LOTO Placards are NOT a substitute for LOTO training. General LOTO training and
machine specific LOTO training are mandatory. Every individual who locks out must
use his or her training knowledge when performing lockout. Placards are never to be
used as a substitute for following the basic lockout steps taught in the LOTO training,
especially verification.

C.3

Which Machines must have an LOTO Placard?

Each complex piece of machinery or equipment must have an LOTO Placard and all
energy sources labeled on the machine and identified on the Placard.
An LOTO Placard is not required on machines where:
a) the application of a single lockout device will achieve lockout, and
b) the location of the lockout point is on or close to the machine and
appropriately labeled.

30

"Close to the machine" means the main disconnect is:

in the direct line of sight (visible) of a person standing at the main control
panel; AND
closer than 10 meters from the main control panel, AND
it is readily apparent where the energy disconnect is located.
Examples of machines that do not need an LOTO Placard includes: most workshop
powered machines, e.g. lathes, bench drills, bench grinders, circular saws; but remember
that the lockout points must still be labeled.
C.4

Who is responsible for implementing the LOTO Placard system?

The responsibility for implementing the LOTO Placard system rests with facility
engineering. However, the Company Safety Engineer(s) and Safety Representative(s)
must be involved in the process and should be actively involved in the daily progress of
the project. In addition, the department supervisor must be involved in the process
during the verification of LOTO Placards.

C.5

Who is permitted to make LOTO Placards?

LOTO Placards are to be made only by qualified persons. Facility engineering must
designate personnel for making LOTO Placards and these personnel must be trained for
the task.
Training includes:
Successfully completing the full LOTO training, and
Completing LOTO Placard training
Existing machines
For existing machines, the person qualified to make the LOTO Placard must arrange for
assistance from a knowledgeable person/s, i.e. personnel who by experience or training
are thoroughly familiar with specific aspects of the machine such as electrical,
pneumatic, hydraulic, or mechanical and with the LOTO procedures for that machine.
New machines
In the case of new machines, the supplier is to be required to prepare a draft LOTO
Placard and install energy labels on the machine. The final LOTO Placard must be made
by a qualified person; this will usually be the facility engineer responsible for the
project.

31

C.6

Who may sign (authorize) LOTO Placards?

For existing machines, the area maintenance manager signs and thereby authorizes the
Placard.
For new machines, the production engineer responsible for the project signs and thereby
authorizes the Placard. Where the design work for a new machine is done by a
contractor, it is permissible to get the supplier to make the Placard, but it must still be
signed by the production engineer responsible for the project before it is put into service.

C.7

What Does Authorizing an LOTO Placard Mean?

The authorization (signing) of the LOTO Placard by the designated manager is intended
to indicate that the Placard is ready to be posted on the machine and that the correct
process has been followed in making the Placard. The steps in creating a Placard are
described in the following section.
To assist is clarifying the responsibilities of the authorizer of a Placard, a sign-off
checklist is described below. This checklist is reproduced on the Form to be used to
make draft LOTO Placards.
Sign-off Requirement

The maker of the LOTO Placard is qualified (i.e. completed the full LOTO
training and LOTO Placard training)

Maintenance personnel were involved who are knowledgeable on the

particular machine (i.e. personnel who by experience or training are thoroughly
familiar with specific aspects of the machine such as electrical, pneumatic,
hydraulic, or mechanical and with the correct LOTO procedures for that machine).

The safety specialist and the safety representative were involved (their role
is to check the logic and format of the Placard when the final Placard is ready to be
verified)

Labels installed (this means LOTO Labels AND switch identification labels)

Maintenance has verified that the lockout procedure is correct

C.8
1

Summary of the Steps in Making LOTO Placard

Steps
Assemble qualified

Summary
Consider the need for electrical, hydraulic, pneumatic, mechanical or other

32

people and materials

Evaluate the machine

Prepare Draft Of
Placard

Install Energy Labels

Print Final Color

Placard
Hold Verification
Meeting

6
7

Sign, laminate and

install Final Placard

C.9

specialized areas of expertise.

Make a copy of the LOTO Placard Worksheet (Attachment 1) and the
machine layout or take a sketch pad.
Take the LOTO Placard Worksheet and layout to the machine site.
Evaluate the machine to determine how many LOTO Placards are required.
Determine which energies must be locked out.
Always start with the main Placard. Repeat, as necessary, for workstation
Placards.
Fill in the machine specifications block.
o Identify all energy types, sources, and magnitude.
Complete
o Identify lockout/release locations
Procedures
Section:
o Describe exactly what the energy controls.
o Describe lockout/release procedures.
o Describe verify procedures.
o Add appropriate hazard warnings.
o Add any useful advice for troubleshooting
o Decide exactly where the LOTO Placard is going to be
Complete
posted. Remember to place the diagram in the layout so
Machine
the "YOU ARE HERE" symbol is pointing straight up.
Layout
o Confirm accuracy of layout, correct as needed or make
Section:
new.
o Mark lockout/release locations, and what it controls.
o Mark positions of other hazards.
o Indicate primary, associated and adjacent machinery.
Coded energy labels for primary and stored
energy sources are installed at the actual
location of each disconnect on the machine
when the draft copy of the LOTO Placard is
completed. Use a label for each energy
disconnect identified in the procedures
section and marked on the machine layout.
A template for making LOTO Placards in Microsoft Excel is available form
the safety department.
The LOTO qualified team attends a machine-site review
Verify final Placard agrees with machine conditions
The designated member of management signs Placard.
A copy is filed with facility engineering.
Laminate the final Placard.
Securely Install Placard of the Machine

LOTO Safe Work Procedures

The purpose of LOTO Safe Work Procedure is to provide more information than can be
provided on a LOTO Placard. Critical or high-risk tasks may require additional
information about the correct sequence of steps and additional safety information. SOP
(STANDARD OPERATION PROCESS) sheets may be used for this purpose.

33

SAMPLE OF AN ENERGY CONTROL PROCEDURE

34

APPENDIX D LOTO Step-By-Step Process

Only Authorized individuals who are trained in the LOTO program should perform the
LOTO process. The step-by-step process defines the actions required in the LOTO
process. The following actions should be done in the following sequence:
1.

Identification of Energy sources: Authorized individuals shall understand the

applicable procedures and should be able to identify the machine energy source.

2.

Notify others: All personnel associated with the equipment on which the work will
be done shall be notified prior to the application and after the removal of lockout
devices and tag out devices (Personnel may include operators, technicians,
engineers or area managers).

3.

Shutdown Equipment: Turn off all energy switches and/or buttons to the
equipment.

4.

Isolation equipment: Authorized individuals physically locate all energy-isolating

devices (disconnects, valves, etc.) required by the equipment-specific LOTO
procedure. The energy-isolating devices are then positioned (closed, blocked, etc.)
to stop energy flow to the machine, equipment, process and circuit. The authorized
individuals shall verify the condition of the energy-isolating devices and their
capability to stop energy flow.
NOTE
Partial or localized LOTO may be used on complex machinery,
equipment, processes and circuits where it is necessary to:

isolate power or motion for a specific component while maintaining

power to other systems,

support utilities and other devices and components.

Such procedures shall be documented in the equipment-specific LOTO
procedure, or may be established through the risk assessment
procedures.

5.

Lockout or tag out device application: The authorized individuals shall attach and
secure lockout or tag out devices. Use the following guidelines:
Individual LOTO Lock and red tag shall be attached and secured to the
machine, equipment, process or circuit energy-isolating device (disconnect,
valves, etc.). When an energy isolating location is not designed to accept a
lock, use of a lockout device such as a clamshell, ball valve, circuit breaker,
wall switch or gate valve is required. Note that 1 lock, 1 key, 1 person is the
rule that must be followed.

35

NOTE
Group lockout with lock box may also be used in complex, multi-person
applications.

Verify that the energy-isolating devices remain locked out and in a safe
or off position.
Where a red tag cannot be attached and secured directly to the energy
isolating device, the red tag shall be located as close as safely possible to the
device, in a position that will be immediately obvious to anyone attempting to
operate the machine, equipment, process or circuit. In addition, a tag shall be
placed at the operators control position to alert personnel that the machine,
equipment, process and circuit are de-energized. For example, where an
electrical bus with integral isolating switches is located overhead, the tag would
be placed conspicuously on the operator panel warning not to use the
equipment.
6.

Release stored energy: The authorized individual shall ensure that all potentially
hazardous energy (stored, residual, chemical or potential) is relieved, dissipated,
restrained, drained or otherwise controlled. Additional measures may be necessary
to prevent re-accumulation of energy to protect individuals. Examples of stored
energy systems include accumulators, capacitors, gravity, surge tanks, chemical
lines and springs.

7.

Verification of isolation: The authorized individual shall verify that isolation and
de-energization have been accomplished using the procedures in the equipmentspecific LOTO procedure prior to starting servicing and/or maintenance on
machines, equipment, processes and circuits that have been locked out or tagged
out. Verification must confirm that the machine, equipment, process or circuit has
achieved a zero energy state such as 0 electricity, 0 pneumatic, 0 fluid or gas
pressures, etc. (Verification of a zero energy state can be accomplished by test
equipment, circuit activation attempts, gages, visual inspection, etc.)

8.

Keep LOTO enforced while performing intervention: Avoid open any energy and
doing anything that could potentially reactivate the equipment. If you want to
restate the equipment, please follow the step 9.

9.

Return to service: The authorized individual shall perform the following before
returning the equipment to service:
Inspect the work area to ensure that non-essential items have been removed,
guards are in place, the machine, equipment, process or circuit is operationally
intact, and all personnel are in a safe location.
36

 Remove locks, tags and lockout devices from each energy-isolating device
by the authorized individual who applied the device.
Notify affected personnel that energy is about to be restored to the machine,
equipment, process and circuit.
Visually inspect and/or cycle test the equipment for servicing and/or
maintenance task completion. If the task is completed the machine, equipment,
process and circuit may be returned to service. If the task is not completed,
repeat the necessary LOTO steps.
Follow the proper sequential startup steps for the equipment, process or
circuit.

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APPENDIX E TRAINING OVERVIEW

Table 1. Training Requirements
Affected Individuals

Authorized Individuals

Applications

Yes

Yes

Definitions

Yes

Yes

Elements

Yes

Yes

Requirements

Yes

Yes

Machine Specific Procedures

No

Yes

Step-by-Step Methods

No

Yes

Yes

Shift Personnel Change

* Must understand the continuity of LOTO when shifts change.

Table 2. Training Frequency Summary

Initial training

Initial demonstration

Affected Individuals

Authorized Individuals

Required

Required

(on topics outlined in Table

1)

(on topics outlined in Table 1)

Not applicable

Required
(must be observed and verified by another
authorized employee, i.e. "hands on")

Annual refresher
training

Recommended

Required

Annual demonstration

Not applicable

Required
(must be observed and verified by another
authorized employee every third year, i.e. "hands
on" and in the other years may be accomplished
by use of computer simulated demonstrations)

E.1

Affected Individual Training

The site/operation shall provide all affected individuals with LOTO awareness training.
This training allows affected individuals to identify LOTO situations, understand their
responsibilities and to take no action that might defeat the LOTO. Training requirements
and objectives are listed below:

38

Training shall be specific to the site/operation written program.

Affected individuals shall recognize that authorized employees are performing

service and/or maintenance to the machine, equipment, process and circuit that
require LOTO.

Affected individuals shall be able to identify locked out equipment.

Affected individuals shall have a general understanding of shift or personnel

LOTO changes.

Every effort should be made to structure training to make it understandable to all

affected individuals regardless of their level of education, primary language or
disabilities. Annual refresher training should be conducted to maintain an appropriate
level of awareness.
E.2

Authorized Individual Training

The site/operation shall provide initial training, prior to performing a LOTO that will
demonstrate that all authorized individuals understand the purpose and function of the
energy control program. Training shall be such that all authorized individuals have an
understanding that is appropriate for the level of hazard exposure they may encounter.
Training requirements and objectives are listed below:

Individual training shall be carried out prior to authorize individuals performing

service and/or maintenance tasks or being potentially exposed to hazardous
energy.

Training shall be specific to the site/operation written program.

Field Service personnel shall receive training on electrical safety and the SaintGobain China LOTO programs. Specific information regarding hazardous
energy in the field locations shall be discussed during pre-job safety meetings
with customer representatives.

Each authorized individual shall receive training in the type of energy that
might be encountered during servicing and/or maintenance and methods or
means to control and isolate that energy.

The site/operation shall document that all initial and additional training has been
conducted. The documentation shall contain each individuals name, dates of
training, the training topic and the assessment result.

Each person completing the training MUST be required to successfully

demonstrate LOTO to an authorized employee prior to being authorized to
perform LOTO without direct supervision by a fully qualified authorized
employee. (Note: a computer-simulated demonstration is not an acceptable
method for this demonstration. Hands-on demonstration is required during
39

initial training, and must be repeated no less often than every three years
thereafter. It must be performed on real equipment under the observation of an
authorized individual.)
The site/operation should avoid exclusive use of generic training programs to ensure that
authorized individuals adequately understand the site/operation-specific program.
Documentation of the information covered during training shall be maintained.
Training methods may include, but are not limited to, formal instruction (direct
instructor contact), computer-based or interactive training.
Annual refresher training should be conducted to maintain an appropriate level of
awareness.
E.3

Additional Training
Retraining shall be provided for all authorized individuals whenever there is a change in
their job assignments, a change in machine, equipment, process or circuit that presents a
new hazard, or when there is a change in the energy control procedures.
Additional retraining shall also be conducted immediately whenever an audit reveals, or
whenever the site/operation has other reason to believe, that the authorized individuals
knowledge or use of the energy control procedures is inadequate or inconsistent with the
requirements.

E.4

Demonstration of Training
The site/operation shall conduct an annual demonstration of the effectiveness of the
training that is conducted for each authorized individual. This "hands on" demonstration
is observed and verified by another authorized employee. The demonstration shall be
done in such a way as to ensure that authorized individuals demonstrate the following:

knowledge of the program;

recognition and understanding of hazardous energy types;

Use of appropriate hazardous energy control procedures.

Authorized individuals who do not demonstrate an adequate level of knowledge or use

of appropriate hazardous energy control procedures shall be retrained.

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APPENDIX F DESIGN
F.1

Exposure Minimization
Verify that Saint-Gobain China machines, equipment, processes and circuits employ
available safeguards that are reliable, work to minimize hazard exposure and minimize
any adverse effect on the process. The machines, equipment, processes and circuits
should be designed or modified so that personnel are not exposed to hazardous energy
during routine and repetitive servicing and maintenance activities.
NOTE
This can be accomplished by positioning controls outside
hazardous areas, adding controls at appropriate locations,
providing external lubrication points or providing guarding.

F.2

Partial Energization
For those functions when partial energization is necessary, Saint-Gobain China
authorized individuals shall perform a risk assessment similar to that outlined in to
determine the safest method of machine, equipment, process and circuit access. When it
is necessary for machines, equipments, processes and circuits to remain partially
energized (e.g., in order to hold parts, save information, retain heat or provide local
lighting); alternative control methodologies shall be provided for personnel safety.

F.3

ENERGY- ISOLATING DEVICES

Verify that machines, equipment, processes and circuits are designed, manufactured,
supplied and installed with energy-isolating devices. Consideration shall be given to the
intended use of the machine, equipment, process and circuit. Devices shall be capable of
controlling or dissipating hazardous energy, or both. The devices should be an integral
part of the machine, equipment, process and circuit.
F.3.1 Location
Verify that energy-isolating devices shall be accessible and, when feasible, be
conveniently located to facilitate the application of lockout devices during service and
maintenance.
NOTE
Energy-isolating devices are best located outside any hazardous
areas, and at a convenient height away from any adjacent

41

walking areas (i.e., not overhead, on ladders or under

machinery).

F.3.2 Identification
Verify that all energy-isolating devices shall be adequately labeled or marked unless
they are located and arranged so their purpose is clearly evident. The identification
should be of consistent format within each facility or operation and shall include the
following:

machine, equipment, process and circuit supplied;

energy type and magnitude. Examples of appropriate labeling or marking (tags,

embossing, engraving, stenciling, etc.) language is as follows:

Main Power Press (480V);

Natural Gas;
Hydraulic Pump Discharge (800 psi);
Bay a Compressed Air (100 psi).
NOTE
The potential for error will be reduced if personnel are not
expected to rely on memory or experience when determining
which isolating devices apply to which machine, equipment,
process and circuit. When Placard or posting contains the
required energy isolating device identification, individual devices
may be marked or coded and their identity referenced on the
Placard or posting information. Where conditions such as
security are warranted, coded identification is acceptable.

F.3.3 Capability
Verify that energy-isolating devices shall be capable of either being locked or otherwise
secured in an effective isolating position. Examples of effective isolating devices may
include, but are not limited to the following:

levers with aligning lock tabs (holes);

ball cocks with aligning lock tags;

locking covers that only work when the switch is in the safe position;

wheels with locking tabs (and position indicators);

physical blocks with locking, aligning tabs.

42

F.4

SPECIAL TOOLS OR DEVICES

If special tools or devices are necessary for servicing and/or maintaining the machine,
equipment, process or circuit or their component parts, the tools or devices shall be
provided with the machine, equipment, process or circuit.

F.5

WARNINGS AND SPECIAL INSTRUCTIONS

It is the responsibility of the manufacturer to determine if warnings and special
instructions are necessary for servicing and/or maintaining the machine, equipment,
process or circuit. Saint-Gobain China shall require appropriate information from the
manufacturer, integrator, modifier or remanufacturer in a written manual. In addition,
where the manufacturer determines that warnings or special instructions should be
located in the area of the hazard on a label, Placard or sign, the manufacturer shall so
affix or provide appropriate Placard material to the site/operation for later installation.

F.6

COMPONENT ISOLATION
Verify that the machine, equipment, process or circuit installation shall provide for the
local isolation of component parts or component systems if they are to be serviced or
maintained separately. The number and location of energy-isolating devices shall be
determined by the configuration of the machine, equipment, process or circuit and the
intended application. Warning labels should be affixed to the machine, equipment,
process and circuit when remote or separate sources of hazardous energy must be
controlled.

F.7

DOCUMENTATION REQUIREMENTS
Each site shall require that written manual(s) (documentation) be provided by the
manufacturers, systems integrators, modifiers and remanufacturers. The written manual
(documentation) must detail:

the specific location and procedures for use of the provided energy-isolating
devices;

step-by-step procedures for servicing and/or maintenance on any machine,

equipment, process and circuit that must be performed under partial energization
based on the results of a risk assessment;

specific instructions for safely addressing such conditions as malfunctioning,

jamming, misfeeding or other interruptions of the operation;

installation instructions intended for the installer of the machine, equipment,

process or circuit that identify the location of necessary energy-isolating devices.

43

F.8

STORED AND RESIDUAL ENERGY

When stored or residual energy has been determined to be a hazard, a means for nonhazardous dissipation or safe restraint of the stored or residual energy shall be
incorporated into the machine, equipment, process and circuit. Devices and methods
used for the dissipation of stored energy shall be designed with a means or method of
verifying their position and state.
When machinery run-down or coasting is determined to be a hazard, guarding shall be
installed that protects against the hazard or prevents access until the motion has ceased.

F.9

TOOL CHANGE, SET-UP

Some activities, such as set-up or troubleshooting, may require full or partial
energization. For activities such as this, alternate protection systems are required.
Alternate protection systems shall be used to ensure that a device or system will stop or
prevent initiation of hazardous motion or release of hazardous energy in the event of a
single component failure within the device or system. Typical methods of accomplishing
this task are:

a hardwired, control-reliable (redundant and safety relay monitored) safety

interlock system;

safety-rated, multiple-channel, Programmable Logic Controllers (PLC), when

manufactured specifically for safety applications, applied per manufacturers
instructions, and a risk assessment is performed (see sample in ).

If control systems such as those listed above are not available, then LOTO procedures
must be applied.
F.10

PHYSICAL SAFEGUARDS
Verify that physical safeguards (e.g., pins, blanks, blocks, restraints, chains or blinds)
shall be designed, with the appropriate safety factor, to withstand all forces to which
they will be subjected. Physical safeguards vary for different stored energy sources.
Fabrication of special safeguard devices may be required when risk assessment of
machines, equipment, processes and circuits is completed. Physical safeguards must be
designed to minimize hazardous exposure.

44

APPENDIX G PRIMARY, SECONDARY ENERGY SOURCE &

STORED ENERGY SOURCE
Primary and Secondary Energy Sources
Electrical
Steam
Pneumatic
Chemical/Coolant
Hydraulic
Gases

Radiation
Magnetic
Water

Stored Energy Sources

Rotation (mechanical motion that can cause machine or equipment movement):

flywheels, circular blades, etc.
Gravity (suspended material or parts that will move when energy is disconnected):
dies, heads, elevators, etc.
Mechanical Energy (stored mechanical energy that can cause machine or
equipment movement): compressed or extended springs, etc.
Thermal Energy (extreme heat above 140 degrees Fahrenheit, or cold below 41
degrees Fahrenheit): ovens, boiling water, chillers, etc.
Electrical Energy (stored electricity): batteries, capacitors, etc.
Hydraulic Energy (residual pressure): accumulators, lines, cylinders, etc.
Pneumatic (residual pressure): storage or surge tanks, lines, etc.
Gas (residual pressure): pipes, tanks, etc.
Water (residual pressure or stored): pipes, tanks, etc.
Steam (residual pressure): pipes, boilers, etc.
Chemicals/Coolant (residual pressure or stored): pipes, tanks, containers, etc.

45

APPENDIX H VALIDATION CRITERIA FOR THE LOCKOUT &

TAG OUT PROGRAM IMPLEMENTED
The implementation of this LOTO program is proposed to sites or their equivalents in
Saint-Gobain China where no similar program has been implemented yet. This
Validation Criteria is a part of the LOTO program. All special words are defined in the
LOTO program.
If a similar program already exists, it may continue to be used, provided it respects the
validation criteria for the method identified in this procedure. In any case, it is the
responsibility of Sector EHS to validate this internal program, on the basis of the
identified validation criteria in this procedure:
The site should appoint a LOTO Champion. He/she is the guarantor of the method
and he/she carries out trainings. He/she is the adviser of the site General
Manager/Plant Manager on the program implementation. He/she has the right to
stop any servicing/maintenance requiring LOTO, if this activity does not comply
with LOTO procedure.
All equipment energy should be able to be stopped. All locks should be locked on
energy isolating device. If there is no energy-isolating device, the site should
make engineering improvement to make sure authorized person can lock his/her
lock on an energy isolating device.
The program must include at least 9 steps including:
1. Identify tasks to be done, equipment involved and identity energy source on all of the
2.
3.
4.
5.

6.
7.
8.
9.

equipment. There may be more than one source of energy.

Notify all personnel associated with the equipment on which the work will be done.
Shut down the equipment, turn off all switches and/or buttons to the equipment.
Isolate the equipment energy; turn off all primary and secondary energy sources.
Block all energy sources by using electrical disconnect, blocks, pins, etc. Use a lock to
lock these devices in place so the energy can not be accidentally turned on. Place tag on
all locks which have been used to block energy sources. If more than one person will be
working on a piece of equipment, each person needs to place his/her own lock and tag on
all power blocks. This can be done using a multi-lock, lockout device.
Release stored energy. Recheck all energy sources and cycle the equipment to be sure
there is no stored energy in the equipment.
Verify isolation. Double check all switches and buttons to be sure they are in the "off"
position. Perform servicing/maintenance.
Keep LOTO enforced while performing intervention. Avoid doing anything that could
potentially reactivate the equipment.
Before the last lock is removed all workers should be informed that the locks are being
removed and that the power will be turned on. Put back the machine guarding on.
Remove all power blocks, and reconnect all power sources.

46

 All authorize and affected person should receive comprehensive LOTO training
and refreshing training on a regular basis and not exceeding 12 months time.
Managers are responsible to check if his/her team members are trained effectively.
The Maintenance Manager and/or Supervisor or equivalent must be trained in the
LOTO procedure. He is responsible to check if his/her team is applying it
correctly and must perform regular audits.
Each complex piece of machinery or equipment must have an LOTO Placard and
all energy sources labeled on the machine and identified on the Placard.
The maximum permitted duration for a LOTO is one shift or the end of the task,
whichever is shorter. If the duration of the task exceeds one shift, please follow
shift or personnel change requirements.
Shift or personnel change: The immediate hand-off of LOTO in progress.
Authorized individuals of the outgoing shift remove their individual LOTO locks
and red tags. Authorized individuals of the next shift simultaneously apply and
secure their individual LOTO locks and red tags at the same energy-isolating
device and verify that a zero energy state exists in the system via the "tryout"
process. If the job is not completed by the end of a shift workers are not to
REMOVE their LOCK & TAG until their relief person has attached their own
lock & tag.
Red Tag Danger Do Not Operate: Red tags (must be red in color) are used with
every Personal LOTO Lock to indicate that the energy source is locked out and an
authorized employee is actively working on the machine, equipment, process or
circuit.
One Lock, One Key, and One Person: When require servicing and/or maintenance
by more than one authorized individual. Each authorized individual performing
service and/or maintenance must apply his/her Individual LOTO Lock.
After an employee completes their work, they are to only to remove THEIR OWN
lock & tag. Only the person to whom the lock is assigned is to have a key to that
lock or is to remove the lock & tag.
Only specific dedicated LOTO device can be used as LOTO device, it is usually in
red color. Each Lock and Tag should be nominative.
Emergency stops are not considered as energy-isolating device.
Master keys are not allowed unless the site Sector EHS approves it due to very
special conditions.
When the authorized individual who applied the lockout or tag out device is not
available to remove it, the authorized manager, together with at least three
individuals knowledgeable of the work being performed, may remove the device
47

only after verification that the employee is not at the facility, all reasonable efforts
to inform the authorized individual that the device has been removed have been
made, and ensuring that the authorized individual has been informed before he/she
resumes work at that facility that his/her lockout or tag out device has been
removed.
Specific procedures and training for such removal have been developed,
documented and incorporated into the energy control program.
When Saint-Gobain employees are performing work in another company (our
customer) as a contractor, we should use our own LOTO procedure unless our
customer LOTO procedure is safer than ours.
The LOTO procedure should be reviewed each year and improved if needed.

48