ISG FACILITIES MANAGEMENT

(HEALTH, SAFETY AND ENVIRONMENT)

Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 1 of 10

1. PURPOSE
The purpose of this document is to define the Lock Out, Tag Out Procedure to be followed during
maintenance operations at a location, in order to avoid unexpected or accidental energizing or
start-up of machines/equipment or the release of stored energy may cause injuries.

2. SCOPE
This procedure covers all maintenance operations including, but not limited to; new equipment
installation, systems trouble shooting, working on energized electrical systems etc. which are within
ISG’S FACILITIES MANAGEMENT scope of work and services.

3. ABBREVIATIONS
3.1. ISG INITIAL SAUDI GROUP
3.2. FM FACILITIES MANAGEMENT
3.3. LOTO LOCK OUT, TAG OUT
3.4. PTW PERMIT TO WORK
3.5. SOW SCOPE OF WORK
3.6. EID ENERGY ISOLATION
3.7. WCC WORK CONTROL CENTRE
3.8. PLC PROGRAMMABLE LOGIC CONTROLLERS

5. DEFINITIONS
Lock Out-Tag Out (LOTO) is a safety procedure which is used in industries to ensure that machines
are properly shut off and not able to restart, prior to completion of maintenance or servicing work.

As a general rule, specific procedures must be documented for each piece of equipment subject to
LOTO. Written procedures are not required if ALL of the following conditions are met:

 Machinery has no potential for stored or residual hazardous energy or re-accumulation of

stored energy after shutdown.
 Equipment has a single energy source which can be readily identified & isolated.
 Isolation & locking out of that energy source will completely de-energize & deactivate
equipment.
 Equipment is isolated from one identified energy source & locked-out during servicing or
maintenance.
 A single lockout device will achieve a locked-out condition.
 The lockout device is under the exclusive control of the “Authorized Employee” performing
the service or maintenance; (please refer to 6.4 Maintenance Supervisor)
 The servicing or maintenance does not create hazards for other employees;

While written procedures are not required if ALL of the above conditions are met, all mandatory
LOTO steps, as previously discussed, must be completed in the prescribed order.
 ISG FACILITIES MANAGEMENT
(HEALTH, SAFETY AND ENVIRONMENT)
Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 2 of 10

6. RESPONSIBILITIES
6.1. OPERATION/PROJECT/MAINTENANCE MANAGER
6.1.1. Coordinate with client; ensure the quality of services, satisfaction of client and to
Monitor compliance to Health & Safety Policy.
6.1.2. To ensure compliance of all ISG staff to this procedure.

6.1.3. Ensure this process is communicated to all employees, service providers &
contractors.
6.1.4. It is implemented in areas of responsibility & to meet all requirements under this
process.

6.2. SUPERVISOR
6.2.1. Implement LOTO Program at site where maintenance operations are being
performed.
6.2.2. Inspect and check for proper application of locks, tags and controlling LOTO keys.
6.2.3. Ensure Emergency Response plan is in place.
6.2.4. Ensure List of Emergency Contacts is available at all times.
6.2.5. Ensure Isolation of systems & equipment and communicated to all involved Dept. or
Personnel.
6.2.6. Ensure proper application of locks, tags and controlling LOTO keys.
6.2.7. Coordinate & monitor LOTO activities.
6.2.8. In-charge for installing and LOTO devices.
6.2.9. Responsible for full control of LOTO devices such as lock & keys.
6.2.10. Monitor all employees performing activities involving LOTO.
6.2.11. To secure PTW if necessary.

6.3. TECHNICIANs
6.3.1. To follow instructions in-line with this LOTO Procedures.
6.3.2. Properly use Personnel Protective Equipment.

6.4. HEALTH, SAFETY AND ENVIRONMENT DEPARTMENT

6.4.1. The dept. is responsible to periodically monitor the implementation of this
procedure,
6.4.2. Review this procedure on a periodic basis and provide assistance in developing
related procedures as necessary.
 ISG FACILITIES MANAGEMENT
(HEALTH, SAFETY AND ENVIRONMENT)
Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 3 of 10

7. PROCEDURE
7.1. ISOLATION PROCEDURE
Following is the 4 step process to ensure that the equipment is properly isolated.
7.1.1. Isolation is effective only when no associated control device, i.e. push button, control
interlock or automatic start-up control circuit, has the capability of energizing the
equipment.

7.1.2. In situations where it is not possible to lock out or chain off an isolating device;
isolation may be accomplished by removing fuses, disconnecting electrical cables
&/or physical removal of a component from the system supplying energy to the
equipment. The point of physical interruption shall be identified with a fully
completed “Hold Tag”. Test equipment must be tested on a known power source
before & after isolation.

7.1.3. When isolation has been completed (or before if appropriate), operations will de-
energize equipment and ensure that it contains no residual energy. If more than one
team is working on the same isolated equipment & sharing the same isolation point,
then “All Teams” shall install their locks & tags. In such condition multiple lockout
clips shall be used if necessary.

7.1.4. Each lock on a piece of equipment, or on a multiple lockout clip, must be identified.
Where a Tag shall be installed on each lock indicating (See the appendix)

1. Facility, Location, Name & Number.

2. Equipment name.
3. Date & Time of Lockout.
4. Name, badge number, company, contact phone & signature of individual
who installed the lock.

7.2. LOCKS & TAGS

7.2.1. Locks & tags shall be standardized with at least one of these criteria: Color, Shape &
Size. In regards to tagging devices, the print and format must be standardized.
7.2.2. Locks & tags must be of high quality & durability to prevent deterioration in extreme
environment & maintain their effectiveness. They must be durable enough to
prevent inadvertent or accidental removal.
7.2.3. A variety of devices will be provided to apply locks on a variety of energized
equipment (i.e., fuses, breaker switches).
7.2.4. All Tag Out devices must include a legend such as Do Not Start, Do Not Open, Do
Not Close, Do Not Energize, etc. written in clear, bold & bright fonts.
7.2.5. Information placed on the tag must include name of the authorized staff that locked
out the equipment; the authorized staff’s “radio &/or phone number”, including
 ISG FACILITIES MANAGEMENT
(HEALTH, SAFETY AND ENVIRONMENT)
Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 4 of 10

outside contractors; the date and time of the lockout & brief description of work
being performed.

Prior to commencing work, operations shall:

7.2.6. Identify isolating locations & types of isolating devices required. If necessary, consult
with third parties, such as electrical specialists.
7.2.7. Electrically isolate the equipment & lock &/or tag it.
7.2.8. Clear the work area of equipment & personnel.
7.2.9. Confirm by switching the machine it on. If it does NOT start, the machine has been
isolated.
7.2.10. Each organization issuing locks shall have a system of uniquely identifying locks.
Acceptable Methods include colour coding, stamping or engraving locks.
7.2.11. Each lock shall be keyed separately, with NO DUPLICATE KEY, to ensure removal only
by the authorized user.
7.2.12. The use of multiple lockout clips will ensure that isolation cannot be removed unless
all teams remove their individual locks upon completion of their respective tasks.
7.2.13. Verification tests, in which all affected parties participate, shall be conducted by in-
charge person on each isolating device and on each piece of equipment isolated
where each isolating device, such as a disconnect switch, shall be physically tested by
moving its operating mechanism against the padlock, multiple lockout clip, or
chain, to confirm that it cannot be operated.
7.2.14. When the in-charge person leaves the job site temporarily, but intends to return to
complete the work, his locks and tags may be left installed. Upon his return to work,
the employee shall verify his locks and tags are still in place ensuring the equipment
is still isolated prior to re-starting his work.

If for any reasons, the locks and tags are to be removed as a result of temporary suspension
of task then:

7.2.15. The removal of locks & tags shall not create hazard of any kind to anyone who may
gain access to the equipment area.
7.2.16. All affected persons shall be informed about such removal.
7.2.17. In the event of shift change while the work is not complete, the oncoming shift may
either:
 Transfer keys between shifts. This transfer must be recorded.
 Replace locks & tags i.e. out-going shift removed its locks & tags and incoming
shift installs its own.

This transfer or replacing requires shift in-charge to conduct a detailed review of installed locks and
tags. The existing tags may be endorsed by the in-charge person of the incoming shift or new tags
may be installed. When an operation shift change occurs, the original authorized employee working
on the piece of equipment is replaced by another authorized employee, the original employee will
remove his lock and the incoming employee will insert his lock onto the energy-isolating device. If
the first employee leaves the area before the incoming employee arrives, an authorized supervisor
 ISG FACILITIES MANAGEMENT
(HEALTH, SAFETY AND ENVIRONMENT)
Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 5 of 10

can place his lock on the system to ensure the system remains safe until the second employee
arrives. The incoming employee must then place his lock on the energy-isolating device and verify
that all other energy sources are locked out before beginning work.

7.2.18. When the person in-charge of the task completes his work, or leaves the job site
permanently, his tags & lockout devices will be removed. Outgoing personnel will:

 Remove his locks & tags & ensure no hazard is created by such removal.
 Inform area in-charge of his above & permanent departure.

7.3. LOTO PROCEDURAL STEPS

Each step must be accomplished in the stated order & recorded as described in LOTO procedure.
All affected and authorized employees must receive LOTO training, including procedures specific to
their work.

7.3.1. STEP 1: HAZARD IDENTIFICATION

First step in LOTO involves identifying all forms of potential hazards associated with the specific
machinery or equipment and task at hand. This involves evaluating and understanding all
potentially hazardous energy sources as there may be more than one including potential
magnitude of damage and injuries that each energy source could cause, if uncontrolled; and
isolation point(s) for each type of hazardous energy. Types of energy to consider include
electrical, hydraulic, pneumatic, thermal, chemical, mechanical, gravity, and radiation energy.
Conduct a detailed risk assessment and record findings on Risk Assessment Form.

7.3.2. STEP 2: COMMUNICATE

All affected & associated employees working on, or near, the machinery or equipment must be
informed of the intent to apply LOTO. They must be advised to refrain from attempting to
restart the unit or other action that may adversely affect safety during the duration of the LOTO.
They must be informed of the person who is responsible for LOTO & the method that will be
used to notify them when LOTO is complete.
7.3.3. STEP 3: SHUT-DOWN
Shut down must be conducted/performed intend for the machine or equipment such as
instruction on how to operate equipment.
7.3.4. STEP 4: ISOLATE
After shutting down the machinery or equipment, next step is to physically locate and activate
all Energy Isolation Devices (EID). An EID is a mechanical device that, when activated, physically
prevents the transmission or release of energy, including, but not limited to the following:
 A manually-operated electrical circuit breaker.
 A disconnect switch
 ISG FACILITIES MANAGEMENT
(HEALTH, SAFETY AND ENVIRONMENT)
Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 6 of 10

 A manually-operated switch by which the conductors of a circuit can be

disconnected from all ungrounded supply conductors & no pole can be operated
independently.
 A line valve, bolted blank flange, and bolted slip blinds.
 A block (e.g., a safety block).
 Any similar device used to block or isolate energy.

Push-buttons, selector switches, safety interlocks and other control circuit type devices are NOT
categorized as EID. Programmable Logic Controllers (PLCs) are used in many machine
applications. These circuit control devices are NOT considered EID for purposes of LOTO
standard.

7.3.5. STEP 5: APPLY LOTO DEVICE

After applying or activating an EID, the next step is to apply LOTO devices to every EID. Tag Out
devices can be used in line of lockout devices only in very limited situations. Generally, only
when an EID is not capable of being locked out. A Lockout Device is a device that utilizes a
positive means such as a lock, either key or combination type, to hold an EID in the “safe”
position and prevent energizing of machinery or equipment. Flanges & bolted slip blinds are
also categorized as EID.

 LOTO devices must be personalized, meaning they must be “Labelled” to identify the
NAME of the specific personnel who are authorized to Apply & Remove it.

 LOTO devices must be Unique, Distinct & Durable. LOTO devices should NOT be used
for any purpose other than controlling hazardous energy sources. LOTO devices used
must be standardized according to colour, shape & size. Devices must be able to
withstand harsh environments and cannot be easily removed i.e. require excessive
force and special tools e.g. bolt cutters etc.
7.3.6. STEP 6: RELIEVE STORED ENERGY
Following application of LOTO apparatus to all EID, all potentially hazardous stored or residual
energy must be relieved, disconnected, restrained, or otherwise rendered safe. Stored energy
must be released in accordance with manufacturer’s recommendations or recognized industry
standards.
7.3.7. STEP 7: VERIFY
The last step before actually commencing repair &/or service work is to verify that LOTO
procedures have been applied; energy sources associated with the machinery or equipment are
effectively isolated & de-energized. Verification must consider both primary and stored-energy
sources. If there is potential for build-up of energy during the service, maintenance or repair
then it must be constantly monitored throughout the entire period. Monitoring includes both
visual inspection & physical testing.
Visual inspection involves confirmation that switches, valves, breakers, etc. have been, properly
moved to, & secured in the “off” or “safe” position. Visual inspection also verifies that LOTO &
 ISG FACILITIES MANAGEMENT
(HEALTH, SAFETY AND ENVIRONMENT)
Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 7 of 10

other protective devices have been applied to the control points in a manner that prevents
unsafe movement of the switches or valves. Additionally, a visual inspection is used to verify
that isolation has taken place by determining that all motion has stopped and all coasting parts
such as flywheels, grinding wheels, saw blades, etc. have come to rest.
In the majority of situations, visual inspection techniques must be accompanied by physical
testing to ensure that the steps taken to isolate hazardous energy have worked successfully to
isolate energy from machinery or equipment. Physical tests are conducted with appropriate
instruments e.g. voltmeters, combustible gas indicators, bleeder valves, etc. or techniques i.e.,
flange breaking and may also involve deliberate attempts to start-up the machine or equipment.
When an instrument is used as part of verification process, it must be checked for proper
operation before & after being used to check the effectiveness of energy isolation and LOTO.
This will ensure that the instrument is reliable. It is also important to maintain the instrument in
accordance with manufacturer’s recommendations & OP 760 Control of Monitoring &
Measuring Devices.

7.3.8. STEP 8: SERVICE

All service & maintenance should be conducted only by Qualified & Competent Individuals who
have knowledge of the machinery or equipment & in accordance with manufacturer’s
specifications &/or industry standards, as applicable.

7.3.9. STEP 9: INSPECT

After the service &/or repair work is complete, the work area must be inspected before LO/TO
devices are removed and energy is restored to machinery & equipment, to ensure that:

 Non-essential items, tools etc. are removed from machine & operating area.
 Machinery or equipment components are operationally intact.
 Employees are safely positioned.

7.3.10. STEP 10: REMOVE LOTO

Once it is confirmed through the inspection process that a safe condition exists and guards have
been replaced or properly re-positioned, LOTO devices may be removed by the “Authorized
Employee” who placed them.

7.3.11. STEP 11: COMMUNICATE

Associated employees should then be notified that LOTO devices have been removed. This
communication must occur before the equipment or machine is restarted and only after
inspection confirms a safe condition.

7.3.12. STEP 12: RESTART

The machinery or equipment should be restarted using the appropriate start-up sequence and
procedures.
 ISG FACILITIES MANAGEMENT
(HEALTH, SAFETY AND ENVIRONMENT)
Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 8 of 10

Appendix

The name of the authorized employee will be written in this part which is the
Maintenance Supervisor along with the date when the LOTO is started
 ISG FACILITIES MANAGEMENT
(HEALTH, SAFETY AND ENVIRONMENT)
Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 9 of 10

8. FLOW CHART
PROCESS FLOW ACTIVITY DOCUMENTS & RECORDS

-AS PER DIRECTIONS FROM OPERATION MANAGER; SUPERVISOR WILL

TASK REQUIRED
LOTO PROCEDURES ASSEMBLE TEAM OF COMPETENT STAFF AND ASSIGN JOB RESPONSIBILITIES
TO THEM.

COMMUNICATE
LOTO ACTIVITIES TO
OTHER AFFECTED
PARTY

OBTAING WORK IF THE TASK IS IDENTIFIED AS A HIGH RISK ACTIVITY THE RESPONSIBLE IN-
-PERMIT TO WORK
PERMIT, EVALUATE CHARGED WILL OBTAIN PERMIT TO WORK TO QHSE DEPT. TO IDENTIFY
ASSOCIATED FORM
NECESSARY SAFETY MEASURES PRIOR TO COMMENCEMENT OF THE HIGH RISK
HAZARDS AND RISK TASK

-AS PER IDENTIFIED MATERIALS, EQUIPMENT & RESOURCES IDENTIFIED FROM

PREPARE REQUIRED THE SNAGGING INSPECTION THE SUPERVISOR WILL REQUEST NECESSARY
MATERIALS,
MATERIALS, EQUIPMENT & RESOURCES TO EFFECTIVELY & EFFICIENTLY
EQUIPMENT &
RESOURCES CARRY OUT THE WORK.

-SUPERVISOR WILL CARRY OUT WORK AS DETAILED IN SCOPE OF WORK. HE

WILL ALSO ABIDE BY THE GUIDE LINES AS MENTIONED IN OCCUPATIONAL
HEALTH & SAFETY HANDBOOK AND OPERATIONAL PROCEDURES RELATED TO
-SUPERVISOR WILL CARRY OUT WORK AS DETAILED IN SCOPE OF WORK. HE
PERFORMED SAFETY I.E. OP 430, OP 431, OP 721 & OP 610; TO ENSURE SAFE WORK
WILL ALSO ABIDE BY THE GUIDE LINES AS MENTIONED IN OCCUPATIONAL
PRACTICES ARE FOLLOWED AND RISK OF WORK RELATED MISHAPS ARE
IDENTIFIED CONTROL
MEASURES & HEALTH & SAFETY PERFORMED,
REDUCED.WORK HANDBOOK AND OPERATIONAL
MATERIALS USED ANDPROCEDURES RELATED TO
ANY COMMENTS
NECESSARY SAFETY I.E. OP 430, OP 431, OP 721
RELATED TO THE TASK MUST BE RECORDED. & OP 610; TO ENSURE SAFE WORK
PROCEDURES PRACTICES ARE FOLLOWED AND RISK OF WORK RELATED MISHAPS ARE
REDUCED.WORK PERFORMED, MATERIALS USED AND ANY COMMENTS
RELATED TO THE TASK MUST BE RECORDED.

Task
completed?

RESTART MACHINE
OR EQUIPMENT FOR
OPERATION

OBTAIN CLIENT -AFTER REVIEWING ALL THE TASKS, SUPERVISOR WILL OBTAIN SIGNATURE OF WORK COMPLETION
SIGNATURE
THE CLIENT ON WORK COMPLETION REPORT. THE REPORTS WILL BE REPORT
(ACKOWLEDGE THAT
THE TASK WAS
SUBMITTED TO OPERATIONS MANAGER FOR ONWARD PROCESSING.
DONE)

DONE
 ISG FACILITIES MANAGEMENT
(HEALTH, SAFETY AND ENVIRONMENT)
Document Name LOCK OUT, TAG OUT (LOTO) PROCEDURE
Document No. ISG-FM-HSE-WR-OP-002 REV: 00
Issue Date 8 October 2020 Page 10 of 10

PREPARED BY: REVIEWED BY: APPROVED & AUTHORIZED BY:

JULIO GREGORIO AHMED AL-MALKI MOHAMMED MOUSA

QHSE OFFICER HSE MANAGER COO