LOTO挂牌上锁程序

挂牌上锁管理程序
1.0 目的
为了识别、控制在设备检修过程中的危险能量，防止因为危险能量意外释放造成
的安全事故，保障 A.K. Stamping Company, Inc.员工生命和财产安全，特制定本标准。

2.0 适用范围
本标准适用于对机器、设备或系统进行能源释放、能源锁定以及所有涉及由于设备能源意外失控而需要将所涉及能源进行恰当处理从而不致于使其影响或伤害人员及对设备破坏的所有工作。

对于非维修/保养活动，例如取样、润滑、清洁、调整、更换工具/磨具、清除阻塞、维修等不能进行能量隔离的作业需进行单独的作业安全评估并制定详细的标准操作流程。

只有那些经过培训和特别授权的人员才可以进行上述带能作业。

本标准同样适用于在企业管辖区域内的承包商维修作业
3.0 职责
各区域应明确规定能量隔离和挂牌上锁管理的管理责任人，负责推动和管理该区域内所有与危险能源和挂牌上锁有关的风险识别和控制，并定期回顾本程序执行情况。

4.0 能源隔离和挂牌上锁标准的具体内容
4.1 企业实施本标准的一般要求
a)应制定危险性能量控制计划和LOTO程序的详细要求。

通过实施该计划，使任
何可能发生突发性恢复能量、启动或存储能源释放，并造成伤害的活动之前，可以消除或降低暴
露于危险的可能性
b)应在所有可锁定的能量隔离装置上使用上锁挂牌。

一个能源隔离装置在其具备以下之一的条件时
才能被锁定：
✓配备有搭扣或其他附加装置，使锁可固定于该装置之上或通过该装置予以固定
✓内部配置有可供锁定的结构
✓无需拆卸、重新组建或重装能源隔离装置或无需永久性地破坏其能源控制能力即可予以锁定。

c)如果一台机械/设备上没有可供上锁的能源隔绝点，则应建立改造计划，确保
使其可以进行上锁挂牌操作，在没有改造前，应有详细的操作流程以避免危险能量意外释放造成
的伤害事故
d)挂牌上锁作业属于高风险作业之一，企业许可证管理制度应包括LOTO内容
4.2 危险能源和挂牌上锁的实施要求
4.2.1 识别危险能量源和与其有关的维修维护的任务全面识别需隔离的能量源是我们实施有效隔
离的前提。

应对企业范围内所有设备（或区域）进行危险能源识别，可能的能量源有：
离
我们要根据相关的工艺流程图（P&ID）、图表、供应商提供的文件和其他文件，将相关的有可能产生危害的电能、工艺流程中的流体压力、机械驱动、气动和液压等能量识别出来，作为要隔离的不同类型的能量源。

4.2.2 确定能源隔离点和选择隔离方法
a)确定并明确标出所有隔离点（即通过在每一个点上做标签或在
LOTO 程序标牌上注明隔离点）
b)确定需要的能量隔离装置，如断路器、阀门锁、盲板等，适用的锁具应摆放在现场（或
LOTO 工作站）
c)配备各种锁具并定义其使用要求，如个人锁、主管锁/小组锁的使用要求
对于每类能量的隔离点，要根据作业的类别采用不同的隔离方法。

在涉及可燃气
体、有毒有害气体吹扫和进入受限空间等作业的隔离时，隔离类型必须是可以取
得的最高合理级别。

特别需要注意的是蝶阀、控制阀、节流阀、调节阀等类型的
阀门不能作为系统的隔离阀门，电能类的隔离中控制用的启动、停止按钮和急停
开关不能作为隔离设备，必须用独立的手工断路开关作为隔离点。

小组锁和个人
锁的定义：
紧急去锁的规定：
可能会有以下偶然情况出现，如受影响的员工没有取下自己的个人锁就离开了工
厂并且是在机器/系统被再次起动之前。

在这些情况下，应尽可能采取一切努力来
联系该员工并告知他，他的锁需要被破坏打开。

如果这样做不行，则只有工厂总
经理或工厂指定的工程师有权取下这种锁，并且仅在确认以下行动之后：a)亲
自证实该人不在单位
b)评估分配给该人的工作
c)关闭其门禁卡权限，明确书面告知保安室不允许其再次进入，直
到工厂经理或工厂工程师书面批准。

4.2.3 隔离的实施、释放残余能量及验证隔离效果
LOTO 的实施需要专业人员根据作业程序（SOP）或作业许可证中给出的能量隔离计划，
选取合适的隔离锁具、标签和链条等装置对隔离计划中的隔离点进行隔离操作。

需要注意
的是同一工作许可涉及多类隔离时要遵从电气→系统→流程→机械的顺序分别进行隔离，
在解除隔离时应按反序进行。

在隔离程序或隔离计划中应选规定如何放残余能量，并验证隔离效果，确保相关的能量源
已彻底断开，设备不能被意外启动，符合完全隔离要求。

比如对待电能的隔离，要特别注
意电容器和感应器的放电，因为这类器件在隔离完成后将保持一段时间的带电状态(约
5min)。

残余能量释放后，待作业区域应处于“零能量”状态。

因此，释放残余能量和验证
隔离效果是LOTO 作业的关于步骤。

4.2.4 上锁和挂牌的要求
完成隔离并进行验证后，应上锁并挂牌，在标签上写明对应的隔离单号码（或许可证号码）、隔离日期、隔离人等信息。

同时在隔离单上填写隔离锁号、隔离时间，隔离人员签名。

复核人员（许可证签发人员）根据隔离单的隔离内容进行逐项核实，然后在复核栏内签名，这样整个隔离作业才算完成。

隔离单和对应的小组锁钥匙应由中控室（或作许可证签发人）集中管理。

只有作业许可所对应的隔离全部完成后，才能开始实施相应的维修作业任务。

4.2.5 能量隔离的解除要求
当所有的维修作业任务完成后，对应的负责人在隔离单（作业许可证）解除隔离许可栏内签字，专业隔离人员从中控室（工作许可证签发人）取回隔离单对应的钥匙，将维修作业前所做的全部隔离解除，把设备恢复到维修前的状态(待机状态或运行状态)。

4.2.6 书面操作程序（下称SOP）
撰写机器、设备或系统关闭、切断能源、核实、恢复能源及启动流程（场地和设
备/流程）专有的书面操作程序。

SOP 完成后，每个机器、设备或系统的LOTO 程
序应悬挂在作业现场（或LOTO 工作站）。

除了上述 4.2.2~4.4.6 的要求外，
每个机器、设备或系统内能量隔离和挂牌上锁的SOP 还应包括以下内容：
a)实施LOTO 前、任务完成后和撤销LOTO 均需及时告知受影响的人员
b)LOTO 实施后需要由一名胜任的授权人员释放剩余能量并确认隔离有效，使用紧急停止
按钮或其他控制电路是不可接受的隔离方法。

应有明确的授权操作人员名单。

c)如实填写隔离清单和标牌
d)所有需要在设备上进行作业的人员都必须对隔离点进行锁定，如使用小组锁，则需定期
监控隔离的有效性，例如交接班时、工作计划改变时（关于锁的使用要求见 4.2.3）
e)最后一个移除个人挂锁和标签的必须首先检查整个机器、设备或系统内外，以确保它在
重新投入运行之前的安全
f)在重新调试机械，撤去隔离和标签之前，所有的防护和安全系统都
必须经由胜任人员重新建立等。

4.2.7 培训和授权作业
LOTO 作业属于高风险作业，能源隔离的实施人员、涉及LOTO 作业人员和批准人员均应接受本标准
的培训，只有接受过培训并得到企业最高领导（或其代表）授权的作业人员才可以进行行此类作业。

因此，在LOTO 实施之前应提供初期的培训，使所有被授权人员都已了解本标准要求，熟知责任范围内设备、区域或流程能源隔离和挂牌上锁的标准操作程序（SOP）。

同时，通过培训提高所有受影响人员实
施LOTO 的意识，使受影响员工识别使用LOTO 的环境、认识自身职责和避免采取使LOTO 失效的
行动。

培训包括在企业内长期作业的承包商，临时作业的承包商需要在承包商导入培训中包括本标准的
内容。

以下人员需要参加培训：
a)挂牌上锁作业的实施人员（尤其是SOP 的培训）
b)能量隔离和LOTO 的批准人员
c)设备管理人员
d)区域管理人员
e)可能受LOTO 作业影响人员
f)EHS 管理人员
以下情况需要进行更新培训：
a)有新的或更改后的能量控制程序。

b)授权员工的LOTO 作业职责发生变化。

c)LOTO 作业方案发生变化。

d)额外LOTO 作业危险产生，如有新设备、改动的工艺或使用不同的
LOTO 装置。

e)定期检查或评估发现员工在LOTO 实施技术上存在不足。

4.2.8 中断能源隔离LOTO 的规定在LOTO 作业中如果需带能测试/调整/定位等作业，需
要暂时从能量隔离装
置上拆除上锁挂牌装置，应执行附录二第9 步（即拆除LOTO）所规定的步骤。

如果上述作业完成后，则应重新执行上锁挂牌的各项步骤（附录二第1~8 步）后方可作业。

4.2.9 对于没有预先制作SOP 的涉及危险能源的非常规工作任务，应执行工作安全风险评估
（JSA），涉及能源隔离和挂牌上锁的部分的控制措施应符合上述程序要求，尤其是
剩余能量释放和隔离确认部分的内容。

此
类作业同样需遵守许可证管理制度要求
4.3 变更管理
4.3.1 任何计划改造/改良涉及能量隔离和LOTO 的机器、设备或系统必须遵循变更管理程序，即事先经过
有能力人员进行风险评估，重复
4.2.2~4.2.8 的所有步骤，重新制定LOTO 的标准操作流程并需再次进行培训。

4.3.2 LOTO 作业进行中如发生人员变更、作业条件变更时，需重新评估能源隔离效果，并采取必
要行动确保所有操作在“零能源”状态下进行
4.4 事故管理与持续改善
4.4.1 与机器安全、危险能量的隔离有关的违章操和事故作必须得到调查，对不符合标准的设备和
流程进行改进以防止事故再次发生。

4.4.2 应每年评估能源隔离和LOTO 的执行情况，评估出的改进项应列入改进计划并定期跟踪整
改。

4.5 设备早期管理
4.5.1 对于新采购的涉及能源隔离的设备应征求LOTO 工作小组的意见，在采购设计阶段就考虑到
设备的能源隔离问题，尤其是能源隔离点和隔离装置的设定。

附件一：上锁挂牌9 步法
附件二：本标准中涉及的名词解释
附件一：上锁挂牌9 步法
只有经过上锁挂牌培训、通过考核的被授权员工才能执行上锁挂牌程序。

上锁挂牌分步走详细指出了各步骤的规定操作。

规定操作应该按照以下顺序进行：
1. 识别动力源：被授权员工应该了解都有哪些步骤，应该能够识别机器的动力源。

2. 通知其他人：在上锁装置和挂牌装置使用前和摘除后应通知所有受到作业机器影响的人（包
括操作员、技术员、工程师或区域经理）。

3. 关闭设备：关闭该设备的所有动力开关和/或按钮。

4. 隔离装置：被授权个人识别有针对性的上锁挂牌程序规定的所有能量隔离装置（断路器，阀
等）的位置。

把动力隔离装置置于（关闭、阻塞）阻止能量流向机器、设备、程序和电路
的位置。

接下来，被授权个人应验证动力隔离装置所处的状态和它们是否能够阻断能量流
动。

5. 实施上锁挂牌：被授权个人应根据以下要求悬挂并固定上锁和挂牌装置：
• 应把个人 LOTO 锁具和红色标牌悬挂和固定在机器、设备、程序或电路的动力隔离装置
上（如断路器、阀门等）。

如果动力隔离装置不便上锁，要求使用抓斗、球阀、断路
开关、墙壁开关或闸门阀等上锁装置。

注意必须遵守“1 人、1 锁、1 钥匙”的原则。

备注：在复杂的多人场合，也可使用带锁箱的多人LOTO 。

• 验证动力隔离装置是否仍处于“锁定”状态，即处于“安全”或“关闭” 位置。

• 如果无法把红色标牌直接固定在动力隔离装置上，则应把它置于最安全且最近的地方，
使试图操作该机器、设备、程序或电路的人能一眼看见。

此外，应在操作员的控制处
放置一个标牌，提示该机器、设备、程序和电路已经去能。

比如，如果电动公共汽车
的整个隔离开关位于顶部，那么就应该把标牌放在处于操作台显而易见的地方，提示
不要此刻使用该设备。

第一步 识别能量源 第二步 通知其他人 第四步 切断 / 隔离设备 第五步 上锁并挂牌 第三步 关闭设备
第六步 释放 / 控制储存能量
第七步
验证设备切断 / 隔离 第八步 实施维护时保证锁定 第九步 拆除上锁挂牌
6.释放储存的能量：被授权个人应确保所有潜在的危险性能量（附录B）（包括储存的或残留
的能量、化学能或势能）都得以释放、驱散、控制或消耗。

可能需要采取额外措施来预
防能量的重新蓄积。

可能储存能量的系统可包括蓄电池、电容器、重力、缓冲罐/稳压罐/
气室、化学管道和受力弹簧。

7.验证隔离成功：在开始对已上锁或挂牌的机器、设备、程序和电路维护和/或维修前，被授权
个人应，依照有针对性的上锁挂牌程序，验证动力源是否已经成功隔离和去能。

经验证必
须证实该机器、设备、程序或电路已经处于“零”能量状态，如达到零电流、零气压或零液
体等。

（验证是否处于零能量状态可采用以下方法：设备测试、电路激活、计量器测量、
目测等。

）
8.在对机器进行干预作业时强化上锁挂牌：避免开启任何动力或任何可能重新启动设备的行为。

如果想重新启动设备，请遵循第9 步。

9.恢复正常：在使设备恢复正常运作之前，被授权个人还应完成下列操作：
•检查工作地点，确保无关物件已经被清除，防护设施摆放到位，机器、设备、程序或电路的运行未受影响，所有员工都处于安全的位置。

•由上锁挂牌的被授权个人依照规定从每个动力隔离装置摘除锁具、标牌。

•通知受影响员工机器、设备、程序和电路的供能即将恢复。

•察看和/或循环测试该设备的维护和/或维修作业是否完成。

如果作业已经完成，该机器、设备、程序和电路可恢复正常使用。

如果作业尚未完成，重复必要的上锁挂牌步骤。

•按照适当步骤启动设备、程序或电路。

附件二：本标准中涉及的名词解释
临近设备/程序：临近机器能量源指和作业机器无关但因位于作业机器附近而可能给工带来
危险的机器、设备、程序和电路的原有和储存动力源。

为了确保全，也应
识别临近设备/程序的危险能量。

受影响人员：在上锁或挂牌的被或维护维修的设备上或附近操作的员工，他们没有授权
执行上锁挂牌。

关联设备/程序：关联能量源指与作业机器、设备、程序和电路相互影响，但能量供给立于它
们的动力源。

比如，钻夹具从机器人手中接过零件，而机器人从传送器上获
取零件。

关掉钻夹具的电源并不意味着关掉机器人和传器的电源。

机器人和
传送器分别独立供能，但由于它们与钻夹具物理连，只有把它们也锁定才能
确保万无一失。

因此，也要识别机器人和
送器携带的关联动力源。

被授权人员：是指经过上锁挂牌培训、考核合格并被授权实施危险性能量控制（上锁或
挂牌）的员工。

能量隔离装置：能从物理上阻止动力的释放或传送的装置，它包括但不限于以下的装置：
手动操作的电气断路器；断开开关；手动操作的开关，它可以将路的导线
与所有非接地导线断开，并且没有电极可以独立使用；管路阀；堵头；其
他类似可以堵住或隔离动力源的装置。

通过使用锁具等主动地确保动力隔离装置处于关闭状态，防止设备赋能。

LOTO 锁具还包括法兰盖和盲板。

使用锁具的被授权员工具有对该锁的个
人独控权力。

危险性能量：所有可能伤害员工的电能、机械能、液压能、气能、化学能、核能、能、
重力能或其他能量（包括势能和/或动能）。

个人LOTO 锁具：一种LOTO 专用锁具，个人只持有一把钥匙，不提供万能钥匙。

分配
被授权人员（个人锁具），或者可从LOTO 锁具中心储藏室获得。

在人使
用时为个人所专有。

LOTO 锁具一般为红色。

上锁装置：通过使用锁具等工具主动地确保动力隔离装置处于关闭状态，防止机
器、设备、程序和电路赋能。

上锁挂牌（LOTO）：按照规定程序在动力隔离装置上挂上锁具和红色的标牌，提示只有按规定程序移
除锁具和红色标牌才能开启动力隔离装置。

风险评估：综合评估在某种危险情况下导致工人损伤或健康损害的概率和严重程
度。

在评估风险之后，可选择适当的防护手段来减少暴露。

通过风险估
来识别高风险行为并采取矫正手段把风险降至可接受水平。

安全标识：一种可视警示设备，形式包括标牌、标签、贴纸、程序标牌等，用来醒
可致损伤或死亡的潜在危险的性质和严重程度。

维护和/或维修：对机器、设备、程序和电路实施的修理、预防性维护、改造和安装。

进行以上操作时要求机器、设备、程序、电路或其部件处于“零能量状态”。

执
行上述操作的员工必须按规定步骤实施上锁挂牌。

挂牌装置：一种醒目
的警示手段，通过标牌以及其悬挂方法提示动力隔离装置此正处于安全状态，
防止机器、设备、程序或电路赋能。

1.0 Purpose
To identify and control hazardous energy in the process of equipment maintenance, to prevent the accidents caused by accidental release of hazardous energy, and to ensure A.K. Stamping Company, Inc.’s employee
and property safety.
2.0 Scope
This standard is applicable to the machinery, equipment or system of energy, energy release locking and
all equipment accidents due to out of control energy, and the need to for proper treatment for energy and
to prevent damage to equipment and personnel and destruction of all the work.
For non-repair / maintenance activities, such as sampling, lubrication, cleaning, adjustment, change of tools, to remove the obstruction and maintenance, which energy cannot isolate operations, are required
to separate operation safety assessment and develop standard operating procedures. Only those who
are trained and authorized personnel can carry out the operation.
This standard applies to the enterprise within the jurisdiction of the contractor maintenance work.
3.0 Responsibility
The enterprise shall clearly define the person responsible for the energy isolation management and lockout / tag out management. He shall be responsible for the promotion and management of the entire enterprise risk in all energy related activities. He shall conduct risk identification and control, and regularly review the implementation of this standard.
4.0 The energy isolation and LOTO detail requirements
4.1 General requirements
a)Company should establish requirements of energy control programme and LOTO program.
Through the implementation of this programme, the possibility of exposure to risk tofpossible
emergency recovery energy, start or stored energy release, and harm, can be eliminated or
reduced.
b)All devices should be locked if possible. An energy isolating device needs to have one of the
following conditions in order to be locked:
✓Equipped with other additional devices, so that the lock can be fixed on the device
✓Has internal configuration structure for locking
✓No disassembly, re-establishment or reinstalling of energy isolating device or without permanent damage to its energy control ability..
c) If a mechanical / equipment is not available for locked energy isolation, transformation plan
should be established to ensure that it can operate in LOTO. Before transformation, there should be a detailed operating procedures to prevent the risk of injury accidents caused
by the accidental release of energy
d) LOTO operation is the one of the high risk operations, Permit To Work management system
should include the content of LOTO.
4.2 Hazardous energy and locking.
4.2.1 Identification of dangerous source of energy and related repair and
maintenance tasks
Comprehensive identification of isolated power source is the first step to effective
isolation. Possible energy source:
ased on the Process and Instrumentation Diagram (P&ID), charts, and other documents
provided by the supplier, the related potentially dangerous electrical energy, fluid
pressure, mechanical drive, hydraulic and pneumatic can be identified as different types
of energy source to be isolated.
4.2.2 Identify the LOTO point and choose the isolation way
a) Identify and mark all isolated points clearly (i.e. indicate separation point in the
LOTO document through labelling)
b) Determine the energy isolating device needed, such as circuit breakers, blind plate,
plate valve and application lock to be placed in the field (or LOTO station)
c) Equip with all kinds of locks and define the requirements, such as personal lock,
supervisor lock / group lock.
Different isolation methods should be used for different isolated points of energy. In the
isolation of combustible gas, toxic and harmful gases to purge and confined space
operations, isolation type must be of the highest level achievable. Stop and emergency
stop switch cannot be used as isolation equipment start-up; independent manual control
switch circuit can be electrical isolated.
Group lock and personal lock:
There may be incidents where the employee did no bring their personal lock. In these circumstances, as far as possible, all efforts should be taken to contact the employee that his locks need to be broken open. If contact is not possible, only the general manager of the factory or factory designated engineer has the right to remove the lock, and only after confirming the following actions:
A) Confirm that the person is not in the plant
B) Evaluation of the situation
C) Deactivate the card access, clearly inform the security room that the person is not allowed to enter it again,
until written approval is attained from plant manager or plant engineer
4.2.3 Isolation, residue energy release and confirmation effect of isolation
Implementation of LOTO requires professionals according to standard operating
procedures (SOP) to conduct the following: issue work permit in the energy isolation plan,
select the isolation lock, tag and chain suitable device isolation of isolated points in
isolation plan. Different order for lock should be considered for different energy type.
Procedures to release the residual energy should be included in the isolation procedure to
ensure energy source is completely broken down. The equipment should not be started up
until the isolation requirements is completed. Special attention should be paid to
discharge the capacitor and inductor, as the charged state of this kind of device will be
maintained for a period of time after the completion of the isolation (about 5min). The
working area should be in “zero energy” state after residual energy is released. The release
of the residual energy and the verification of isolation effect are the key steps of LOTO.
4.2.4 LOTO requirements
Completed isolation and verification, should be locked and tagged, indicating the
corresponding isolated permit number on the label (or license number, date of isolation,
operator’s name) and other information. Review staffs are to verify according to the
permit content and endorse at the signature column. Isolation of single and group key
should be corresponding to the central control room (or permit issued by the people)
centralized management. Maintenance work can only begin after all verification and
approval work is completed.
4.2.5 Energy isolation dismantle
4.2.6 When the repair work is completed, the person in charge of isolation permit (permit to work) will
endorsed on the quarantine permit column.
Professional personnel in the control room (isolated from issuing work permits) will
retrieve the isolated single keys, repair the homework before the full isolation is remove,
restore the device to repair before the state (the standby state or condition). Standard
operation procedure
Specific procedure for machine/equipment should be written and posted on the
machine/equipment. Procedure should include steps to turn off, stop, turn on and recover
the energy used.
Except 4.2.2~4.4.6, all specific procedure for the machine and equipment should include:
a) Affected person should be informed before, during and after LOTO work.
b) After implementation of LOTO, the residual energy should be released and confirmed
by authorised person. The emergency stop button or other control circuit as isolation
method is not acceptable. The authorized operator should be the person in charge.
c) Fill in the isolation list and sign
d) All work on the equipment personnel are required to lock the LOTO point. If group
lock is in use, regular inspection is required. For example, the shift change and the
working plan change. (for how to use the lock see 4.2.3)
e) The person who last removed the lock and tag should check all the machine and
equipment to ensure the safety of this machine and equipment.
f) Before commissioning, remove the isolation and tag, all protection and safety system
should be established by authorised person.
4.2.7 Training and authorization
LOTO is a high risk operation. LOTO operation related person and approval person should
attend the training. Training and approval from relevant manager are the prerequisites to
conduct any LOTO related work. Therefore, before the implementation of LOTO, initial
training should be provided, so that all authorized personnel have an understanding of the
requirements of this standard. At the same time, improving the awareness of all affected
personnel carrying out LOTO through training, the affected employee will recognise the
LOTO environment and know their responsibility. The training includes involved
contractors. For the temporary working contractor, the orientation should include LOTO
information.
The following personnel are required to attend the training:
a) LOTO operator (include SOP training)
b) energy isolation personnel and LOTO approve personnel
c) equipment management personnel
d) area management personnel
e) affected personnel
f) EHS personnel
Training should be updated under the following situation:
a) New or updated LOTO procedure
b) Authorization person change
c) LOTO work plan change
d) Additional LOTO risk occur, for example, new equipment, new process, new LOTO device.
e) Personnel found to be not as competent in LOTO
4.2.8 Break off energy isolation
If work needs to be done during the LOTO
If the above work has been finished, we should execute all steps of LOTO (attachment
steps1~8) before working.
4.2.9 JSA should be conducted for all energy related work without specific SOP. All energy isolation
and LOTO control measure should follow the above permit to work process.
4.3 Change Management
4.3.1 All changesfor energy isolation and LOTO related machine and equipment should follow the
change management procedure. Trained personnel should conduct the risk assessment and
conduct procedure 4.2.2~4.2.8 before the change. Special LOTO procedure should be
updated and training conducted for all related person.
4.3.2 If there are changes to people or work environment, energy isolation should be re-assessed, and
ensure all operat ion should be in “Zero Energy State”.
4.4 Incident Management and Continual Improvement
4.4.1 All incidents should be investigated. All equipment and process that are not according to the
standards should be improved.
4.4.2 Conduct energy isolation and LOTO assessment every year. All suggestions should be in the
improvement plant and tracked regularly.
4.5 Early Equipment Management
4.5.1 Requirements on LOTO should be communicated to the acquisition team and taken into
consideration during acquisition of equipment.
Attachment 1: LOTO 9 steps
Attachment 2: Terms and definitions
Attachment1： LOTO 9 steps
operation should be as follow:
1. Identify energy: authorized person should know the LOTO 9 steps and can identify the
energy. O nly trained, approved and authorized person can conduct the LOTO work.
LOTO Step1
I d entify energy Step 2 I n form a ffected p e rson Step 4
Disconnect All Energy
Sources Step 5 Apply Lockout - T agout Step 3 Shut d o wn the
equipment
Step 6 Release All Stored Energy
Step 7
Verify the Isolation and
Lockout Step 8 Keep safe and lock Step 9 Dismantle LOTO
2. Inform affected person: before the LOTO start and after dismantle the LOTO, all affected
person should be informed. (including operators, technician, engineer and area manager)
3. Shut down the equipment: shut down all power switch and buttons on the equipment.
4. Identify and disconnect all energy sources (eg, electrical, hydraulic, pneumatic etc) so that
the machine or equipment is isolated from all energy source(s). Energy isolating devices
such as manually operated circuit breakers or isolating switches are used for disconnecting
energy sources.
5. Apply Lockout-Tagout: authorized person should conduct the LOTO operation as one of
the following requirements:
•Install LOTO locks, red signs and fix them on the machine, equipment, program or circuit power isolation device (such as circuit breaker, valves etc.). If the power isolation device is inconvenient to lock, the use of grab bucket, valve, switch, wall switch or gate valve locking device is required. "1 person, 1 lock, 1 key"
must be followed
Note: in the group working situation, can also be used with a lock box. •Verification of dynamic isolation device is still in the state of "locking", which is "safe" or "off" position.
•If the red label is not directly fixed on a power isolating device, it should be placed on safe and the nearest area. In addition, signages should be put up at the operator’s work station to indicate which
machine/equipment has been energy disabled. For example, if it is located at the top of the electric bus isolation switch, the sign should be placed at the station. Do not use the equipment.
6. Release All Stored Energy:Release or restrained any residual or stored energy (such as
that in capacitor, spring, elevated machine members, rotating flywheels, hydraulic
systems, air, gas, steam, or water pressure, etc) to ensure the effectiveness of lockout so
that the lockout will not create any hazard to workers. This can be done by methods
such as grounding, repositioning, blocking, bleeding down, etc.
7. Verify the Isolation and Lockout:Check that all personnel are clear from hazardous
area and verify the isolation and lockout. Ensure that the equipment reduced to zero
energy state by operating the push button or other normal operating control(s) or other
means of testing to confirm that the equipment will not operate.
8. Keep safe and lock: avoid any attempt to re-start the equipment.
9. Dismantle LOTO: before Dismantle LOTO, authorized person should follow below
steps:
•Check the machine or equipment and the immediate area around the machine to ensure that items not supposed to be on there have been removed and all items previously removed (eg, machine guarding, parts etc) are operationally intact. All affect people are safe。