Essentials for Locking and Tagging

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Explanations of related concepts regarding lockout tags ● LOCKOUT: A safety measure that involves locking out a device whose power supply has been disconnected, or that can be locked out, in order to prevent others from restoring the power supply or energy supply (such as by opening valves); it is also referred to as locking. ● TAGOUT is a safety measure, also known as labeling, which involves attaching appropriate warning signs or labels to devices that have had their power and energy sources disconnected (such as “Do not close – someone is working here”), in order to alert others not to restore power or energy to those devices. ● Disconnecting Means: Devices that can disconnect one or a group of equipment from the power supply circuit to which they are connected. ● Relevant personnel: Those who are directly or indirectly exposed to the risk of electric shock, including those responsible for designing locking and labeling mechanisms. ● Professionals: Individuals who have received specialized training and possess experience, enabling them to identify risks and avoid electrical hazards. ● Non-professionals: persons who are neither professionals nor have received any basic training. ● Electrical safety working conditions: A state in which, at or near the location where conductors or conductive components are installed, live parts are isolated, locked, or marked in a specified manner; testing ensures that there is no voltage present, and the area is grounded as required. ● Hazardous energy sources: Refer to the energy contained in process materials or equipment that may cause injury to people or property damage. ● Hazardous energy sources include: – Power sources: such as electrical, hydraulic, and pneumatic ones. – Energy storage: such as that generated by gravity or compressed springs. – Others: thermal energy, such as that from chemical substances. Why lockout/tagout is necessary: Lockout/tagout is used to prevent workers from facing dangers resulting from unexpected or abnormal startup of machines, as well as from the release of power sources, thereby protecting their safety. The key to carrying out the lockout/tagout procedure is to disconnect the machine from its power source, lock the power source, and release any residual energy in it. Where locking and labeling are required: 1. For the daily maintenance, repair, adjustment, cleaning, inspection, and calibration of equipment. Operations such as working under voltage, entering confined spaces, performing hot work, and disassembly in facilities like towers, tanks, axes, heat exchangers, etc. 2. High-pressure operations. 3. Operations that require the temporary shutdown of safety systems. 4. Non-process-related maintenance and operations during debugging. Requirements for lockout/tagout: 1. When multiple people are authorized to perform the same task, each worker must personally carry out their own lockout/tagout procedures, rather than relying on others to do so. 2. Never authorize anyone to remove your locked tag device. 3. Operate only on equipment whose safety devices have been locked and tagged. 4. When taking over shift duties, you must never remove the existing lockout/tagout devices on your own; the previous lockout/tagout must be removed only after the next shift worker applies the lockout/tagout procedures as required. At the same time, the new replacement must recheck whether the lockout/tagout measures are safe and reliable, and only after confirming this can they proceed with the operations. 5. Never rely on someone else’s locked padlock for your safety; always remember to use your own lock to protect yourself. 6. Use the correct lock; for example, if you are locking a 3-inch pipe gate valve but use a safety lock designed for a 5-inch to 6.5-inch gate valve, do not opt for a mismatched lock out of convenience. Instead, obtain a lock of the appropriate size immediately. 7. Ensure that your locking and labeling device can withstand the conditions of its environment, such as humidity and corrosivity; otherwise, it will lose its effectiveness. 8. Locks and tags must be used together; they cannot replace each other. 9. As of January 2, 1990, whenever mechanical equipment is replaced, overhauled, modified, or upgraded, and whenever new mechanical equipment is installed, the energy isolation devices for such equipment shall be designed to include locking mechanisms. 10. The operator shall conduct regular inspections of the capacity control procedures at least once a year to ensure that the procedures and requirements of this standard are fulfilled, and these regular inspections shall be carried out by authorized personnel, rather than by those responsible for implementing the energy control procedures. 11. If there is a possibility that the stored energy could build up to a dangerous level, the isolation status should continue to be verified until repairs or maintenance are completed, or until such a possibility no longer exists. 12. Whenever external maintenance personnel are involved in maintenance activities within this scope, the on-site operator and the external operator shall inform each other of their respective locking or tagging procedures. The eight steps for locking out and tagging out: 1. Understand the equipment. Employees authorized to perform these tasks must have a thorough understanding of the location, performance of the power sources in the equipment being repaired or maintained, as well as how to control those power sources. The lockout/tagout procedure will tell you what power sources the equipment contains, as well as which switches need to be locked out. Even when dealing with a device that you are very familiar with, never assume that you know everything – situations can change rapidly, so please follow the locking and labeling procedures for that device. 2. Inform the relevant personnel: The locking and tagging procedure you carry out may affect other workers. Therefore, to prevent issues such as others accidentally starting the machine, please inform all personnel associated with that equipment before performing locking and tagging. 3. Turn off the device: Turn off the power switch or ground it, and place a sign to warn others. 4. Shut off or lock all hazardous power sources. Lock and tag those power sources that could pose a risk; for example, use circuit breaker locks to secure circuit breaker switches, or use gate valve locks to secure pipeline gate valves. 5. Release of residual power sources. Residual power sources are usually quite hidden, but they can cause equipment to start operating suddenly without any apparent reason, thereby posing a risk of injury to people. Therefore, before carrying out repairs, the remaining power source must be discharged. 6. Verify the possibility of locking. Do not take it lightly; before proceeding, open the device controller again to confirm that the machine has not been restarted, that the power indicator light is not on, and that all components of the device are at rest. After the test is completed, turn off the device controller. This step can only be carried out by personnel authorized to lock and tag out; the verification results of other persons are considered invalid. 7. Restore the lockout device that was temporarily removed: If you need to remove a lockout tag to test a device, reapply the lockout tag as soon as the testing is complete. Always remember to ensure that the equipment is in a completely safe state; otherwise, it will be you who ends up in danger. 8. Remove the locks and tags. Once the work is completed, ensure that no one is in the dangerous area around the equipment before removing the locks and tags, and inform all relevant personnel that you are about to restart the equipment. Only authorized personnel may remove the locks and tags; this task must never be delegated to others.