Why LOTO is important in the Petrochemicals

4 min readJun 5, 2021

An introduction to LOTO

In the beginning, when machinery was introduced in the petrochemicals there were several incidents and accidents because the preventive maintenance was carried out in the switched-on condition but when it increased to a large extent, then rules were introduced for the prevention of the incidents and accidents.

We know that in the construction industry and petrochemicals there are several types of machinery and equipment that needs time to time servicing and maintenance for soundness and smooth running so that work and productivity don’t hamper to maintain that order periodic servicing and maintenance is required but performing this task when the machinery is in switched on was very lethal that is why to prevent man, material, and equipment we need to shut off the machine and place some tag and locks on it for identification purpose so that others can be aware that periodic maintenance is ongoing and that is called Lock/out and Tag/out(LOTO).

Types of energy in the petrochemicals

Electrical:-The Energy that is being generated because of the electrical parts attached to the machinery.
Mechanical:-It is generated due to the running machinery of the plant.
Chemical:-The Energy that is produced due to the chemical reaction inside the vessel or any said closed equipment.
Thermal:-Generates due to the produced heat of the equipment and the machinery.
Hydraulic:-It is being produced due to the hydraulic pressure of the fluid inside the vessel.
Pneumatic:-The energy that is associated with the air pressure of the equipment

The procedure of the Lockout and Tag-out(LOTO)

Preparation to shut down the machinery or the said equipment.
Shut down of the Equipment
Isolation of all the energy sources
Placing Locks & Tags on the [particular equipment and machinery which is undergoing maintenance
Releasing of the Stored Energy
Verify Equipment Isolation physically and technically

What to be considered in preparation for the Shutdown

Types of the stored energy
Types and potential dangers of the stored hazards
Methods and required steps to control it
The personnel’s to be notified.

How to shut down the Equipment prior to LOTO

Use basic and normal processes for the shutdown of the equipment and machinery.
Switch off all the power to the machinery and equipment.
All the attached control valves to the machinery need to be shut-off
All the energy sources need to be de-energized or disabled.

Isolate the Equipment

Shut off the equipment and machinery from the main breaker.
All the attached valves to it need to be closed.
All the process lines need to be disconnected
The main plugs of the machinery need to be pulled from the main socket.

Attach the Lock and Tag

All the employees who work on the machinery and equipment need to place their own lock and tag.
Multiple Locking procedures need to be followed.

Release or Block all the Stored Energy before LOTO

We know that capacitors store charges so all of them need to be discharged.
It poses great dangers so the springs either need to be blocked or released from their position.
All the elevated parts of the machinery need to be blocked in order to avoid any dangers.
The rotating flywheel needs to be stopped to avoid entanglement or any other dangers.
System pressure needs to be released.
All the fluids in the pipeline or process line need to be drained.
The vents connected to the lines need to open to release the gases.
Let the system cool down incompletely manner prior to the start of the work.

The Equipment Isolation needs to be verified in LOTO

Prior to the start of the work all the areas of the machinery must be made clear.
Cross-check that the locking devices are securely placed in the correct position or not.
The isolation need to be checked and cross verified with the help of the drawing and by physical means
Initially, the normal start-up has to be made.
The controls need to be returned in an off position or neutral.

Process of releasing the equipment from LOTO

All the areas need to be inspected prior to release from LOTO.
The guards of all the machinery need to Ensure all Machine Guards in place
All the tools must be moved away from the machinery and equipment
Inform all the parties prior to the start-up of the equipment.
The connection of the system needs to be restored.
All the locks and tags attached to the equipment need to be removed.
Restore the equipment to normal mode.
Conduct normal start-up

Personnel who can remove Locks & Tags in LOTO

The said employee can remove the tag or the one who gets authorization from him can be the Foreman of the Job or the Supervisor.

Conclusion

It is very dangerous to perform preventive maintenance on any equipment or machinery without LOTO so all the standards practice needs to be established and practiced to avoid the imminent dangers of the stored energy so LOTO must be applied without a third thing coming into mind if the workforce is going for periodic maintenance on any equipment or machinery and all the requisite safety practice must be followed keeping an eye on the general safety law without any breach.

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Why LOTO Is Important In The Petrochemicals — The Sense Mission