Approval

Project manager

0 October ‘25 Initially Sorin Nicula Adrian Bednarovschi Neacșu Alexandru

NO. DOCUMENT
REV. DATE DESIGNED CHECKED APPROVED
DESCRIPTION
Revision Sheet
CUSTOMER:
MINISTRY OF ELECTRICITY (MOE)
REPUBLIC OF IRAQ
PROJECT :
IFB no. M21-21-2016
Rehabilitation of Unit 3
Facilities and Common System, Al Mussaib Thermal Power Plant Rehabilitation

CONTRACTOR:

BLACK SEA POWER GENERATING FZCO

DESIGNED BY DATE

Sorin Nicula October ‘25

TITLE:
CHECKED BY DATE

Adrian Bednarovschi October ‘25 Lock Out and Tag Out Procedure for
APPROVED BY DATE
Waste Water Treatment Plant

Neacșu Alexandru October ‘25

Contract No. DOCUMENT NUMBER REV.NO.

IFB no. M-21-2016 350-BSP- 0151 0

 Contents
1 PURPOSE.............................................................................................................................. 3
2 DEFINITIONS ........................................................................................................................ 3
3 RESPONSIBILITIES .............................................................................................................. 4
4 REQUIREMENTS .................................................................................................................. 5
5 LOCK OUT FOR ISSUER ..................................................................................................... 6
6 LOCK OUT FOR RECEIVER (MAINTANANCE & CONTRACTORS) ................................. 7
7 CUTTING LOCKS ................................................................................................................. 8
8 PAD LOCK COLOR CODING ............................................................................................... 9
9 ATTACHMENTS .................................................................................................................. 10
ATTACHMENT 1: UNIT LOCKOUT LOG BOOK ...................................................................... 11
ATTACHMENT 2: LOCK/ HOLD TAG ........................................................................................ 12

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1 PURPOSE
1.1 This instruction outlines the means of control over operation o all energy
systems including electrical, pressure (hydraulic and pneumatic), kinetic
(motor), potential (position), thermal (hot and cold), chemical (hazardous
and flammable material) systems to prevent unintentional operation.
1.2 The purpose for Lockout System is to render controllers inoperative i.e.
circuit breakers, disconnect switches, valves, etc on any systems
(electrical, steam, hydrocarbon, water, acid, etc) where the operation of
the control device could be hazardous to personnel working on the
system

2 DEFINITIONS
2.1 Car–Seal – The term “car-seal” comes from the railroad industry.
Railcars were loaded with goods. To assure that goods were not
tampered with agents on the shipping end would but a wire though a
hole in the handle and then through a hole in the car. They would then
use a lead ball with a hole in that end of the wire was put together. A
hand press would be used to squeeze the lead tight on the wires and
imprint a seal of the agency. If the wire where cut or the seal was
broken, they knew the shipment was tampered with. In plants were use
the concept, but not always the exact for of the car seal. Or better
stated, the valve is placed in either the open or closed position, In the
Lock, Tag, and Try safety rules, the valves should have locks with strict
controls on keys, this is a form of car sealing. Lock Open/ Lock Closed
(LO/LC) and Car Seal Open/ Car Seal Closed (CSO/CSC) are methods
administratively controlling the opening and closing of a valve, and the
intent is the same.

2.2 Padlock - A removable Lock with a shackle that can be passed through
a staple or link and then secured.
2.3 Lockout device - A device which passes through an electrical breaker
lock position, which has several holes for locks, this allows multiple
locks to be applied to the same piece of equipment for isolation
purposes.

2.4 Blinding - The placing of a metal plate in the flange of a line with the
purpose of preventing the products of the line from traveling through it.

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 2.5 Hold tag - A cardboard tag that can be written on and then attached to
a lock to announce the details and purpose of the Lock. See
ATTACHMENT 2 of this instruction.

2.6 Verification test - After a piece of equipment has been locked out, a
test is performed by trying to start a motor or open a valve to verify the
correct equipment has been isolated.

3 RESPONSIBILITIES
3.1 The Supervisors for Operations Team, Maintenance and Project
Management Team (PMT) contractors shall be responsible for ensuring
that all personnel under their supervision understand the use of and
purpose of Isolation Locks and Hold Tags. Work Permit Issuers and
Operations Team supervisors shall ensure that hold tags and lockouts
are used and noted on the Work Permit. The use of Hold Tags/ Lock
Outs shall be strictly enforced.
3.2 The safe isolation of any device which requires Locks and Hold Tags
must be covered by a valid Work Permit.

3.3 The Electrical System Operator shall be responsible for authorizing

installation and removal of Locks and Hold Tags on electrical equipment
of above 480 volts.
3.4 Tags are useful to tell who is working on the equipment and who
authorized the shutdown. Teach your men the Lockout procedure and
insist they follow it.

3.5 Workers may be injured while working on equipment when the controls
have not been locked and tagged in the off position. People do make
mistakes and start equipment on which maintenance men are working;
vibrations and ineffective mechanisms can cause controls to move or
valves to open. Protection is simple: lock the control in the off position
and prevent an accident.

3.6 Hold Tags and locks are primarily intended to protect the individual
doing the work from being injured by an inadvertent start-up.
3.7 When more than one man is going to work on a system or on a number
of pieces of equipment within the system, the multiple Lockout clip
enables each man to lock out the circuit or machine control. If your man
can't get his lock on the clip, work should not proceed until a suitable
clip is found.
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4 REQUIREMENTS
4.1 Each lock on a piece of equipment, or on a multiple lockout clip, must
be able to be identified. The preferred approach is to install a tag
(ATTACHMENT 2) on each lock indicating plant numbers or location,
the date and time of lockout, name, badge number, organization,
contact phone and signature of the individual who installed the lock and
the reason for the lock's installation.

4.2 Each organization issuing locks shall have a system of uniquely

identifying locks.

4.3 Maintain sufficient quantity of lockout devices i.e., padlocks, multi clips,
lockout tags, and lockout tag logbook. The approved color coding and
marking of each pad lock shall be complied with accordingly. Please
refer section 9 of this instruction.

4.4 Both Operations Team and Maintenance Supervisors are responsible in

ensuring that each padlock used in this instruction shall have only one
key. Duplicate and master keys shall be disposed of accordingly.

4.5 When carrying out Preventive Maintenance (PM) on any equipment, it

is permissible for the Craft to remove his lockout to facilitate testing
of that equipment without closing the Work Permit. Such testing of
equipment should only be done after checking that no hazard will
exist to personnel or equipment as a result of that test. If further work is
to be carried out, then the lockout must be restored as soon as the test
completed and before the work starts.

4.6 All installed locks must have a completed and signed (Attachment 2).

4.7 The Operations Section lock shall, in all cases, be the first to install lock
and the last to remove lock.

4.8 Each group or Craft working on an isolated system shall install their own
lock and tag.

4.9 A lock shall be installed through the mechanical connection devices

on breakers, motor controllers and disconnect switches.
4.9.1 The breaker shall be pulled out on all devices that cannot be
positively locked out. A hold tag will be placed on the breaker
cabinet door.

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 4.10 In situations where it is not possible to lock out or chain off an isolation
device, isolation may be accomplished by removal of fuses,
disconnection of electrical cables, installation of blind flanges, or
physical removal of a component of the system supplying energy to the
equipment. The point of physical interruption shall be identified with a
completed tag.

4.11 Physical restraint in the form of a bar, chain or rope should be used to
tie or anchor large rotating parts that could move due to natural draft like
fin fan blades, boiler forced draft fans, etc.

4.12 Verification tests, in which all affected parties participate, shall be

conducted on each isolating device or on each piece of isolated
equipment.
4.12.1 Each isolating device, such as a disconnect switch, shall be
physically tested by moving its operating mechanism against the
lock to confirm it cannot be operated.
4.12.2 Each remote control device shall be tested and tagged to insure
the equipment is isolated.
4.12.3 Each local Start/ Stop or Open/ Close switch shall be tried,
tagged and a lock installed by Operations Team if possible.
4.13 Each Operations Team and Maintenance Section shall maintain a
separate logbook and key rack to enable the identification of any
equipment that has been locked out. The log shall record the equipment
number, the lock number, date of installation, and signature of installer,
date of removal and signature of remover. See Attachment 1.

4.14 This Logbook and key rack should be available for 24 hours and 7 days
a week in the shift office.

5 LOCK OUT FOR ISSUER

5.1 If the controller is to be held inoperative for operating reasons, the Shift
Supervisor or higher authority shall authorize attachment and removal of
locks and hold tags.
5.2 The person authorizing use of locks and hold tags shall be responsible
for ensuring that these are installed and attached to the correct
equipment.

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 5.3 The Shift Supervisor or his designate shall lock the controller through
the use of a cascade lock, multiple lockout clip or a chain and lock. The
Shift Supervisor shall complete a hold tag and attach it to the lock.

5.4 The isolation of the equipment shall be verified by trying all remote and
local switches, tagging and locking the switches where possible.

5.5 When the equipment is no longer to be held inoperative, the Shift

Supervisor shall remove the lock and tag, date and sign the tag, enter
the removal in the logbook and retain the tag in his office for 90 days.

5.6 The preferred method to retain hold tags is by month, clipped to a file
and stored in filing cabinet.

6 LOCK OUT FOR RECEIVER (MAINTANANCE &

CONTRACTORS)
6.1 If work is to be performed on any portion of a system, the Shift
Supervisor or his designate shall identify the controlling valves, circuit
breakers or disconnect switches and lock, tag and try the switches
following procedures in section 3 of this instruction.

6.1.1 When isolating piped system,

 The block valves upstream and downstream of the work area shall
be closed, tagged and chain locked.
 Open the drains to depressurize the line.
 If blinding is required, after the line has been depressurized, install
blinds between the up and downstream valves and the work area.
6.1.2 To repair or replace a transmitter/ DP cell, the operator shall close
and tag the valves on the impulse lines and vent off the pressure
before allowing work on the equipment.
6.2 Prior to starting work on a system, the Craftsman shall install his lock
and his completed tag on each controller.

6.3 The Craftsman shall have the key to the Maintenance lock in his
possession during the time he has a valid Work Permit for the
equipment or system.

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 6.4 A separate lock and tag shall be installed by each different Maintenance
group working on the system. Each group receiving a separate Work
Permit shall install their own lock and tag.

6.5 If work is to continue from one shift to the next, responsibility for the
Maintenance lock will be passed to the next shift by having the new
Craftsman sign the hold tag and receive the key.

6.6 A Craftsman shall remove his lock when the job is completed and
maintenance work order is ready for closure.

6.6.1 When a Craft shift change occurs and work is not complete, the
oncoming shift may either:
6.6.1.1Install their own locks and tags at locations where the previous shift
had them, in which case the off-going shift shall remove their tags
and locks, or Effect a transfer of keys between shifts. This transfer
requires the Craft Deputy Section Head or Supervisors to conduct a
detailed review of installed locks and tags. Craft tags may be
endorsed by the oncoming shift or new tags may be installed.
6.7 After work has been completed on the system and the Shift Supervisor
has determined that the system can be safely returned to service
he shall energize the system and follow the instructions in section 3
of this instruction.

7 CUTTING LOCKS
7.1 Before any padlock is cut, padlock owner working on the system must
first be determined and that the system is safe to restore to service. The
Shift Superintendent shall supervise the cutting of all lock out locks and
record the action in the Unit lock out log book and Shift Superintendent
Shift report

7.2 No padlock/lockout device shall be cut or forcefully removed, without the

permission of the lock owner's Section Head, the Operations Team Shift
Superintendent or Deputy Section Head.

7.3 The operations Department Deputy Section Head will attempt to contact
the individual who installed the lock, or his Supervisor, to confirm that
the employee is safe and that the padlock can be removed.

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 7.4 If the individual, his Supervisor, or Section Head cannot be contacted,
the Shift Superintendent may supervise the remove the lock(s) and
tag(s) only after reviewing the equipment/ process to be energized, to
ensure that personnel and facilities are safe from injury or damage.

7.5 The Shift Superintendent shall verbally advise the Operations Team
Section Head of the action taken and record the removal of the lockout
device in the Operations Team log book. He will then document the
incident in a written memo to the Operations Team Section Head with a
copy to Unit Deputy Section Head, stating why the lockout device was
removed, the original purpose of the lockout device, and employees
involved.

8 PAD LOCK COLOR CODING

8.1 To provide a standard procedure for the isolation of equipment and
systems from all sources of energy prior to servicing, to reduce the
possibility of accidental injury or damage due to the equipment or
systems being energized while individuals are present or prior to the
maintenance or construction being completed.

8.2 Each individual is responsible for their own, and other's safety. All
individuals who normally work on electrical, mechanical or piping
equipment and systems, will be issued a color coded lock, with their unit
organization code and lock serial number stamped on it.
8.3 Each lock will be keyed individually, there will be no "master" key, and
individuals will be responsible for their assigned lock.

8.4 Color codes are as follows;

8.4.1 Operations Team Department & Utility Department (Tank Farm/

Offsite): Yellow.
8.4.2 Maintenance Department: Blue.
8.4.3 Machinist: Blue with White Band.
8.4.4 Instrument: Blue with Yellow Band.
8.4.5 Electrician: Blue with Red Band.
8.4.6 Electrical System Operator: Red.
8.4.7 Contractors: Green.

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9 ATTACHMENTS

ATTACHMENT 1: UNIT LOCKOUT LOG BOOK

ATTACHMENT 2: LOCK/ HOLD TAG

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 ATTACHMENT 1: UNIT LOCKOUT LOG BOOK

Note: This is a recommended example for each unit's logbook.

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ATTACHMENT 2: LOCK/ HOLD TAG

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