XXX / WHS ISOLATION, LOCK OUT, TAG OUT PROCEDURE / Version No: / 1.0
Issued: / XXX
Next Review: / XXX

1.Overview

1.1.XXX,as part of its commitment under its Hazardous Work Policy, recognises its obligation to ensure that, as far as is reasonably practicablefixtures, fittings and plant are without risks to the health and safety (WHS) of workers and risks associated with plant are managed and controlled.

1.2.This procedure aims to facilitate legislative compliance by:

1.2.1.Managing hazardsand risks associated with plant and eliminating or minimising risksthrough isolation, lock out and tag out.

1.2.2.Providing a system for the use of lockout or isolation devices, danger tags, permit to work systems and other control measures.

1.2.3.Outlining the minimum standards to prevent unauthorised alterations to, or interference with, plant.

1.2.4.Outlining the minimum standards to ensure plant that is not in use it is left in a state that does not create a WHS risk to others.

1.2.5.Outlining the minimum standards for information and training.

2.Core components

2.1.The core components of our isolation lock out and tag out procedureare:

2.1.1.Energy and hazard sources are identified.

2.1.2.To ensure the completion of risk assessments/Job Safety Analyses (JSAs) related to the maintenance and activity cycle for work requiring isolation, lock out and tag out.

2.1.3.The identification and implementation of controls where it is not reasonably practicable to eliminate risk.

2.1.4.To ensure workers have been trained in the isolation lock out and tag out procedure.

2.1.5.That monitoring and inspection processes have been identified and are regularly scheduled and conducted.

2.1.6.To ensure corrective actions are identified and implemented.

2.1.7.Records are maintained and available.

3.Definitions

Refer to the Definitions list.

4.Procedure

4.1.Introduction

4.1.1.The purpose of this procedure is to ensure all energy sources related to plant are made safe so that unexpected start-up, energisation, or the release of stored energy that could cause injury does not occur.

4.1.2.Management should ensure operator controls associated with plant under their control are:

  1. Identified on the plant to indicate their nature, function and direction of operation;
  2. Located so as to be readily and easily operated by workers;
  3. Located or guarded to prevent unintentional activation; and
  4. Able to be locked into the "off" position to enable the disconnection of all power.

4.1.3.When isolation of plant is required, this procedure should be read in conjunction with the Safe Work Instruction (SWI) for the task and any risk assessments.

4.1.4.If access to any item of plant is required for the purpose of maintenance, cleaning or repair the plant should be stopped and one or more of the following controls used:

  1. The use of tags, i.e. out of service tag and/or personal danger tag.
  2. Lockout or isolation devices, i.e.personal lock and danger tag.
  3. Permit to work systems.

4.1.5.Management should notify workers about the schedule and duration of isolation, prior to plant maintenance, cleaning or repairworks commencing.

4.1.6.If it is not reasonably practicable to carry out cleaning or maintenance while the plant is stopped, operational controls that permit controlled movement of the plant should be fitted and safe systems of work used, e.g. controlled access, buddy systems and higher levels of supervision.

4.1.7.Managersshallensure an adequate supply of out of service tags, danger tags, personal locks, isolating devices and any other equipment required by this procedure.

4.1.8.Management shall identify an authorized person to control permits and coordinate and oversee the isolation, lock out and tag out process.

4.2.Hazard identification and risk assessment

4.2.1.Management shall ensure risk assessments/JSAs that include isolation requirements are to be completed for plant prior to use or maintenance activities. The risk assessment /JSA process should:

a.Be done in consultation with the following people, a competent person to lead the risk assessment/ JSA process,workers who are to undertake the activity, a worker representative, a manager and other stakeholders or experts, where relevant.

b.Cover the entire activity from preparation to work until return to service.

c.Identify all hazardous energy sources that may potentially re-activate the plant, such as:

  1. Electrical, mains, solar and by generator.
  2. Mechanical.
  3. Hydraulic.
  4. Pneumatic.
  5. Potential energy, stored or kinetic.
  6. Gravitational.
  7. Radiation.
  8. Battery or capacitor banks.
  9. Solar panels.
  10. Fuels.
  11. Heat.
  12. Steam.
  13. Fluids or gases under pressure, i.e. water, air, steam or hydraulic oil.

d.Identify all plant isolation points:

  1. Manufacturers, suppliers, designers or importers instructions should be referenced during the hazard identification and risk assessment process.
  • If original diagrams of plant installations are not available, new information, e.g. diagrams, photographs etc, should be sourced or developed by a competent person showing isolation points, switches, valves, energy lines, pipes, power sources and control points.
  1. Emergency stop buttons, lanyards and similar stop devices should not be relied uponon their own as isolation devices,as they will not necessarily achieve isolation.
  • If plant is designed to be operated or attended by more than oneworker and more than one emergency stop control is fitted, managementshould ensure that the multiple emergency stop controls are of the "stop and lock-off" type so that plant cannot be restarted after an emergency stop control has been used unless that emergency stop control is reset.

e.Identify all reasonably foreseeable hazards associated with the task, such as:

  1. Associated equipment that may need to be isolated or locked out to prevent re-activation.
  2. Hazardous substances, such as gases, acids, alkalis, solvents, glues or pooled liquids.
  3. Falls.
  4. Burns.
  5. Asphyxiation.
  6. Impact.

f.Identify other permits that may be required for the work to be carried out, e.g. hot work and/or confined space entry. The authorised person shall ensure all permits are issued as required.

4.3.Risk Control

4.3.1.Risks should be eliminated in so far as is reasonably practicable. However, where risks cannot be reasonably eliminated controls must be selected in accordance with the Hierarchy of Control and documented in the risk assessment/JSA.

4.3.2.The risk assessment/JSA process may require a safe work instruction (SWI) to be developed which should include the:

  1. Isolation procedure is to be implemented.
  2. Shut down sequence for the plant/machinery/equipment.
  3. Isolation means and sequence for the isolation of energy sources.
  4. Lock out sequence for isolation points.
  5. Tags to be applied to machinery controls, energy sources and other hazards.
  6. Checks and tests to be performed prior to the commencement of work.
  7. Positions and competencies of persons authorised to perform work and issue permits.

4.3.1.The controls developed from the risk assessment/JSA should be in place before work commences.

4.3.2.Each person involved in the job should sign their acknowledgement of the risk assessment/JSA and controls prior to commencing work.

4.4.Out of service tags

4.4.1.If an item of plant is identified as being unsafe and requires removal from service an out of service tag should be completed and attached to the plant. An incident or Hazard Report form may also require completion.

4.4.2.The tag should be placed in a prominent position on the plant and should be clearly visible from the position where plant is be started and secured so it cannot be easily dislodged.

4.4.3.Out of service tags should not be relied upon to provide personal protection and are only to be used as a means of providing information to others at the workplace.

4.4.4.The worker who tagged out the item shouldensure their manager and those who use the plant are aware it has been removed from service as soon as possible.

4.4.5.Out of service plant should be moved from the usual work environment to one of restricted access and/or quarantined, whenever possible.

4.4.6.Only an authorised person may remove the out of service tag oncethe item of plant is fit for use or disposal occurs.

4.5.Isolation, lock out, tag out

4.5.1.Workers carrying out plant maintenance, cleaning or repair should:

  1. Shut the plant down in accordance with the risk assessment/JSA or SWI.
  2. Restrict access to the area while the task is being carried out.
  3. Obtain a permit to work, when required.

4.5.2.Identify and isolate all energy sources other hazards and isolation points:

  1. The isolation of all energy sources and other hazards shall be coordinated withthose involved in the task.
  2. The isolating device should be suitable for the specific type of isolation required:
  1. This may include switches with built in locks, lock out circuit breakers, fuses and valves, chains, hasps and safety padlocks
  2. For some plant, isolation may only require removal of the power cord from the electricity supply, removal of the keys from the ignition of a vehicle or removal of air hoses and the tag placed over the power source. This is allowable as the only form of isolation if the risk assessment /JSA permitsit, e.g. if the repairer is in total control of the plant and the work environment and the plant cannot be restarted by any other means or person.
  3. In the case of equipment connected via a plug and socket, an electrician should isolate and disconnect the electricity supply to an item of electrical plant, not just the control circuit, so that equipment cannot be inadvertently energized via another source or control system.

4.5.3.De-energise or control all stored energies

  1. A competent person shouldtake steps necessary to guard against energy left in plant after it has been isolated, such as:
  2. Inspecting plant to ensure all parts have stopped moving.
  3. Installing ground wires.
  4. Relieving trapped pressure.
  5. Releasing tension on springs, or blocking the movement of spring-driven parts.
  6. Blocking or bracing parts that could fall because of gravity.
  7. Blocking parts in hydraulic and pneumatic systems that could move from a loss of pressure.
  8. Bleeding lines and leaving vent valves open.
  9. Drainingprocess piping systems and closing valves to prevent the flow of hazardous material.
  10. If a line should be blocked where there is no valve, use a blank flange.
  11. Purging reactor tanks and process lines.
  12. Dissipating extreme cold or heatand/or providing protective clothing and/or equipment.
  13. If stored energy can re-accumulate ensure monitoring occurs to maintain below hazardous levels.
  14. Plant should be tested, e.g. by activating and deactivating controls, to confirm no stored energy is present and that plant is not likely to activate or move.

4.5.4.Lock out all isolation pointsand tag out machinery controls, energy sources and other hazards.

a.One worker, one lock:

  1. If more than one worker is working on the same plant each workershould attach their individual lock to prevent the isolator being activated.
  2. If two or more worker are working on plant that is isolated through several lockout points each workershould attach a lock and tag to each lockout point or a lock box should be used.

b.One lock, one key:

  1. Each worker working on isolated plant should attach their own lock, key and tag. There should be no duplicate key available for any lock, except a master or duplicate for use in an emergency that is secured and not readily available.
  2. During maintenance, cleaning or repair of plant one key to each worker’s lock should be held by only that worker.

c.Multiple energy sources:

  1. If more than one energy source or hazard has to be locked out to enable safe shutdown of the plant, each energy source should be locked out by each worker working on the plant, via the use of multi-lock hasps etc. Otherwise, each energy source should be locked out by a single lock, with the key to each lock being placed in a lock out box and that lock out box secured by a multi-lock hasp and a personal lock for each worker working on the plant.

d.Apersonal danger tagshould be attached to an isolator in a visible position whenever the isolator is used to lock out an energy source. It should accompany each lock used in the isolation process and show the name of the worker who put the tag and lock in place, the time and date this occurred and the item of plant being isolated.

  1. Out of service and personal danger tags should not be used together. An out of service tag should be removed when a personal danger tag is added and, vice versa.

e.Each worker working on isolated plant should fasten their personal danger tag on all lockout devices.

4.5.5.Testing isolation devices

  1. Acompetent person should test all isolated energy sources first and then attempt to activate the plant before any person attempts to start work.
  2. Work must not begin until tests have confirmed it is safe to do so.

4.5.6.Repairs and maintenance

  1. As each worker completes their task they should remove their personal lock(s) anddanger tag(s). No person should remove another person’s personal danger tag.
  2. If work is not completed by the end of a shift, and the plant is required to remain isolated, arrangements should be made forout of service tagsto be placed on each isolating point before personal danger tags are removed.
  3. If work on the plant is to continue during the next shift there should be a hand over by the shift leaving the site to those taking over. The hand over should include the status of the work and the removal and replacement ofindividual danger tagsand locks.
  4. Any guarding that may have been removed should be replaced and secured before energy is restored.
  5. When work is complete and all locks and tags have been removed, the authorised personshouldensure all workers are clear of the plant before energy is restored and the machine is returned to service.
  6. The authorised personshould notify those responsible for the plant that work has been completed and the plant has been restored to an operational condition.

4.5.7.Failure to remove locks and tags

  1. Where a worker has failed to remove a personal lock and danger tag the authorised person can request the person to return to the worksite and remove the lock and tag so the plant can be returned to normal operation.
  2. If the authorised person is unable tocontactthe owner of the potentially redundant lock and tag, they should contact management and where available, a HSR, and:
  3. Determine the method of isolation in use and the reason for its implementation.
  4. Undertake a risk assessment relating to the removal of the isolation device(s).
  5. Remove the lock and tag and re-energise the plant or equipment, if safe to do so, otherwise keep the plant tagged as out of service.
  6. Monitor and review the operational safety of the plant once re-energised.
  7. An incident report should be completed and contain a full record of the above activities, including the name the worker who did not remove their lock and tag.

4.5.8.Isolation not practical

  1. There may be plant that can only be cleaned, maintained or repaired by moving components slowly under power. If the need for plant to be operated during cleaning or maintenance cannot be eliminated:
  1. The plant should be fitted with controls that allow safe controlled movement.
  2. The operational controls must not be able to be operated by anyone other than the worker carrying out the maintenance or cleaning or, if it must be operated by someone else, that worker must be authorised to operate the plant for that purpose.
  3. The operational controls must allow the operation of the plant in such a way that any risk associated with the activities of those carrying out maintenance or cleaning are eliminated so far as is reasonably practicable, or minimized.
  4. A risk assessment for the task shall be undertaken by a competent person in consultation with workers.
  5. SWIsshould be developed and implemented.

4.7.Monitoring and evaluation

4.10.1.Managers should review and revise any existing risk control measures related to isolation, lock out and tag out procedures:

a.When the control measures do not minimise the risk so far as is reasonably practicable.

b.Before a change at the workplace that is likely to give rise to a new or different WHS risk that the control measure may not effectively control.

c.If a new hazard or risk is identified.

d.If the results of consultation indicate that a review is necessary.

4.10.2.Managers should monitor isolation, lock out and tag out processes by:

  1. Periodically inspecting:
  1. Isolation, lock out and tag out documentation, i.e. risk assessments and tags, to ensure proper completion.
  2. Isolation work to check compliance with documented procedures.
  1. Checking that training and competency requirements are maintained.

4.10.3.Management should:

a.Review hazard and incident statistics, audit results, legislative changes and other information relating to the isolation, lock out and tag out procedure and direct action when required. Minutes shall record outcomes of discussions and actions undertaken.