Lockout/Tagout (LOTO) Procedure

Document Number: [SWP-NUMBER]

Revision Date: [DATE]

Next Review Date: [NEXT REVIEW DATE]

Department: [DEPARTMENT NAME]

1. Scope

This Safe Work Procedure (SWP) outlines the minimum requirements for lockout/tagout (LOTO) procedures to prevent accidental startup or release of stored energy during maintenance or servicing of equipment and machinery. It applies to all employees, contractors, and visitors who may be exposed to hazardous energy.

2. Definitions

Lockout/Tagout (LOTO) A planned sequence of actions to isolate energy sources and prevent the release of hazardous energy. Lockout Device A device that physically prevents the operation of a piece of equipment (e.g., a padlock). Tagout Device A warning device attached to an energy-isolating device to indicate that the equipment is not to be operated until the tag is removed. Hazardous Energy Any source of energy that could cause harm to personnel, including electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and gravitational. Energy Isolation The process of removing all potential energy from a system, such as releasing pressure from a pneumatic system or allowing a spring to decompress.

3. Responsibilities

3.1 Supervisors

Ensure all workers are trained and competent in lockout/tagout procedures.
Provide necessary lockout/tagout equipment and ensure it is maintained in good working order.
Enforce the lockout/tagout procedure and ensure compliance by all workers.
Verify that all energy sources are isolated and locked out before work begins.
Conduct regular audits of lockout/tagout procedures to identify and correct any deficiencies.

3.2 Workers

Follow the lockout/tagout procedure at all times.
Attend required training and demonstrate competency in lockout/tagout procedures.
Inspect lockout/tagout devices before each use.
Report any hazards or unsafe conditions to the supervisor.
Never remove a lockout/tagout device unless authorized to do so.

3.3 Health and Safety Representative

Participate in the development and review of the lockout/tagout program.
Assist in investigating incidents related to lockout/tagout.
Promote awareness of lockout/tagout procedures among workers.
Monitor the effectiveness of the lockout/tagout program.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Accidental machine startup	Serious injury or death	Ensure proper training and competency. Use appropriate lockout/tagout devices. Verify energy isolation before starting work.
Defective lockout/tagout devices	Failure of energy isolation, leading to injury	Inspect lockout/tagout devices regularly. Replace damaged or worn devices immediately.
Inadequate lockout/tagout procedures	Incorrect energy isolation, leading to injury	Develop and follow a written lockout/tagout procedure. Ensure all steps are clearly defined and understood.
Failure to identify all energy sources	Uncontrolled release of energy, leading to injury	Identify all potential energy sources. Verify that all energy sources are isolated and locked out.
Lack of communication	Accidental startup due to misunderstanding or lack of awareness	Communicate clearly with all personnel involved. Ensure everyone understands the lockout/tagout procedure and their role in it.
Exposure to hazardous materials or conditions during maintenance	Injury due to contact with hazardous substances or conditions	Use appropriate PPE, such as safety glasses, gloves, and hearing protection.
Poor working conditions	Slips, trips, falls, or other injuries	Ensure proper lighting and ventilation. Use appropriate tools and equipment for the task.

5. Personal Protective Equipment (PPE)

Safety Glasses: ANSI-approved safety glasses with side shields protect eyes from debris and splashes.
Gloves: Gloves appropriate for the task protect hands from cuts, abrasions, and chemical exposure.
Steel-Toed Boots: Steel-toed boots protect feet from impact and compression hazards.
Hearing Protection: Hearing protection (earplugs or earmuffs) reduces the risk of hearing damage in noisy environments.

6. Equipment and Tools

Lockout Devices: Lockout devices (padlocks, hasps, etc.) are used to secure energy-isolating devices in the safe position.
Tagout Devices: Tagout devices (tags, labels) are used to warn others not to operate the equipment.
Energy-Isolating Devices: Energy-isolating devices (circuit breakers, valves, etc.) are used to disconnect equipment from energy sources.
Voltage Tester: Voltage tester to verify electrical isolation.

8. Safe Work Procedure Steps

Notification: Notify all affected personnel that a lockout/tagout is going to be performed and the reason for it.
Identify Energy Sources: Identify all energy sources that need to be isolated and the appropriate energy-isolating devices.
Equipment Shutdown: Shut down the equipment using normal operating procedures.
Energy Isolation: Isolate all energy sources by operating the energy-isolating devices (e.g., circuit breakers, valves).
Lockout/Tagout Device Application: Apply lockout/tagout devices to each energy-isolating device. Ensure that the devices are properly secured and cannot be easily removed.
Stored Energy Dissipation: Dissipate or restrain any stored or residual energy (e.g., release pressure from pneumatic systems, discharge capacitors).
Verification of Isolation: Verify that the equipment is completely de-energized by testing the equipment. Use appropriate testing equipment (e.g., voltage tester) to ensure that no energy is present.
Maintenance/Servicing: Perform the necessary maintenance or servicing work.
Remove Tools and Equipment: Remove all tools and equipment from the work area.
Equipment Inspection: Inspect the equipment to ensure that all components are reassembled correctly and that there are no loose parts or other hazards.
Lockout/Tagout Device Removal: Remove lockout/tagout devices, ensuring that each device is removed only by the worker who applied it.
Notification of Restart: Notify affected personnel that the lockout/tagout has been removed and that the equipment is ready to be restarted.

9. Precautions and Safety Measures

Never attempt to operate equipment that is locked out or tagged out.
Always verify that the equipment is de-energized before starting work.
Use only approved lockout/tagout devices.
Ensure that all workers are properly trained in lockout/tagout procedures.
Regularly inspect lockout/tagout devices for damage or wear.

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, immediately stop work and evacuate the area. Contact emergency services and provide them with the location and nature of the emergency. Do not attempt to restart the equipment until the emergency has been resolved and the equipment has been properly inspected.

10.2 Specific Emergency Scenarios

Fire: Evacuate the area immediately. Contact emergency services and provide them with the location and nature of the fire. Do not attempt to extinguish the fire unless you are trained and equipped to do so.
Injury: Provide first aid and contact emergency services if necessary. Investigate the cause of the injury and take steps to prevent recurrence.
Hazardous Material Spill: Evacuate the area immediately. Contact emergency services and provide them with the location and nature of the spill. Do not attempt to clean up the spill unless you are trained and equipped to do so.

11. Incident Reporting and Investigation

All incidents, including near misses, must be reported to the supervisor immediately. The supervisor will then complete an incident report and submit it to the safety department.

The safety department will investigate all incidents to determine the root cause and identify corrective actions. The investigation will involve interviewing witnesses, reviewing documentation, and inspecting the work area.

Approved by: [NAME AND POSITION]

Date: [APPROVAL DATE]