Safe Work Procedure: Lockout Tagout

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 steps and safety precautions to be followed when performing Lockout Tagout (LOTO) procedures. It applies to all employees, contractors, and visitors who may be required to perform maintenance, repair, or service on equipment and machinery where unexpected energization or start-up could occur and cause injury.]

[This procedure applies to all areas where machinery and equipment require LOTO, including but not limited to production floors, maintenance shops, and construction sites.]

[This SWP should be used in conjunction with the site's overall LOTO program and any equipment-specific LOTO procedures.]

2. Definitions

Lockout The placement of a lockout device on an energy-isolating device, following an established procedure, ensuring that the equipment being controlled cannot be operated until the lockout device is removed [1].

Tagout The placement of a tagout device on an energy-isolating device, following an established procedure, to warn that the equipment being controlled cannot be operated until the tagout device is removed [1].

Energy Isolating Device A mechanical device that physically prevents the transmission or release of energy, such as a circuit breaker, disconnect switch, or valve [1].

3. Responsibilities

3.1 Supervisors

[Ensure that all workers are properly trained and competent in LOTO procedures.]
[Provide the necessary LOTO equipment and ensure it is maintained in good working order.]
[Enforce compliance with this SWP and the site's overall LOTO program.]

3.2 Workers

[Follow the steps outlined in this SWP when performing LOTO.]
[Inspect LOTO equipment before use and report any defects to the supervisor.]
[Participate in LOTO training and refresher courses.]

3.3 Health and Safety Representative

[Assist in the development and review of the site's LOTO program and this SWP.]
[Conduct regular audits to ensure compliance with LOTO procedures.]
[Investigate incidents related to LOTO and recommend corrective actions.]

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Unexpected energization or start-up	Electrocution, crushing, amputation	Verify isolation of energy sources, use proper LOTO devices, follow established procedures
Failure to properly identify energy sources	Exposure to hazardous energy	Conduct thorough hazard assessment, review equipment-specific LOTO procedures
Use of incorrect LOTO devices	Ineffective energy isolation	Use only approved LOTO devices, inspect devices before use
Premature removal of LOTO devices	Unexpected start-up, injury	Ensure proper communication and coordination, verify equipment is safe to operate before removing devices
Release of hazardous materials during maintenance	Exposure to chemicals, burns	Identify hazardous materials, use appropriate PPE, follow safe handling procedures

5. Personal Protective Equipment (PPE)

[The proper use of personal protective equipment (PPE) is essential to minimize the risk of injury during LOTO procedures.]

[Safety glasses] - [To protect eyes from potential splashes or debris.]
[Gloves] - [To protect hands from electrical hazards, chemicals, or sharp objects.]
[Safety shoes] - [To protect feet from falling objects or electrical hazards.]
[Hearing protection] - [To protect hearing in noisy environments.]
[Appropriate clothing] - [To protect skin from chemicals or other hazards.]

[Inspect PPE before each use for damage or defects. Replace damaged PPE immediately. Clean and store PPE properly after use.]

6. Equipment and Tools

[Using the correct equipment and tools is crucial for performing LOTO safely and effectively.]

[Lockout devices] - [To physically prevent the operation of energy-isolating devices.]
[Tagout devices] - [To warn against the operation of energy-isolating devices.]
[Lockout hasps] - [To allow multiple workers to lock out a single energy-isolating device.]
[Circuit breaker lockout devices] - [To lock out electrical circuit breakers.]
[Valve lockout devices] - [To lock out valves controlling the flow of liquids or gases.]

[Inspect all equipment and tools before each use for damage or defects. Replace damaged equipment immediately. Use equipment only for its intended purpose.]

7. Pre-Job Requirements

7.1 Training and Competency

[All workers performing LOTO must be properly trained and competent in the following areas:]

[Hazard recognition and assessment]
[LOTO procedures]
[Use of LOTO devices]
[Equipment-specific LOTO procedures]

7.2 Pre-Job Briefing

[Before beginning any LOTO procedure, conduct a pre-job briefing to discuss the following:]

[Scope of the work]
[Potential hazards]
[LOTO procedures]
[Individual responsibilities]
[Emergency procedures]

7.3 Work Area Preparation

[Before beginning any LOTO procedure, prepare the work area by:]

[Identifying all energy sources]
[Notifying affected personnel]
[Shutting down equipment properly]
[Positioning equipment to minimize hazards]

8. Safe Work Procedure Steps

Step 1: Preparation for Shutdown

[Identify all energy sources that need to be isolated and controlled. This includes electrical, mechanical, hydraulic, pneumatic, thermal, and other energy sources.]

[Consult equipment-specific LOTO procedures.]
[Identify the types and magnitudes of energy involved.]
[Plan the sequence of steps for shutting down and isolating the equipment.]

[Ensure that all affected employees are notified of the impending shutdown.]

Step 2: Shutdown the Equipment

[Follow the normal shutdown procedure for the equipment to avoid any additional hazards.]

[Turn off all switches and controls.]
[Allow moving parts to come to a complete stop.]
[Close valves and disconnect any connections.]

[If the normal shutdown procedure does not de-energize the equipment, use an emergency shutdown procedure.]

Step 3: Isolate the Equipment from Energy Sources

[Locate and operate all energy-isolating devices to cut off the energy supply to the equipment.]

[Open circuit breakers and disconnect switches.]
[Close and lock valves.]
[Block or disconnect mechanical linkages.]

[Ensure that all energy-isolating devices are in the OFF or SAFE position.]

Step 4: Apply Lockout/Tagout Devices

[Attach LOTO devices to each energy-isolating device to prevent accidental re-energization.]

[Attach a lockout device to each energy-isolating device.]
[Affix a tagout device to each lockout device.]
[Ensure that each tagout device includes the name of the worker applying the LOTO and the date.]

[If a lockout device cannot be attached, use a tagout device only. The tagout device must be placed at the same location where the lockout device would have been attached.]

Step 5: Verify the Isolation

[Test the equipment to ensure that all energy sources have been effectively isolated.]

[Check that all moving parts are stopped.]
[Test electrical circuits with a voltage tester.]
[Verify that pressure gauges read zero.]

[If any energy is still present, repeat steps 3 and 4 until the equipment is completely de-energized.]

Step 6: Perform Maintenance or Service

[Once the equipment is de-energized and verified, perform the necessary maintenance or service.]

[Follow all safety procedures for the specific task being performed.]
[Use appropriate tools and equipment.]
[Be aware of any potential hazards.]

[If the maintenance or service requires the temporary removal of LOTO devices, follow the procedures for temporary removal and reapplication of LOTO.]

Step 7: Remove Lockout/Tagout Devices

[After the maintenance or service is complete, remove the LOTO devices in a safe and orderly manner.]

[Inspect the equipment to ensure that all tools and materials have been removed.]
[Notify affected employees that the equipment is about to be re-energized.]
[Remove the LOTO devices, one at a time, ensuring that no one is in a hazardous position.]

[Each worker must remove their own LOTO devices. LOTO devices must not be removed by anyone other than the worker who applied them.]

Step 8: Re-energize the Equipment

[Follow the normal start-up procedure for the equipment.]

[Turn on all switches and controls.]
[Monitor the equipment for proper operation.]
[Report any problems to the supervisor.]

[If the equipment does not start up properly, shut it down immediately and repeat the LOTO procedure.]

9. Precautions and Safety Measures

[Never attempt to operate equipment that is locked out or tagged out.] - [Operating locked out equipment could result in serious injury or death.]
[Always follow the established LOTO procedures.] - [Following procedures ensures consistent and safe energy isolation.]
[Use only approved LOTO devices.] - [Using unapproved devices may lead to LOTO failure.]
[Inspect LOTO devices before each use.] - [Inspecting devices ensures they are in good working condition.]
[Communicate with all affected personnel before and after LOTO.] - [Communication prevents misunderstandings and potential hazards.]

10. Emergency Procedures

10.1 General Emergency Response

[In the event of an emergency, follow these general procedures:]

[Assess the situation and ensure your own safety.]
[Activate the emergency alarm system.]
[Evacuate the area, if necessary.]
[Provide first aid to injured personnel.]
[Contact emergency services.]

10.2 Specific Emergency Scenarios

[Unexpected start-up] - [Immediately shut down the equipment and reapply LOTO.]
[Electrical shock] - [De-energize the circuit and provide first aid.]
[Release of hazardous materials] - [Evacuate the area and follow the site's emergency response plan.]

10.3 Emergency Contact Information

[List of emergency contacts and their phone numbers]

[Emergency Services: 911]
[Security: [PHONE NUMBER]]
[First Aid: [PHONE NUMBER]]

11. Incident Reporting and Investigation

[All incidents, near-misses, and hazards related to LOTO must be reported immediately to the supervisor.]

[The supervisor will investigate the incident and take corrective actions to prevent recurrence. The investigation will include:]

[Gathering information about the incident]
[Identifying the root cause of the incident]
[Developing and implementing corrective actions]
[Documenting the investigation and corrective actions]

Approved by: [NAME AND POSITION] Date: [APPROVAL DATE]