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 precautions necessary for the safe lockout and tagout of equipment and energy sources during maintenance, repair, or servicing activities. It applies to all employees, contractors, and visitors who may be required to perform work on equipment that requires lockout/tagout to prevent unexpected energization or startup, or release of stored energy, that could cause injury.

2. Definitions

Lockout: The placement of a lockout device on an energy-isolating device, in accordance with an established procedure, ensuring that the energy-isolating device and 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, in accordance with an established procedure, to indicate that the energy-isolating device and the equipment being controlled may not be operated until the tagout device is removed [1].

Energy Isolating Device: A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following: a manually operated electrical circuit breaker; a disconnect switch; a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors and, in addition, no pole can be operated independently; a line valve; a block; and any similar device used to block or isolate energy [1].

3. Responsibilities

3.1 Supervisors

Ensure that all workers are properly trained and competent in lockout/tagout procedures.
Provide the necessary lockout/tagout equipment and ensure it is properly maintained.
Enforce the requirements of this SWP and address any deviations or unsafe practices.

3.2 Workers

Follow the steps outlined in this SWP when performing lockout/tagout activities.
Inspect and verify the proper functioning of lockout/tagout equipment before use.
Report any hazards or unsafe conditions to the supervisor immediately.

3.3 Health and Safety Representative

Assist in the development and review of this SWP.
Provide guidance and support to supervisors and workers on lockout/tagout procedures.
Investigate incidents or near-misses related to lockout/tagout and recommend corrective actions.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Unexpected energization or startup of equipment	Electrocution, crushing, amputation, or other serious injuries	Implement proper lockout/tagout procedures to isolate energy sources and prevent accidental activation.
Release of stored energy (e.g., electrical, pneumatic, hydraulic, or mechanical)	Burns, crushing, or other serious injuries	Identify and control all sources of stored energy before starting work.
Failure to properly identify and isolate all energy sources	Incomplete isolation of equipment, leading to potential hazards	Conduct a thorough hazard assessment to identify all energy sources and ensure they are properly isolated.
Use of incorrect or damaged lockout/tagout equipment	Failure of lockout/tagout system, leading to potential hazards	Inspect and maintain lockout/tagout equipment regularly. Replace any damaged or defective equipment.
Inadequate training or competency of workers	Improper lockout/tagout procedures, leading to potential hazards	Provide comprehensive training to all workers on lockout/tagout procedures and ensure they are competent to perform the task safely.
Removal of lockout/tagout devices by unauthorized personnel	Unexpected energization or startup of equipment, leading to potential hazards	Implement strict controls to prevent unauthorized removal of lockout/tagout devices.

5. Personal Protective Equipment (PPE)

Always use the appropriate PPE for the task and environment. At a minimum, the following PPE is required:

Safety glasses with side shields - To protect eyes from potential splashes or debris.
Gloves - Wear chemical resistant, impermeable gloves [2] to prevent skin contact.
Protective clothing - Use chemical resistant, impermeable clothing including gloves and either an apron or body suit to prevent skin contact [2].

Inspect all PPE before use and replace if damaged or defective.

6. Equipment and Tools

Lockout/tagout devices (locks, tags, hasps, etc.) - To secure energy-isolating devices in the safe position.
Energy source identification labels - To clearly identify the type and location of energy sources.
Voltage tester - To verify the absence of voltage on electrical equipment.
Hand tools (screwdrivers, pliers, wrenches, etc.) - To operate energy-isolating devices.

Inspect all equipment and tools before use and replace if damaged or defective.

7. Pre-Job Requirements

7.1 Training and Competency

All workers performing lockout/tagout activities must be trained and competent in the following areas:

Recognition of hazardous energy sources.
Types and magnitude of energy available in the workplace.
Methods for energy isolation and control.
Requirements of this SWP.

7.2 Pre-Job Briefing

Before starting any lockout/tagout activity, conduct a pre-job briefing to discuss the following:

Scope of the work to be performed.
Identification of all energy sources and their locations.
Step-by-step lockout/tagout procedure.
Potential hazards and control measures.
Emergency procedures.

7.3 Work Area Preparation

Ensure the work area is clear of obstructions and hazards.
Provide adequate lighting and ventilation.
Barricade the work area to prevent unauthorized access.

8. Safe Work Procedure Steps

Step 1: Preparation for Shutdown

Identify all energy sources that need to be controlled [1].
Notify all affected employees that a lockout/tagout system will be implemented and the reason therefore [1].

Step 2: Shutdown the Equipment

Use the normal shutdown procedure for the equipment [1].
Shut down the equipment in a safe and orderly manner [1].

Step 3: Isolation of the Equipment

Locate all energy-isolating devices for the equipment [1].
Operate the energy-isolating devices to isolate the equipment from the energy source [1].

Step 4: Lockout/Tagout Application

Apply lockout/tagout devices to each energy-isolating device [1].
Ensure that the lockout/tagout devices are securely attached and cannot be easily removed [1].

Step 5: Release Stored Energy

Dissipate or restrain all stored or residual energy [1].
This may include grounding electrical circuits, bleeding hydraulic or pneumatic lines, or releasing tension from springs [1].

Step 6: Verification of Isolation

Verify that the equipment is properly isolated from all energy sources [1].
Attempt to start the equipment to ensure it cannot be energized [1].
Use a voltage tester to verify the absence of voltage on electrical equipment [1].

Step 7: Performance of Work

Perform the necessary maintenance, repair, or servicing activities [1].

Step 8: Removal of Lockout/Tagout Devices

Inspect the work area to ensure all tools and materials have been removed [1].
Ensure that all employees are safely positioned or removed from the area [1].
Remove the lockout/tagout devices, one at a time, by the authorized employee who applied them [1].

Step 9: Notification and Equipment Start-up

Notify affected employees that the lockout/tagout system has been removed [1].
Restore energy to the equipment and start it up using normal operating procedures [1].

9. Precautions and Safety Measures

Never attempt to operate equipment that is locked out or tagged out [1].
Always verify the isolation of equipment before starting work [1].
Never remove a lockout/tagout device unless you are the authorized employee who applied it [1].
Report any damaged or defective lockout/tagout equipment to your supervisor immediately [1].
If the authorized employee who applied the lockout/tagout device is not available, follow the established procedure for removal of the device [1].

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, immediately stop work and evacuate the area.
Call for emergency assistance and provide details about the situation and location.
Do not attempt to handle the emergency unless you are trained and authorized to do so.

10.2 Specific Emergency Scenarios

Electrical Shock: De-energize the circuit if possible. If not, use a non-conductive object to separate the victim from the electrical source. Call for medical assistance immediately.
Release of Hazardous Materials: Evacuate the area and notify emergency responders. Avoid contact with the material and follow their instructions.
Fire: Activate the fire alarm and evacuate the building. Use a fire extinguisher only if you are trained and the fire is small and contained.

10.3 Emergency Contact Information

Emergency Services: 911
[Company Security]: [PHONE NUMBER]
[Health and Safety Department]: [PHONE NUMBER]

11. Incident Reporting and Investigation

All incidents, near-misses, and hazards related to lockout/tagout must be reported to the supervisor immediately.
The supervisor will investigate the incident and take corrective actions to prevent recurrence.
A written report of the incident and investigation findings will be submitted to the Health and Safety Department.

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