Lockout/Tagout (LOTO) Safe Work Procedure

Document Number: [SWP-NUMBER]

Revision Date: [DATE]

Next Review Date: [NEXT REVIEW DATE]

Department: [DEPARTMENT NAME]

1. Scope

This safe work procedure outlines the requirements for lockout/tagout (LOTO) to ensure machinery and equipment are properly isolated and de-energized, preventing hazardous energy release and complying with safety regulations.

2. Definitions

Authorized Employee A person who has been properly trained to perform lockout/tagout procedures on machinery or equipment that is to be serviced. [7]

Affected Employee A person who operates the machinery or equipment, but does not perform the lockout procedures, or a person who works in the area where machine or equipment maintenance is being done. [7]

Hazardous Energy Any energy source that, if not isolated or controlled, could create a hazard. Common energy sources are electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other sources in machines and equipment that can be hazardous to workers. [1]

Lockout Device A device that positively holds energy isolating devices or measures in a safe position to prevent the re-energizing of equipment. It can be a key or combination lock, or blank flanges in piping. It includes a tag or other notice that identifies the person authorized to remove the lock. [8] [8] [8]

Tagout Device Prominent warning devices securely fastened to energy-isolation devices to warn employees not to re-energize equipment being serviced. Tagout devices are easier to remove and provide employees with less protection than lockout devices. [6] [6]

3. Responsibilities

3.1 Supervisors

• Ensure all workers are trained and competent in LOTO procedures.
• Provide necessary LOTO equipment and devices.
• Enforce adherence to this safe work procedure.

3.2 Workers

• Follow all LOTO procedures as outlined in this document.
• Report any unsafe conditions or equipment to supervisors.
• Participate in LOTO training and refresher courses.

4. Potential Hazards and Risks

5. Personal Protective Equipment (PPE)

Proper PPE is essential for protecting workers during Lockout/Tagout procedures.

• Safety Glasses: To protect eyes from potential hazards during the lockout/tagout process.
• Gloves: Insulated gloves to protect from electrical hazards and general-purpose gloves to protect from cuts and abrasions.
• Safety Shoes: To protect feet from falling objects or electrical hazards.
• Hearing Protection: If working in noisy environments during the lockout/tagout process.

Inspect all PPE before each use. Replace any damaged or worn items immediately.

6. Equipment and Tools

Regular inspection and maintenance of tools and equipment are critical to ensuring safe and effective Lockout/Tagout procedures.

• Lockout Locks: Durable, standardized locks used to secure energy-isolating devices in the safe position. Each lock should have a unique key and be labeled with the authorized employee's name.
• Lockout Tags: Clearly visible tags attached to energy-isolating devices to warn employees not to re-energize equipment. Tags should include the authorized employee's name, date, and reason for the lockout. [6]
• Energy Isolation Devices: Devices used to physically isolate energy sources, such as circuit breakers, valves, and disconnect switches. These devices must be capable of being locked out.
• Voltage Tester: A device used to verify that electrical equipment is de-energized before starting work.

Inspect all LOTO devices before each use. Ensure that they are in good working condition and that tags are legible. Remove any damaged or defective devices from service.

7. Pre-Job Requirements

7.1 Training and Competency

Training and Competency: All authorized employees must receive comprehensive training on LOTO procedures, including the identification of hazardous energy sources, the use of LOTO devices, and the verification of energy isolation. Refresher training should be provided periodically. [1] [6]

7.2 Pre-Job Briefing

Pre-Job Briefing: Conduct a pre-job briefing with all involved employees to discuss the LOTO procedure, potential hazards, and control measures. Ensure that everyone understands their roles and responsibilities.

7.3 Work Area Preparation

Work Area Preparation: Ensure that the work area is clear of obstructions and hazards. Provide adequate lighting and ventilation.

8. Safe Work Procedure Steps

1. Preparation: Identify all energy sources and potential hazards. Inform all affected employees about the planned lockout/tagout. [2]
2. Shutdown: Turn off or shut down the equipment using normal operating procedures. [2]
3. Isolation: Disconnect or isolate the equipment from all energy sources. This may involve shutting off circuit breakers, closing valves, or disconnecting equipment from power sources. [2]
4. Lockout/Tagout Application: Apply lockout devices to all energy-isolating devices. Attach tags to the lockout devices, indicating the authorized employee's name, date, and reason for the lockout. [2]
5. Stored Energy Check: Relieve, disconnect, restrain, or otherwise render safe all potential hazardous stored or residual energy. This may involve grounding electrical circuits, bleeding hydraulic or pneumatic systems, and releasing spring tension. [2]
6. Isolation Verification: Verify that the equipment is completely de-energized and isolated. This may involve testing circuits with a voltage tester, checking pressure gauges, and visually inspecting equipment. [2]
7. Periodic Verification: If the servicing or maintenance is extended, regularly verify that stored energy has not reaccumulated to hazardous levels. [5]
8. Removal of Lockout/Tagout Devices: Before removing lockout/tagout devices, inspect the equipment to ensure that all tools and materials have been removed and that all components are in place. Notify all affected employees that the equipment is about to be re-energized.
9. Re-energizing Equipment: Remove lockout/tagout devices and re-energize the equipment. Follow normal startup procedures.
10. Notification: Notify all affected employees that the equipment has been re-energized and is ready for use.

9. Precautions and Safety Measures

• Always follow the specific LOTO procedures for the equipment being serviced.
• Never attempt to operate equipment that is locked out or tagged out.
• Report any damaged or malfunctioning LOTO equipment immediately.
• Ensure that all employees are properly trained in LOTO procedures. [1]
• Verify the isolation of energy sources before starting any work.

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency during LOTO, immediately stop work and assess the situation. Evacuate the area if necessary. Contact emergency services if required.

10.2 Specific Emergency Scenarios

• Equipment starts up unexpectedly: Immediately shut down the equipment if possible. Evacuate the area and report the incident to a supervisor.
• Employee injured during LOTO: Provide first aid and call for medical assistance. Secure the area and investigate the incident.

11. Incident Reporting and Investigation

All incidents, near misses, and hazards related to LOTO must be reported to a supervisor immediately. The report should include a detailed description of the event, the equipment involved, and any injuries sustained.

All reported incidents will be investigated to determine the root cause and prevent recurrence. The investigation will involve interviewing employees, reviewing procedures, and inspecting equipment.

Approved by: [NAME AND POSITION]

Date: [APPROVAL DATE]

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