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 necessary steps and precautions for the effective 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 where unexpected energization or startup could cause injury. This procedure aims to prevent the accidental release of hazardous energy and ensure a safe working environment.

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 N/A.

Tagout: The placement of a tagout device on an energy-isolating device, following an established procedure, to indicate that the equipment being controlled cannot be operated until the tagout device is removed N/A.

Energy-Isolating Device: A mechanical device that physically prevents the transmission or release of energy, such as a circuit breaker, disconnect switch, valve, or blank flange N/A.

Authorized Employee: An employee who has been trained and authorized to perform lockout/tagout procedures N/A.

Affected Employee: An employee whose job requires them to operate or work in an area where lockout/tagout procedures are being used N/A.

3. Responsibilities

3.1 Supervisors

Ensure that all employees are properly trained on lockout/tagout procedures N/A.
Provide the necessary lockout/tagout devices and equipment N/A.
Enforce compliance with this SWP and all related safety policies N/A.
Conduct periodic inspections of lockout/tagout procedures to ensure effectiveness N/A.

3.2 Workers

Follow this SWP and all related safety policies N/A.
Participate in lockout/tagout training programs N/A.
Report any unsafe conditions or practices to their supervisor N/A.
Never attempt to operate equipment that is locked out or tagged out N/A.

3.3 Health and Safety Representative

Assist in the development and implementation of the lockout/tagout program N/A.
Provide guidance and support to supervisors and workers on lockout/tagout procedures N/A.
Investigate incidents related to lockout/tagout and recommend corrective actions N/A.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Unexpected energization or startup of equipment	Electrocution, crushing, cutting, amputation	Verify isolation of energy sources, use lockout/tagout devices, test equipment before starting work N/A
Release of stored energy (e.g., pressure, gravity, springs)	Injury from sudden movement or release of energy	Relieve or restrain stored energy before starting work, use appropriate tools and equipment N/A
Failure to properly identify and isolate energy sources	Exposure to hazardous energy, equipment damage	Conduct thorough hazard assessment, use energy source identification procedures, verify isolation N/A
Inadequate training or communication	Incorrect lockout/tagout procedures, increased risk of accidents	Provide comprehensive training, conduct pre-job briefings, use clear and concise communication N/A
Removal of lockout/tagout devices by unauthorized personnel	Unexpected startup of equipment, potential for serious injury	Enforce strict policy on device removal, provide training on the importance of lockout/tagout N/A

5. Personal Protective Equipment (PPE)

Always use the proper PPE for the job N/A.

Safety glasses with side shields - Protects eyes from potential splashes or debris N/A.
Chemical-resistant, impervious gloves - Should be worn at all times when handling chemical products if a risk assessment indicates this is necessary 2, 3, 4, 10, 13, 14, 20.
Protective clothing - Avoid all unnecessary exposure 6, 13.
Appropriate footwear - Should be selected based on the task being performed and the risks involved and should be approved by a specialist before handling this product 2, 10.

Inspect PPE before each use for damage or wear. Replace damaged PPE immediately N/A.

6. Equipment and Tools

Always use the proper equipment and tools for the job N/A.

Lockout devices (e.g., padlocks, circuit breaker locks, valve locks) - Used to secure energy-isolating devices in the safe position N/A.
Tagout devices (e.g., tags, labels) - Used to identify the equipment and the reason for lockout/tagout N/A.
Energy source identification labels - Used to clearly identify all energy sources associated with the equipment N/A.
Testing equipment (e.g., voltage testers, pressure gauges) - Used to verify the isolation of energy sources N/A.
Hand tools (e.g., screwdrivers, wrenches) - Used for removing or installing equipment components N/A.

Inspect equipment and tools before each use for damage or defects. Replace damaged equipment immediately N/A.

7. Pre-Job Requirements

7.1 Training and Competency

All authorized employees must receive comprehensive training on lockout/tagout procedures, including the recognition of hazardous energy sources, methods for energy isolation, and the proper use of lockout/tagout devices. Refresher training should be conducted periodically or whenever there are changes to the lockout/tagout program N/A.

7.2 Pre-Job Briefing

A pre-job briefing must be conducted before starting any work involving lockout/tagout. The briefing should cover the scope of the work, potential hazards, energy sources involved, isolation methods, lockout/tagout procedures, and emergency procedures. All authorized and affected employees must participate in the briefing N/A.

7.3 Work Area Preparation

Identify all energy sources associated with the equipment to be locked out/tagged out N/A.
Notify all affected employees that a lockout/tagout will be performed N/A.
Ensure that the equipment is properly shut down and de-energized N/A.
Locate and identify all energy-isolating devices N/A.

8. Safe Work Procedure Steps

Step 1: Preparation for Shutdown

Review the equipment's operating procedures and identify all potential hazards N/A.
Identify the types and magnitudes of energy that the equipment utilizes N/A.
Locate all energy-isolating devices for the equipment N/A.

Safety considerations for this step: Ensure that you have a clear understanding of the equipment and its energy sources before proceeding N/A.

Step 2: Shutdown the Equipment

Use the normal operating controls to shut down the equipment N/A.
Follow the manufacturer's instructions for proper shutdown procedures N/A.
If the equipment malfunctions or cannot be shut down properly, notify your supervisor N/A.

Safety considerations for this step: Avoid any sudden or unexpected movements that could cause injury N/A.

Step 3: Isolate the Equipment from Energy Sources

Operate the energy-isolating devices to disconnect the equipment from its energy sources N/A.
This may involve switching off circuit breakers, closing valves, or disconnecting power cords N/A.
Ensure that all energy-isolating devices are fully engaged and in the safe position N/A.

Safety considerations for this step: Use caution when operating energy-isolating devices to avoid electrical shock or other hazards N/A.

Step 4: Apply Lockout/Tagout Devices

Attach lockout devices to each energy-isolating device N/A.
Ensure that the lockout devices are properly secured and cannot be easily removed N/A.
Attach tagout devices to each lockout device, indicating the date, time, and the name of the authorized employee who applied the lockout/tagout N/A.

Safety considerations for this step: Use only approved lockout/tagout devices that are durable and standardized N/A.

Step 5: Dissipate or Restrain Stored Energy

Check for any stored energy, such as pressure, gravity, or springs N/A.
Use appropriate methods to relieve or restrain the stored energy N/A.
This may involve bleeding pressure from a system, lowering a suspended object, or releasing tension on a spring N/A.

Safety considerations for this step: Be aware of the potential hazards associated with stored energy and take appropriate precautions N/A.

Step 6: Verify Isolation

Before starting work, verify that the equipment is completely isolated from all energy sources N/A.
Use testing equipment to check for the presence of voltage, pressure, or other forms of energy N/A.
Ensure that the equipment cannot be started up or energized N/A.

Safety considerations for this step: Double-check all energy sources to ensure complete isolation N/A.

Step 7: Perform Work

Once the isolation is verified, perform the necessary maintenance, repair, or servicing work N/A.
Follow all safety procedures and use appropriate tools and equipment N/A.
If any unexpected hazards are encountered, stop work and notify your supervisor N/A.

Safety considerations for this step: Maintain a safe work environment and be aware of your surroundings N/A.

Step 8: Remove Lockout/Tagout Devices

After the work is completed, inspect the equipment to ensure that all tools and materials have been removed N/A.
Notify affected employees that the lockout/tagout will be removed N/A.
Remove the lockout/tagout devices, ensuring that the equipment is safe to operate N/A.
Each lock must be removed by the person who installed it. Never remove another person's lock N/A.

Safety considerations for this step: Ensure that all employees are clear of the equipment before removing lockout/tagout devices N/A.

Step 9: Notify affected employees prior to re-energizing the system or equipment N/A.

Step 10: Re-Energize the Equipment

Operate the energy-isolating devices to restore power to the equipment N/A.
Follow the manufacturer's instructions for proper startup procedures N/A.
Monitor the equipment to ensure that it is operating correctly N/A.

Safety considerations for this step: Be prepared for unexpected movements or sounds during startup N/A.

9. Precautions and Safety Measures

Never bypass or override lockout/tagout devices - This can lead to serious injury or death N/A.
Always follow the established lockout/tagout procedures - This ensures that all energy sources are properly isolated N/A.
Communicate effectively with all affected employees - This helps to prevent misunderstandings and accidents N/A.
Use only approved lockout/tagout devices - This ensures that the devices are durable and standardized N/A.
Regularly inspect and maintain lockout/tagout devices - This ensures that the devices are in good working condition N/A.

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency, immediately stop work and assess the situation. Evacuate the area if necessary and contact emergency services. Provide first aid to any injured personnel and report the incident to your supervisor N/A.

10.2 Specific Emergency Scenarios

Equipment starts up unexpectedly - Immediately shut down the equipment if possible and evacuate the area. Contact emergency services and report the incident to your supervisor N/A.
Employee is injured during lockout/tagout - Provide first aid and contact emergency services. Report the incident to your supervisor and initiate an investigation N/A.
Lockout/tagout device is missing or damaged - Stop work and notify your supervisor. Do not proceed until the device is replaced or repaired N/A.

10.3 Emergency Contact Information

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

11. Incident Reporting and Investigation

All incidents, near-misses, and hazards related to lockout/tagout must be reported to your supervisor immediately. An investigation will be conducted to determine the root cause of the incident and implement corrective actions to prevent future occurrences N/A.

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