Safe Lockout Procedure for a Press

Document Number: [SWP-NUMBER]

Revision Date: [DATE]

Next Review Date: [NEXT REVIEW DATE]

Department: [DEPARTMENT NAME]

1. Scope

This procedure outlines the steps required to safely lockout a press to prevent accidental startup during maintenance. It applies to all employees, contractors, and visitors who may perform maintenance on the press. This procedure covers all energy sources including electrical, mechanical, hydraulic, and pneumatic.

2. Definitions

Lockout Procedure A planned and documented sequence of actions for de-energizing equipment and applying lockout devices to prevent unexpected energization or startup. Lockout Device A device that physically prevents the operation of a piece of equipment, such as a lock, tag, or blank flange. Energy Source Any source of energy that could cause harm if released unexpectedly, such as electrical, mechanical, hydraulic, pneumatic, or thermal energy.

3. Responsibilities

3.1 Supervisors

Ensure that all workers are properly trained and competent in lockout procedures.
Provide the necessary lockout devices and equipment.
Enforce the lockout procedure and ensure it is followed correctly.
Verify that the equipment is safe to return to service after maintenance.

3.2 Workers

Follow the lockout procedure as outlined in this document.
Report any hazards or concerns related to the lockout procedure to the supervisor.
Use the provided lockout devices correctly.
Do not attempt to operate equipment that is locked out.

3.3 Health and Safety Representative

Participate in the development and review of the lockout procedure.
Monitor the implementation of the lockout procedure.
Investigate any incidents related to lockout procedures.

4. Potential Hazards and Risks

Hazard	Risk	Control Measures
Accidental startup of the press	Serious injury or death	Ensure proper lockout procedures are followed. Verify energy isolation before starting work.
Electrical shock	Electrocution or burns	Use appropriate PPE, including safety glasses, gloves, and hearing protection. Ensure proper grounding of electrical equipment.
Musculoskeletal injuries	Strains, sprains, or back injuries	Use proper lifting techniques and equipment. Ensure adequate lighting in the work area.
Slips, trips, and falls	Minor to serious injuries	Keep the work area clean and free of obstructions. Use appropriate spill control measures.
Exposure to hazardous substances	Respiratory irritation or illness	Ensure proper ventilation. Use respiratory protection if necessary.
Contact with moving parts	Cuts, lacerations, or amputations	Use machine guarding to prevent contact with moving parts. Ensure all guards are in place and functioning correctly.

5. Personal Protective Equipment (PPE)

The following personal protective equipment (PPE) is required when performing the lockout procedure:

Safety Glasses: To protect eyes from flying debris or splashes.
Gloves: To protect hands from cuts, abrasions, or chemical exposure.
Hearing Protection: To protect hearing from excessive noise levels.

Inspect all PPE before each use to ensure it is in good condition. Replace any damaged or defective PPE immediately. Clean and store PPE properly after each use.

6. Equipment and Tools

The following equipment and tools are required for the safe lockout of the press:

Electrical Lockout Device: Used to disconnect electrical power to the press.
Mechanical Lockout Device: Used to block mechanical movement of the press.
Valve Lockout Device: Used to close valves to isolate hydraulic and pneumatic energy sources.
Voltage Tester: Used to verify the absence of energy.

Inspect lockout devices before each use to ensure they are in good working condition. Replace any damaged or defective devices immediately. Store lockout devices in a designated area when not in use.

7. Pre-Job Requirements

7.1 Training and Competency

Training and Competency: All workers who perform lockout procedures must be trained and competent in the procedure. Training must include the identification of energy sources, the use of lockout devices, and the verification of energy isolation. Refresher training must be provided at least annually.

7.2 Pre-Job Briefing

Pre-Job Briefing: A pre-job briefing must be conducted before each lockout procedure. The briefing must include a review of the lockout procedure, the identification of potential hazards, and the assignment of responsibilities.

7.3 Work Area Preparation

Work Area Preparation: The work area must be inspected to ensure it is safe for the lockout procedure. This includes ensuring adequate lighting, ventilation, and housekeeping. Any hazards must be corrected before starting the lockout procedure.

8. Safe Work Procedure Steps

Notification: Notify all affected personnel that the press will be shut down for maintenance.
Equipment Shutdown: Shut down the press using the normal shutdown procedure.
Energy Source Identification: Identify all energy sources for the press, including electrical, mechanical, hydraulic, and pneumatic.
Energy Isolation: Isolate all energy sources by disconnecting or de-energizing them. This may involve disconnecting electrical power, closing valves, or blocking mechanical movement.
Lockout Device Application: Apply lockout devices to all energy isolation points. Each worker who will be performing maintenance on the press must apply their own lockout device.
Energy Isolation Verification: Verify that all energy sources are isolated by testing the equipment. This may involve attempting to start the press or testing for the presence of energy.
Maintenance: Perform the necessary maintenance on the press.
Tool Removal: Remove all tools and equipment from the work area.
Notification: Notify all affected personnel that the press is ready to be returned to service.
Lockout Device Removal: Remove all lockout devices from the energy isolation points. Only the worker who applied the lockout device can remove it.
Energy Restoration: Restore energy to the press by reconnecting or re-energizing the energy sources.
Equipment Startup: Start up the press using the normal startup procedure.

9. Precautions and Safety Measures

Never attempt to operate equipment that is locked out.
Always verify energy isolation before starting work.
Use only approved lockout devices.
Ensure that all workers are aware of the lockout procedure.
Keep the work area clean and free of obstructions.

10. Emergency Procedures

10.1 General Emergency Response

In the event of an emergency during the lockout procedure, immediately stop work and ensure the safety of all personnel. Evacuate the area if necessary and contact emergency services.

10.2 Specific Emergency Scenarios

Worker Injury: If a worker is injured during the lockout procedure, provide first aid and seek medical attention immediately. Report the incident to the supervisor and safety department.
Unexpected Startup: If the equipment starts up unexpectedly during the lockout procedure, immediately shut it down and evacuate the area. Investigate the cause of the startup and correct any deficiencies in the lockout procedure.

11. Incident Reporting and Investigation

All incidents, including near misses, must be reported to the supervisor and safety department immediately. The incident report should include a detailed description of the incident, the cause of the incident, and any corrective actions taken.

All incidents will be investigated by the safety department to determine the root cause and prevent recurrence. The investigation will include interviews with workers, a review of the lockout procedure, and an inspection of the equipment.

Approved by: [NAME AND POSITION]

Date: [APPROVAL DATE]