Lockout Tagout Procedure

Lockout Tagout Procedure

This lockout tagout procedure template can assist your business comply with ISO 45001, OH&S Management Systems clauses:

  • 6.1.2. Hazard Identification and Assessment of Risks and Opportunities.
  • 8.1.2. Eliminating hazards and reducing OH&S risks.


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What are Lockout Tagout Procedures?

A lockout tagout procedure is a written document that gives instructions for lockout and tagout (LOTO) safety, protecting workers and controlling energy.

The procedure’s intent is to prevent an uncontrolled energy release that would present a risk to a person or equipment.

What is Lockout and Tagout?

Lockout and tagout is a safety process that involves the use of locks, tags and other devices. These prevent access to dangerous energy sources and prevent machines from starting or releasing stored energy.

Employers must create rules to control dangerous energy and keep workers safe from injuries caused by its release.

Lockout and Tagout Steps and Processes

You can follow these important steps to safely isolate and control energy for safety.

Step 1. Identify the Hazardous Energy Source

Assess the various types of controls with hazardous energy sources on the moving parts of machines and/or equipment. Determine the effective methods to disable and label them in order to mitigate risks associated with machinery or equipment.

Step 2. Notify All Affected Parties

The person authorizing the work must notify all affected employees and parties (e.g. management, supervision, operators and workers in the area) of:

  • The specific procedural scope of work that will be conducted.
  • The systems of isolation, circuit breaker or tagout devices being used.
  • The requirement not to disturb or attempt to restart the equipment until the work is completed, the isolation devices are removed, and it is safe to resume normal operations.

Note: Individuals must only carry out isolation and control of energy to the level of their competence and authorization. Refer to and always comply with any specific equipment procedures in relation to isolations.

Step 3. Shut Down the Equipment and the Control of Hazardous Energy

If the equipment is operating, the person authorizing the work must verify that it is safe to shut down the machine and types of hazardous energy. You can then stop the equipment using the established methods and procedures for that item of equipment.

Step 4. Isolate, Dissipate and Restrain All Energy Sources

Physically interrupt the supply of energy to complete the isolation of energy sources.

You can achieve this by implementing measures such as:

  • Turning off power switches in electrical circuits.
  • Release the stored or residual energy.
  • Closing supply valves.
  • Removing mechanical drives.
  • Disconnecting batteries, leads, cables or hoses.
  • Blanking off pipelines.

The means of isolation should be of a type that can be readily checked by a visual inspection, and it should act directly on the supply line. It should not act through control circuits or emergency stop mechanisms.

Once you isolate the energy sources, you should dissipate any stored energy in the equipment.

You can achieve this by implementing measures such as:

  • Opening valves to drain pipelines, pressure vessels and hydraulic accumulators.
  • Opening access hatches and inspection covers.
  • Earthing electrostatic separators.
  • Releasing springs.
  • Lowering counterweights.
  • Purging process lines.

 Note: The method of energy dissipation must ensure that energy does not re-accumulate over time, or during work.

If internal sources of energy cannot be dissipated, they must be adequately restrained by measures such as:

  • Inserting mechanical locking devices such as chocks or pins.
  • Securing items that can move, such as fans and mechanical linkages with chains.
  • Closing cover plates on radioactive gauges.
  • Applying brakes.

Step 5. Secure and Identify Isolation Devices (Lock-Out and Tag-Out)

Each of the lockout devices or energy isolating devices used to isolate, dissipate and restrain energy sources must be secured and identified in accordance with the risk management hierarchy of controls to prevent inadvertent energizing or release of energy.

Isolations Locks

Securing Isolation Devices (Lock-Out)

Where practicable, the isolation device must be secured by a lock to provide assurance that:

  • The isolation device cannot be inadvertently removed.
  • The person who applied the isolation device is the only person who can remove the isolation device.

When more than one person is working on the same equipment, each person working on the equipment should have their own lock, key and tag, a multi-lock hasp, or group lock box may be used. There should be no duplicate key available for any lock, except a master or duplicate key for use in an emergency that is secured and not readily available.

In cases where isolation devices are not capable of being locked out, a ‘tag-out only’ procedure may be used if:

Tag Out Procedure

  • There is a justifiable and verifiable reason why a lock-out procedure cannot be applied.
  • The alternative method of securing the isolators offers the persons working on the equipment an equivalent level of protection.
  • Formal approval is obtained from a manager or supervisor.

Step 6. Verify the Effectiveness of the Energy Controls

The person authorizing the work must ensure that competent persons verify that all hazardous energies have been effectively isolated, dissipated or restrained.

Note: if the equipment that is being worked on is not ready for operation or testing by the end of the shift, then all locks and tags must be systematically removed and replaced with ‘Out of Service Tags’ and all necessary details completed.

Step 7. Complete the Work and Confirm Completion

As each person completes their work on the equipment they must:

  • Clear the work area of any tools or materials that they have used that are not required by other people still working on the equipment.
  • Replace any guards that are not required to be left open for access by other people still working on the equipment.
  • Restore and verify all safety devices that have been removed or bypassed.
  • Report the completion of the work to the person in charge of the equipment (or their nominated supervisor).

Step 8. Remove the Isolation Devices (Locks and Tags)

After confirming the completion of work, each person must remove their personal isolation locks and isolation tags.

Step 9. Confirm the Return to Service and Start-Up

Before removing the last isolation lock(s) and tag(s), the person responsible for re-energizing the equipment must ensure:

  • All work has been successfully completed.
  • The equipment is clear of any tools and materials.
  • All guards and safety equipment have been replaced and are in good working order.
  • When the equipment is fit for use, it must be restarted in accordance with the standard operating procedures or manufacturer’s instructions.

Lockout Tagout Procedure

Contents of this Lockout Tagout Procedure

  • Approval.
  • Purpose.
  • Scope.
  • Terms and Definitions.
  • Roles and Responsibilities.
  • LOTO procedures.
  • Isolation and Energy Control Program.
  • Related Procedures, Forms and Documents.
  • Review Criteria.
  • Record Management.
  • References.

Why Choose to Buy this Lockout Tagout Procedure

This 10-page procedure can help you control energy during servicing or maintenance tasks. Implementing this procedure will reduce the risk of harm to personnel and meet the requirements of legislated obligations.

After purchasing this template you will be able to:

  • Very easily edit and customize the template to create your own procedure.
  • Apply your own style, format and brand to the procedure.
  • Use it in any industry or sector regardless of the size or type of organization.

Availability and Use of this Lockout Tagout Procedure

  • This lockout tagout procedure is accessible to you right now by clicking the ‘Buy Now’ button.
  • The procedure will be delivered to you in fully editable Microsoft Word format for immediate and full use in your business.
  • There are no subscriptions, contracts or ongoing costs.

Lockout Tagout Procedure Guarantee

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