Isolation and Lockout Procedure

Purpose. Sets out how energy sources are isolated, locked, tagged and tested before any person works on plant, and how isolations are removed when work is complete.

1.Scope

This procedure applies to any work that requires a person to place any part of their body in a position where unexpected start-up, movement or release of energy could cause injury. It applies to all workers and contractors at all sites and to all energy sources including electrical, pneumatic, hydraulic, gravity, stored material and rotating equipment.

2.Principles

No person will work on plant that has not been isolated, locked and tested. Every person working on the plant must fit their own personal lock. A lock must only be removed by the person who fitted it. Isolation points for each item of plant are listed on the isolation schedule held at the permit office.

3.Steps to isolate

The authorised isolator must identify every energy source on the isolation schedule, shut down the plant using the normal stopping sequence, isolate each source at the listed point, fit an isolation lock and danger tag, release or restrain stored energy and then test that the plant cannot start by attempting a start at the local control. The test result must be recorded on the isolation record before any work begins.

• Identify all energy sources on the isolation schedule
• Shut down using the normal sequence
• Isolate each source at the listed point
• Fit isolation lock and danger tag
• Release or restrain stored energy including material in hoppers and silos
• Test for zero energy and record the result

4.Personal locks

Every worker and contractor who will work on the isolated plant must fit their personal lock to the lockbox or the isolation point before starting and must remove it when they finish. A worker who leaves site with a lock in place will be contacted and returned to site. If the worker cannot be contacted, the lock will only be removed under the forced lock removal steps approved by the Maintenance Manager and the Safety and Environment Manager.

5.Returning to service

Before isolation is removed, the authorised isolator must confirm that all personal locks have been removed, guards are refitted, tools and materials are cleared and all people are clear of the plant. The isolator must then remove the isolation locks in the order on the schedule and complete the return to service section of the isolation record.

6.Training and audit

Only workers who have completed isolation training and are listed on the authorised isolator list are permitted to perform isolations. The Safety and Environment Manager will audit at least four isolations each month and record the results in the permit register.