OM00039 – Plant and Equipment Lock Out/Tag Out Policy

Plant Lock Out/Tag Out (LOTO) Policy

Objective To avoid hazards related to accidental start-up, movement of a machine part or the uncontrolled release of energy. 

Scope: This procedure applies to all workers who, in the course of their duties, may be required to perform a LOTO procedure.

Policy: A2Z Services recognises its responsibility to provide and maintain a safe workplace, including the control of risks associated with accidental start-up, movement of a machine part or the uncontrolled release of an energy system.

A2Z Services will endeavour to prevent injury and eliminate hazards associated with a LOTO process by ensuring:

• A LOTO procedure is in place;
• LOTO equipment is available for use (e.g. safety tags, locks etc.);
• Adequate training, information, instruction and supervision of LOTO procedures is provided;
• All workers undertaking a LOTO procedure are licensed where required (e.g. electrical);
• safe work procedures e.g. SOPs for items of plant and equipment that need LOTO operations are developed and put in place.

Definitions:

Lockout – A device is placed on, around, or through an energy-isolating mechanism to lock it in a safe position. 

Tag out – The process by placing an energy-isolating device for an item of plant/equipment in the off position, and a written warning tag is attached. A ‘tag out’ should be used only when the energy-isolating device is not capable of being locked out, e.g.  A small item or power tool.

Lockout-Tag out (LOTO) – A device is placed on, around, or through an energy-isolating mechanism to lock it in a safe position and attach a written warning tag.Locks and Tags must be substantial enough to prevent casual or accidental removal. Locks and tags must also identify the worker applying and be using the device.

Cause	E.g.
Fluid	Water, steam, hydraulic fluid
Gas	Pressurised gases, vacuum
Pneumatic pressure	Compressed air
Mechanical	Gears linkages, rings, flywheels
Chemical	Volatile chemicals, radiation
Electrical	Mains, generator

Plant Lock Out/Tag Out (LOTO) Procedure

Responsibilities:

At A2Z Services the PCBU is responsible for ensuring that:

• A safe system in place for management of LOTO procedures;
• Standard Operating Procedures for shutdown-isolation-working under power LOTO for unit specific plant or equipment instructions. (Document instructions for the LOTO of plant/equipment by engaging with HSR /workers who work with the relevant plant or equipment).These specific instructions must contain the following information:
• Method and order of identifying, locating, isolating, and locking out or tagging out each energy source;
• Process of verifying a zero-energy state, including testing of the energy state;
• Method and order of reconnecting each energy source to the system;
• Workers responsible for the LOTO operation hold current licenses and are fully trained and competent to undertake the task;
• Equipment not requiring licensing:
• Workers are trained to safely operate the equipment by a person who is suitably competent/experienced in its operation;
• If an experienced person is not available, the worker’s manager must ensure the manufacturer’s operating instructions are available, read and understood by the worker before operation commences;
• A Safe Work Procedure shall be explained and demonstrated during training, including any risk assessment for the equipment;
• The workers must be able to demonstrate the safe operation of the equipment under supervision before being allowed to operate the equipment for LOTO purposes unsupervised.

Managers/Supervisors are responsible for ensuring:

• A copy of the following procedure is provided to all contractors working at A2Z Services before they undertake work;
• The LOTO Procedure is implemented when necessary and, that all workers are familiar with the procedure, and that the process is followed;
• A Safe Work Procedure is explained and demonstrated during training, including any risk assessment for the equipment;
• The workers can demonstrate the safe operation of the equipment under supervision before being allowed to operate the equipment for LOTO purposes unsupervised.

Workers are responsible for ensuring:

• Reasonable care for their health and safety; 
• Reasonable care for the health and safety of others;
• They follow the LOTO procedure at all times.

Contractors:

All contractors working at a A2Z Services workplace must comply with this procedure (exceptions agreed only in writing). Contractors are expected to provide all locks, tags, and other devices required for LOTO associated with their contract (exceptions in writing for of LOTO items unique to A2Z Services). No Contractor may participate in work on plant or equipment until they have obtained and applied the required devices.

LOTO Procedure:

1. Acquire Isolation Permit to Work;
2. Notify all affected workers that a lockout is required and that it will be undertaken at a particular date and time;
3. Identify all energy sources and hazards by conducting a risk assessment. Review any written LOTO instructions if applicable;
4. If the equipment is in operation, shut it down by following the standard procedure (e.g. stop button);
5. Identify devices used to maintain the energy source (electrical, hydraulic, gas, other) and disconnect or isolated from the equipment;
6. Lockout energy isolating devices with an appropriate lock and tag;
7. Ensure work areas is clear before dissipating any stored energy (e.g. hydraulic systems, compressed air, steam or water pressure;
8. Ensure work areas is clear before testing plant or equipment is isolated;
9. Operate the start button or other operating controls (if applicable) to ensure the equipment will not operate and is in a zero-energy state;
10. Return operating/startup controls to off/neutral position after the test;
11. The equipment is now locked out and tagged;
12. Undertake the maintenance or servicing task.

Restoring Equipment to Service Procedure:

1. Notify all affected workers that the plant/equipment will be back in service and that it will be undertaken at a particular date and time;
2. Ensure work areas is clear before devices used to maintain the energy source (electrical, hydraulic, gas, other) are reconnected;
3. Remove all tools and parts;  
4. Re-secure all guards;
5. Remove all locks and tags;
6. Restore energy to equipment;
7. Inform Supervisor/Manager/other staff that all isolation has been removed and equipment/plant has been returned to operational status.

Forms and Registers

Document Number	Document Name
OF0032	Isolation Permits to work
OF0033	Lock Out Tag Out Standard Operation Procedure
OM00038	Plant And Equipment Policy
OM00032	Electrical Safety Policy

Amendment Record

Issue#: 1 Issue Date: 13/7/2022

Rev#	Date	Section#	Para.#	Description of Change	Prepared By	Approved By
1
2
3

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Disclaimer: This documentcontains material to assist in meeting environmental management, Work Health and Safety and Quality obligations under the International Standard ISO AS/NZS ISO 9001:2016,14001:2016 and other legislative bodies. This document contains material sourced from Safe Work Australia. Any such material remains subject to copyright © Commonwealth of Australia. https://www.safeworkaustralia.gov.au/copyright. Although every effort has been made to ensure the accuracy of this information at the time of publication, it is provided as guidance only and does not provide legal advice on meeting your obligations. This document and its contents are © A2Z services 2018 and or the originating source authors and no permission is given for its duplication or copying, in part or in its entirety, for use outside its original purposes as stated within the company.