Date Adopted 8/04/2008 Due for Review 8/4/2009 Business Unit HR & Safety Current Policy Date 8/4/2008 LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 1.0 PURPOSE 2.0 SCOPE To prevent injuries to persons or damage to property from the unexpected energizing, start-up or release of stored energy in plant with / on which they are working. This procedure applies to any plant (as defined) on any Tasports property, whether owned by Tasports or not, on which Tasports personnel whether employees, contractors, subcontractors or visitors are required to work, whether for maintenance, operational or any other reason/s. 3.0 REFERENCES Workplace Health & Safety Act 1995 (Tasmania) Workplace Health & Safety Regulations 1998 (Tasmania) Tasports Health & Safety Policy Statement Tasports Employee Safety Rules Tasports Contractors Safety Rules Tasports Risk Assessment & Control Procedure 4.0 4.0 DEFINITIONS Accountable Person: is; a) Any person who is responsible for the management or control of the relevant place at which work is undertaken; or b) any person temporarily acting in the capacity of a person referred to in paragraph a) An accountable person in a workplace may be any person who has a responsibility or an obligation for the health and safety of any other person or persons in that workplace. This means such a person could be any person in the hierarchy of a workplace, from chief executive to cleaner. Workplace Health & Safety(WHS) Regulations 1998. LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 1 of 10
Lock-out: is the use of a special system incorporating locks and tags to prevent the inadvertent activation of plant. Plant: includes any machinery, equipment scaffolding, amusement structure, appliance, implement or tool and any component or fitting of any of those things. WHS Act 1995. Power: includes any remote or stored energy source such as electricity, compressed fluids, gases or springs. Responsible Officer: means a person appointed as a responsible officer under section 10 of the WHS Act 1995 Tag-out: is the application of an Out of Order tag to warn potential users of plant that the plant is defective and is not to be used. 5.0 PROCEDURE An accountable person must ensure that where there is a possibility of injury being caused, plant must be fitted with an effective system of isolation in order to protect persons in the proximity of that plant from injury. Where appropriate the isolation system is to include mechanical locks and whole current isolators. Any plant that is designed to be operated automatically or from more than one location must be fitted with stop and lock-out type controls that effectively isolate the power source. In the case of electrically powered plant isolation must be effected by the interruption of the power circuit, not the control circuit. WHS Regs 1998. Appropriate accountable persons are to use Tasports Risk Assessment & Control Procedure to carry out risk assessments on all existing items of plant and any future plant items that may be purchased, leased or hired to determine whether; there is a possibility of injury being caused by the unexpected energizing, start-up or release of stored energy of / in machines on which persons may be required to perform maintenance, servicing and or cleaning; and if this is the case whether, the lock-out requirements outlined above are able to be complied with; compile and implement a Safe Work Procedure (SWP) which shall incorporate as appropriate, the steps outlined in 5.2 below for the effective isolation of each such item of plant (refer appendix A ); and, file all such SWPs electronically; and, ensure that all persons involved in, or affected by the lock-out of plant know how to access the SWPs and are trained in and understand both the reasons for, and operation of the lock-out system. Where it is determined that an item of plant presents a risk of injury as described and is not able to be locked-out as required the accountable person must implement the necessary corrective action to ensure compliance. 5.1 Lock-out system Accountable persons will set up, operate and maintain a lock-out system as follows: LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 2 of 10
1. Sufficient lock-out devices including lock-out kits, locks, multi lock scissor clasps and lock-out tags (refer appendix B ) to meet the needs of the particular site / area are to be purchased. 2. Lockout equipment; a) All Tasports electricians shall be issued with a lock-out kit. b) All other employees trained to lock-out plant or required to work on plant that has been locked-out are to be issued with a personal lock and tag. c) Contractors are to be issued with lock-out equipment as and when required and the issuing officer is to ensure the return of such equipment upon the completion of the work. d) The accountable person responsible for each employee / contractor issued with lock-out equipment will keep a log recording the details of such issues. (Refer appendix C.) 3. Only one key is to be made available for each lock. All duplicate or master keys must be stored in a single, secure area at each site, the location of which shall be decided by the designated site Responsible Officer in consultation with system users. 4. Only persons trained in the lock-out procedure are to lock-out plant. 5. Work shall not be carried out on or near de-energized exposed conductors unless the plant has been locked-out and tested for dead by an electrician. 6. The appropriate accountable person is to ensure that all personnel who may be affected by the lock-out are advised the plant is to be locked-out giving reasons for and expected timing of the shut down. 7. The accountable person will, on each occasion, appoint a competent person to carry out the lock-out procedure and that person will be responsible for lock-out of the plant in accordance with the SWP and for communications between the work area and the accountable person as to progress / completion / plant restart. 8. Every individual who is required to work on the locked-out equipment must personally fit his / her own lock and tag before commencing work and must remove their own lock and tag on completion of their individual task/s. a) Failure to fit a personal lock and tag to locked-out equipment prior to working on the equipment; or fitting a lock and tag for another individual will be treated as a serious disciplinary issue. b) Removal of another persons lock and tag other than in accordance with this procedure may result in summary dismissal. 9. Wherever possible work is to be planned in such a way that the equipment does not need to be re-energized prior to the completion of the maintenance. If this is not possible then the procedures outlined in 5.2 below must be followed for restart / shutdown / lockout. 10. Where handover to another work group is required it must be done in the following manner: a) The person in charge of the lock-out will ensure that the locks and tags of all off-going personnel have been removed. They will then; b) Either hand over to the on-coming person in charge who will fit their own lock and tag before the off-going person removes theirs (when using a multi lock scissor clasp) or immediately after where a single lock is being used as detailed in k) below; or, c) Hand over to the accountable person who will be responsible for maintaining the equipment in the locked-out state pending arrival of the next work group. LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 3 of 10
This may be done by fitting a personal lock and tag or, where no work is to be carried out on the equipment for an extended period the accountable person may choose to fit a spare lock and a completed Caution Out of Order tag. 11. Where it is impracticable to use a multi lock scissor clasp and multiple locks, e.g the isolation point is in a substation then a lockbox system (appendix B ) is to be used as the alternative. 5.2 Lock-out procedure Where possible bring any part of the equipment that can move due to the effect of gravity or as a result of action upon it of a spring or other pressure system to its lowest energy state. Disconnect primary and secondary power sources and lock in the off position using a multi lock scissor clasp, lock and tag. Check that; a) all parts have stopped moving; b) electrical circuits are de-energized; and, c) block or brace any part that may still move under the force of gravity or pressure or the release of pressure; d) drain or bleed any pressurized hydraulic, pneumatic or compressed air lines and / or accumulators as required in accordance with the manufacturers instructions and / or Tasports SWPs. On completion of the work; e) check that all controls and stop / start switches are in the off position; f) remove any blocks or braces; g) remove all tools; h) replace machine guards; i) ensure all personnel are a safe distance from the equipment; j) remove the final lock and tag; k) re-energize and then re-check the equipment. 5.3. Removal of lock by Management 5.4 Tag-out If a person is unable to remove a lock and tag due to incapacity or because he / she has left the site and is unable to return and the equipment is ready to be reenergized an accountable person must carry out a risk assessment using the Risk Assessment & Control Procedure in order to determine whether or not it is safe to remove the remaining lock and tag. In the event it is decided it is safe to remove the lock and tag the person conducting the risk assessment must obtain final approval from the Manager Maintenance or the GM Infrastructure & Property before removing the lock. Tag-out is the fitting of an Out of Order tag (appendix B ) to a piece of plant to warn a potential user that the plant is unsafe and not to be used. These tags may be fitted by any individual to any defective item of plant. All defective equipment must either be tagged-out or locked-out and reported immediately to your supervisor / manager as appropriate. Accountable persons are to ensure that; sufficient quantities of Out of Order tags are readily available in appropriate locations at each site; LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 4 of 10
employees and contractors for whom they are directly responsible know where the tags are kept and how to use them. Any person fitting an Out of Order tag must include on it their name, employer s name (if a contractor) contact details, date, time and reason for applying the tag. These details must be written in ink or other indelible material and must be legible. The use or operation of tagged plant for anything other than the purpose of effecting repairs or the unauthorised removal of an Out of Order tag will be treated as a serious disciplinary matter. Out of Order tags may be removed following satisfactory repair of the defect/s listed on the tag. They are to be removed with the approval of their supervisor by the person who has completed the required repair/s. Out of Order tags may not be removed under any other circumstance other than by following the steps outlined in 5.3 above. 5.5 Record keeping An accountable person who carries out a risk assessment must ensure that a copy of the assessment and any associated documentation is kept for a period of not less than 5 years. Accountable persons are to keep records of the issue and return of lock-out equipment. Responsibility The General Manager of each Business Unit is responsible for the overall implementation of this system and procedure. Site Coordinators and Supervisors are responsible for the set up and maintenance of the system and procedure. All employees/users are responsible for correct operation of the procedure. The HSE Manager is responsible for ensuring that this procedure is maintained and updated. Audit records Plant risk assessments Shut down lock-out & restart procedures Lock-out device logs Training records 6.0 FORMS Appendix A TYPICAL LOCK-OUT / TAG-OUT SYSTEM DEVICES. Appendix B SHUT DOWN LOCK-OUT & RESTART PROCEDURE. Appendix C LOCK-OUT DEVICE LOG LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 5 of 10
Appendix A TYPICAL LOCK-OUT / TAG-OUT SYSTEM DEVICES Typical multi lock scissor clasp Personalised lock-out tag. Brady self laminating Cat. No. 65501 Brady Out of Order tag. Cat. No. 842368. Reverse side. Typical Lock box. LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 6 of 10
Appendix A SHUT DOWN LOCK-OUT & RESTART PROCEDURE PLANT NAME/NUMBER: PROCEDURE LOCK-OUT DEVICE USED HOW TO VERIFY LOCATION Notify all affected personnel of impending plant shut down. LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 7 of 10
Remove any blocks or braces RESTART Replace machine guards Inspect work areas and remove tools and other non-essential items. Check that all controls and stop/start switches are in the off position. Notify affected employees in the area of the impending restart and make sure they are safely positioned away from plant. LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 8 of 10
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Appendix C LOCK-OUT DEVICE LOG All lock-out devices issued are to be listed below, along with the date and time of issued and the name and signature of the individual to whom the device is issued. All devices issued to contractors must be returned after use, at which time the date and time of return must be noted. Devices issued to employees are to be returned on termination. DEVICE OUT - DATE/TIME IN DATE/TIME NAME SIGNATURE LOCK-OUT / TAG-OUT SYSTEM & PROCEDURE 10 of 10