Energy Isolation Tags and Lock-Off

Purpose
Definitions
Roles and Responsibilities
Procedure
Performance Measures
Documents/Forms
References

Purpose

This procedure outlines the requirements for the management of energy isolation through a tag and lock off system at all University of South Australia workplaces. The intention is to minimise risks to health and safety from any potential accidental or unexpected start-up of machinery or plant, movement of materials during servicing or any other interaction or contact with or exposure to hazardous energy.

Definitions

Energy - electricity, gas, oil, water and other fluids, air, steam, oxygen, or other stored energy source, flywheel, mechanical, gravitational, kinetic, chemical, the level or intensity of which could pose a threat to a person(s) safety.

Isolator - a device that physically prevents the transmission or release of potentially damaging energy.

Isolated - the condition into which equipment or plant is placed when all sources of potentially damaging energy are prevented or blocked by the operation of isolators.

De-isolation - the restoration of the plant, equipment or process to operational condition.

Non-positive Isolator - a device such as a valve, push button, emergency stop, wedge, controller etc that does not directly or positively prevent or block the source of potentially damaging energy.

Personal Lock - a lock identified as a personal lock and being used by the protected person for personal protection.

Working on the plant, equipment or a process - means the carrying out of repairs, cleaning or making adjustments to the plant, equipment or process.

Danger Tag - a RED & BLACK tag used to indicate the isolation of an energy source, to identify the person to be protected by the isolation and the status of equipment and machinery regarded as unsafe in normal usage conditions.

Out of Service Tag - a BLACK & YELLOW tag used to prevent damage to plant and equipment, and/or prevent people from using or operating equipment that is faulty and in need of repair.

Roles and Responsibilities

Line Managers/supervisors are responsible for:

the implementation of this procedure in their area of responsibility and accountability.
consulting with and coaching staff in relation to the implementation of this procedure.
monitoring staff conformance to the requirements of this procedure.

Staff are responsible for:

not placing themselves or others at risk of injury.
conforming to the requirements of this procedure.
consulting with Line Managers/supervisors and other staff in relation to a hazard analysis associated with energy isolations and out of service requirements.

Procedure

Energy Isolation

Prior to starting work where a person could be endangered by the operation of plant or equipment or the release of stored energy, the plant, equipment or process must be properly isolated, stored energy released, the source of energy isolated and a Danger Tag and Personal Lock affixed to the main isolator(s).

The following steps shall be followed by the person carrying out the isolation in consultation with the person responsible for the plant, equipment or process to be isolated by:
1. The person responsible for the plant, equipment or process shall be notified as to the reason and duration of the isolation.
2. The person responsible for the plant, equipment or process is to notify all affected personnel.
3. The person responsible for the plant, equipment or process and the person(s) carrying out the isolation shall complete a hazard analysis on form OHSW2 – General Hazard Identification & Risk Assessment by, identifying the type and magnitude of the energy source, understanding the hazards associated with the energy source and ensuring the isolation controls the hazard(s).
4. Identifying the type and location of every energy source control and isolation point. Place the isolators in a safe position. In the case of electrical equipment, ‘whole current isolation’ such as the main isolator should be used instead of ‘control isolation’ by way of the stop button on a control panel.
5. The person(s) who are to work on the plant, equipment or process shall place a personal lock on each isolation point.
6. The person responsible for the plant and the person(s) who are to work on the plant, equipment or process shall confirm that the correct isolator(s) have been identified and placed in a safe position.
7. Dissipating all stored energy. This may include ensuring inertia in mechanical parts, parts likely to move by gravity, electrical capacitors, accumulators, springs and pressurized fluids.
8. Verifying that the isolation is effective by trying to start the plant or equipment or process.
9. Following verification of the isolation a personal Danger Tag shall be affixed to each personal lock by all personnel who are to work on the plant, equipment or process. The staff member will complete all information on the Danger Tag.
Out of Service Tags

Out of Service Tags shall be attached to any item of plant, equipment or process which is taken out of service due to a fault, damage or malfunction or is not safe.

Out of Service Tags shall be used when repairs, cleaning or the adjustment of any item of plant, equipment or process is not completed and is still unserviceable or unsafe.

The Tag must be placed in a prominent position which is clearly visible from the position where the plant or equipment is started

The Out of Service Tag shall be securely fixed to the isolator with the appropriate details completed on the tag explaining the reason for the out of service condition.

To remove an out of service tag, see section 4 below.
Danger Tags and Locks

Danger Tags must be placed on the isolation control to make it clear to staff that the plant is NOT to be started or operated. If a staff member is working on/in or near a piece of plant or equipment, the operation of which would place them at risk of injury, that staff member shall attach a correctly completed Danger Tag, which will be IN ADDITION TO the Out-of-Service Tag.

Each staff member who is placed in a situation as described above, must attach as previously described their own Danger Tag. These tags should be dated and signed at every use.

Locks should be accompanied by a corresponding tag to identify who has locked out the plant.

To remove a tag and locks see section 4 below.
Exemptions from the application of Danger Tags and Locks

Danger tags and locks are not required in the following circumstances but Out-of-Service tag procedures (section 2. above) must still be applied where:
- Minor adjustments and other minor servicing activities that take place during normal operations where:
  - the plant is under the control of an authorised person;
  - the authorised person has a line of sight to all access points of the plant and equipment which would place a person at risk if the plant or equipment commenced operation; and
  - there is no risk of contact with electricity when undertaking the task.
- Cords and plugs-connected electrical equipment if exposure to unexpected start-up is controlled by unplugging it from its energy source. The plug must also be under the exclusive control of the staff member doing the servicing, maintenance or cleaning of the plant or equipment.
- Situations where the isolation of the plant or equipment will also isolate essential services, provided that:
  - continuity of services is essential and shutdown of the system is impractical;
  - equipment is used that will provide proven effective protection for people
  - a risk assessment has been conducted; and
  - an approved safe operating procedure is being followed.
De-isolation

The restoration of the plant, equipment or process to operating condition is to be carried out by the person who is responsible for completing the work on the plant, equipment or process.

De-isolation shall be achieved by:
- checking the plant, equipment or process for operational integrity, including the completion of all work and the removal of non-essential items, tools and equipment from around the work area
- verifying that operation controls for the plant, equipment or process are in the “Off” or Neutral” position.
- if the equipment has been modified then form OHSW41 – Plant Hazard Identification & Risk Assessment for the equipment must be reviewed.
- removing Out of Service Tags and any Danger Tag(s) and personal locks from isolation point(s) and placing the isolations in the required position.
  Tags and locks are only be removed by the person who applied them or by the supervisor after consultation with the signatory of the tag.
  In the event that the person who applied the tag is unavailable the tag or lock may only be removed in accordance with this procedure:
  - an authorised person (an authorised person for the purposes of this procedure is defined as the line manager or OHSW Services ) who will inspect the job;
  - declare the situation safe after consulting any relevant experts
  - remove the Danger Tag and record in the workplace register
- Notifying the person responsible for the plant, equipment or process that work is completed and the plant, equipment or process is restored to operational condition.
Supply of Danger Tags and Out of Service Tags

Local worksites are to ensure that a supply of Danger Tags and Out of Service Tags is maintained in locations accessible to users.

Danger Tags and Out of Service Tags shall be the form as indicated in the attachment to this procedure.

Performance Measures

All OHSW legislative non compliant plant is tagged and locked off to prevent use.

Document/Forms

Examples of Danger Tag and Out of Service Tag
OHSW2 – General Hazard Identification & Risk Assessment
OHSW41 – Plant Hazard Identification & Risk Assessment