Isolation of Plant Procedure

Company Name: [Insert Company Name] Document Number: [Insert Number] Review Date: [Insert Date]

1. Purpose

The purpose of this procedure is to ensure the safety of all personnel involved in the maintenance, servicing, cleaning or inspection of plant and machinery at [Insert Company Name]. This procedure outlines the steps to isolate all energy sources to prevent accidental start up.

2. Scope

This procedure applies to all workers, contractors and visitors at [Insert Workplace Location]. It applies to all plant and machinery listed in the Plant Register that requires isolation. This includes but is not limited to [List Machines e.g. Conveyor Belt, Hydraulic Press, Wood Saw].

3. Responsibilities

• Manager: Ensure this procedure is implemented and maintained. Provide locks, tags and training.
• Supervisor: Ensure workers follow this procedure. Audit compliance weekly.
• Worker: Follow this procedure at all times. Never operate a machine with a lock attached.

4. Personal Protective Equipment (PPE)

Before starting isolation, workers must wear:

• [Insert PPE e.g. Safety Helmet, Safety Glasses, High Visibility Vest, Cut Resistant Gloves].

5. Hazard Identification

Before isolating plant, check for the following hazards:

• Live electrical parts
• Stored hydraulic or pneumatic pressure
• Hot surfaces or steam
• Moving parts
• Gravity (falling objects)

6. The Lockout Tagout Process

Workers must follow these steps in order:

Step 1: Notify

Inform all affected operators and supervisors that the machine is being shut down for maintenance.

Step 2: Normal Stop

Turn off the machine using the normal stop controls. Follow the specific shutdown sequence for the [Insert Machine Name].

Step 3: Isolate

Locate the main energy isolation point for the [Insert Energy Type e.g. Electricity, Air, Gas]. Turn the switch, valve or lever to the OFF position.

Step 4: Lockout

Apply your personal safety lock to the isolation device. Use a lock hasp if more than one person is working on the machine.

Step 5: Tagout

Attach a 'Danger Do Not Operate' tag to the lock. The tag must have your name, date and the reason for isolation.

Step 6: Verify

Test the isolation point to ensure it cannot be turned on. Check that all stored energy (pressure, fluids, springs) has been released.

Step 7: Perform Work

Proceed with the maintenance or cleaning task.

7. Restoring Plant to Service

Once the work is complete, follow these steps:

1. Check the work area is clear of tools and debris.
2. Replace all safety guards.
3. Remove all personal locks and tags. Only the person who applied the lock may remove it.
4. Notify all personnel that the machine is about to restart.
5. Energise the machine using the normal start sequence.

8. Group Lockout

If a group is working on the same machine, each person must apply their own lock to a group lockout hasp. The supervisor will apply a master lock once all personal locks are attached. The supervisor removes the master lock only after all personal locks are removed.

9. Emergency

In an emergency, if a worker leaves site without removing their lock, the Manager or Supervisor may remove the lock. This must only happen after all reasonable attempts to contact the worker have failed. The work area must be checked to ensure no one is inside the machine before restart.

10. Sign Off

Employee Name: ______________________ Signature: ______________________ Date: ______________________