What are Lockout Tagout Australian standards and how to comply with them

Lockout tagout (LOTO) is a safety procedure that involves isolating and securing all forms of hazardous energy in a plant or equipment before performing any maintenance, repair, installation or cleaning work. LOTO aims to prevent the accidental start-up or release of energy that could cause injury or death to workers or damage to the plant or equipment.

In this blog post, you will understand the relevant Australian standards for LOTO, such as AS/NZS 4836:2011 and AS 4024.1603-2006, and what they mean for your workplace. You will learn how to design controls, interlocks and guards, prevent unexpected start-ups, and conduct risk assessments for LOTO.

Why is LOTO important?

According to SafeWork NSW, LOTO is an integral process to ensure that employees who are required to provide maintenance and repair of the plant are as safe as possible to carry out their work. LOTO can minimise the risk of injuries and fatalities, increase productivity, reduce equipment downtime and damage and save costs through lower insurance premiums.

LOTO is also a legal requirement under the Work Health and Safety Regulation 2017, which states that a person conducting a business or undertaking (PCBU) at a workplace must ensure that any operator controls can be locked into the “off” position to enable the disconnection of all motive power.

What are the Australian standards for LOTO?

The Australian standards for LOTO are:

•  AS/NZS 4836:2011 – Safe working on or near low-voltage electrical installations and equipment. This standard provides guidance on how to safely isolate electrical equipment from its supply source and verify that it is de-energised before commencing work. It also covers the use of locks and tags, testing devices, personal protective equipment, and safe work procedures.

•  AS 4024.1603-2006 – Safety of machinery – This standard specifies the requirements for the design of controls, interlocks and guards that prevent the unexpected start-up of machinery during maintenance or cleaning operations. It also highlights the use of warning devices, emergency stop devices, and isolation devices.

How to comply with the Australian standards for LOTO?

To comply with the Australian standards for LOTO, you should follow these steps:

1. Shut down the plant or equipment – Stop the operation of the plant or equipment by using the normal shut-down procedure. This may involve turning off switches, valves, levers or buttons in a specific sequence or location.

2. Identify all energy sources and other hazards – Identify all forms of potentially hazardous energy that could place workers at risk or activate the plant or equipment. It includes electricity, fuels, heat, steam, fluids or gases under pressure, stored energy, gravity and radiation. You should also identify any associated hazards, such as moving parts, sharp edges, chemicals or noise.

3. Isolate all energy sources – Ensure all energy sources from the plant or equipment are isolated by using appropriate devices, such as circuit breakers, switches, valves, plugs or blanks. You should also isolate any control points like computers or remote controls that could be activated remotely.

4. Control or de-energise all stored energy – Release any stored energy in the plant that could cause movement or harm. This may involve bleeding, venting, draining, grounding or blocking. You should also ensure that any suspended parts are supported by mechanical means.

5. Lock out all isolation points – Secure all isolation devices in the “off” position using suitable locks that can only be removed with a key. You should use one lock per isolation point and one key per lock. If more than one worker is involved in the work, each worker should attach their own lock and key to a lockout hasp or use a Group Lock Box that holds all the locks together.

6. Tag out all isolation points – Attach a personal danger tag to each lockout device that identifies the worker performing the work and warns others not to operate the plant or equipment. The tag should include critical information like name, contact number, date and time of isolation and the reason for isolation.

Conclusion

LOTO is a vital safety procedure that protects workers from hazardous energy sources. By following the Australian standards for LOTO, such as AS/NZS 4836:2011 and AS 4024.1603-2006, you can ensure that your workplace is compliant and safe. At Tuffa Products, we offer a range of reliable and durable LOTO devices and tags that can help you implement the LOTO process effectively and efficiently. Contact us today to find out more about our products.

Tuffa Products is an Australian company that offers a wide range of Lockout Tagout products, such as padlocks, hasps, cable lockouts, valve lockouts, pneumatic lockouts, decals, stations, and more. The products are made with 100% Australian materials and are designed to withstand the harshest conditions. Tuffa is trusted by many of Australia’s leading brands and has a reputation for quality and safety. Whether you need a custom tag, a flange and torque tag, a valve tag, or a sign, Tuffa has you covered. Visit our website to explore the range and order online.

FAQs

1 –  How can I encourage my employees to practice LOTO?

You can encourage your employees to practice LOTO by providing them with adequate training, information and supervision on how to perform LOTO correctly and safely. You can also establish a LOTO policy and programme that outlines the roles and responsibilities of everyone involved, as well as the procedures and rules to follow. You can also monitor and audit the performance of LOTO regularly and provide feedback and recognition to your employees.

2 – Can lockouts be forcibly removed?

Lockouts should not be forcibly removed by anyone other than the authorised worker who applied them unless there is an emergency that requires immediate removal. In such cases, a designated person who has been trained and authorised to remove lockouts should follow a specific procedure that ensures the safety of workers and equipment. The procedure should include notifying and consulting with the original worker who applied the lockouts, verifying that the plant or equipment is safe to operate, removing lockouts carefully, and documenting the removal process.

3 – What are Lockout Tagout (LOTO) standards, and why are they important?

Lockout tagout (LOTO) standards refer to a set of safety procedures and practices used to control hazardous energy during the maintenance or repair of machinery or equipment. They are crucial to prevent unexpected startup or release of stored energy, ensuring the safety of workers and preventing accidents.

4 – Are there any penalties for non-compliance with Lockout Tagout standards in Australia?

Yes, non-compliance with Lockout Tagout standards can result in penalties and fines. The specific penalties may vary depending on the jurisdiction and severity of the violation. However, the primary concern should always be ensuring the safety of workers and preventing accidents.