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STANDARD OPERATING PROCEDURES	SOP #		Revision
STANDARD OPERATING PROCEDURES	Subject
Issue Date		Review Date
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2026/03/23: Lockot / Tagout SOPDocument Number: LOTO/01Version: 01Compiled By: Dean JacobsReview Date: 2027/03/23 1. PURPOSETo establish a safe and controlled procedure for isolating hazardous energy sources during maintenance and servicing activities to ensure:<ul><li>Prevention of accidental start-up of machinery </li><li>Protection of employees from injury or fatality </li><li>Compliance with the Occupational Health and Safety Act 85 of 1993 </li><li>Safe maintenance and repair of equipment  </li></ul> 2. SCOPEThis procedure applies to:<ul><li>All maintenance personnel </li><li>All contractors performing maintenance work </li><li>All departments where machinery or energy sources are present </li></ul>It covers:<ul><li>Electrical, mechanical, hydraulic, pneumatic, and thermal energy sources </li><li>Maintenance, cleaning, repair, and servicing activities </li></ul> 3. LEGAL COMPLIANCEThis SOP complies with:<ul><li>Occupational Health and Safety Act 85 of 1993 </li><li>General Machinery Regulations </li><li>Electrical Installation Regulations </li><li>Relevant SANS standards </li></ul> 4. DEFINITIONS<ul><li>Lockout: Physical isolation of an energy source using a lock </li><li>Tagout: Placement of a warning tag indicating equipment must not be operated </li><li>Isolation: Disconnecting equipment from its energy source </li><li>Authorized Person: Trained individual permitted to perform LOTO </li><li>Affected Person: Any person working near or using the equipment </li></ul> 5. ROLES AND RESPONSIBILITIESMaintenance Manager / Safety Officer (Dean Jacobs)<ul><li>Ensure implementation of LOTO procedures  </li><li>Provide training and resources </li><li>Monitor compliance </li></ul>Maintenance Supervisor<ul><li>Ensure LOTO is applied before work begins </li><li>Verify isolation is effective </li><li>Enforce compliance </li></ul>Authorized Employees<ul><li>Perform LOTO procedures </li><li>Use correct locks and tags </li><li>Ensure personal safety </li></ul>Affected Employees<ul><li>Must not operate locked/tagged equipment  </li><li>Follow safety instructions </li></ul> 6. WHEN LOTO MUST BE APPLIEDLOTO is mandatory when:<ul><li>Performing maintenance or repairs </li><li>Cleaning or servicing machinery </li><li>Removing guards or safety devices </li><li>There is a risk of unexpected start-up </li><li>Working on electrical systems </li></ul> 7. LOTO PROCEDUREStep 1: Preparation<ul><li>Identify all energy sources </li><li>Notify affected employees </li><li>Understand equipment hazards </li></ul> Step 2: Shutdown<ul><li>Turn off equipment using normal operating controls </li></ul> Step 3: Isolation<ul><li>Disconnect all energy sources: <ul><li>Electrical </li><li>Mechanical </li><li>Hydraulic </li></ul></li></ul> Step 4: Lockout/Tagout<ul><li>Apply personal lock(s) </li><li>Attach warning tag(s) </li><li>Each worker must apply their own lock </li></ul> Step 5: Release Stored Energy<ul><li>Discharge residual energy (pressure, heat, etc.) </li><li>Block moving parts if required </li></ul> Step 6: Verification<ul><li>Attempt to start equipment (test isolation) </li><li>Ensure zero energy state </li></ul> Step 7: Perform Work<ul><li>Proceed with maintenance only after verification </li></ul> Step 8: Removal of LOTO<ul><li>Ensure work is complete </li><li>Remove tools and personnel </li><li>Remove locks and tags (only by person who applied them) </li><li>Restart equipment safely </li></ul> 8. GROUP LOCKOUT<ul><li>When multiple workers are involved: <ul><li>Each person must apply their own lock </li><li>Use lock boxes where required </li></ul></li><li>Equipment must not be energised until all locks are removed </li></ul> 9. CONTRACTOR CONTROL<ul><li>Contractors must comply with LOTO procedures </li><li>Must follow site-specific requirements </li></ul> 10. EQUIPMENT REQUIREMENTSLOTO equipment must include:<ul><li>Locks (unique keys) </li><li>Tags (clearly labelled) </li><li>Lockout devices (valves, breakers, etc.)  </li></ul> 11. TRAINING REQUIREMENTSAll relevant personnel must be trained in:<ul><li>LOTO procedures </li><li>Hazardous energy identification </li><li>Safe isolation practices </li></ul>Refresher training must be conducted periodically. 12. INSPECTIONS AND AUDITS<ul><li>LOTO procedures must be inspected regularly </li><li>Non-compliance must be addressed immediately </li></ul> 13. NON-COMPLIANCE<ul><li>Failure to follow LOTO procedures is a serious violation </li><li>Disciplinary action may be taken </li><li>Work must stop immediately if unsafe conditions exist </li></ul> 14. RECORD KEEPINGThe following must be maintained:<ul><li>Training records </li><li>Inspection reports </li><li>Incident reports related to LOTO </li></ul> 15. REVIEW AND REVISIONThis SOP must be reviewed:<ul><li>Annually </li><li>After incidents </li><li>After changes in equipment or legislation</li></ul>

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