PROCEDURE: ISOLATION AND LOCKOUT

1.0 INTRODUCTION
Failure to isolate and lockout machinery or equipment before working on it can cause serious
injuries or fatalities. This procedure establishes the minimum requirements for locking out all
energy sources and shall be used to ensure that any equipment and machinery is isolated from
all potentially hazardous energy sources prior to work commencement

2.0 SCOPE
2.1 This procedure applies to the isolation of all sources of energy. The forms of energy
involved in Matcoy includes but not limited to;
2.1.1 Electrical energy (electrical power supply, static charges, stored energy in
batteries, inductors, cables, capacitors, power factor correction units, rectifiers)
2.1.2 Mechanical energy (mechanical drives, moving and rotating machinery)
2.1.3 Pressure energy (compressed air, vacuum, hydraulics);
2.1.4 Gravitational energy (counterweights, vehicle runaways, hung-up material, etc.)
2.1.5 Thermal energy (hot or cold surfaces and substances, heat radiation)
2.1.7 Noise
2.1.8 Vibration
2.1.9 Non-ionizing radiation (lasers, welding, electro-magnetic fields, microwaves)
2.1.11 Hazardous substances (corrosive, poisonous, asphyxiates, flammable, explosive,
2.1.13 Biological hazards (bacteria, insects, etc.)
Energy associated with processes such as material handling, transport, pressure,
vacuum, hydraulic, pneumatic and a chemical process is also included. Moving
and stationary machinery are included.

3.0 OBJECTIVES
3.1 Workers suffer severe crushing injuries or are fatally injured because machinery is
inadvertently turned on while it is being maintained, repaired or adjusted. These
injuries can be prevented by adherence to an effective isolation and lockout procedure,
the Fatal Risk Control Standard on isolation and the Mines, Quarries and Machinery
Act regulation 202.
3.2 The objective of this procedure is to eliminate the risk of fatalities and injuries arising
from the uncontrolled release of energy or hazardous materials.
4.0 DEFINITIONS
4.1 Authorized person-A competent person tested and appointed in writing by the responsible
supervisor to conduct isolation activities in a specific operation.
4.2 Specialist – A duly qualified person, specifically trained and appointed in a particular
energy source e.g. electrician in so far as the electrical energy is concerned.
4.3 Permit Issuer – A competent person who has been authorized to issue permit and has
been legally appointed according to Regulations 13.2: 14.2 or 17.1 of MQWM Act.
4.4 Permit Acceptor/Receiver – Authorised person (trained, tested and authorized to conduct
isolation) who shall be responsible for a specific task of a specific trade.
4.5 Competency Based Training-CBT is training which develops the skills, knowledge and
attitudes required to achieve competency standards. A competent person shall mean a
person who;
4.5.1 Is qualified by virtue of their knowledge, skills and experience to organize work
and its performance.
4.5.2 Is familiar with the provisions of the Mines, Quarries, Works and Machinery Act
and regulations which apply to the work to be performed
4.5.3 Has been trained to recognize any potential or actual danger to health or safety in
the performance of the work
4.6 Is in possession of the appropriate certificate of competency.
4.7 De-energize-To remove effectively all possible sources of energy from the item, system,
process, area or equipment in question.
4.8 Dissipation-The safe release and discharge of energy stored or contained in a plant and/or
equipment.
4.9 Earthed-Connected to the general mass of earth in such a manner that will ensure at all
times an immediate discharge of electrical energy, without danger.
4.10 Isolation-To physically remove any connection or means to supply any form of energy
to equipment in order to make energisation of such equipment impossible. In the
context of the standard title, the term Isolation incorporates process of equipment
identification, stopping of energy flow, de-energizing, isolation, lock out, tagging,
making safe, testing for dead and recording in the permit-to-work document and/or
control room logbook.
4.11 Lock Out-To put a personal lock onto an isolating device in such a way that it would be
impossible to connect, switch on or start, utilize or energize the equipment without
removing the personal lock.

5.0 RESPONSIBILITIES
5.2 It shall be the responsibility of all Line Managers to ensure that this procedure is adhered
to.
5.3 It shall be the responsibility of all appointed Engineers BMQWM CAP 44:02 regulation
13.2 and
14.2 appointees to ensure the following:
5.3.1 All new plant and equipment purchased are designed to conform to the
requirements of Debswana Isolation Standards and Procedures; AFRS 6
Isolation Standard and BMQWM CAP 44:02 regulations 202.
5.3.2 Isolation shall provide physical separation or protection from an energy source
and be achieved by use of locking devices.
5.3.3 All designated isolation points are clearly labelled.
5.3.4 Risk Assessment process shall be used to determine the appropriate isolation for
new activities and determine gaps in current isolation activities.
5.3.5 No isolation processes shall be modified or altered except through the application
of a risk based change management process
5.3.6 There shall be a Planned Job Observation for the adherence to the isolation and
lockout procedure.
5.3.7 To ensure that system specific isolation procedures are in place for critical
equipment which if isolated increase the risk exposure rate to other systems or
equipment such as a fire pump or fire suppression system.
5.3.8 To ensure induction and training of persons has been done and make available the
necessary policies, procedures and guidelines for reference.
5.4 It shall be the responsibility of the Maintenance Foreman, Shift Foreman or
Project/Construction Site Manager to ensure that:
5.4.1 Locks out stations are provided where all locks and tags will be kept when not in
use.
5.4.2 Issue based risk assessments, including Job Safety Analysis (JSA), are conducted
for all equipment.
5.4.3 A suitable lock register and identification system is maintained.
5.4.4 All personnel have at least three (3) personalized padlocks and three (3) tags.
Padlocks and tags shall be marked so as to identify the user.
5.4.5 Personal locking padlocks must be uniquely keyed and with only one key.
5.4.6 Planned task observations specific to isolation are conducted.
6.0 GENERAL
6.1 Authorized person obtains a work order or a job card
6.1.1 Obtain a work order or job card for the work to be carried out from your
supervisor.
6.1.2 For callout jobs, obtain a work order or job card from control room.

6.2 Risk Assessment

6.2.1 The risk assessment is the most critical part of the process as it identifies what
needs to be de-energized, isolated, tested or made safe. The lock-out process
shall begin with a job safety analysis to ensure that work is undertaken safely.
6.2.2 All parties involved shall identify the equipment before the authorized person
deenergizes, isolates and locks out equipment.
6.2.3 Identify all sources of energy coming into the plant. Energy fed into the plant may
have more than one source and supply line.
6.2.4 Identify all sources of energy contained within the plant.
6.2.5 Identify all sources of energy going out of the plant
6.2.6 Identify any plant or contents likely to move.
6.2.7 If there is/are existing lock(s) applied on the equipment to be worked on, the
authorized person shall find the team that has locked out and evaluate how the
risk changes when working in proximity to the other team.
6.3 Removal of locks and tags
6.3.1 As each authorized person completes or stops work on the plant, he or she shall
clear the plant of any tools, equipment or materials that he or she has been
using.
6.3.2 Replace all guards that had been removed.
6.3.3 The crew members shall sign the workmen declaration declaring that they have
been told that it is no longer safe to continue working on the apparatus
specified on the permit to work.
6.3.4 The authorized person shall clear the working crew from site. Each crew member
shall remove their isolation locks and tags.
6.3.5 The authorized person shall then remove his or her isolation locks and tags.
6.4 Hand-over of equipment or plant to operations
6.4.1 The authorized person shall check and ensure that the plant is clear of tools,
equipment, materials and persons.
6.4.2 He or she shall check and ensure that all guards have been replaced, and the
equipment or plant is fit for use.
6.4.3 The authorized person shall re-energize the plant.

6.5 Transfer of isolation

6.5.1 If the authorized person who has locked out has to leave the work place, such as
at the end of a shift and needs to hand over to another authorized person their
locks shall be changed as part of the handover.
6.5.2 The handover shall be recorded in the permit to work under transfer of permit.
6.5.3 The new authorized person shall review the job safety analysis (JSA) with the
crew.
6.5.4 Any changes to the crew members shall be reflected in the workman declaration
and JSA. 6.13 Extended lockouts
6.5.1 In the event that the equipment/plant is to remain locked-out for an extended time
i.e.
longer than 3 shifts, the authorized person shall handover the equipment to
their foreman.
6.5.2 The foreman shall apply his/her locks and record this in the permit to work under
transfer of permit.
6.5.3 The equipment shall remain locked out by the foreman until such time that all
preparations have been made to finish off the work.
6.5.4 A new permit to work shall be issued by the foreman for the work to be
completed.
6.5.5 An example of extended lockout is where a machine remains locked out because
it is awaiting delivery of spares and there is no one working on it during the
lockout period.

6.6 Extended lockouts

6.6.1 In the event that the equipment/plant is to remain locked-out for an extended time
i.e.
longer than 3 shifts, the authorized person shall handover the equipment to
their foreman.
6.6.3 The equipment shall remain locked out by the foreman until such time that all
preparations have been made to finish off the work.
6.6.4 A new permit to work shall be issued by the foreman for the work to be
completed.
6.6.5 An example of extended lockout is where a machine remains locked out because
it is awaiting delivery of spares and there is no one working on it during the
lockout period.
6.6.6 Long plant shutdowns and machine overhauls are not regarded as extended
shutdown, as there would be activity throughout the duration of the lockout.
6.7 Action if plant is not fit to return to service
6.7.1 If any authorized person and the associated team stop work on the
equipment/plant without finishing their tasks, or otherwise leave the plant unfit
for use, the plant shall remain isolated and tagged out.
6.8 Removal of locks and tags if authorized person is unavailable
6.8.1 In the event it becomes necessary to remove an authorized person’s lock and/or
tag, due to their absence from the site, the lock cutting and removal process
must be strictly adhered
6.8.2 The Authority to Remove Authorized Person’s Locks and Tags Form shall be
completed with all mandatory signatures acquired.
6.8.3 The General Shift Foreman shall make a thorough inspection of all equipment
involved to prevent any injury to personnel or damage to machinery.
6.8.4 The General Shift Foreman shall then obtain permission from the Line Manager
responsible, to destroy and remove the lock and danger tags
6.8.5 The authorized person’s immediate supervisor is contacted and informed as to the
reason for the request.
6.8.6 The Line Manager will assess the request and will authorize the lock to be
destroyed, after completing the Authority to Remove Authorized Person’s
Locks and Tags Form.
6.8.7 This form shall provide the following information.
6.8.7.1 Lock owner’s name and security number
6.8.7.2 Name of person requesting removal
6.8.7.3 Reason for request and alternatives considered
6.8.7.4 Attempt to contact lock owner by phone (date and time)
6.8.7.5 Authorizing signature
6.8.8 A copy of completed Authority to Remove Authorized Person’s Locks and Tags
Form is then hand delivered to the supervisor and appropriate action will be
taken.
6.16 Detached tags
6.16.1 Any person finding a loose undestroyed isolation tag shall refer the matter to the
worker named on the tag or to a supervisor.
6.17 Visitors and Consultants
6.17.1 Visitors and consultants shall be accompanied my authorized persons all the
time for the duration of their stay at Matcoy Supplies and services.
6.18 The authorized person shall isolate and lockout for visitors and consultants.
6.18.1 The keys shall be kept by the authorized person
6.19 Workshop Power Tools & Equipment
6.19.1 Workshop power tools (pedestal grinders, drilling machine, power saws, etc.)
shall be kept isolated and locked-out to prevent unauthorized use.
6.19.2 The access control lock used shall be different (not plastic type and not colored)
from the personal isolation lock.
6.19.3 The keys shall be kept and maintained by the Workshop Foreman or
Responsible Supervisor.
6.19.4 Safe operating procedures shall be displayed by each power tool.
6.19.5 A pre-use checklist shall be completed before one uses a power tool.
6.20 Out of Service Equipment
6.20.1 Any out-of-service (obsolete or faulty) equipment shall be tagged “OUT OF
SERVICE”
6.20.2 The equipment shall be isolated and locked out by the Foreman or Responsible
Supervisor using their personal isolation lock.
6.20.3 The equipment shall remain locked out until it gets repaired, decommissioned
and/or disposed.
6.21 Visible indication of isolation
6.21.1 All isolation points shall be labelled and marked with a highly visible sticker.
6.21.2 All isolations shall have an isolation tag which shall have a highly visible danger
notice.
6.22 Live Work
6.22.1 In some circumstances, it is necessary to work on the plant/equipment when the
sources of energy to it have not been isolated. Work such as adjustment,
monitoring, fault tracing, some kinds of maintenance, replacement of
components, etc. may require the plant to be energized or operated.
6.22.2 In other cases, it may be necessary to keep the plant operating to ensure
continuity of service, or it may not be practicable to shut down the plant.
6.22.3 Any such work on live plant shall only be carried out in strict accordance with
procedures carefully designed to ensure the safety of the workers involved and
such approval will be in writing by the relevant appointed manager.
6.24 Isolation Lock
6.24.1 Isolation locks shall:
6.24.1.1 Be sufficiently durable to withstand the environment in which they are used;
6.24.1.2 Be standardized (plastic type, not conductive) throughout the site;
6.24.1.3 Be sufficiently substantial to minimize the likelihood of accidental
removal;
6.24.1.4 Be identifiable and assigned to an individual worker.
6.24.1.5 Be uniquely keyed and not be combination locks.
6.24.1.6 Not have an unauthorized second-party master override key.
6.24.1.7 Be kept under the exclusive control of the owning individual, and key
shall not be transferred to another person for lock removal.
6.24.1.8 Be of the kind that cannot be opened by hand when locked with a
multi-lock tool.
6.24.1.9 Not be used for any other purpose.
6.27 Isolation Tags
6.27.1 Isolation tags shall have the following information permanently marked on the
tag
6.27.1.1 The name of the owning individual
6.27.1.2 Security number of the owning individual
6.27.1.3 Date isolation done
6.27.1.4 Contact details of the owning individual
6.27.2 The isolation tag shall carry the prohibition “Danger, Do not operate” on both
sides.
6.27.3 Isolation tags shall not be used for any other purpose.
6.27.4 Tags do not provide means of restraint on the device as they can be removed
inadvertently by mistake or by accident. The essential purpose of a tag is to provide
information, not security 6.27.5 Isolation tags shall be:
6.27.5.1 highly visible
6.27.5.2 sufficiently durable to withstand the environment in which they are
used
6.27.5.3 standardized throughout the site
6.27.5.4 sufficiently substantial to minimize the likelihood of accidental
removal
6.27.5.5 identifiable
6.27.5.6 Provided with a substantial tie or other means of attachment.
6.28 Equipment specific isolation procedures
6.28.1 Equipment specific isolation procedures shall be informed by a risk assessment.
6.28.2 Equipment with multiple energy sources (more than 3) shall generally have
equipment specific procedures.
6.28.3 Equipment operating at high voltages (greater than 1000V) shall have specific
procedures.

Signed …………………….……….. Title……………………………………………………

Time……………….. Date………………….