Isolation Plants
Isolation Plants
Department of Commerce
GUIDANCE NOTE
Guidance note
Isolation of plant
2010
ISOLATION OF PLANT
C OM MIS SION
commission
for occupational
safety and health
guidance note isolation of plant
Guidance note
Isolation of plant
2010
commission
for occupational
safety and health
guidance note isolation of plant
Foreword
This guidance note is issued by the Commission for Occupational Safety and Health (the Commission)
under the Occupational Safety and Health Act 1984 (the OSH Act).
The OSH Act established the tripartite Commission, which consists of representatives of employers,
unions and government, as well as experts. The Commission has the function of developing
the occupational safety and health legislation and supporting guidance material, and making
recommendations to the Minister for Commerce for their implementation. To fulfil its functions, the
Commission is empowered to establish advisory committees, hold public inquiries, and publish and
disseminate information.
The Commission’s objective is to promote comprehensive and practical preventive strategies that improve
the working environment of Western Australians. This guidance note has been developed through a
tripartite consultative process, and the views of employers and unions along with those of government
and experts, have been considered.
The following information is provided as background to understanding this guidance note.
The OSH Act provides for the promotion, co-ordination, administration and enforcement of occupational
safety and health in Western Australia. It applies to all industries with the exception of mining and
petroleum.
With the objective of preventing occupational injuries and diseases, the OSH Act places certain duties on
employers, employees, self-employed people, manufacturers, designers, importers and suppliers.
The broad duties established by the OSH Act are supported by a further tier of statute, commonly referred
to as regulations, together with lower tiers of non-statutory codes of practice and guidance notes.
The Occupational Safety and Health Regulations 1996 (the OSH Regulations) have the effect of spelling
out specific requirements of the legislation. They may prescribe minimum standards and have a general
application, or define specific requirements related to a particular hazard or type of work. They may also
allow licensing or granting of approvals and certificates.
Codes of practice published under the OSH Act provide practical guidance on how to comply with a
general duty or specific duties under the legislation.
Codes of practice may contain explanatory information. The preventive strategies outlined do not represent
the only acceptable means of achieving a certain standard.
A code of practice does not have the same legal force as a regulation and is not sufficient reason, of itself,
for prosecution under the legislation, but it may be used by courts as the standard when assessing other
methods or practices used.
A guidance note is an explanatory document issues by the Commission providing detailed information
on the requirements of legislation, regulations, standards, codes of practice or matters relating to
occupational safety and health.
guidance note isolation of plant
Authority
This guidance note has been issued by the Commission under section 14 of the OSH Act. It provides
guidance to people at work and in control of workplaces for developing safe isolation procedures to
minimise the risk of injury while workplace plant is being inspected, repaired, maintained, assessed,
adjusted or cleaned.
Disclaimer
Information in this publication is provided to assist you in meeting your occupational safety and health
obligations. While information is correct at the time of publication, readers should check and verify any
legislation referenced in this publication to ensure it is current at the time of use.
Changes in law after this document is published may impact on the accuracy of information. The
Commission provides this information as a service to the community. It is made available in good faith
and is derived from sources believed to be reliable and accurate at the time of publication.
guidance note isolation of plant
Contents
1. Introduction................................................................................................... 2
3. Strict adherence........................................................................................... 3
4. Risk management........................................................................................ 3
6. Shutting down............................................................................................... 4
8. Energy sources............................................................................................ 5
9. Other hazards............................................................................................... 5
19. Tagging......................................................................................................... 8
21. Guarding..................................................................................................... 10
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guidance note isolation of plant
1. Introduction
Every year people at work are injured, sometimes fatally, when plant is inadvertently activated. These
injuries can be prevented by introducing and following correct isolation of plant procedures.
Before any plant is inspected, repaired, maintained or cleaned it must, where practicable, be shut down
and its energy sources locked out and tagged as part of an isolation procedure to ensure the safety of
those doing the work.
‘Plant’ means more than you might think. Plant is a general name for machinery, tools, appliances and
equipment. It can include items as diverse as a press in a foundry or a computer in an office. Plant
includes, but is not limited to: electric drills, lifts, escalators, tractors, hand trolleys, cranes, commercial
fishing nets and arc welding gear.
The people with duties in relation to isolation of plant are employers, main contractors, self-employed
people, workers and people in control of a workplace or its access.
The Occupational Safety and Health Regulations 1996 covered in this guidance note are:
• regulation 4.37 Duties of certain persons as to the use of plant;
• regulation 4.37A Duties of certain persons for the purposes of regulation 4.37(1)(b) or (c); and
• regulation 4.38 Duties of employers as to damaged plant.
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guidance note isolation of plant
Written isolation procedures should be developed where plant is combined with other machinery or
equipment and may involve different processes, hazards or power sources. Only people with the right
skills should develop these procedures.
The procedures should be developed in consultation with safety and health representatives, people
doing adjustments, cleaning, maintenance, repairs or inspections and, if possible, plant manufacturers,
suppliers and people who designed and installed the plant. Where practical, people experienced in
operating the plant should also be consulted.
The effectiveness of isolation procedures relies on providing workers involved with the plant with
information, instruction and training, and appointing an authorised person to supervise and ensure
isolation procedures are rigorously applied.
The isolation procedure should be displayed in a prominent position on or adjacent to the plant
where possible.
3. Strict adherence
Once an isolation system has been introduced, it must be strictly followed, or it can become ineffective
and dangerous. The system should be reviewed from time to time to ensure it remains relevant
and appropriate.
4. Risk management
A risk management approach to the adjustment, inspection, cleaning, maintenance or repair of plant, and
the isolation procedure itself, requires:
1. hazards to be identified;
2. associated risks to be assessed;
3. risks to be eliminated or controlled; and
4. the controls to be reviewed from time to time to ensure they remain effective.
The employer, main contractor, self-employed person and person in control of the workplace or its access
must ensure all hazards are identified, and procedures are written and followed to control identified
hazards. Before work commences, contractors and workers new to the plant should be briefed on the
procedures to be followed and the need to observe all safety requirements.
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guidance note isolation of plant
6. Shutting down
Plant that has only one energy source can usually be shut down by the operation of a single control such
as a switch or valve. More complex plant may have to be shut down in a certain sequence such as one
conveyor before another, or by shutting down several energy sources eg electricity, petrol, diesel, oil,
steam, pressurised air, LPG, LNG or coal.
Shutting the plant down may require other potential hazards, for example pipes and lines carrying gases,
water, acids or alkalis, to be turned off and locked-out to prevent re-activation. An alternative to closing
and locking-off a valve may be blanking or the insertion of a spade, sometimes called a spectacle plate
because of its shape.
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guidance note isolation of plant
8. Energy sources
Plant energy sources include:
• electricity (mains, solar and by generator);
• chemicals;
• fuels;
• heat;
• steam;
• pneumatic pressure (compressed air);
• fluids under pressure, such as water or hydraulic oil;
• energy storing devices, such as batteries, springs, flywheels, accumulators and capacitors;
• gravity; and
• radiation.
9. Other hazards
Depending on the type of plant, other hazards may include:
• hazardous substances, such as gases, acids, alkalis, solvents, glues or pooled liquids in which a
person may drown;
• falls;
• burns;
• asphyxiation; and/or
• impact.
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guidance note isolation of plant
NOTE
In some circumstances electrical isolators may only isolate control circuits – this is not sufficient for
the safety of people required to work on the equipment.
The mains power source feeding the plant must be isolated.
For example, a piece of plant is connected via a switch panel to the main power board. Not only does
the switch panel need to be isolated but also the circuit feeding the panel from the main power board.
Care must be taken to ensure all electricity sources are identified and isolated as some equipment
will have several control stations and sections which could have independent electricity sources. If
programmable logic devices are used to control the equipment, then it is essential to use local isolating
switches as the means to achieve secure and safe isolation. It is not acceptable to rely on the controls of
the programmable logic devices for the isolation of equipment.
Isolating programs with step by step instructions must be developed and implemented wherever there is a
danger of the plant being operated during periods of maintenance etc.
Isolating the electricity supply to an item of plant must include checking that the electrical supply has been
isolated, not just the control circuit, and disconnected if necessary by an electrician. There should be no
possibility of the plant being inadvertently energised via another source or control system.
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guidance note isolation of plant
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guidance note isolation of plant
The above describes the common lock-out system in use at most work places. ‘Captured key’
systems and group lock-out systems are also acceptable.
19. Tagging
A tag is NOT in itself an effective isolation device. A tag acts only as a means of providing information to
others at the workplace. When practicable, a lock must be used in preference to a tag as an
isolation device.
A personal danger tag should accompany each lock used in an isolation procedure and identify the
person who put the tag and lock in place, the time and date this occurred and the item of plant being
isolated. In a large workplace it should also identify the work group of the person who attached the tag.
The tag system requires a notice to warn personnel against using the equipment to which a tag is
attached. No one should interfere with or operate any tagged equipment such as a main switch, push
button or other electrical device until the item has been cleared for safe operation and the attached tag
has been removed. The tag must only be removed by the person who attached it, or by the ‘authorised
person’ in accordance with an approved procedure. The ‘authorised person’ is responsible for ensuring
procedures affecting the use of tags are followed.
Locks are available that have a personal danger tag incorporated to ensure that the tag can only be
removed by the person who put the lock in place.
The person doing the work must personally fasten their personal danger tag on all lockout devices
involved in the isolation procedure.
A personal danger tag attached to an isolation device means the person is currently engaged in work on
the plant, and that it is likely that the person will be injured if the isolating device is not maintained in the
safe position.
If more than one person is involved in the work, each person must attach their own lock and personal
danger tag to the lockout device.
A personal danger tag should be removed only by the person whose name is written on the tag.
All disposable personal danger tags should be destroyed after use.
Removal of a personal danger tag from an isolating device should be carried out as soon as practicable
after completing the work. In every case a personal danger tag should be removed before leaving the
worksite at the end of the shift. The isolation procedure needs to include the action to be taken if a person
should fail to remove a personal danger tag before leaving the worksite.
If work on plant is not completed by the end of a working shift and the plant is required to remain isolated,
arrangements must be made for ‘out of service’ tags to be placed on each isolating point before personal
danger tags are removed. If work on the plant is to continue during the next shift there must be a ’hand
over’ briefing by the shift leaving the site to those taking over the work. The briefing should include the
status of the work and the removal or replacement of personal danger tags and locks.
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guidance note isolation of plant
Personal danger tags should be used whenever work is required to be undertaken in or about equipment
or machinery that could cause injury.
It may be necessary when placing an ‘out of service tag’ on a piece of plant to also record on any
computer controlling the plant that it is out of service.
While the above relates to tagging systems used in most workplaces, group tagging is also acceptable.
21. Guarding
Guarding designed to protect workers from moving parts may need to be removed or de-activated before
adjustment, inspection, cleaning, repairs or maintenance. The plant’s energy source must always be
isolated and locked out before guarding is removed. When work on the plant is complete, guarding must
be replaced and secured before energy is restored and normal operations re-commence.
Duties of employers
The safety and health duties of the employer include:
• ensuring workers are not exposed, as far as practicable, to workplace hazards of a safety and health
nature;
• providing workers with adequate information, instruction, training and supervision;
• consulting workers and safety and health representatives, where they exist, about workplace safety
and health;
• where it is impractical to eliminate or control hazards, providing workers with adequate personal
protective clothing and equipment; and
• establishing and maintaining safe systems of work.
Duties of workers
The safety and health duties of the worker include:
• taking reasonable care of their own and others’ safety and health; and
• cooperating with employers in carrying out safety and health requirements.
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guidance note isolation of plant
Legislation
• Occupational Safety and Health Act 1984
• Occupational Safety and Health Regulations 1996
Copies of the above legislation can be downloaded from the website of the State Law Publisher at
www.slp.wa.gov.au
Printed copies can be purchased from the State Law Publisher at 10 William Street, Perth.
Copies are also held in the WorkSafe library, 5th floor, 1260 Hay Street, West Perth.
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guidance note isolation of plant
UnionsWA
Level 4, 445 Hay St
PERTH WA 6000
Telephone: (08) 9328 7877
Facsimile: (08) 9328 8132
Email: unionsyes@unionswa.com.au
Internet site: www.unionswa.com.au
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commission
for occupational
safety and health
2010
ISBN 978-1-920836-43-6
ISBN 978-1-920836-44-3 (web)
Email: safety@commerce.wa.gov.au