Standard Operating Procedure for Energy Control Procedures in Gels Production

1) Purpose

The purpose of this SOP is to establish procedures for the control of energy sources during maintenance, servicing, and cleaning of equipment in gels production to prevent accidents, injuries, and equipment damage.

2) Scope

This SOP applies to all personnel involved in operating, maintaining, servicing, and cleaning equipment used in gels production within the pharmaceutical manufacturing facility.

3) Responsibilities

Production Operators: Follow energy control procedures during equipment operation and maintenance.
Maintenance Technicians: Perform lockout/tagout procedures and verify equipment isolation.
Supervisors: Ensure compliance with energy control procedures and provide oversight during maintenance activities.
Health and Safety Officers: Monitor and enforce safety regulations related to energy control.

4) Procedure

4.1 Energy Control Program
4.1.1 Develop and maintain an energy control program that complies with regulatory requirements and company policies.
4.1.2 Identify all energy sources (electrical, mechanical, hydraulic, pneumatic, etc.) that need to be controlled.

4.2 Lockout/Tagout Procedures
4.2.1 Obtain authorization and a work permit before starting any maintenance or cleaning activities.
4.2.2 Notify affected personnel about the equipment shutdown and lockout/tagout procedures.
4.2.3 Isolate energy sources by placing lockout devices and tags on appropriate switches, valves, or controls.

4.3 Verification of Isolation
4.3.1 Verify that all energy sources are effectively isolated and equipment is in a zero-energy state before beginning work.
4.3.2 Test equipment controls to ensure they are inoperative and cannot be started accidentally.

4.4 Work Activities
4.4.1 Perform maintenance, servicing, or cleaning activities as per approved procedures and work instructions.
4.4.2 Use appropriate tools and equipment in accordance with safety guidelines.

4.5 Release of Lockout/Tagout
4.5.1 After completing work, remove lockout/tagout devices only by authorized personnel.
4.5.2 Verify with affected personnel that work is complete and equipment is safe to operate.

4.6 Training and Communication
4.6.1 Provide training to personnel on energy control procedures, including lockout/tagout techniques and safety measures.
4.6.2 Maintain clear communication between operators, maintenance technicians, and supervisors throughout the process.

5) Abbreviations, if any

SOP: Standard Operating Procedure

6) Documents, if any

– Energy Control Program Documentation
– Lockout/Tagout Procedures
– Work Permits

7) Reference, if any

– OSHA 29 CFR 1910.147: Control of Hazardous Energy (Lockout/Tagout)
– ANSI/ASSE Z244.1: Control of Hazardous Energy – Lockout/Tagout and Alternative Methods
– Company-specific safety guidelines and procedures

8) SOP Version

Version 1.0