Lockout Tagout

What is Lockout Tagout?

Lockout/Tagout (LOTO) is a safety procedure used in industrial and construction workplaces to ensure that machinery or equipment is properly shut off and cannot be started up again prior to the completion of maintenance, repair, or servicing work. The purpose of LOTO is to prevent accidents caused by the unexpected startup of equipment, which can result in serious injury or death.

During the LOTO procedure, a designated employee will place a lock and a tag on each energy-isolating device (such as a circuit breaker or valve) that controls the flow of energy to the machinery or equipment. The lock ensures that the energy-isolating device cannot be turned on until the lock is removed by the same person who placed it there. The tag provides information about who placed the lock and why, and serves as a visual warning to other employees that the equipment is not to be used.

LOTO procedures vary depending on the specific equipment and workplace, but generally involve a series of steps to ensure that all sources of energy have been identified, isolated, and locked/tagged. Proper training and education on LOTO procedures is essential for all employees who may be involved in maintenance, repair, or servicing of machinery or equipment.

Why is Lockout Tagout Safety Important?

Lockout/Tagout (LOTO) safety is important because it helps to prevent accidents and injuries in the workplace. The unexpected startup of machinery or equipment during maintenance, repair, or servicing can result in serious injuries or fatalities, including amputations, electrocutions, and crushing injuries.

By using LOTO procedures, employees are able to identify and isolate all sources of energy that could potentially cause harm, and prevent the equipment from being turned on while maintenance, repair, or servicing work is being performed. This helps to ensure that employees are not exposed to hazardous energy sources and reduces the risk of accidents and injuries.

In addition to protecting employees, LOTO safety is also important for employers. By implementing LOTO procedures, employers can reduce the risk of work-related injuries, decrease the likelihood of costly equipment damage, and comply with legal and regulatory requirements. Failure to comply with LOTO regulations can result in fines and penalties, as well as damage to the company's reputation and legal liabilities.

Overall, LOTO safety is a critical component of workplace safety programs, and its proper implementation can help to protect both employees and employers from accidents and injuries.

The Purpose of Lockout Tagout

What is the Purpose of Lockout Tagout

The purpose of Lockout/Tagout (LOTO) is to protect employees from hazardous energy sources that can cause injury or death during maintenance, repair, or servicing work on machinery or equipment.

The LOTO procedure involves the placement of a lock and a tag on each energy-isolating device that controls the flow of energy to the machinery or equipment. The lock prevents the energy-isolating device from being turned on until the lock is removed by the same person who placed it there. The tag provides information about who placed the lock and why, and serves as a visual warning to other employees that the equipment is not to be used.

The purpose of the LOTO procedure is to ensure that all sources of energy have been identified, isolated, and locked/tagged prior to the start of maintenance, repair, or servicing work. This helps to prevent the unexpected startup of machinery or equipment, which can result in serious injuries or fatalities, including amputations, electrocutions, and crushing injuries.

By implementing LOTO procedures, employers can protect their employees from hazardous energy sources and reduce the risk of work-related injuries. LOTO also helps employers to comply with legal and regulatory requirements, reduce equipment damage, and minimize production downtime. Overall, the purpose of LOTO is to create a safer workplace environment for all employees.

Legal and Regulatory Requirements

The legal and regulatory requirements for Lockout/Tagout (LOTO) procedures vary depending on the country and industry, but generally include the following:

OSHA in the United States: The Occupational Safety and Health Administration (OSHA) has established standards for the control of hazardous energy sources in the workplace, including the LOTO standard (29 CFR 1910.147). This standard requires employers to develop, implement, and enforce an energy control program that includes written procedures for LOTO.
EU Machinery Directive: The EU Machinery Directive (2006/42/EC) requires that machinery and equipment be designed and constructed in a way that allows for safe maintenance, repair, and servicing work. The directive also requires employers to provide information and training to employees on the safe use of machinery and equipment, including LOTO procedures.
Canadian Standards Association: The Canadian Standards Association (CSA) has established standards for LOTO procedures, including CSA Z460-13 Control of Hazardous Energy – Lockout and Other Methods.
Australian Standards: The Australian Standard AS 3012:2010 Electrical Installations – Construction and Demolition Sites outlines the requirements for LOTO procedures in Australia.
International Standards: The International Organization for Standardization (ISO) has developed a number of standards related to LOTO procedures, including ISO 12100:2010 Safety of machinery – General principles for design – Risk assessment and risk reduction.

In addition to these standards and regulations, employers are responsible for ensuring that their employees are trained on LOTO procedures and that they are following them correctly. Failure to comply with LOTO regulations can result in fines and penalties, as well as damage to the company's reputation and legal liabilities.

The Lockout Tagout Process

Steps Involved

The steps involved in Lockout/Tagout (LOTO) procedures generally include the following:

Preparation: Before starting the LOTO procedure, the employee must identify all energy sources that need to be controlled and determine the type and amount of energy that is present.
Shutdown: The employee must shut down the machinery or equipment using the normal shutdown procedure.
Isolation: The employee must isolate the energy sources by placing locks and tags on all energy-isolating devices, such as circuit breakers, valves, or switches. The locks and tags must be placed in a way that prevents the machinery or equipment from being started up.
Release of Stored Energy: The employee must release any stored energy, such as pressure or residual electricity, from the machinery or equipment to ensure that it is safe to work on.
Verification: Once the energy sources are isolated and the stored energy is released, the employee must verify that the machinery or equipment cannot be started up by attempting to start it using the normal startup procedures.
Maintenance, Repair, or Servicing: The employee can now safely perform maintenance, repair, or servicing work on the machinery or equipment.
Removal of Locks and Tags: Once the maintenance, repair, or servicing work is complete, the employee must remove the locks and tags from the energy-isolating devices and ensure that the machinery or equipment is ready for use.

Proper training and education on LOTO procedures is essential for all employees who may be involved in maintenance, repair, or servicing of machinery or equipment. LOTO procedures vary depending on the specific equipment and workplace, but following these steps can help to ensure that all sources of energy have been identified, isolated, and locked/tagged, and that employees are protected from hazardous energy sources during maintenance, repair, or servicing work.

Preparation

Preparation is a critical step in the Lockout/Tagout (LOTO) procedure, as it ensures that all energy sources are identified, and the procedure is executed safely and efficiently. The following steps are involved in the preparation stage of LOTO:

Notify Affected Employees: The employer must inform all employees who may be affected by the LOTO procedure about the nature and duration of the work, the reason for the LOTO procedure, and the hazards associated with the energy sources.
Identify Energy Sources: The employee must identify all energy sources that need to be controlled, including electrical, mechanical, hydraulic, pneumatic, thermal, and gravitational energy sources.
Determine Type and Magnitude of Energy: The employee must determine the type and magnitude of energy that is present, as this will determine the type of lockout device or tag that is required.
Identify Lockout Points: The employee must identify the specific points where the lockout devices or tags will be placed to isolate the energy sources.
Gather Equipment: The employee must gather all necessary equipment, including lockout devices, tags, hasps, and lockout kits.
Develop Written Procedures: The employer must develop written LOTO procedures that outline the steps for controlling hazardous energy sources, including the specific procedures for each type of equipment or machinery.
Train Employees: The employer must train employees on the LOTO procedures, including the hazards associated with hazardous energy sources, the proper use of lockout devices and tags, and the importance of following the LOTO procedures.

By properly preparing for the LOTO procedure, employers can help ensure that all energy sources are identified, and the procedure is executed safely and efficiently. This can help to prevent injuries, equipment damage, and production downtime.

Shut Down Procedures

Shutdown procedures are the steps taken to safely turn off equipment or machinery before performing maintenance, repair, or servicing work. The specific steps involved in shutdown procedures may vary depending on the equipment or machinery, but some general guidelines include:

Follow Manufacturer's Instructions: The employee should follow the manufacturer's instructions for shutting down the equipment or machinery. The manufacturer's instructions may include specific steps to take, such as turning off power sources or releasing stored energy.
Alert Other Employees: The employee should alert other employees who may be working near or with the equipment that it will be shut down. This can help to prevent accidents and ensure that everyone is aware of the shutdown.
Remove Materials: The employee should remove all materials, tools, and equipment from the equipment or machinery before shutting it down. This can help to prevent damage to the equipment or machinery and reduce the risk of injury.
Shut Down Power Sources: The employee should shut down all power sources to the equipment or machinery. This may involve turning off circuit breakers, unplugging electrical cords, or shutting down generators.
Ventilate Equipment: The employee should ensure that the equipment or machinery is properly ventilated before shutting it down. This can help to prevent the buildup of hazardous fumes or gases.
Secure Equipment: The employee should secure the equipment or machinery to prevent it from moving or shifting during maintenance, repair, or servicing work. This may involve using wedges, chocks, or blocks.

By following proper shutdown procedures, employees can help to ensure that equipment or machinery is safely turned off before performing maintenance, repair, or servicing work. This can help to prevent accidents, equipment damage, and production downtime.

Equipment Isolation

Equipment is isolated for lockout tagout (LOTO) by using lockout devices, tags, and other safety equipment to ensure that energy sources are controlled and hazardous energy is prevented from being released. The following steps are typically involved in isolating equipment for LOTO:

Shut Down the Equipment: The employee should shut down the equipment or machinery by following the manufacturer's instructions and standard operating procedures.
Disconnect Energy Sources: The employee should disconnect all energy sources to the equipment, including electrical, mechanical, hydraulic, pneumatic, thermal, and gravitational energy sources.
Release Stored Energy: The employee should release any stored energy that may be present in the equipment, such as pressure in pneumatic systems or tension in springs.
Isolate Energy Sources: The employee should isolate energy sources using lockout devices, such as locks, hasps, and chains, to prevent the energy from being restored while maintenance, repair, or servicing work is being performed.
Apply Lockout Tags: The employee should apply lockout tags to the lockout devices, indicating that the equipment is being serviced and that it should not be operated until the tags are removed.
Verify Isolation: The employee should verify that all energy sources have been properly isolated and that the equipment cannot be restarted. This may involve testing the equipment to ensure that it cannot be operated and checking for any residual energy that may still be present.

By properly isolating equipment for LOTO, employees can help to prevent accidents and injuries caused by hazardous energy sources. This can help to ensure that maintenance, repair, or servicing work is performed safely and efficiently.

Lockout Tagout Applied

The tag used for lockout tagout (LOTO) is applied after the lockout device has been installed to control the energy sources of the equipment. The tag serves as a visual reminder that the equipment is locked out and cannot be operated until the lockout device and tag are removed by the authorized person who installed them. Here are the general steps for applying the tag for LOTO:

Select the Appropriate Tag: The tag used for LOTO should be made of durable material, be easily visible, and include information such as the reason for the lockout, the name of the person who installed the lockout device, and the date and time the lockout was applied.
Fill Out the Tag: The person who installed the lockout device should fill out the tag with the necessary information, including the equipment identification, the date and time of the lockout, and their name and contact information.
Attach the Tag to the Lockout Device: The tag should be attached securely to the lockout device using a durable tag holder or tie.
Position the Tag: The tag should be positioned so that it is clearly visible and easily accessible. It should not be obstructed by other equipment or objects, and it should be located in a place where it can be easily seen by anyone approaching the equipment.
Verify the Tag is in Place: The person who installed the lockout device should verify that the tag is securely attached to the lockout device and that it is positioned correctly.

By following these steps, employees can apply the tag for LOTO properly, which helps to ensure that hazardous energy is controlled, and maintenance, repair, or servicing work can be performed safely.

Verifying Equipment Isolation

Verifying that equipment has been properly isolated is an essential step in lockout tagout (LOTO) procedures. The purpose of this step is to ensure that the equipment cannot be energized while maintenance, repair, or servicing work is being performed. Here are some general methods that can be used to verify that equipment has been isolated:

Visual Inspection: A visual inspection can be performed to verify that all energy sources have been properly isolated and locked out. This can include checking to see that valves are closed, switches are off, and power cords are disconnected.
Testing: If possible, testing can be performed to verify that the equipment cannot be energized. This can include attempting to start the equipment or testing for any residual energy that may still be present.
Use of Test Equipment: Test equipment, such as a voltage tester or multi-meter, can be used to verify that the equipment is not energized. The tester should be applied to each energy source to confirm that it has been de-energized.
Communication: Communication with other employees who may have knowledge of the equipment or the lockout tagout procedure can be used to verify that all energy sources have been properly isolated.

It is important to note that verification should always be performed by an authorized person who is trained in lockout tagout procedures and understands the hazards associated with the equipment being serviced. If any doubts or concerns exist about the verification process, additional measures may need to be taken to ensure that the equipment is properly isolated.

Lockout Tagout Removal

Lockout tagout (LOTO) devices should only be removed by an authorized person who is trained in LOTO procedures and has verified that the equipment is safe to operate. Before removing the LOTO devices, the following steps should be taken:

Inspect the Equipment: The authorized person should visually inspect the equipment to ensure that it is safe to operate and that all tools and equipment have been removed.
Verify that Energy Sources are Restored: The authorized person should verify that all energy sources have been restored, such as by checking that power is available or that valves have been opened.
Notify Affected Personnel: The authorized person should notify any affected personnel that the equipment is about to be restored to service.

Once these steps have been taken, the LOTO devices can be removed using the following general steps:

Remove the Tag: The tag should be removed from the lockout device.
Remove the Lockout Device: The lockout device should be removed from the energy source.
Restore the Equipment: The equipment should be restored to its normal operating condition, such as by turning on power or opening valves.
Inspect the Equipment: After restoring the equipment, the authorized person should visually inspect it again to ensure that it is operating normally and safely.

It is important to note that only authorized persons who are trained in LOTO procedures should remove the lockout tagout devices. If any issues or concerns arise during the removal process, the equipment should be shut down again, and additional measures should be taken to ensure that it is safe to operate.

Restart Procedures

Restarting procedures in lockout tagout (LOTO) requires several important steps to ensure the safety of personnel and the equipment. Here are some general steps that can be followed:

Notify Affected Personnel: Before restarting procedures, notify any affected personnel that the equipment is about to be restarted.
Inspect the Equipment: Visually inspect the equipment to ensure that it is safe to restart. Check for any signs of damage or wear, and make sure that all tools and equipment have been removed.
Restore Energy Sources: Energy sources should be restored in the reverse order of the lockout tagout procedure. For example, if a valve was closed during the lockout procedure, it should be opened first.
Remove LOTO Devices: Remove the lockout and tagout devices from the energy sources.
Test the Equipment: Test the equipment to ensure that it is operating normally and safely. Start the equipment and let it run for a few minutes to make sure that everything is working as expected.
Notify Personnel: Once the equipment has been restarted and tested, notify any affected personnel that the equipment is back in service.

It is important to note that restarting procedures in LOTO should only be done by authorized personnel who are trained in LOTO procedures and understand the hazards associated with the equipment being serviced. If any issues or concerns arise during the restart process, the equipment should be shut down again, and additional measures should be taken to ensure that it is safe to operate.

Common Lockout Tagout Hazards and How to Mitigate Them

Common Electrical Hazards

Electrical hazards are some of the most common and potentially deadly hazards associated with lockout tagout (LOTO) procedures. Here are some of the most common electrical hazards that workers may encounter during LOTO:

Electric Shock: Electric shock is a serious hazard that can occur when workers come into contact with live electrical wires or components that have not been properly de-energized.
Arc Flash: An arc flash is an electrical explosion caused by a sudden release of energy when current flows through the air. Arc flashes can cause severe burns and other injuries.
Electrical Burns: Electrical burns can occur when workers touch live electrical wires or components. These burns can be severe and may require medical attention.
Electrocution: Electrocution is the most serious electrical hazard and occurs when workers are exposed to high levels of electrical current, which can cause the heart to stop.

To prevent these hazards from occurring during LOTO procedures, it is essential to follow proper lockout and tagout procedures, including de-energizing and isolating electrical equipment and components. Additionally, workers should be properly trained on LOTO procedures and should always use appropriate personal protective equipment (PPE) when working with electrical equipment. Regular maintenance and inspection of electrical equipment can also help to identify potential hazards and prevent accidents from occurring.

Mechanical Hazards

Mechanical hazards are another common type of hazard associated with lockout tagout (LOTO) procedures. These hazards can result in serious injuries or even fatalities if proper safety precautions are not taken. Here are some examples of mechanical hazards that can occur during LOTO procedures:

Crushing: Workers can be crushed by moving parts of machinery or equipment, such as conveyor belts, gears, or hydraulic systems.
Cutting or Shearing: Sharp edges or blades on machinery can cause serious cuts or amputations if workers come into contact with them.
Pinching: Workers' fingers or hands can be pinched or caught between moving parts of machinery, such as rollers or gears.
Entanglement: Loose clothing or hair can become entangled in moving parts of machinery, which can result in serious injuries or even death.

To prevent these hazards from occurring during LOTO procedures, workers should be properly trained on the specific hazards associated with the machinery and equipment they will be working on. Proper lockout and tagout procedures should be followed, and workers should wear appropriate personal protective equipment (PPE) to protect themselves from flying debris, moving parts, and other hazards. Machinery and equipment should also be regularly inspected and maintained to ensure that it is functioning properly and that all safety guards and devices are in place and functioning correctly.

Thermal Hazards

Thermal hazards are another common type of hazard associated with lockout tagout (LOTO) procedures. These hazards can result in serious burns or other thermal injuries if proper safety precautions are not taken. Here are some examples of thermal hazards that can occur during LOTO procedures:

Burns: Burns can occur from hot surfaces or materials, such as pipes, boilers, or hot liquids.
Fire: The release of flammable gases or liquids during maintenance or repair work can cause fires or explosions.
Thermal Stress: Workers may experience thermal stress, which can cause heat exhaustion or heat stroke, particularly in hot and humid environments.

To prevent these hazards from occurring during LOTO procedures, workers should be properly trained on the specific hazards associated with the equipment they will be working on. Proper lockout and tagout procedures should be followed, and workers should wear appropriate personal protective equipment (PPE) to protect themselves from thermal hazards. Equipment should also be properly maintained to prevent leaks or other hazards that could result in fires or explosions. Workers should also take regular breaks in cool or shaded areas to prevent thermal stress.

How to Mitigate These Hazards

Lockout tagout (LOTO) procedures can help mitigate electrical, mechanical, and thermal hazards by ensuring that equipment is safely de-energized, locked, and tagged before maintenance or repair work begins. Here are some ways that LOTO procedures can help mitigate these hazards:

Electrical Hazards: LOTO procedures help ensure that electrical equipment is de-energized and that workers are protected from live electrical wires or components. Workers must follow strict procedures to isolate and test electrical equipment before performing maintenance or repairs. Additionally, workers must use appropriate personal protective equipment (PPE), such as insulated gloves or rubber mats, to protect themselves from electrical hazards.
Mechanical Hazards: LOTO procedures help prevent accidents caused by moving parts of machinery or equipment. Workers must follow strict procedures to isolate and lock out the machinery or equipment before performing maintenance or repairs. Additionally, workers must use appropriate PPE, such as safety glasses, hard hats, or steel-toed shoes, to protect themselves from flying debris or other hazards associated with mechanical equipment.
Thermal Hazards: LOTO procedures help prevent thermal hazards by ensuring that equipment is properly cooled, drained, or depressurized before maintenance or repair work begins. Workers must follow strict procedures to isolate and lock out the equipment before performing maintenance or repairs. Additionally, workers must use appropriate PPE, such as heat-resistant gloves, aprons, or face shields, to protect themselves from thermal hazards.

In summary, LOTO procedures are essential to mitigate electrical, mechanical, and thermal hazards by ensuring that equipment is safely isolated and that workers are properly trained, equipped, and protected from potential hazards.

Importance of Training

Why This Training is Important

Lockout tagout (LOTO) training is important for several reasons:

Worker Safety: LOTO procedures involve potentially hazardous work environments, and proper training is essential to ensure that workers are aware of the hazards and know how to perform their work safely. Workers who are not trained in LOTO procedures may be at a greater risk of accidents, injuries, or fatalities.
Compliance with Regulations: Many countries have regulations and standards related to LOTO procedures. These regulations require that employers provide proper training to their employees who perform maintenance or repair work on potentially hazardous equipment. Failure to comply with these regulations can result in penalties or fines.
Equipment Protection: Proper LOTO procedures help protect equipment from damage during maintenance or repair work. If workers do not properly isolate and lockout equipment before performing maintenance or repair work, the equipment can be damaged, leading to additional downtime and repair costs.
Productivity: Proper LOTO procedures can help minimize downtime and improve productivity. If workers are properly trained in LOTO procedures, they can perform maintenance or repair work more efficiently and effectively, minimizing the time that equipment is out of service.
Reputation: Failure to properly train employees in LOTO procedures can damage a company's reputation. Accidents, injuries, or fatalities resulting from failure to follow LOTO procedures can lead to negative publicity and harm a company's reputation.

In summary, LOTO training is essential for worker safety, compliance with regulations, equipment protection, productivity, and reputation.

What Training is Required

The training requirements for lockout tagout (LOTO) can vary depending on the country and regulatory agency. However, in general, LOTO training should cover the following topics:

The purpose and scope of the LOTO standard
The types of energy sources that need to be controlled during LOTO procedures
The specific LOTO procedures that are required for each piece of equipment
The proper use and maintenance of LOTO devices and equipment
The importance of following proper LOTO procedures to ensure worker safety
The responsibilities of authorized and affected employees during LOTO procedures
The importance of communication and coordination between workers during LOTO procedures
The specific hazards associated with the equipment being serviced or maintained
The importance of reporting and correcting any problems or violations related to LOTO procedures

In addition, LOTO training should include hands-on demonstrations and simulations to ensure that workers understand how to properly implement LOTO procedures in their workplace.

The training requirements for LOTO are often set by the regulatory agency in charge of workplace safety. For example, in the United States, the Occupational Safety and Health Administration (OSHA) requires that employers provide LOTO training to all employees who perform maintenance or repair work on potentially hazardous equipment. OSHA's LOTO standard (29 CFR 1910.147) requires that employees receive initial training and then periodic refresher training to ensure that they remain proficient in LOTO procedures. Employers are responsible for providing the necessary training to their employees to comply with the regulatory requirements.

Different Types of Lockout Tagout Training

There are different types of lockout tagout (LOTO) training, depending on the needs of the employer and the level of training required for the employees. Here are some examples:

General LOTO Awareness Training: This type of training is intended for all employees who work in an environment where LOTO procedures are used. The training covers the basics of LOTO procedures, including the purpose of LOTO, the hazards associated with energy sources, the types of LOTO devices, and the importance of communication and coordination.
Equipment-Specific LOTO Training: This type of training is intended for employees who are responsible for performing maintenance or repair work on specific pieces of equipment. The training covers the specific LOTO procedures that are required for that equipment, including the types of energy sources that need to be controlled, the specific LOTO devices that are required, and the sequence of steps that need to be followed.
Authorized Employee LOTO Training: This type of training is intended for employees who are responsible for performing LOTO procedures on equipment. The training covers the requirements for becoming an authorized employee, including the specific procedures for controlling energy sources, the types of LOTO devices that are required, and the responsibilities of authorized employees during LOTO procedures.
Refresher LOTO Training: This type of training is intended for employees who have previously received LOTO training. Refresher training is typically required on a periodic basis to ensure that employees remain proficient in LOTO procedures and to cover any updates or changes to the LOTO procedures or equipment.
Train-the-Trainer LOTO Training: This type of training is intended for employees who will be responsible for training other employees in LOTO procedures. The training covers the basics of LOTO procedures, as well as how to design and deliver effective LOTO training.

In general, LOTO training should be tailored to the specific needs of the employer and the employees, and should include both classroom instruction and hands-on training to ensure that employees are proficient in LOTO procedures.

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