8-Step Lock Out Tag Out Procedure: Guide and Checklist

Published Date: July 16, 2024 Herbert Post

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Lock out tag out procedure guide

An 18-year old worker was cleaning a portable mortar mixer when his arm got stuck in it. A painter working near him tried to turn off the machine but the gears would not disengage, so the painter asked for help. A co-worker was finally able to shut off the mixer. Emergency medical services were able to extricate the worker but he was already dead at the scene.

Tragedies like this could have been prevented with proper lockout tagout training in place. Employers are responsible for keeping the workplace safe and providing their employees with the necessary training and PPE. While hazards cannot be eliminated in settings such as a construction site or manufacturing floor, steps can be taken to prevent or mitigate workplace risks. And that is what a lockout tagout (LOTO) procedure is for.

What is Lock Out Tag Out?

A lockout tagout procedure aims to protect workers from injury risks due to unexpected energization or energy release from equipment and machines while an employee is doing maintenance or servicing on it. This procedure should be part of an entire lockout tagout program. With lockout, energy is isolated from a machine or equipment using a lockout device. Tagout, on the other hand, is a labeling process whenever lockout is required. This involves attaching an information tag with certain details that must be filled out.

Lockout vs Tagout

While both lockout and tagout are integral components of hazardous energy control procedures, they have two different functions in ensuring occupational safety. The lockout process involves placing physical locking devices on an energy-isolating mechanism to ensure that the equipment cannot be energized. Tagout, on the other hand, involves attaching a warning tag to an energy-isolating device. Although tagout does not physically prevent the activation of equipment, it serves as an important alert mechanism.

In terms of enhancing occupational safety, lockout is considered more reliable because it secures the equipment in a safe mode through a physical barrier. Tagout, while effective as a part of the safety procedure, depends heavily on the adherence to protocols and awareness by all employees.

Importance of Lockout Tagout Procedures

LOTO safety is important for the following reasons:

Prevention of Accidental Start-Up: Ensures machines are properly de-energized to prevent unexpected startups, protecting against severe injuries like amputation or death.
Control of Hazardous Energy: Systematically identifies and neutralizes hazardous energies such as electrical, mechanical, and chemical, safeguarding workers during maintenance.
Regulatory Compliance: Adheres to safety regulations to avoid legal penalties and demonstrates commitment to worker safety.
Maintenance of Safe Work Environment: Promotes a culture of safety, enhancing employee retention and productivity through a secure work setting.
Reduction in Workplace Injuries and Fatalities: Decreases the incidence of maintenance-related injuries, lowering medical costs and insurance premiums.
Protection from Legal and Financial Consequences: Prevents accidents that could lead to fines, legal actions, and damage to company reputation.
Best Practices Encouragement: Regular training on LOTO procedures keeps all employees updated on safety protocols, fostering continual improvement in safety standards.

Essential Lockout Tagout Devices

A key element of effective and successful lock out tag out procedure relies heavily on the tools and devices used in its implementation. Here we explore the essential devices used in LOTO procedures, their functions, and why they are critical for maintaining safety in the workplace.

Lockout Tagout Locks

Lockout tagout padlocks are the primary devices used in LOTO to ensure that energy-isolating devices cannot be activated or removed. Reliable LOTO locks should be made using durable materials that can withstand harsh industrial conditions and excessive force. The standard procedure for lockout locks is that similar locks be used throughout the organization to avoid confusion and ensure that all employees are familiar with their operation

LOTO Tags

While locks physically secure the energy-isolating device, lockout tagout tags provide a visible warning that machinery should not be operated. These tags are designed to communicate vital information regarding the lock out tag out procedure, including the reason for lockout, the date and time of application, and the name of the authorized person who attached the tag.

Electrical Equipment Lockout Devices

These devices are specifically designed to isolate electrical energy sources such as circuit breakers, push-button stations, and electrical plugs. They come in various forms, including circuit breaker lockouts, plug lockouts, and push-button lockouts, each engineered to fit different types and sizes of electrical controls and connectors to prevent accidental energization.

Valve Lockouts

Valve lockouts are used to prevent the movement of valve handles that control the flow of liquids and gases. Available in various sizes and designs, these devices can lock valves in either an open or closed position, depending on the maintenance needs. They are crucial for preventing unintended activation of valves during repair or maintenance of piping systems.

Lockout Tagout Kits

Lockout tagout kits are comprehensive sets of tools that include a variety of locks, tags, hasps, and sometimes, specialized devices tailored for specific types of machinery or energy sources. These kits are portable and often organized in easy-to-carry cases or bags, ensuring that all necessary LOTO devices are readily available and can be transported to different locations as needed.

LOTO Stations

LOTO stations are centralized locations where LOTO devices are stored and organized. These stations are typically mounted on walls or placed in accessible areas close to machinery that frequently requires maintenance. By housing all necessary LOTO devices, including padlocks, tags, and lockout devices, these stations ensure that employees can quickly and easily access the tools they need to safely lock out equipment.

LOTO Safety Standard Compliance

Adhering to established safety standards is crucial for any lockout tagout (LOTO) procedure. Compliance not only ensures the safety of employees but also aligns with legal requirements, helping to mitigate risks of penalties and liabilities. One of the primary standards governing LOTO practices in the United States is OSHA 1910.147, which outlines the minimum requirements for controlling hazardous energy. Key elements of this standard include:

Scope and Application: OSHA 1910.147 applies to the servicing and maintenance of machines and equipment in which the unexpected energization or startup, or the release of stored energy, could harm employees.
Energy Control Program: Employers are required to develop, implement, and enforce an energy control program. This program must include energy control procedures, employee training, and periodic inspections.
Energy Control Procedures: Detailed documents must be created for each piece of equipment, outlining specific steps for shutting down, isolating, blocking, and securing machines to control hazardous energy.
Employee Training: Employees must be trained to ensure that they understand the purpose and function of the energy control program. They must have the skills necessary to safely apply, use, and remove energy control devices.
Periodic Inspections: To maintain the effectiveness of the energy control procedures, periodic inspections must be conducted at least annually. These inspections help verify that the procedures and requirements are being followed.

For effective compliance with OSHA 1910.147, maintain a set of written energy control procedures for machines and equipment that detail the required steps to disable machinery and control hazardous energy. Additionally, regularly train employees on the LOTO procedures relevant to their duties

It is also important to ensure that suitable lockout or tagout devices are provided and are readily accessible to employees. These devices must be durable, standardized, and substantial enough to prevent removal without the use of excessive force or unusual techniques. Moreover, conduct regular audits of the LOTO practices and procedures to identify and rectify any deficiencies. This includes reviewing accident records and near-misses to improve safety measures continually.

Lock Out Tag Out Procedure: Step-by-Step Guide

LOTO follows a series of steps that help in the proper isolation of hazardous stored energy. This step-by-step guide provides a clear framework for executing LOTO procedures, ensuring both compliance and safety during energy isolation.

1. Shutdown Preparation

The first step to proper energy isolation in lockout tagout procedures revolves around planning and communicating the desire to perform LOTO on a particular machine or equipment. Begin by conducting a comprehensive review of all machines and equipment that require maintenance or servicing. This involves understanding not only the primary operational controls but also all potential energy sources associated with the equipment.

Then, create or update documentation that details all energy control points for each piece of equipment. This includes electrical switch boxes, hydraulic and pneumatic systems, and any other energy sources that must be isolated to safely perform maintenance. All employees affected by the upcoming lockout, whether they are involved in the maintenance or operate in the vicinity of the equipment, must be informed about the lockout.

2. Shutdown Initiation

Once preparation is complete, the next step is the orderly shutdown of the equipment. This step is critical to prevent any accidental startup during the lockout procedure. During this step, it is essential to consult the manufacturer’s instructions or company-specific procedures for the correct sequence and method of shutdown.

3. Energy Source Location and Isolation

To start the actual energy isolation process, it is first necessary to identify potential sources of energy from the machine - whether it’s electrical, mechanical, hydraulic, pneumatic, chemical, or thermal. Isolate these energy sources using methods such as turning off power at a breaker or closing a valve.

Once each energy source has been identified and manually isolated, apply appropriate lockout devices to each energy isolation point. These devices physically prevent the operation or movement of energy isolation controls, ensuring that the equipment remains in a safe and stable state. Lockout devices should be robust, clearly identifiable, and only operable by authorized personnel who hold the keys or combinations.

4. Lockout Tag Placement

To properly perform the lock out tag out procedure, it is equally important to apply tagout devices to the isolated equipment. Clear and visible tagout tags should be attached at each lockout point to serve as a warning sign to all employees not to operate the equipment.

5. Stored Energy Release or Blocking

Even after the initial isolation and lockout, some equipment may still retain hazardous stored energy, which can pose significant risks during maintenance. Before any service or maintenance procedure, identify all possible forms of stored energy related to the equipment. This could include electrical charges in capacitors, compressed air or gases in cylinders or tanks, springs under tension, elevated components that could fall, or hydraulic systems under pressure.

Once identified, take steps to safely release or dissipate stored energy. In situations where energy cannot be safely released, use blocking or other restraint devices to securely hold the energy to ensure that the energy remains contained and cannot cause unexpected movement or harm during maintenance.

6. Lockout Tagout Verification

The verification process is designed to check that all lockout and tagout steps have been successfully implemented and that the equipment is safe to work on. It includes testing the equipment controls by attempting to start the machine and verifying that all sources of hazardous energy and stored energy have been controlled or released.

7. Equipment Maintenance or Service

Once the equipment has been verified to be de-energized and secure, the maintenance or repair activities can begin. This step is critical as it involves actual interaction with the now-safe equipment. However, it is still important to take extra precautions while working on service machines. Maintenance workers should wear proper personal protective equipment (PPE), adhere to safety protocols, and monitor their work area to prevent injury or accidents.

8. Equipment Service Restoration

After maintenance is complete, the process of removing lockout/tagout devices and re-energizing the equipment must be handled with care to ensure safety is maintained throughout this final phase.

Before removing any lockout or tagout devices, thoroughly inspect the work to verify and check that it was completed correctly and that all tools and foreign materials have been removed from the equipment. Lockout/tagout devices should only be removed by the individuals who applied them. If this isn't possible, ensure that the removal is done under the supervision of authorized personnel according to a documented and approved process. Then, gradually re-energize the equipment following a predefined sequence and perform a functional check before releasing the machine for regular operation.

Lock Out Tag Out Procedure Checklist

The LOTO procedure checklist is a systematic list that outlines all the specific actions required to implement lockout tagout procedures effectively. It is used to check off each step as it is completed, ensuring that no critical steps are missed. The checklist is tailored to include all aspects of locking and tagging out equipment, from the initial planning and communication stages to the final steps of removing locks and tags and re-energizing the equipment.

A comprehensive LOTO checklist typically includes the following key elements to ensure maximum safety and compliance:

Procedure	Details
Preparation	Identification of all equipment and energy sources involved. Notification of all affected employees about the LOTO procedures. Availability and readiness of all necessary LOTO devices and personal protective equipment (PPE).
Shutdown	Specific steps to shut down equipment safely according to manufacturer instructions or internal protocols. Verification that all operational controls are in the off position.
Isolation	Identification and isolation of all primary and secondary energy sources connected to the equipment. Application of appropriate lockout devices to each energy isolation point.
Lockout/Tagout	Proper attachment of lockout devices and placement of tagout signs with clear information. Verification by attempting to operate the equipment via normal controls to ensure it remains non-functional
Stored Energy Check	Identification and mitigation of all forms of residual or stored energy. Ensuring that any potential residual energy is safely discharged or restrained.
Verification	A thorough check to confirm the isolation and de-energization of the equipment. Use of testing equipment to verify zero energy state.
Perform Maintenance or Servicing	Documentation of all maintenance activities performed. Adherence to safety protocols throughout the maintenance process.
Restore Equipment to Service	Inspection of the work area to ensure all tools and parts have been removed. Notification of completion to all affected employees. Sequential removal of LOTO devices by authorized individuals. Careful re-energization of equipment and functional testing to ensure operational safety.
Documentation	Recording each step of the LOTO process, including who performed it and any observations or incidents that occurred. Keeping records of all LOTO checklists as part of compliance and safety audits

Most Common Mistakes in a Lockout Tagout Procedure

Mistakes that are mostly committed or most likely committed while doing LOTO can lead to dangerous incidents that can cause injury or death. Considering this, it is critical to gather data and evidence of noncompliance to know which aspect of the LOTO steps requires more attention or intervention. For maximum safety, a periodic audit of the machine-specific LOTO procedure and staff retraining should be conducted.

Here are some of the most common mistakes in performing a LOTO procedure:

A worker not using a lock just because they think that the task will only take a few minutes
A worker doing a lockout but leaving the key in the lock
A worker entrusting someone else to do the shutoff and lockout for him or her
A worker only locking out the control unit and not the main switch or other power sources
A worker immediately performing repair or maintenance on a correctly locked out machine without testing first whether the controls are indeed inoperable

Lockout Tagout Procedure Sample and Template

Here is a sample lockout tagout procedure for a TMC ice machine/walk-in box cooler/freezer:

1. Notify the following persons:

HVAC supervisor
Electrician supervisor
Supervisor in the area where the machine is to be locked out
People working or currently present in the area

2. Explain that the machine must be shut down and locked out for servicing or maintenance
3. Identify the location and energy type and magnitude of the machine.
4. Understand the hazards associated with the source of energy and how to control it. “Electrical Energy Hazard – 208/230 v, 3 phase power (controlled by breakers)” is applicable on this machine.
5. Check machine for proper operation.
6. Do the normal stopping procedure to shut down the machine.
7. Go to the machine’s electrical panel, open it, and turn off the breakers to the machine.
8. Apply locks and lockout devices to these breakers.
9. Return to the TMC ice machine. Ensure that this has been indeed disconnected from the energy source by:

Confirming no one is exposed
Checking the machine with a voltmeter

10. After confirming that the machine’s energy source is isolated, return the machine’s operating controls to an “off” or neutral position.
11. Servicing personnel can now safely work on this machine.

FAQs

What is the proper procedure for lockout tagout?

The proper energy control procedure for lockout tagout involves several key steps: preparing for shutdown, shutting down the equipment, isolating it from its energy sources, applying lockout and tagout devices, checking for stored energy, verifying the lockout, performing maintenance, and finally, restoring the equipment to service. Each step must be documented and followed meticulously to ensure safety.

When dealing with equipment, when is LOTO required?

LOTO is required whenever maintenance or servicing work involves exposure to hazardous energy, or when the unexpected energization, start-up, or release of stored energy could harm employees. This applies to tasks such as repairing, cleaning, installing, and inspecting equipment.

Who is responsible for lock out tag out procedure?

The employer is responsible for implementing and enforcing a comprehensive LOTO program. This includes training employees, providing the necessary lockout/tagout devices, and ensuring that procedures are followed. Within the workplace, specifically trained and authorized employees are responsible for carrying out the LOTO procedures.

Can anyone lock out tag out?

No, not everyone can perform lock out tag out. Only employees who are authorized and trained in the LOTO procedures specific to the equipment and the facility are permitted to carry out lockout and tagout. These authorized individuals must understand the hazards associated with the equipment and be trained in the proper means to isolate and control these hazards.

Is cutting a LOTO lock illegal?

Yes, cutting a LOTO lock without authorization is illegal and against safety regulations. LOTO locks are personal safety devices that should only be removed by the individual who applied them, or under specific circumstances outlined in an employer's LOTO policy, typically involving the supervision of management and following strict procedures to ensure safety. Unauthorized removal can lead to serious injuries or fatalities and legal consequences for the individuals involved.