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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?
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Lockout vs Tagout
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
- 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
Lockout Tagout Locks
LOTO Tags
Electrical Equipment Lockout Devices
Valve Lockouts
Lockout Tagout Kits
LOTO Stations
LOTO Safety Standard Compliance
- 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.
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
1. Shutdown Preparation
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
3. Energy Source Location and Isolation
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
5. Stored Energy Release or Blocking
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
7. Equipment Maintenance or Service
8. Equipment Service Restoration
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
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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 |
|
Shutdown |
|
Isolation |
|
Lockout/Tagout |
|
Stored Energy Check |
|
Verification |
|
Perform Maintenance or Servicing |
|
Restore Equipment to Service |
|
Documentation |
|
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.