Ultimate Guide to Lockout Tagout: Important Things You Need to Know

Key Takeaways

• LOTO is essential for safeguarding workers from hazardous energy during equipment maintenance, requiring strict adherence to specific steps to prevent accidental re-energization.
• Effective LOTO depends on thorough employee training and clear communication, ensuring everyone understands procedures and hazards, and minimizing risks during maintenance.
• Industry 4.0 integrates advanced tech like IoT sensors and smart locks, enhancing traditional LOTO with real-time monitoring and automated energy isolation.
• Common LOTO errors, like missing energy sources or using improper energy control devices, are avoided through detailed energy evaluations, regular audits, and using quality, environment-appropriate lockout tools.

What is Lockout Tagout?

Lockout Tagout (LOTO) is a safety procedure that involves isolating energy sources and applying lockout devices to prevent the accidental release of hazardous energy during maintenance activities. The primary goal of the lockout tagout procedure is to safeguard workers from injuries caused by unexpected startup or release of energy sources.

Types of Hazardous Energy:

• Electrical: High-voltage machinery, wiring, and circuits
• Mechanical: Moving parts, gears, and machinery under tension
• Hydraulic: Pressurized fluids in systems
• Pneumatic: Compressed air systems
• Thermal: Heat sources like furnaces and hot pipes

LOTO procedures vary across industries due to the different types of hazardous energy present. In manufacturing, the focus is often on isolating electrical and mechanical energy to prevent unexpected machine or equipment startup. In chemical plants, LOTO might involve controlling thermal energy from heated pipelines or hazardous chemical reactions.

Similarly, the construction industry may emphasize hydraulic and pneumatic energy isolation, given the prevalence of heavy machinery and tools.

Developing a Lockout Tagout Program

Once the industry-specific hazards are identified, the next step is to develop a comprehensive lockout tagout program. A well-structured program includes clearly written procedures, employee training, and regular audits to maintain compliance. Key components of a lockout tagout program involve:

1. Energy Source Identification: Documenting all energy sources that require isolation.
2. Procedure Documentation: Creating step-by-step guides for safely locking out each piece of equipment.
3. Employee Training: All workers must understand the procedures and know how to implement them correctly.
4. Routine Audits: Regularly inspect lockout tagout practices to ensure they remain effective and up-to-date.

What is the Difference Between Lockout and Tagout?

Lockout involves physically securing an energy isolating device with a lock, preventing the machinery from being powered on until the lock is removed by an authorized employee. This method provides a high level of safety by directly controlling the energy source.

Tagout, on the other hand, uses a lockout tag placed on the energy isolation device to indicate that the equipment should not be operated. While it alerts others to the potentially hazardous stored energy, it doesn't provide the same physical restraint as a lock, making it less secure.

When can you use tags only in lockout tagout?

Lockout tags can be used alone in situations where the equipment is not capable of being locked out, and the employer can demonstrate that tagout can protect workers equivalent to that of lockout. However, this is rare, and the limitations of tagout must be clearly understood and strictly followed.

Tagout devices are designed to be durable, weather-resistant, and tamper-resistant, ensuring they remain securely in place and aren't easily tampered with or removed. These LOTO tags are prominent warning device to employees, indicating the equipment's current status and preventing unauthorized operation.

When is Lockout Tagout Required?

Lockout tagout is required whenever there is a potential for injury due to unexpected energization or release of hazardous stored or residual energy in equipment. This applies to a variety of situations, including:

• Routine maintenance and repair tasks like cleaning, adjusting, lubricating, or unjamming machinery that require exposure to hazardous energy sources
• Installation, setup, or adjustment of equipment
• Removal or bypassing of a machine guard or other safety device
• Exposure of any part of the worker’s body in a danger zone during the operation
• Non-routine work, such as troubleshooting or repair during the operation

Lockout Tagout Standard: Legal and Regulatory Framework

The primary regulations governing LOTO in the United States are set by the Occupational Safety and Health Administration (OSHA). The OSHA standard 29 CFR 1910.147, titled "The Control of Hazardous Energy (Lockout/Tagout)." This standard outlines the requirements for employers to establish procedures and practices to prevent the release of hazardous energy during the servicing and maintenance of machine or equipment.

Key elements of the OSHA lockout tagout standard include:

1. Written LOTO Procedures

Employers must develop and maintain written LOTO procedures specific to each piece of equipment. These procedures should detail the steps for shutting down, isolating, and securing hazardous energy sources, as well as the steps for safely restoring equipment to service.

2. Employee Training

OSHA requires that all employees involved in or affected by lockout procedures receive proper LOTO training. This includes both authorized employees who perform the lockout and tagout, and affected employees who work around the equipment. Training must cover the purpose of LOTO, how it is implemented, and the potential hazards involved.

3. Periodic Inspections

Employers must conduct periodic inspections of lockout procedures at least annually. These inspections ensure that the procedures are being followed correctly and that employees are adequately trained. The inspection must be performed by an authorized employee who is not using the procedure being inspected.

4. Proper Use of LOTO Devices

OSHA mandates that energy isolating devices must be durable, standardized, and substantial enough to prevent removal without excessive force or special tools. Lockout tag devices, while less secure than lockout devices, must be equally durable and legible to communicate warnings effectively.

5. Energy Control Program

Employers are required to establish an energy control program that includes hazardous energy control procedures, employee training, and periodic inspections. The program should cover all aspects of lockout tagout, from identifying energy sources to verifying the isolation of equipment.

OSHA Penalties for Non-Compliance

Failure to comply with OSHA standards can result in hefty fines and penalties. OSHA conducts inspections and issues citations for violations, with penalties that can reach thousands of dollars per violation. In cases of willful or repeated violations, fines can be significantly higher, and employers may face additional legal consequences.

Employer and Employee Responsibilities

Under OSHA guidelines, both employers and employees have specific responsibilities:

Employer Responsibilities

• Develop and implement lockout procedures tailored to the specific equipment and energy sources in their workplace.
• Provide the necessary energy isolating devices and provide training for proper usage.
• Train employees on lockout procedures and their importance in preventing injuries.
• Conduct regular inspections and audits of lockout procedures to ensure ongoing compliance and effectiveness.

Employee Responsibilities

• Follow the lockout procedures as trained, using the provided devices correctly.
• Report any issues or concerns with lockout procedures or equipment to supervisors.
• Participate in training sessions and stay informed about any updates or changes to LOTO practices.

Who Can Perform Lockout Tagout?

Only individuals who have been trained and deemed competent by their employer are allowed to perform lockout tagout procedures. These individuals are referred to as "authorized employees." These employees understand the type and magnitude of energy they are controlling, the hazards involved, and the means to isolate and control hazardous energy.

Authorized employees are mostly the ones working on energy control procedures. Prohibiting attempts to restart or reenergize machines or other equipment using lockout tagout devices is one of their main responsibilities.

Who is responsible for placing or removing lockout tagout devices?

The responsibility for placing and removing LOTO devices lies exclusively with authorized employees who have received specific training on lockout procedures and the associated hazards. When placing a lockout or tagout device, the authorized employee must follow the company’s written procedures so that the energy source is effectively isolated and the equipment cannot be inadvertently energized.

Similarly, only the authorized employee who originally applied the energy isolating device is permitted to remove it. This practice enables the individual most familiar with the equipment’s status and potential hazards are the ones to restore it to service safely.

If the original authorized employee cannot report to work, due to illness, injury, or other valid reasons, the supervisor must have a formal process in place to transfer responsibility to another authorized personnel. An example of this process is provided below:

1. Identity of the authorized employee whose device is being removed;
2. Describes all reasonable efforts to locate the employee;
3. Describes the action taken to ensure that, prior to their resumption of work, the employee knows that their energy isolating device was removed
4. Signs and dates to certify that the above steps were taken.

It’s important to note that the responsibilities and documents required may slightly vary depending on the companies’ energy control procedure or service contract agreement.

Lockout Tagout During Shift Changes

In other situations where a shift change occurs, and the original employee is no longer available, a formalized process must be followed. This process involves the transfer of responsibility to another authorized employee, which includes documented communication about the equipment’s status and verification of the lockout or tagout conditions to keep the continuity of safety and compliance with LOTO protocols.

Group Lockout Procedure

Group lockout procedures are used when multiple employees are working on the same equipment. This often occurs during complex maintenance operations where each worker needs assurance that the equipment will not be re-energized while they are working.

In such scenarios, a “lead authorized employee” applies the initial lockout device to isolate the energy sources and secures the key in a group lock box. Each worker then attaches their personal lock to the group lockbox, ensuring that the equipment remains locked out until all workers have completed their tasks.

The removal of lockout devices follows a strict protocol to maintain occupational safety. Each employee must verify that their work is finished and that it is safe to remove their lock. Once all workers have removed their locks from the group lock box, the lead authorized employee can remove the initial lockout device and restore energy to the equipment. This specific process for group lockout guarantees that no equipment is re-energized until every worker involved has completed their work and safely exited the area.

8-Step Lockout Tagout Procedure

A lockout tagout procedure is a systematic process designed to enable the safe shutdown and isolation of equipment during maintenance or servicing. Below is an overview of the key steps involved:

1. Shutdown Preparation: The first step in a lockout procedure involves preparing for the shutdown by identifying all energy sources associated with the equipment. Authorized employees must also notify all affected employees about the upcoming maintenance and the LOTO process to prevent any accidental re-energization.
2. Shutdown Initiation: Once the preparation is complete, the equipment is powered down according to standard operating procedures (SOPs). This step involves following the manufacturer's equipment shutdown instructions to safely stop the machine or system without causing any unintended electrical hazards.
3. Energy Source Location and Isolation: After the equipment is shut down, the next step is to locate and isolate all energy sources. This means disconnecting or blocking the energy supply to the equipment, such as unplugging electrical cables, closing valves, or deactivating circuit breakers.
4. Lockout Tag Placement: With the energy sources isolated, lockout devices are applied to secure the isolation points, and lockout tag devices are attached to provide a visual warning. Each authorized person involved in the procedure must place their own lock and lockout tag on the equipment to prevent anyone from accidentally re-energizing it.
5. Stored Energy Release or Blocking: Even after isolation, some energy may remain stored within the equipment, such as in capacitors, springs, or pressure lines. This stored energy must be safely released or blocked to prevent accidental release during maintenance. For example, pressure in hydraulic lines can be relieved, or springs can be safely locked in place.
6. Lockout Tagout Verification: Before any maintenance begins, the authorized employee must verify that the equipment is fully isolated and locked out. This step is also called LOTOTO and involves attempting to start the equipment using the normal operating controls to confirm that it will not operate. LOTOTO verifies that the lockout tagout process has been correctly implemented and that it is safe to proceed with maintenance.
7. Equipment Maintenance or Service: Once verification is complete, maintenance or repair work can begin. Throughout this phase, the LOTO devices must remain in place, and no attempt should be made to re-energize the equipment until the work is finished.
8. Equipment Service Restoration: After maintenance is completed, the equipment is prepared to be brought back into service. The authorized employee removes the lockout and tagout devices and restores the energy sources following the correct procedures. The equipment is tested to confirm it operates safely before it is returned to normal use.

Best Practices for Effective Lockout Tagout

Implementing an effective lockout tagout requires more than just following the basic steps. Avoid procedural dangers and adopt these practices that help enhance the reliability, safety, and compliance of LOTO programs:

Training and Education for Employees

Three types of employees need lockout tagout training: authorized employees, affected employees, and other employees working in an area where LOTO is used. It includes comprehensive training on procedures, the hazards of uncontrolled energy, and the proper use of lockout and tagout devices.

Training should also not be a one-time event; regular refresher courses are essential to keep skills sharp and knowledge up to date. This training should also be tailored to the specific needs of the workforce, including both classroom sessions and hands-on practice with the actual equipment and devices used in their facility.

Regular Inspection and Maintenance of LOTO Devices

Regular inspections should be conducted to make sure that all LOTO equipment—such as locks, tags, and other isolation devices—are in good working order, free of damage, and compliant with occupational safety standards. Any damaged or worn-out devices should be replaced immediately to maintain the integrity of the LOTO process.

Additionally, periodic audits of the LOTO program itself should be conducted to identify any areas for improvement and ensure ongoing compliance with regulatory requirements.

Communication and Documentation Procedures

All employees must be notified about when and where LOTO is being applied, and any changes in the status of equipment should be communicated promptly.

Detailed records should be kept for every LOTO procedure, including who applied the locks and tags, when they were applied, and any steps taken to verify isolation. This documentation not only helps maintain LOTO safety but also serves as a valuable resource during audits and inspections.

Involvement of All Employees in LOTO Processes

All employees, regardless of their role, should be involved in LOTO processes. This involvement can be as simple as understanding the basic principles of lockout tagout and recognizing the importance of the locks and tags they may encounter in their work area.

Organizations can maintain a consistently safe environment by fostering a safety culture where everyone understands and respects LOTO procedures. Encouraging employees to participate in LOTO safety meetings, provide feedback on lockout procedures, and report any potential hazards also helps in creating a more robust and effective LOTO program.

Common LOTO Mistakes and How to Avoid Them

• Overlooking Energy Sources: Missing secondary energy sources, such as residual pressure or stored electrical charge, can lead to dangerous, unexpected energy releases during maintenance. Conducting comprehensive energy evaluations for each piece of equipment helps identify and document all potential energy sources, preventing these hazards.
• Improper Device Application: Using substandard lockout tagout devices or relying solely on tags leaves room for safety breaches. Selecting high-quality, standardized devices that are durable and appropriate for the environment enables proper isolation of hazardous energy.
• Insufficient Training: Employees may skip critical steps or misunderstand procedures due to insufficient training, increasing the risk of accidents. Regular, detailed training sessions, along with periodic refreshers, keep employees knowledgeable and compliant with LOTO protocols.
• Poor Communication: Failing to communicate clearly during LOTO procedures, including forgetting to fill in critical information on the lockout tag devices, can cause confusion and increase risks. Enhancing communication by properly tagging out and documenting processes helps prevent misunderstandings and ensures everyone knows the equipment's status.
• Lack of Regular Audits: Without regular audits, gaps or errors in LOTO procedures can go unnoticed, compromising safety. Performing consistent audits helps identify and correct any deficiencies, keeping the LOTO program effective and up to date.

Lockout Tagout in Industry 4.0

As Industry 4.0 advances, lockout tagout is evolving with the integration of smart technologies. Traditional methods are being enhanced by digital solutions, such as the Industrial Internet of Things (IIoT) and smart locks. IIoT-enabled sensors now allow real-time monitoring of equipment, automatically triggering lockout when hazardous conditions are detected. Smart locks provide electronic control and monitoring, offering data on their status and alerting supervisors to any unauthorized access attempts.

These technologies reduce human error and improve safety, while workers are increasingly trained to manage both traditional and digital LOTO systems. As industries continue to adopt these innovations, lockout procedures will become more efficient and robust, meeting the demands of increasingly complex industrial environments.

FAQs about Lockout Tagout

What is the purpose of LOTO?

The purpose of Lockout Tagout (LOTO) is to protect machine operators from the unexpected release of hazardous energy during maintenance or repair work of equipment, preventing accidents and injuries.

How to use a lockout tagout kit?

A lockout tagout kit contains devices like locks, tags, and hasps used to isolate and secure energy sources. To use it, identify the energy sources, apply the appropriate lockout devices to each isolation point, attach tags to warn others, and verify that the equipment is fully isolated before beginning work.

Who needs lockout tagout training?

LOTO training is required for all employees involved in or affected by the lockout process, including those who perform the lockout (authorized employees) and those who work around the locked-out equipment (affected employees).

What are the exceptions to lockout tagout?

Exceptions to LOTO include minor servicing activities that are routine, repetitive, and integral to the production process, provided that alternative measures offer effective protection.

Is it okay to try and remove someone else's lockout lock and tag?

No, it is never okay to remove someone else's lockout lock and tag. Only the person who applied the lock and tag is authorized to remove it, ensuring their safety and preventing unauthorized re-energization of the equipment.