It was supposed to be a regular working day for workers from an electrical company, but one employee did not return home alive that day.
The reason for this fatality is that earlier the previous day, the electrical power company had installed the meter in the wrong house. This means that the workers were unaware that power had been applied to a house intended to be free of electricity.
In a similar story, an electrical engineer went to work like any other day but went home seriously injured after falling from a height due to a high voltage shock. As part of the procedure, the engineer locked the equipment before he started the repair, but the control switch malfunctioned and accidentally re-energized the equipment.
These incidents are totally avoidable. The first one could have been prevented through an efficient implementation of lockout tagout procedures. However, the second story goes beyond applying lockout measures; the incident could have been avoided by verifying or trying out the equipment before performing repair.
This article discusses the concept of lock out tag out try out, or LOTOTO, and why it is crucial for ensuring optimum safety in the workplace.
Key Takeaways
- Lockout, Tagout, and Tryout (LOTOTO) procedures are essential for preventing accidents by isolating hazardous energy before maintenance.
- Identifying and isolating all energy sources, including secondary ones, is critical to avoid unexpected equipment activation.
- Proper use of lockout tagout devices is critical for an effective energy control program, ensuring all hazardous energy sources are securely isolated.
- Following a detailed energy control procedure helps machine operators safely shut down and lock out equipment, reducing the risk of accidents.
- The tryout step in LOTOTO is a key safety practice in verifying the proper implementation of lockout procedures.
What Is LOTOTO?
Most people in the industry are familiar with lockout tagout (LOTO) but not with lock out/tag out/try out (LOTOTO). Like lockout tagout, LOTOTO protects workers by preventing accidental energizing and unauthorized reactivation of equipment, machines, and other stored energy sources while service, maintenance, or repair is being done. The difference is that LOTOTO emphasizes the importance of testing controls and equipment before performing any task.
LOTOTO stands for Lockout, Tagout, and Tryout. It is a critical safety procedure used in industrial settings to ensure that hazardous energy sources are completely isolated before equipment is serviced or maintained. It involves three key steps:
Lock Out
In a lockout, a device specifically used for energy control procedures is placed on the energy isolating device, such as a valve, switch, or circuit breaker in accordance with a specific procedure. The primary purpose of a lockout, as noted by OSHA’s Control of Hazardous Energy standard, is to ensure that the energy-isolating device and the equipment being controlled cannot be operated until the lockout device has been removed.
Tag Out
Tag out refers to the labeling process that should always be done after a lockout procedure. In practice, a tag is placed on an energy-isolating device alongside the lockout devices in accordance with a specific lockout tagout procedure. The primary purpose of a tagout is to indicate that the equipment, machine, or energy sources being controlled may not be operated until both lockout and tagout devices have been removed. Tags also provide vital information such as the lockout procedures being done on the equipment, the LOTO device owner, and the issues being solved.
Try Out
The tryout or verification step involves testing controls and attempting to operate the equipment after applying a LOTO procedure. OSHA’s lockout tagout toolbox talk noted that this procedure tests if the machinery and equipment have been properly locked out.
In traditional LOTO procedures, the focus is on de-energizing and locking out the equipment, with safety tags indicating that it is not to be operated. However, in LOTOTO, after the equipment is locked out and tagged, the tryout phase involves actively testing the machinery to confirm that it cannot be reactivated. This ensures that all sources of energy have been effectively isolated, offering an additional layer of safety verification before work begins.
Importance of LOTOTO in Energy Isolation
In industrial environments, there are 5 types of hazardous energy that can cause harm or serious injury if not controlled or isolated properly. These are:
- Electrical Energy – Power stored in electrical circuits or systems. If not isolated, electrical energy can cause shocks, burns, or even electrocution.
- Mechanical Energy – Energy stored in moving parts such as gears, springs, or rotating shafts. Uncontrolled release of mechanical energy can result in crushing, cutting, or entanglement.
- Hydraulic and Pneumatic Energy – Pressure from liquids (hydraulic) or gases (pneumatic) can cause significant harm if released unexpectedly. Hydraulic systems, for example, store energy in pressurized liquids that can cause sudden and forceful movements.
- Thermal Energy – Equipment like boilers, furnaces, or pipes may retain heat or cold, posing burn or freeze hazards.
- Chemical Energy – Chemicals stored under pressure or in reactive states can cause explosions, fires, or toxic exposures if not properly contained.
Going back to the story of the electrical engineer who suffered serious injuries due to a high voltage shock, if a tryout procedure had been done before the engineer performed a task, injuries could’ve been avoided.
Companies often forget that verifying isolation is just as crucial as the lockout procedure itself. LOTO procedures prevent accidental re-energization and unauthorized reactivation of stored energy sources, equipment, or machines. However, in cases where, like in the story, a control switch malfunctioned, applying a LOTO procedure may not be enough to achieve optimum safety.
If a locked out energy isolating device malfunctions, the equipment could accidentally start up, leading to serious injuries or even fatalities. For this reason, testing isolation devices and equipment before any task is performed is essential for safety. This step identifies if there are any faults with the isolation point and if it is safe to continue performing any task with the equipment, machine, or energy source. Such a step can help the employee be more confident about his safety while performing service or maintenance.
Below are the other reasons why LOTOTO is important:
- Identifying Residual Energy: The tryout step confirms that all residual energy, such as electricity, pressure, or kinetic energy, is fully dissipated.
- Testing the System for Unintentional Start-Up: The tryout ensures the equipment cannot be unintentionally re-energized by attempting to restart it in a controlled manner.
- Minimizing Human Error: The tryout provides a final safeguard against human error by confirming the equipment is fully de-energized and cannot operate.
- Ensuring Worker Safety Before Maintenance: The tryout step ensures workers are protected from hazardous energy, preventing unexpected start-up during maintenance.
- Building Confidence in the Lockout Process: The tryout reassures workers that the equipment is safe to handle, reducing fear of accidental energy release.
- Compliance with Regulations: Verifying energy isolation through the tryout step helps employers meet regulatory requirements for safe maintenance procedures.
Standards and Regulations on LOTOTO Procedures
While implementing the lockout tagout tryout process is not a legal requirement, it is widely considered a key safety practice. By incorporating the tryout phase, a traditional lockout tagout procedure can be enhanced to meet, even exceed, the standards and regulations governing it such as the following:
- OSHA 1910.147 - Specifically addresses the control of hazardous energy during the servicing and maintenance of machines and equipment.
- ANSI/ASSE Z244.1 - Provides guidance on the control of hazardous energy beyond what is covered by OSHA. It offers more detailed procedures and best practices for implementing a robust lockout tagout system.
- ISO 45001 - An international standard that provides a framework for managing occupational health and safety risks, including hazardous energy control.
- NFPA 70E - Provides specific guidelines for controlling electrical hazards, including procedures for lockout tagout in electrical systems to prevent arc flash.
Basic Components of LOTOTO
LOTOTO Policy
Companies need to establish a clear lockout tagout tryout policy which includes job titles with specific roles and responsibilities. The LOTOTO policy should be a zero-tolerance policy because lives are on the line with every failed adherence. It should also be supported by management and implemented by appropriate department employees.
LOTOTO Training
As stated by OSHA, employers need to train their workers to make sure that they know, understand, and follow the provisions of the lockout tagout procedures. Establishing a LOTOTO program, therefore, should also be accompanied by the necessary training to ensure that authorized employees understand and follow the requirements of the procedure, especially when it comes to the tryout or verification step.
Effective training should be delivered by an authorized instructor who would be able to detail the process for locking out and isolating equipment. The instructor should be able to train employees in the whole process of lockout, tagout, and tryout.
Here is an overview of the key topics that should be covered in a comprehensive LOTOTO training program:
- Understanding Hazardous Energy Sources: Employees must be trained to identify different types of hazardous energy and understand where these energy sources exist in the workplace as well as the risks they pose during maintenance.
- LOTOTO Procedures and Steps: Training should cover the full Lockout Tagout Tryout (LOTOTO) process, from preparation to tryout. Workers must know how to identify energy sources, properly shut down equipment, and perform the tryout to verify isolation.
- Lockout Devices and Their Use: Employees should be trained on how to use different lockout devices like locks, chains, and valve covers. The training must emphasize secure application to prevent tampering or accidental removal.
Tryout Step for Verifying Isolation
The tryout process varies depending on the type of equipment and the nature of the energy source. Workers should be trained in verifying isolation for the following:
- Electrical Equipment: For electrically powered machinery, workers use tools like voltage testers or multimeters to check for any remaining electrical charge in the system. Additionally, they may attempt to turn on the equipment using its control panel or switches to verify that the machine does not power up.
- Mechanical Equipment: In systems with moving parts, workers may manually check for tension in springs or gears, ensuring that no mechanical energy is stored in the components. Tryout for mechanical equipment can involve attempting to move parts to ensure they remain locked.
- Hydraulic and Pneumatic Systems: Workers test the system to make sure that all pressure has been safely released by activating valves or gauges to verify that no pressure remains.
- Thermal Energy: In systems involving heat, the tryout process may involve using temperature sensors or testing controls to confirm that the equipment has cooled and no heat energy remains.
Steps in Implementing LOTOTO Procedures
1. Prepare
Before beginning the LOTOTO process, workers must understand the specific hazards associated with the equipment and the types of energy involved. This includes identifying all energy sources, such as electrical, mechanical, hydraulic, or thermal energy, and determining how to isolate them. Workers should also review the energy control procedure and ensure that all required paperwork, permits, and scheduling are in place.
2. Notify
Notify all affected employees and individuals that the equipment will be locked out or isolated. Employees must be instructed to stay away from the equipment and be reminded not to attempt to energize or operate it while it is locked out. Clear communication during this phase prevents accidental start-up and ensures that no one is placed at risk during the maintenance or repair task.
3. Shutdown
The shutdown process must follow the specific energy control procedure for the equipment. Workers should use the standard operating controls to safely and systematically shut down the machine. It is important that this step is performed in an orderly and controlled manner to avoid creating new hazards, such as sudden equipment movement or pressure build-up
4. Isolation
Using appropriate isolation points, isolate the machine or equipment from hazardous energy. Also, isolate secondary energy sources that might interfere with the isolation procedure. In case of electrical defects, isolate the equipment through its energy isolation devices, not with its controls.
5. Apply locks and tags
Once energy sources have been isolated, LOTO devices must be applied to each isolation point. The rule of "one lock, one person, one energy source" ensures accountability—each person working on the equipment must apply their own lock to the isolation device. In addition to locks, tags must be placed on the lockout points to clearly indicate the status of the equipment and warn others not to operate it.
6. Zero Energy State
Achieving a zero energy state means ensuring that no residual energy remains in the machine or equipment. This includes draining any hydraulic or pneumatic pressure, discharging capacitors, and releasing mechanical tension in springs or other moving parts. Reaching a zero energy state eliminates the possibility of stored energy causing unexpected movements or activations while the equipment is being serviced.
7. Tryout
After isolating the energy sources and achieving a zero energy state, the tryout step involves attempting to operate the equipment using its normal controls. The purpose of this is to verify that the equipment is truly de-energized and cannot accidentally start up. This test ensures that all energy sources have been fully isolated and that no residual energy remains.
8. Perform task
Start and complete the planned task, such as maintenance and repair, while following safety protocols and procedures. In the event of accidental re-energization or other unexpected hazards, the task should be immediately stopped, all workers should withdraw, and control measures must be re-implemented. Near hits or accidents should be reported and investigated to identify what went wrong and to improve safety protocols for the future.
9. Inspect and restore
Inspect the area and equipment, secure the guarding in place, and notify all affected individuals that energy will be restored. Then, remove all personal lockout and tagout devices, restore devices to operating position, verify that all are operating properly, then notify higher-ups regarding the completion of the procedure. Lastly, complete all needed paperwork or permits.
Go home safe today: Lock, Tag, and Try
The concept of LOTOTO may sound new to some, but leading organizations are now adopting this upgraded safety procedure. Due to serious incidents caused by failure to check or test that all isolations and lockouts were performed properly, industries have started to invest in upgrading their LOTO program by including the “tryout” procedure.
The tryout or verification procedure may be the most important step to ensure workers are working on equipment, machine, or energy source in a safe and energy-free state. Help your employees go home safely today. Lock, tag, and try!
FAQs
What is the LOTOTO implementation?
LOTOTO implementation refers to the process of locking out, tagging out, and verifying the isolation of energy sources before servicing equipment to prevent the release of hazardous energy.
What type of hazard control measure is LOTOTO?
LOTOTO is an administrative hazard control that focuses on safely isolating energy sources to prevent unintended equipment activation during maintenance or repair.
Who needs LOTOTO training?
All employees involved in operating, servicing, or maintaining equipment, as well as those working near the machinery, need LOTOTO training to ensure they understand the procedures and risks.
Who is responsible for LOTO safety?
Authorized employees who perform the lockout procedures are responsible for LOTO safety, but employers must ensure proper training and compliance across the workforce.
What is the OSHA standard for LOTO?
The OSHA standard for LOTO is 1910.147, which covers the control of hazardous energy during servicing and maintenance of machinery in the workplace.