Lockout/Tagout (LOTO) procedures are critical safety protocols used to ensure that machinery and equipment are properly shut off and cannot be re-energized until maintenance or repair work is complete. LOTO procedures protect workers from hazardous energy sources, including electrical, hydraulic, mechanical, and thermal energy, by isolating and controlling these sources before any work is done.

Key Elements of Lockout/Tagout Procedures

  1. Purpose of LOTO:
    • Prevent the unexpected release of hazardous energy.
    • Protect workers performing maintenance or servicing tasks on machinery or equipment from accidental startups or energy release.
  2. Key Components of LOTO Procedures:
    • Locks: Used to physically secure energy isolation devices (e.g., switches, valves) in the “off” position.
    • Tags: Tags display a warning that the equipment is being serviced and must not be operated. They identify the person responsible and provide additional information, but tags alone do not physically prevent operation.
    • Authorized Personnel: Only trained and authorized employees can perform lockout/tagout.

Steps for Lockout/Tagout Procedures

  1. Preparation for Shutdown:
    • Identify Energy Sources: Determine all energy sources (electrical, hydraulic, pneumatic, etc.) connected to the equipment.
    • Understand Energy Flow: Understand the flow and possible stored energy that could release unexpectedly.
    • Notify Affected Employees: Inform employees who work with or near the equipment that LOTO is being applied.
  2. Shutdown Procedures:
    • Turn Off Equipment: Follow the normal shutdown procedures to turn off the equipment.
    • Isolation: Isolate all energy sources by disconnecting or switching them to the “off” position. This includes circuit breakers, valves, and any other energy control devices.
  3. Application of Lockout/Tagout Devices:
    • Apply Lock: Place a lock on each energy-isolating device to prevent it from being turned on.
    • Attach Tag: Attach a tag to the lock indicating the person responsible, the reason for LOTO, and a warning not to operate the equipment.
  4. Release Stored or Residual Energy:
    • Drain or Block Residual Energy: Discharge or secure any residual energy that could cause the equipment to move or release energy unexpectedly. Examples include bleeding hydraulic lines or releasing compressed air.
    • Test for Zero Energy: Verify the equipment is completely de-energized by attempting to operate the start switch or engaging mechanisms in a controlled manner.
  5. Verification of Isolation:
    • Test the Equipment: Test all controls to ensure the equipment does not start or move. Verification ensures that LOTO has been applied effectively, and the equipment is safe to work on.
  6. Perform Maintenance or Servicing:
    • Once LOTO is confirmed, authorized personnel can safely work on the equipment. No unauthorized employee should attempt to bypass or remove the LOTO devices.
  7. Removal of Lockout/Tagout Devices (Restoring Equipment to Service):
    • Inspect the Area: Check the equipment and surrounding area to ensure that all tools, materials, and personnel are clear of the equipment.
    • Notify Affected Personnel: Inform nearby employees that LOTO devices will be removed and the equipment will be re-energized.
    • Remove LOTO Devices: Only the authorized individual who applied the lock and tag may remove them. If that person is unavailable, follow site-specific procedures for safe removal by a supervisor.
    • Re-Energize Equipment: Re-energize the equipment following standard startup procedures.
  8. Documentation and Record-Keeping:
    • Document LOTO: Record each instance of LOTO, including the equipment, dates, authorized personnel, and any relevant notes about the procedure.
    • Review and Update Procedures: Regularly review and update LOTO procedures to maintain compliance with safety standards and adapt to any changes in equipment or processes.

Special Situations in LOTO

  1. Group Lockout/Tagout:
    • Multiple Workers: When several workers are involved, each worker must attach their own lock and tag to the lockout device. This ensures that all individuals are protected and the equipment cannot be re-energized until everyone has removed their lock.
    • Lock Boxes: In large-scale operations, lock boxes may be used to store keys or group locks. Each worker attaches a personal lock to the box, preventing access to the keys until all locks are removed.
  2. Shift or Personnel Changes:
    • Shift Handover: When workers change shifts, there must be a system to transfer lockout/tagout responsibility. The outgoing worker should hand over the lock and tag to the incoming worker.
    • Procedures for Absenteeism: If an employee who applied LOTO is unavailable, a supervisor following site-specific procedures can remove the lock, but only after ensuring it is safe to do so.
  3. Contractor LOTO:
    • Coordination with Contractors: Contractors working on-site must follow the facility’s LOTO procedures, and there should be coordination to ensure everyone understands LOTO practices and responsibilities.
  4. Testing or Positioning During Maintenance:
    • Temporary Removal for Testing: If equipment must be energized temporarily for testing, the lock and tag can be removed following a controlled procedure. Once testing is complete, reapply LOTO before continuing maintenance.

Training and Compliance

  1. Training Requirements:
    • Authorized Personnel: Training on LOTO procedures, hazards, and safe practices must be provided for authorized employees performing maintenance.
    • Affected Personnel: Affected employees who do not apply LOTO but work nearby should understand the purpose of LOTO and recognize that they should never bypass locks or tags.
    • Retraining: Regular retraining is required, especially if equipment or procedures change or if an employee demonstrates unsafe practices.
  2. OSHA and WHMIS Compliance:
    • Regulatory Standards: OSHA’s 29 CFR 1910.147 standard and similar WHMIS guidelines require employers to develop and implement LOTO procedures to ensure safe handling of hazardous energy.
    • Documenting Compliance: Maintain records of LOTO procedures, training sessions, and incidents to ensure regulatory compliance and enhance safety practices.

Key Takeaways

  • LOTO Protects Workers: Lockout/tagout is essential for preventing accidental energy release during maintenance or repair, protecting workers from potentially fatal injuries.
  • Comprehensive Procedure: Proper LOTO involves multiple steps, including shutting down equipment, isolating energy, locking and tagging energy sources, verifying de-energization, and communicating with affected personnel.
  • Consistent Training: Training and adherence to OSHA or WHMIS standards ensure that workers understand LOTO processes and follow safe practices consistently.

By following LOTO procedures diligently, workplaces can prevent hazardous energy incidents, maintain compliance, and protect the safety of all workers.