11 Jul Lockout/Tagout – Remember to Lockout & Tagout

Lockout/Tagout – Remember to Lockout & Tagout

Lockout/tagout (LOTO) protects employees from the unexpected startup of machinery or equipment and the unexpected release of hazardous energy during servicing and maintenance. Failure to properly control hazardous energy can result in electrocution, crushing, burns, amputations, or death.

Turning a machine off with its normal operating control is not the same as locking it out. Hazardous energy must be identified, isolated, controlled, and verified before servicing begins.

What Is Hazardous Energy?

Hazardous energy is not limited to electricity. Machinery and equipment may contain one or more energy sources, including:

• Electrical.
• Mechanical.
• Hydraulic.
• Pneumatic.
• Chemical.
• Thermal.
• Pressurized systems.
• Gravity or suspended components.
• Stored energy in springs, capacitors, accumulators, or other devices.

All hazardous energy sources must be identified and controlled before work begins.

When Is Lockout/Tagout Required?

LOTO generally applies when employees perform servicing or maintenance where:

• Unexpected startup or energization could occur.
• Stored or residual energy could be released.
• An employee must remove or bypass a guard or other safety device.
• An employee must place any part of the body into a danger zone or point of operation.
• Cleaning, adjusting, repairing, inspecting, unjamming, lubricating, or maintaining equipment exposes employees to hazardous energy.

Never skip LOTO because the work is expected to take only a few minutes.

Common Causes of LOTO Incidents

Serious incidents frequently occur when:

• Equipment is shut off but not isolated from its energy source.
• An energy source is overlooked.
• Someone unexpectedly restarts the equipment.
• Stored energy is not released, restrained, blocked, or otherwise controlled.
• Elevated or moving components are not blocked against movement.
• Employees fail to verify that isolation was effective.
• Locks or tags are improperly removed.
• Employees are not adequately trained.
• Established energy-control procedures are not followed.

Never assume that equipment is safe simply because it has stopped moving.

Basic Lockout/Tagout Procedure

Only employees who are trained and authorized may perform lockout/tagout.

Follow the equipment-specific energy-control procedure and generally:

1. Prepare for shutdown. Identify the equipment, energy sources, hazards, and methods necessary to control the energy.
2. Notify affected employees. Inform employees that the equipment will be shut down and locked or tagged out.
3. Shut down the equipment. Use established shutdown procedures.
4. Isolate all energy sources. Operate disconnects, valves, breakers, blocks, or other energy-isolating devices.
5. Apply lockout/tagout devices. Each authorized employee applies their assigned lock and identification as required.
6. Control stored energy. Relieve pressure, discharge capacitors, block elevated components, restrain springs, bleed lines, and otherwise control residual or stored energy.
7. Verify isolation. Before work begins, verify that the equipment has been effectively isolated and cannot operate.
8. Perform the work. Maintain LOTO protection throughout the servicing or maintenance activity.

Never begin servicing until zero-energy or otherwise safe-energy conditions have been verified as required by the procedure.

Locks and Tags

A lock physically restrains an energy-isolating device from being operated. A tag provides a warning that the equipment must not be operated.

Employees must:

• Use only designated LOTO locks, tags, and devices.
• Clearly identify the employee applying the device.
• Never share personal LOTO locks or keys.
• Never bypass, defeat, or remove another employee’s lock or tag.
• Never attempt to restart equipment that has been locked or tagged out.

Tags are warning devices and do not provide the same physical restraint as locks. Where an energy-isolating device is capable of being locked out, lockout is generally the required method unless the applicable requirements for a tagout system are satisfied.

Authorized and Affected Employees

An authorized employee applies locks or tags and performs servicing or maintenance under the energy-control procedure.

Authorized employees must understand:

• The hazardous energy sources associated with the equipment.
• The type and magnitude of available energy.
• The methods used to isolate and control that energy.
• Proper application and removal of LOTO devices.
• Equipment-specific energy-control procedures.

An affected employee operates or uses equipment being serviced under LOTO or works in an area where LOTO is being performed.

Affected employees must understand the purpose and use of the energy-control procedure and must never attempt to restart or reenergize locked- or tagged-out equipment.

Group Lockout/Tagout

When multiple employees or crews perform servicing, group LOTO procedures must provide each authorized employee with protection equivalent to personal lockout/tagout.

Each authorized employee must apply their personal lock or other required personal lockout device when beginning work and remove it when their work is complete, according to the established group LOTO procedure.

Never depend solely on another employee’s lock for your personal protection.

Restoring Equipment to Service

Before removing LOTO and restoring energy:

• Inspect the work area.
• Remove tools and unnecessary materials.
• Verify that machine components are operationally intact.
• Make sure employees are safely positioned or clear.
• Confirm that affected employees have been notified.
• Remove locks and tags according to the established procedure.
• Restore energy in a controlled manner.

As a general rule, each lock or tag must be removed by the employee who applied it. Removal by another person may occur only under a specific employer procedure meeting applicable LOTO requirements.

Training and Retraining

Employees must receive training appropriate to their responsibilities.

Retraining is required when necessary, including when:

• Job assignments change.
• Machines, equipment, or processes change and present new hazards.
• Energy-control procedures change.
• Inspections reveal deviations or inadequacies.
• An employee’s knowledge or use of the procedure indicates additional training is necessary.

Employees must understand that failure to follow LOTO procedures can expose themselves and coworkers to life-threatening hazards.

Remember

Lockout/tagout (LOTO) is more than turning off a switch. Identify every hazardous energy source, isolate it, apply the required locks and tags, control stored energy, and verify isolation before beginning work.

Never bypass a lock, remove another employee’s lock, or attempt to start equipment that is locked or tagged out.

If it can move, start, fall, release pressure, become energized, or otherwise cause injury—control the energy before you work on it.