07 Jul Lockout/Tagout Safety – Remember to Lockout and Tagout

Lockout/Tagout Safety

Remember to Lockout and Tagout

Lockout/tagout safety protects employees from the unexpected startup, energization, or release of stored energy from machinery and equipment during servicing and maintenance. Employees who operate, clean, service, adjust, or repair equipment must understand when lockout/tagout (LOTO) applies and follow established energy-control procedures every time.

Failure to properly control hazardous energy can result in electrocution, crushing injuries, amputations, burns, or fatalities.

How Lockout/Tagout Accidents Happen

Serious incidents can occur when:

• Equipment is turned off at the controls but the energy source is not isolated.
• Someone unexpectedly starts or energizes equipment while another employee is working on it.
• A malfunctioning machine remains available for use instead of being removed from service.
• Stored or residual energy is not released, restrained, blocked, or otherwise controlled.
• Moving or elevated equipment is not properly blocked or secured.
• Employees do not identify every source of hazardous energy.
• Lockout/tagout procedures are incomplete, misunderstood, or not followed.
• Employees take shortcuts because the work will “only take a minute.”

Hazardous Energy

Lockout/tagout is not limited to electrical energy. Equipment may contain multiple forms of hazardous energy, including:

• Electrical.
• Mechanical.
• Hydraulic.
• Pneumatic.
• Chemical.
• Thermal.
• Gravity or potential energy.
• Stored energy in springs, capacitors, pressure vessels, or other components.

All hazardous energy sources must be identified and properly controlled before servicing or maintenance begins.

Basic Lockout/Tagout Procedure

Authorized employees must follow the equipment-specific energy-control procedure. In general:

1. Prepare for shutdown and identify all energy sources.
2. Notify affected employees that the equipment will be shut down and locked out.
3. Shut down the machine using normal stopping procedures.
4. Isolate the equipment from all hazardous energy sources.
5. Apply individually assigned lockout devices and required tags to each energy-isolating device.
6. Release, disconnect, restrain, block, or otherwise control stored and residual energy.
7. Verify isolation before beginning work. Attempt a normal start or use other appropriate means to confirm the equipment cannot operate, then return controls to the neutral or “off” position.
8. Perform the servicing or maintenance.
9. Follow the established procedure for removing locks and restoring the equipment to service.

Important LOTO Rules

• Never remove, bypass, or ignore another employee’s lock or tag.
• Each authorized employee should apply and control their own personal lock when required.
• Never assume that turning off a switch, push button, or control panel has isolated the equipment.
• Tags are warning devices and do not provide the physical restraint of a lock.
• Never begin servicing until hazardous energy isolation has been verified.
• If stored energy can reaccumulate, continue verifying and controlling it throughout the work.
• Follow established procedures for group lockout/tagout, shift changes, outside contractors, and removal of a lock when the employee who applied it is unavailable.
• Only authorized employees may perform lockout/tagout. Affected and other employees must understand the restrictions of the energy-control program.
• Never restart or attempt to operate equipment that has been locked or tagged out.

Before Restoring Equipment to Service

Before locks and tags are removed and equipment is reenergized:

• Inspect the work area and ensure tools and unnecessary materials have been removed.
• Verify that machine components are operationally intact.
• Make sure employees are safely positioned or clear of the equipment.
• Remove lockout/tagout devices according to the established procedure.
• Notify affected employees that the lockout/tagout devices have been removed and the equipment is being returned to service.

Remember

Lockout/tagout procedures apply even when the repair or adjustment seems quick or minor. Never place any part of your body in a danger zone until hazardous energy has been isolated, controlled, and verified.