LOTO

GROUND RULES

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REFERENCES

1. QCS 2014
• Section 1 Part 10
• Section 11 Part 2.3.11

2. BS7671 Requirements For Electrical Installations

The Aim of this course (Objective)

To provide information and clear understanding to the

participants regarding LOTO (lock out/Tag out) procedure:

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LEARNING OBJECTIVES

• Understand the purpose of the energy control program

• Recognition of applicable hazardous energy sources, and the
methods necessary for energy control
• Discuss the primary causes of injury from hazardous energy
• Understand the steps necessary to properly control hazardous
energy when servicing equipment
• Know the responsibilities of Authorized and Affected employee in
terms of logout / tagout

INTRODUCTION
• Workers servicing machinery and equipment are exposed to injuries from the
unexpected energization, startup of the machinery or equipment, or release
of stored energy in the equipment
• 120 fatalities and 50,000 injuries each year
• Workers injured from exposure to hazardous energy lose an average of
24 work days for recovery
• Most injuries and fatalities are a result of improper hazardous energy control
procedures
• A Bureau of Labor Statistics study on injuries suffered when servicing
equipment showed
• 80% failed to turn off equipment
• 10% equipment activated by someone else
• 5% failed to control potential energy
• Remaining 5% failed to verify effectiveness

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THE “FATAL FIVE”

• Main Causes of Lockout/Tagout Injuries:

1. Failure to stop equipment before servicing

2. Failure to disconnect equipment from power source

3. Failure to dissipate (bleed, neutralize) residual energy

4. Accidental restarting of equipment
5. Failure to clear work areas before restarting

• All injuries resulting from inadequate hazardous energy control

procedures can be prevented

Lock Out, Tag Out (LOTO) is a safety procedure

used in industry and research settings to ensure
that dangerous machines are properly shut off
and not able to be started up again prior to the
completion of maintenance or repair work.

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 DEFINITION:TAGGING

• Tagging is the addition of a tag to the lock

which indicates the date, time and the
name of the worker as well as a warning
not to start the machine
• Important Note: This
never replaces a lock!

RESPONSIBILITIES

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 Legal Responsibilities

• Ethical and moral duty, you have a legal responsibility for

safety as a supervisor.

• Federal law; supervisors can be held criminally liable for

serious injury or death of an employee if proved negligent in
their duties.

• Fines/prison time for serious and/or willful violations

Fine and Jail Sentence for Worker Electrocution

Company fined $140,000

Supervisor sentenced to a year in jail

Company had received notification and several warnings that no

work was to be accomplished
until a power line crossing the job site was de-energized (locked-out
and tagged-out).

Supervisor knowing the hazard, directed an employee to drive a

dump truck into the hazard area.
Then provided instructions to the employee to raise the truck bed
under the energized power line.

The employee was severely burned and died on the scene.

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 Management Responsibilities

 Develop company policy for implementing lockout/tagout procedures

 for the control of hazard energy during maintenance operations.

 Establish written machine-specific procedures to include applying

 the locks and tags, release, and notification from lockout.

 Train authorized and affected employees on proper use of procedures.

EMPLOYER RESPONSIBILITIES
• No employee shall work on a machine...until he...
• verifies that a competent person has put the machine in a zero
energy state and
• locks out the machine using the safety lock and key provided
• adds a safety tag that contains
• a warning not to start the machine
• the name and signature of the employee
• the date and time
• tests that the machine is inoperative

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 Supervisors Responsibilities

 Ensure initial LOTO training.

 Monitor refresher training.

 Check for shortcuts, mistakes,

or unsafe work practices.

 Ensure retraining if job assignments change, new machines, control

 procedures or modifications occurs.
 Enforcement of machine-specific procedures to include applying
 the locks and tags, release, and notification from lockout.

Employees responsibilities:

• Assist employer/ competent person to identify hazards do not

work in unsafe workplace.
• Comply with work permit.
• Report all incident & damages to manager or supervising
person.
• Report any health issue which
• Pre use inspection method statement developed from risk
assessment & any requirement of equipment .

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 ENERGY CONTROL PROGRAM – 3 CORE
COMPONENTS
• Energy control procedures that detail the scope, purpose, authorization
rules and techniques to be utilized for the control of hazardous energy

• Periodic inspections of the energy control procedures to ensure that the

procedures and the requirements are being followed

• Employee training and ongoing retraining to ensure that the energy

control programs are understood

Written Procedures Inspections Training

LOCKOUT-TAGOUT PROCEDURES ARE REQUIRED IF…

• A worker must remove or bypass machine guards or other

safety devices, or
• A worker is required to place any part of their body into a
point of operation or into the danger zone associated with the
machine's operation
• Examples of activities where proper Lockout-Tagout
procedures would be required include
• Installing
• Lubricating
• Cleaning and un-jamming machines or equipment, and
• Making adjustments or tool changes

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 LOTO
PERSONNEL

Your Role

You are either an


Affected Employee 

An Authorized Employee


Or Both !


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DEFINITION OF PLAYERS

Authorized employee: An employee who locks or tags

machines or equipment in order to perform servicing or
maintenance

Affected employee: An employee who is required to

use machines or equipment on which servicing is
performed under the Lockout/Tagout standard or who
performs other job responsibilities in an area where
such servicing is performed

Other employees: All employees who are or may be in

an area where energy control procedures may be
utilized

Affected Employee

An individual that
operates the machinery
but does not perform
the lockout procedures

Pertains to any employee

whose job require them to
work in an area where
maintenance is performed

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RESPONSIBILITIES OF AFFECTED EMPLOYEES

• Never interfere or tamper with a lock or tag

• Stay clear of the area as much as possible
• Never attempt to assist
• Watch out for others in the area.
• Report any unusual situation or unsafe condition to your supervisor

Authorized Employee

An individual who has been properly trained to use lockout/tagout

procedures on a machinery or equipment that is to be serviced.

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RESPONSIBILITIES OF AUTHORIZED EMPLOYEES

• Identify all energy sources

• Notify all affected employees in the area of work
• Shut down the equipment at the operating controls
• Isolate all energy sources to equipment
• Lock and tag all isolating devices
• Dissipate all stored or residual energy sources.
• Verify the isolation
• Remove lock and tag when repair and testing are complete
• Notify all affected employees that lock and tag were removed

COULD BE BOTH

An authorized employee and an affected employee may be

the same person, when the affected employees’ duties also
include performing maintenance or service on a machine or
equipment that requires lockout tagout procedure.

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 LOTO
ENERGY SOURCES

TYPES OF HAZARDOUS ENERGY

• Mechanical – the potential energy and kinetic energy

present in the components of a mechanical system
• Kinetic – energy possessed by virtue of its motion
• Common injuries: fracture, contusion, laceration,
and amputation
• Potential – energy stored by the mechanical system
• Common injuries: fracture, contusion, laceration,
and amputation
• Electrical – energy as a result of a generated electrical
power source or a static source
• Common injuries: shock, burns, and electrocution
• Thermal – energy as a result of mechanical work, radiation,
chemical reaction or electrical resistance
• Common injuries: burns

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TYPES OF HAZARDOUS ENERGY

• Chemical -- energy released as a result of chemical

reactions
• Common injuries: burns
• Hydraulic – energy released as a result liquids under
pressure
• Common injuries: and contusions
• Pneumatic – energy released as a result of compressed
gasses under pressure
• Common injuries: burns and contusions

Electrical Energy Hazards

Can cause
shock and/or fire

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 ELECTRICAL HAZARDS

• An average of One worker is Electrocuted on the job every

Day
• There are four main types of Electrical injuries:
• Electrocution (Death due to electrical shock)
• Electrical shock
• Burns
• Falls

ELECTRICAL HAZARDS

• SHOCK. Electric shock occurs when the human body becomes

part of the path through which current flows.
• The direct result can be electrocution.
• The indirect result can be injury resulting from a fall or
movement into machinery because of a shock

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 ELECTRICAL BURNS

• Most common shock-related, nonfatal injury

• Occurs when you touch electrical wiring or
equipment that is improperly used or maintained
• Typically occurs on the hands
• Very serious injury that needs immediate attention

FALLS

• Electric shock can also cause indirect or secondary

injuries
• Workers in elevated locations who experience a shock
can fall, resulting in serious injury or death

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 ARC FLASH & ARC BLAST

• When an arc fault occurs, the result is a massive electrical

explosion. The light and heat emitted by the explosion is known
as the ARC FLASH.
• The Pressure Wave is known as the ARC BLAST.
• An arc flash releases hot gas and radiant energy up to four
times the temperature of the sun.
• Up to 77% of all electrical injuries are caused by arc flash
incidents.

ARC FLASH & ARC BLAST

• Intense heat of the arc flash can severely burn human skin and
ignite the clothing of anyone within several feet of the incident.

• Without proper eye protection, projectiles and molten debris can

cause eye damage.

• The blast can knock personnel off their feet; falls may result in
broken bones.

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 ARC FLASH EVENTS

ELECTRICAL SHOCK

• Received when current passes

through the body

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HOW IS AN ELECTRICAL SHOCK
RECEIVED?

• If you are in contact with an energized wire or any energized

electrical component, and also with any grounded object,
YOU WILL RECEIVE A SHOCK
• You can even receive a shock when you are not in contact
with a ground
• If you contact both wires of a 220-volt cable, YOU WILL
RECEIVE A SHOCK and possibly be electrocuted (AC)

ELECTRICAL SHOCK

• Severity of the shock depends on:

• Path of current through the body
• Amount of current flowing through the body
• Length of time the body is in the circuit
• Type of Clothes Worn
• Climatic Conditions ( Humidity & Rain)
• Condition of the Human Body.

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 Hydraulic Energy Hazards

Energy of liquids under pressure

- Pressure can cause parts to move
- Rapid release can cause injury
- Hydraulic fluid can burn you

Next
Slide

Hydraulic values must also be locked out

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 Thermal Energy Hazards

Energy of Heat /Cold

Boiler

Hot equipment Cold fluids can

& fluids will cause severe
burn you injury

Pneumatic Energy Hazards

Energy of compressed gases

Uncontrolled release can cause injury
Properly vent all systems before starting maintenance

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 Six-point hasp used to lockout air valve

Pneumatic energy can be very dangerous

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 Chemical Energy Hazards

Machinery that use any

chemicals have energy
that can start fires, cause
skin burns and generate
harmful gases or fumes

Lubricants, Hydraulic fluid, Fuels, Coolants, Solvents

Mechanical Energy Hazards

Two Types

1. Parts that are still in motion

2. Parts that store energy sources

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 ENERGY ISOLATION DEVICES
A mechanical device that physically prevents the transmission or release of
energy such as…
• Circuit breakers;
• Disconnect switches
• Line valves
• Slide gates
• Blind flanges

NOTE: Push buttons, selector switches and other control circuit type devices
are not energy isolating devices

TYPES OF LOCKOUT DEVICES

• Keyed and combination locks

• Ball valve locks
• Gate valve locks
• Group lockout hasp
• Circuit breaker locks
• Valve hand wheel cover

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 Provision for multiple locks

Single Lock

LoTo on Valve

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 LoTo on Switch Gears

LOCKOUT DEVICE REQUIREMENTS

Devices Must...
• Be capable of withstanding the environment to which
they are exposed
• Be singularly identified
• Be the only devices used for controlling energy
• Not be used for other purposes
• Be standardized within the facility in terms of color,
shape, or size.
• Indicate the identity of the employee applying the
devices
• Prevent removal without the use of excessive force
or unusual techniques

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 LOTO
PROCEDURES

Lockout/Tagout Program

The purpose of lockout/tagout is to prevent energy

sources from accidentally being released while a
machine or equipment is being serviced.

The ultimate goal of lockout/tagout is to protect the

safety and health of employees.

“Over 70% of all accidents come from improperly applied

procedures or non-compliance”

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 law requires employers to develop, document, and
implement machine specific procedures for the control
of hazard energy source(s) during maintenance operations.

Machinery Lockout/Tagout
7-step process

1. Prepare for shutdown 2. Shut down equipment

3. Isolate all energy sources 4. Install Locks and Tags

5. Verify stored energy shut- 6. Verify equipment

down isolation

7. Release from Lockout

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 Step 1:- Prepare for shutdown

Must know what energy sources associated with equipment

Electrical

Hydraulic

Pneumatic

Thermal

Mechanical

Chemical

Step 2:- Shut down equipment

Use standard equipment operating procedures to shut
down equipment
Push “Stop” button
Open Toggle switches
Close valve

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Step 3 :-Isolate all energy sources

Operate all energy-isolating devices so that the equipment is

isolated from its energy sources
Be sure to isolate ALL energy sources!
Primary supplies
Any secondary energy sources

Turn off power at machinery

Turn off power at machinery at electrical circuit breaker

boxes

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 Turn off Air and Hydraulic pressure

Step 4:- Install Locks and Tags

• Locks or tags must be applied to each device

• Must be applied by an Authorized employee
• Locks must be affixed in a manner that will hold the
energy isolating devices in a "safe" or "off" position
• Tags must be affixed in a manner that will clearly
indicate that the operation or movement of energy
isolating devices is prohibited

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Step 5:- Verify stored energy is shut-down

Ensure saw blades have

come to a complete stop
before removing guards

Ensure cutter heads

are not in motion

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Step 6:- Verify equipment isolation

• Before work begins, an authorized employee must verify

that the machine has been properly isolated and de-
energized
• Make sure all danger areas are clear of personnel
• Verify that the main disconnect switch or circuit breaker
can’t be moved to the on position.
• Use normal starting procedure or otherwise verify the
system is completely deenergized
• Return controls to “OFF” position after testing
• Verification is the step which is most frequently skipped
during evaluations

Machinery is now safe for maintenance operations

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 Step 7:- Release from Lockout

Inspect Area and Equipment

Reinstall machine guards

Account for tools and parts

Inform others of equipment start-up

GENERAL ENERGY CONTROL PROCEDURES

SPECIAL CIRCUMSTANCES FOR RELEASE - TESTING

• Lockout-tagout devices may be removed temporarily to test and

/or reposition the equipment under the following procedures:
• The equipment must be cleared of tools and materials
• Employees must be removed from the machine or
equipment area
• All logout / tagout devices may then be removed
• Authorized employees may then energize and test or
position the equipment
• Following testing or positioning, all systems must be de-
energized and energy control measures reapplied

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GENERAL ENERGY CONTROL PROCEDURES
SPECIAL CIRCUMSTANCES FOR RELEASE – SHIFT CHANGE

• If servicing lasts more than one shift, lockout/tagout protection

must not be interrupted

• When the authorized employee who applied the LOTO device

is not available to remove it, the device can only in an
emergency and only under the direction of the supervisor
• Must verify the authorized employee is not in the facility
• Must make all reasonable efforts to contact employee who
applied the device
• Must insure that the authorized employee knows the LOTO
device has been removed

GENERAL ENERGY CONTROL PROCEDURES

SPECIAL CIRCUMSTANCES – GROUP LOCKOUT-TAGOUT

• Group logout / tagout must afford protection for each employee

equivalent to that provided by a personal lockout or tagout
device
• Each authorized employee must affix a personal logout / tagout
when work begins and remove it when work is completed
• Group must designate a single authorized employee to serve
as overall supervisor

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Additional lockout/tagout requirements:

 Conduct annual audits to validate effectiveness of the

lockout/tagout procedures

 Review procedures annually or when required, especially
after an accident has occurred.

 Maintain an equipment survey that list the equipment

required to have lockout/tagout procedures, type(s) of
energy sources, and magnitude of energy.

MACHINERY
LOCKOUT
PRACTICES

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 Lockout Program Awareness Posters

Many employers now post their lockout procedures

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Wooden box used to control electrical hazard for machine plug

Single-point breaker clip used on multiple circuit breaker box

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Single
Point
Breaker
Clip

Holes drilled in handles to lockout with a chain.

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Some manufactures install lockout
devices on their equipment but you
must ensure the device completely
de-energizes the machine.

Manufactures lockout devices

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 Must ensure that manufacture locking devices
are in compliance with requirements

Employee observed clearing wood debris without locking

out machinery or wearing eye protection.

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 Not observing
“Danger Signs”

Employee reaching into machine to clear wood debris

without locking out machine or wearing eye protection

1. Employers are responsible for establishing a program consisting of energy control procedures,
employee training and an annual inspection of the procedures? True

2. Employers have the option of using either lockout or tagout to control hazard energy sources
during maintenance operations? False, lockout devices must be used.

3. Electrical circuit breaker boxes must be labeled as to which machinery item they control to enable
emergency shut down of equipment if necessary? True

4. Every form of energy must be isolated and controlled by lockout/tagout and the lockout verified
before beginning work? True

5. Lockout/tagout training is only required if the employer feels that the employee may be accident
prone or after the employee is involved in an accident that is the result of improper lockout/tagout?
False, initial training, new equipment, and if there has been a change to a procedure

6. The employer must develop and document a company lockout/tagout enforcement policy?
True

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7. It’s okay to restart equipment before you replace machine guards if you have someone watch
the open area? False, guards must be in position prior to equipment start-up.

8. An employee may use any available lock, even combination locks when conducting a lockout?
False, only locks identified for lockout purposes. Combination locks are NOT authorized.

9. Lockout/tagout policies describe how a company will conduct the lockout/tagout program,
whereas lockout/tagout procedures detail machine specific requirements for placing a machine
in a “Zero Energy” state. True

10. You are authorized to share your lock or to barrow one if you and the other employee agree?
False, each authorized employee must have their own lock

Bonus Question
Lockout/tagout is a seven-step process that must be followed in exact sequence?
True

LOCKOUT/TAGOUT
SIGNS
&
ACCIDENTS

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Warning signs you may see

Warning signs you may see

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Warning signs you may see

Warning signs you may see

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Accidents you may see:

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Do you enforce lockout/tagout ??

This worker wished his supervisor

had.

3rd degree burns….failure to deplete

hydraulic pressure -- line ruptured.

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 Page 97

SUMMARY
• Lockout-Tagout prevents energy from accidentally being released while a
machine or equipment is being serviced
• There are 6 types of hazardous energy common to most work environments –
Mechanical, Electrical, Thermal, Chemical, Hydraulic and Pneumatic
• Most injuries and fatalities are a result of improper hazardous energy control
procedures
• If an energy-isolating device is capable of being locked out, a lock out system
MUST be used
• General energy control procedures follow a 7-step process
• Only the authorized employee may attach and remove the logout / tagout
device
• Affected employees or any other employees should NEVER remove or tamper
with a logout / tagout device

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