Lockout/Tagout
Lockout - Tagout
Control of Hazardous
Energy
OSHA Standard
1910.147
What Is Lockout/Tagout?
Referred to
as LOTO
Blocks the flow
of energy from
power source to
the equipment
Provides means
of warning (tag)
Why is Lockout/Tagout
Important?
OSHA’s Top 10 Most Cited Violations:
– Lockout / Tagout has ranked 4th on the list for
the last two years.
– Over 4,000 violations per year.
Types of Energy
Electrical
Mechanical
Chemical
Thermal
Hydraulic
Pneumatic
Use Safe Electrical Practices
Use non-conducting
tools.
Check circuits dead
before working.
Ensure all control
power is de-energized.
Discharge all
capacitors after
lockout.
Mechanical Energy Hazards
Kinetic – energy in motion
Potential - stored energy
Energy stored in machinery
Weights & Springs
Pistons under pressure
Hydraulic controls
Stored potential energy can be
released during work causing
injury or death.
Chemical Energy Hazards
Chemicals have energy that can:
start fires
cause skin burns
generate harmful gases or fumes
Before working – release, drain or vent chemicals
safely.
Thermal Energy Hazards
Energy of Heat and Cold
Hot or cold equipment & fluids can burn you
Quick releases of compressed gases can freeze
your skin
Allow equipment to reach a safe temperature
before starting work.
Hydraulic Energy
Energy of Liquids Under Pressure
pressure can cause equipment to
move
rapid release can cause injury or ejection of
system parts
Block energy or relieve pressure slowly into a
proper container.
Pneumatic Energy Hazards
Energy of Compressed Gases
– uncontrolled release can cause injury
– rapid de-pressurization creates extreme low
temperature
Properly vent all systems before starting work.
LOTO Procedure
1. Prepare for Shutdown
2. Shutdown Equipment
3. Isolate all energy sources
4. Place Locks & Tags
5. Release Stored Energy
6. Verify Equipment Isolation
1. Prepare for Shutdown
Understand equipment hazards!
Notify other employees of shutdown.
2. Shutdown Equipment
Follow normal
shutdown procedure.
Turn all switches to
the OFF position.
Shut all valves.
Disable all sources of
energy!
3. Isolate All Energy Sources
Shut valves
Open breakers &
disconnects
4. Place Locks & Tags
Valves
Breakers / electrical
disconnects
Block or disconnect
all lines
5. Release or Block all Stored
Energy
Discharge capacitors
Block or release springs
Block elevated parts
Stop rotating parts
Relieve system pressure
Drain fluids
Vent gases
Allow system to cool
6. Verify Equipment Isolation
Check all other workers are clear of the
equipment.
Check locking devices securely placed.
Check isolation.
Attempt normal startup.
Return Controls to OFF/Neutral.
Items needed for LOTO
Written LOTO procedures
Locks & Tags
Hasps --for multiple locks
& tags
Breaker Lockouts
Gate Valve Lockouts
Ball Valve Lockouts
Types of Lockout Devices
Locks
Blocks
Chains
Multilock hasps
Wheel valve covers
Ball valve covers
Requirements for
Lockout/Tagout Devices
They must be:
– Durable
– Standardized
– Substantial
– Identifiable
Typical Equipment
Requiring LOTO
Presses
Saws
Conveyors
Pumps
Production
equipment
Trash
compactors
Ovens
Affected Employees
Employees who
Operate
Work around
Occasionally
adjust equipment
that is subject
to LOTO
Affected Employee Responsibilities
Notify maintenance, etc., when equipment
needs repair or adjustment
Leave all LOTO devices in place
Verify equipment is safe to operate
following LOTO
Follow all safety rules while operating the
equipment
Authorized Employee
Maintains equipment
Services equipment
Is trained to use LOTO
Authorized Employee
Responsibilities
Repair or service equipment as needed
Ensure that all energy sources are locked out
Test equipment to verify residual energy is
dissipated
Place a “Danger—Do Not Operate” tag on
equipment
Obtain assistance when necessary
Remove locks and/or tags following LOTO
Coordinate multi-shift repair
Training Requirements
Authorized employees—initially and at
least annually
Affected employees—at least initially
Authorized and affected—whenever
changes are made to jobs or procedures
Authorized and affected—when program
deficiencies are noted
Company Responsibilities
Ensure de-energization of equipment
Ensure employee awareness
Provide appropriate levels of training
Review program effectiveness
Maintain and revise program
Administer appropriate disciplinary actions
When Must LOTO Be Used?
When servicing or maintaining equipment where:
Hazardous energy exists
Unexpected start-up could occur
Employees are required to remove or bypass a
safety device
Employees are required to place any part
of their body in harm’s way
Employees are exposed to hazardous energy
LOTO Exceptions
Work where hazardous energy does
not exist
Activities performed during routine
production processes
Work on cord-controlled devices
Hot tap operations where shutdown
is not feasible
Releasing Equipment from LOTO
Inspect Area and Equipment.
Ensure all Machine Guards in place.
Move tools away from equipment.
Inform others of startup.
Restore system connections.
Remove Locks & Tags.
Restore equipment to normal.
Conduct normal startup.
Know the Equipment!
– Hazards
– Energy isolation points
– Lockout/Tagout
procedures
Working on unfamiliar
machinery is a hazard!
Who Can Lockout Equipment?
Only employees
who have
been trained
and
authorized by
management.
Who can remove Locks &
Tags?
Only the employee who placed the tag
or
a supervisor, after obtaining permission
from the worker who placed the tag.
Lockout-Tagout Protects YOU!
ALWAYS Use
Proper Lockout -
Tagout Procedures
They are for your
protection!!!
