Lockout/Tag out
Definitions
Lockout/Tagout (LOTO) - Risk to individuals working on powered equipment
or machinery can be minimized by adhering to the six step process of LOTO.
- Lockout/Tagout gets its name from the equipment used
- Lockout/Tagout must be used whenever you are performing service or
maintenance on any machine where you or someone else could be injured by the
unexpected startup or release of stored energy
- LOTO DOES NOT APPLY to single source plug and cord equipment when the
equipment is unplugged and under the exclusive control of the person performing
the work
Definitions
LOTO Device - A device such as a lock,
circuit breaker cover, etc. that secures an
energy isolating device and prevents
energization of a machine, equipment or
process
Caution Tag - Yellow Caution Tags are used
to indicate that a machine, equipment,
process or circuit is out of service or
inoperable
Energy Isolating Device - A mechanical
device that physically prevents the
transmission or release of energy, such as
a circuit breaker or disconnect switch
Definitions
Individual LOTO Lock - A type of key lock that is used
for no other purpose in the facility/operation, having
one key, and for which master keys are not available.
Such locks are individually assigned (personal lock) to
Authorized Employees, or can be obtained from a
central repository of LOTO devices, whereupon they
become personal locks while in use by an individual.
LOTO Locks are typically colored red.
Individual LOTO Tags- These tags are used with every
Personal LOTO Lock to indicate that the energy source
is locked out and that an Authorized Employee is
actively working on the machine, equipment, process,
or circuit.
Show employee(s) the individual locks and tags that
are used on site.
Definitions
Supervisor Lock - A key lock for which multiple keys may be
made available and which is used on equipment or processes
when they are not actively being serviced. Key control or
access must be limited to a small, closely controlled group of
Authorized Employees. This lock must be used in
combination with a Supervisor Tag to indicate the equipment
is unsafe to operate.
- This lock must not be used as an Personal Lock and may never
be used on equipment that is being actively serviced.
Supervisor Tag - Must be yellow in color and are used to
indicate that a machine, equipment, process or circuit is out
of service or inoperable, but no one is actively working on
the system. Supervisor Tags are not to be used in place of
Red Tags. No activity to the machine, equipment, process or
circuit may occur when a Supervisor Tag is placed.
Show employee(s) the Supervisor locks and tags that are used on site
Definitions
General LOTO Lock - A key lock that is not assigned to an individual
employee as an Individual LOTO Lock. This lock has only one key and master
keys are not available. When a Group LOTO is used, this lock may be used to
Lock Out individual Energy Isolating Devices or Energy Sources. This lock
may be left on for durations of greater than one shift. This lock is unique
within the facility and is to be used only for LOTO.
Show employee(s) the general LOTO locks that are used on site
Personnel Affected by Lockout Tagout
Every employee who will be in close proximity to any machinery or
equipment being worked on will be affected by Lockout/Tagout.
- Authorized Employee
- Affected Employee
Personnel Affected by Lockout Tagout
Authorized Employee - An employee who has the appropriate technical
background, has completed Lockout/Tagout Authorized Training, has
successfully demonstrated that they know how to apply EC/LOTO, and who
will perform the work on the system. This could include an electrician,
pipefitter or other specialist with knowledge of the equipment.
Affected Employee - An employee who operates equipment that is being
maintained or serviced under EC/LOTO, or an employee working in an area
where the maintenance or servicing is being performed. This could include
machine operators, janitors or any other worker whose job requires him/her
to be in the area. Affected Employees are NOT authorized to perform
EC/LOTO.
Discuss the employee(s) role with lockout tag out and whether or not they are
Affected or Authorized employees.
Energy Isolation Device
A mechanical device that prevents transmission or release of hazardous
energy
- Circuit Breakers
- Disconnect Switches
- Line Valves
- Block Valves
- Manually Operated Switches
Types of Lockout/Tagout Devices
Circuit breaker cover
Gate valve locks
Fuse cover
Wall switch cover
Types of Lockout/Tagout Devices
Plug lock
Hasp
Ball valve locks
Group lockbox
Types of Hazardous Energy
Mechanical
- Relating to springs, rotating parts, etc.
Magnetic
• Can be found in capacitors and superconducting magnetic energy storage
Gravity
• Can be found in machinery or equipment parts that might descend, slide or fall if left
unblocked
Electrical
• Relating to or operated by electricity – AC or DC
Hydraulic
• Involving, moved or operated by a fluid under pressure, either internal or external
Pneumatic
• May be in cylinders, lines and pipes
Thermal
• Can be hot or cold
Types of Hazardous Energy
Chemical
- Produced as a result of a chemical reaction
Steam
- Water vapor kept under pressure so as to supply energy for heating or
mechanical work
Hazardous Energy
Remember: To proceed with any maintenance or servicing, hazardous energy
must be identified and controlled to prevent injury.
All energy sources must be identified and labeled.
Show employees examples of the site’s LOTO procedures including:
•Where they are located
•How the LOTO points are labeled
Employee Training
Authorized Employees must:
- Recognize hazardous energy sources including type and magnitude present in the work
place
- Know the methods and means to isolate and control hazardous energy sources
- Perform an annual demonstration to show they know how to properly apply LOTO
*In addition to this training course, Authorized Employee’s must also go through the periodic
inspection/certification form located in the Lockout/Tagout program. Your Supervisor is
responsible for completing this addition requirement.
Employee Retraining is required when:
- There is a change in job assignment
- There is a change in energy control procedures
- Inspections indicate deviations in procedures
- Employer believes employee needs retraining
Six Step Process
Step 1 - Prepare for Shutdown
- Notify all affected employees in the area that the equipment is going to be shut
down and locked out.
- Understand the problem
• What needs to be fixed?
- Plan
• Are the proper tools available?
- Prepare
• Is the area clear and are warnings posted?
Six Step Process
Step 2 – Shut Down the Equipment
Use established procedures
Involve the worker who normally shuts down the
equipment
If the work is being performed at a customer site,
the customer should shut down the equipment
Six Step Process
Step 3 - Isolate the Equipment
- Disconnect the equipment from each hazardous energy source and know the
proper order of shutdown
- Remember to wear Personal Protective Equipment (PPE) appropriate for any
hazards in the area
- Use common isolation techniques including closing valves and opening electrical
disconnects
- Remember to stand to one side when opening electrical disconnects in the event
an electrical arc occurs
Six Step Process
Step 4 - Apply Lockout/Tagout Devices
- Only use approved colored locks and tags designated for lockout
- NO MASTER KEY is allowed for a personal lock
- Locks must be attached to the energy-isolating device
- There should be one lock per person working on equipment, at each energy
source, unless a group lockbox is used
- If multiple employees a lockbox and/or multiple lock hasps may be used
- Never lend or borrow locks or keys
- Never use lockout locks for any other purpose
Six Step Process
Step 5 - Control Stored and Residual Energy
- Check that all moving parts have stopped.
- Relieve or disconnect any residual hazardous energy that could be present.
• Bleed-off all trapped pressure.
• Blank pipe flanges.
• Install ground wires to discharge electrical capacitors.
• Block or support elevated equipment.
Six Step Process
Step 6 - Verify Isolation/Zero Energy
- Start by verifying that all testing equipment (e.g., voltmeter, etc.) is working
properly
- Try to turn the equipment on
- Test for voltage
- Check gauges
- Check Double Block and Bleed
- Check temperature with an independent device
- Check blocks and pins
- Return switches to the “OFF”
- Notify Affected Employees in the area that work is to begin
Release of Lockout/Tagout
Check for others. When the assigned repair or servicing task is completed and
the machine is ready for testing or return to service, check the area surrounding
the shut off unit to assure that no one will be exposed to danger when that
machine is started up. Replace all guards and reactivate all interlocks.
Notify all affected employees that locks/tags are going to be removed and the
machine is ready for operation.
Remove LOTO equipment. When the area is clear, remove all locks and de-
activate all the energy isolating devices to restore energy and material to the
machine. The same worker who installed the energy isolating devices and
installed the locks must de-activate and remove them.
Test the machine. Perform any necessary testing of the restored machine to
ensure it is in operable condition.
Notify the management that work is completed and the area has been returned
to operational condition.
Things We Cannot Do!
DO NOT
• Rely on emergency stops
• Rely on interlocks and light curtains
• Rely on another worker to “guard the power source”
Why can’t we do these things
• Emergency stops and interlocks can fail
• Human error- people can get distracted
Injuries are not caused intentionally, it happens when things are overlooked and
things “accidentally” happen (doors shutting behind someone, accidentally
pushing a button, etc.)
THE WHOLE POINT OF LOCKOUT TAG OUT IS SO THAT IT CANNOT BE
BYPASSED. IT REMOVES THE FACTOR OF OTHER
COUNTERMEASURES LIKE E-STOPS AND INTERLOCKS FAILING AS
WELL AS REMOVING THE “HUMAN ERROR” ELEMENT!
Special Situations
Group Lockout
- Each authorized individual performing service and/or maintenance must apply
his/her personal lock. Every authorized individual who applies a personal lock shall
verify that the machine, equipment, process or circuit has attained a zero energy
state or observe the verification process. Multiple lock application can be
accomplished with the following:
• Multiple lock devices (hasps) that accommodate several personal Iocks;
• The use of general locks and a lock box. For example, if a machine with
multiple energy sources is going to be serviced by multiple personnel, it may be
useful to use general locks at the energy sources. Keys for the general locks are
held in lock boxes to which employees attach their personal locks.
Discuss the site’s procedure for group lockout including:
•Color of locks used
•When it is to be used (give examples of machines and specific jobs)
Special Situations
Specific procedures shall be utilized during shift or personnel changes to
ensure the continuity of LOTO protection. This includes provisions for the
orderly transfer of LOTO devices between off going and on coming
authorized individuals. There are two distinct methods of shift or personnel
change LOTO transition. These methods should never be mixed or
combined.
- Option 1: The immediate hand-off of LOTO in progress. Authorized individuals of
the outgoing shift remove their personal locks and tags. Authorized individuals of
the next shift simultaneously apply and secure their personal locks and tags at the
same energy-isolating device and verify that a zero energy state exists in the
system.
- Option 2: Application of Supervisor Locks. Authorized individuals use this method
when servicing and/or maintenance continues over multiple shifts, but there is no
immediate hand-off of LOTO in progress.
Discuss the site’s procedure for shift change including:
•Color of locks and tags used (show them the locks and tags that will be used)
•How and when to apply or remove shift change locks and tags
Special Situations
Unauthorized removal of locks and tags is prohibited. The Supervisor or
qualified person shall use the following procedure when the employee is not
available:
- Verify that the authorized employee is not on site and available to remove his or
her own tag.
- Check that employees are not exposed to hazards.
- Verify that the equipment is safe to operate, tools have been removed, and guards
have been replaced.
- Remove lock/tag and energize equipment.
- Remain with affected equipment so that no one returns while equipment or process
is being restarted.
- Require that the affected employee knows the lockout device has been removed
before he/she resumes work.
- The “Lockout/Tagout Removal Notice in the Lockout Tagout program must be
completed.
Discuss the site’s procedure for lock removal
Special Situations
New person(s) working on the system: Any new person working on the
system must follow all lockout procedures.
Returning to do more work: If you return to do more work, follow full lockout
procedure to assure nothing has changed.
Removing another person’s lock: NO ONE ELSE should remove an
individual’s lock and tag.
DO NOT ASSUME ALL IS SAFE – ALWAYS RE-VERIFY
Special Situations
When power must be temporarily restored to a machine to test or position
the machine, equipment or components, the following sequence of actions
shall be followed. At no time should you place any body parts in a danger
area!! This procedure is for observation purposes and adjustments that can
be made outside of the danger area!!!!
- Clear the machine or equipment of tools and materials.
- Notify all affected employees that you are removing lockout/tag out device(s) and
ensure that they are safely positioned or cleared from the area.
- Remove the lockout device as specified in the lockout removal section of this
procedure.
- Energize and proceed with testing or positioning.
- When testing or positioning is completed, de-energize all systems and reapply the
energy control measures in this procedure.
QUESTIONS
