Lockout/Tagout (LOTO)
Control of Hazardous Energy
March, 2021 All photos from Adobe Stock unless otherwise indicated
What will be covered
What is hazardous energy?
How is hazardous energy controlled?
What is lockout/tagout?
Lockout/tagout procedures
Specific tagout requirements
Group lockout/tagout
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What is hazardous energy?
Mechanical – machinery moving parts
Electrical – live or stored electrical energy
Hydraulic – compressed or moving liquids
Pneumatic – compressed air or gas
Gravitational – raised objects that can fall
Thermal – extremely hot liquids or cold gas
Radiation – lasers, microwave, ultraviolet, x-rays
All of these energy sources can either be stored or be active.
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Stored energy
Can include the following:
Fluids or gases still in the
equipment and under pressure,
electrical stored energy in batteries
or capacitors,
parts of machinery that are
affected by springs or gravity or
could otherwise move.
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How to control hazardous energy
Identify all energy sources – potential
(stored) or kinetic (moving or existing).
De-energize equipment by isolating or
blocking the energy source.
Dissipate or release stored energy.
Lock out the equipment’s energy source,
so it cannot be reactivated by anyone
while equipment is being serviced.
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What is lockout/tagout?
"Lockout/Tagout (LOTO)" is specific practices and procedures to
safeguard employees from the unexpected energization or
startup of machinery and equipment, or the release of
hazardous energy during service or maintenance activities.
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Why lockout/tagout is needed
YouTube video – Lockout/Tagout YouTube Video - LOTO is not a choice
- It would have saved his life
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An example of a hay bale cutter LOTO fatality
L&I photos
A worker died when he crawled into this hay bale cutting machine to dislodge a hay
bale without locking it out first. His weight activated the guillotine cutting blade which
struck him.
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When are lockout/tagout procedures needed?
When employees do service or maintenance on or around any
equipment that has hazardous energy,
When equipment or machinery is being installed or removed,
When a guard or other safety device is bypassed or removed.
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When is lockout not required?
Service and maintenance during normal production operations:
if an employee is not required to remove or bypass a guard or other
safety device; or
place any body part into the point of operation or any other hazardous
area created by machine operation.
Minor tool changes, adjustments, and other minor service
during normal production:
If they are routine, repetitive, and integral to the use of the equipment
for production; and
the work is done using measures which provide effective protection
from hazards.
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What is a lockout device?
It is a device that positively holds
energy isolating devices or measures
in a safe position to prevent the re-
energizing of equipment.
It can be a key or combination lock, or
blank flanges in piping.
It includes a tag or other notice that
identifies the person authorized to
remove the lock.
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Authorized and affected employees
An “authorized employee” is a person who
has been properly trained to lockout/tagout
procedures on machinery or equipment
that is to be serviced.
An “affected employee” is a person who
operates the machinery or equipment, but
L & I photos
does not perform the lockout procedures, or a
person who works in the area where machine
or equipment maintenance is being done.
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Six steps of lockout/tagout procedures
1. Preparation – get ready, inform all affected employees
2. Shutdown – turn off or shut down operating equipment
3. Isolation – install isolating devices or implement procedures to
block hazardous energy
4. Lockout/Tagout – apply LOTO devices or procedures
5. Stored energy check – verify that stored energy is released or
restrained
6. Isolation verification – test to make sure LOTO is working
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Once locked out – no unauthorized restart!
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Starting up equipment again
Remove all tools, replace guards,
and make sure the equipment is
ready to re-energize.
Notify all affected employees and
make sure they are clear of area.
The authorized person removes
the lockout/tagout device.
Start-up or reactivate equipment.
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Using tagout devices only
Tags are warning devices and do not
provide the same level of physical
restraint as a lock.
Tags may give a false sense of security.
Tags can’t be removed without the
approval of the person responsible for it.
Tags cannot be bypassed, ignored or
otherwise defeated.
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More tagout rules
Tags must be legible and understandable
Tags must be made of materials that will
withstand the environmental conditions they
are exposed to.
Tags must be securely attached to energy-
isolating devices so they can’t be accidently
removed.
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Group lockout/tagout
A primary authorized employee must
be assigned who has overall
responsibility.
Each authorized person puts a
lockout/tagout device on equipment.
No lockout/tagout device can be
removed until the work is done.
The primary is the last person to
remove their lockout/tagout device.
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LOTO is required on the following equipment
List machinery or equipment here
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Our lockout/tagout procedures
Describe your procedures here
Link to Sample Lockout Procedure Template
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Our lockout/tagout program
Describe your program here or pass out copies of written program
Link to Lockout/tagout Rule
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Further training for authorized employees
Provide training on specific lockout/tagout procedures on
specific machinery or equipment for authorized employees
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