Lockout tagout procedures
Controlling hazardous energy in 8 steps
Manufacturing facilities are usually abuzz with machines running and operators ensuring production
goals are met. But, occasionally, equipment needs to undergo maintenance or be serviced. And when
that happens, a safety procedure called lockout tagout (LOTO) is set into motion to prevent an
unexpected startup or release of stored energy. Equipment is shut down, locked out and tagged, and is
basically non-operational. Or is it?
Accidents resulting from improper LOTO procedures do, unfortunately, occur. In fact, they are often in
OSHA’s annual list of the Top 10 Most Frequently Cited Standards.[1] Failure to contain hazardous energy
can cause serious injuries to workers (or even death) caused by burns, crushing, lacerating, amputating
or fracturing body parts.[2] And, workplaces can incur fines, too, if it’s determined OSHA’s standard for
lockout tagout wasn’t followed.
This standard, The Control of Hazardous Energy (Lockout/Tagout) (29 CFR 1910.147), outlines measures
for controlling different types of hazardous energy.[3] This is incredibly important to workplaces and
workers alike, as compliant lockout tagout programs can prevent workplace injuries and even death.
Long BEFORE a lockout happens …
If you’re updating or adding new machines and equipment to the workplace,
it’s natural to think ahead about how you’ll train your personnel. But before
this happens, you’ll need to write energy-control procedures for the
equipment that outline the scope, authorization, rules and techniques
employees will use.[4] Specifically, you’ll need to include:
How to use procedures
Steps to shut down, isolate, block and secure machines
Steps to place and remove lockout tagout devices
How to identify responsibility for lockout tagout devices
A process for testing machines to verify lockout devices and other energy-
control measures are effective
In order to stay compliant, employees who work with machines and
equipment must be trained so that they know their LOTO duties and
understand the OSHA standard.
Compliance-driving products
you'll need
Lockout Tagout Padlocks
Lockout Tagout Tags
Lockout Tagout Kits
Electrical Equipment Lockout Devices
Valve Lockouts and Hose Lockout Devices
8 Steps of a lockout tagout procedure
Because machines and equipment contain hazardous energy, it’s important
to adhere to site-specific lockout tagout procedures. The steps below are
outlined in OSHA’s 1910.147 App A - Typical minimal lockout procedure. [5]
STEP 1: Notify affected employees
Once it’s been determined a shutdown of equipment or machines
must occur, authorized personnel need to notify all employees who
will be affected by the shutdown. This can happen over radio, during
a briefing in a room or in the physical location where the equipment
is located. Employees need to be informed that equipment will be
shut down and locked out before maintenance will occur. This
required step initiates the LOTO procedure process.
STEP 2: Identify procedure and hazards
If a machine needs maintenance or servicing, company LOTO
procedures apply. As these procedures already exist, it’s easy to
reference them. Specifically, these procedures show:
o Energy type (electrical, mechanical, hydraulic, thermal, pneumatic,
chemical)
o Energy magnitude (volts, temp, psi , etc.)
o Energy hazards
o Methods to control the energy
STEP 3: Shut down
This step requires operating machines or equipment to be shut
down. This can be accomplished through normal stopping procedures
like pushing a STOP button, flipping a switch to an OFF position or
closing a valve. Orderly shutdowns are necessary to avoid additional
hazards caused due to stopping abruptly. These steps are listed in a
particular order, so employees need to pay attention to the exact
sequence.
STEP 4: Isolate machine from energy source
This step requires isolating the machine or equipment from its
source by using energy-isolating devices. It’s important to note these
devices are not the normal operating controls. Energy-isolating
devices should physically prevent the transmission of energy.
Examples include a circuit breaker, a line valve or a block. ON/OFF
and STOP buttons do not qualify as energy-isolating devices.
STEP 5: Apply lockout tagout devices
This step prevents manipulation of equipment or accidental startup.
It’s accomplished in two steps: Lockout and Tagout.
Lockout
A lockout tagout device (e.g., breaker or ball valve lockout) holds the
energy isolating device in a SAFE / OFF position. Safety padlocks (key
or combination) then prevent the removal of the energy-isolating
device to ensure energy cannot flow from its source to the machine.
Assigned locks should be applied to each energy-isolation device.
Tagout
Tagout refers to using a tagout device on an energy-isolating device.
It should be securely fastened to the isolating device to indicate the
energy-isolating device and equipment may not be operated until the
tag is removed. Essentially, it warns others not to restore energy.
The tag should include the name of the employee who applied it and
why. That way, if anyone has questions as to why the equipment is
locked out, they know who to ask.
Personal locks and tags should be used on:
o Line valves
o Circuit breakers / electrical disconnects
o Safety blocks on moveable parts
o Blank flanges on pipelines
STEP 6: Check stored energy
Once energy-isolating devices are locked out, this step requires checking for
stored energy. All residual energy must be depleted or drained from the
equipment to ensure it’s in a controlled state. Examples include:
1. Capacitors
2. Springs
3. Elevated machine members
4. Rotating flywheels
5. Hydraulic systems
6. Air, gas, steam or water pressure
If residual energy remains in a system, it’s a safety risk. You’ll need to
relieve pressure, bleed liquids, vent gasses and release tension in
compressed springs until the energy is dissipated.
STEP 7: Verify isolation
This step is very important. More than just a double-check, it can
save lives.
To verify that the equipment is disconnected from the energy source,
you’ll need to test it. First, check that no personnel can be exposed
to the threat of an energy hazard. Then, verify isolation by trying to
operate it. This can include pushing an ON button or any other
operating control, and visually checking gauges. Then, return the
control / button to the OFF position after verifying isolation.
By performing this step, you’re ensuring the machine or equipment
is now locked out and ready for servicing or maintenance.
STEP 8: Bring equipment back on line
When the machine or equipment has been serviced or repaired, it’s time to
get the work area and personnel ready for startup. Procedures must be
followed in the correct order.
1. Make sure that the machine or equipment is fully reassembled (guards and
safety devices are reinstalled, access panels are closed). Then, check that
tools have been cleared from the work area.
2. Survey the work area, checking to see that all personnel are in a safe spot
or removed from the area.
3. Verify all controls are in neutral.
4. Remove tags and lockout devices (by the same person who applied them).
5. Inform affected personnel that the servicing or maintenance is finished and
the equipment is ready for use.
